HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter Benefits * * Simplifies power system design, reduces design time and technical risk Reduces PCB area occupied by power conversion and power management components Features * * * * * * * * * * * * Applications Next-generation IP Telephony & Power Over Ethernet (Unit is compliant to IEEE802.3af) 260-Watt output power capability Standard 1/2-brick footprint and pinout Fully-regulated 53.7VDC output Efficiency to 93% Input-to-output isolation: 2,250VDC Basic insulation Output overcurrent protection Output overvoltage protection Overtemperature protection Remote sense Remote on/off (primary referenced) rd Safety: UL60950-3 / CSA C22.2 60950-00, TUV EN60950:2001, IEC60950-1:2001 Description The HHS05Z55 dc-dc converter operates over an input voltage range of 36VDC to 75VDC and provides a regulated 53.7V output rated to 4.85 amps (260 watts) of continuous output current. The output is fully isolated from the input, which allows a positive or negative output voltage configuration. The standard feature set includes remote on/off, remote sensing, undervoltage lockout, overtemperature protection, output overvoltage protection, output trim, and a dedicated pin that connects to the baseplate. The highly efficient topology and thermally-optimized construction allow this unit to provide high output current over a wide operating temperature range while maintaining a safe guardband of electrical and thermal component deratings. The addition of an external heat sink further increases the capacity of the unit. The HHS05Z55 employs 100% surface-mount components for consistency and reliability in the production process. Model Selection Model HHS05Z55-NT 1 @ VIN min. 2 REV. OCT 13, 2004 Input Voltage VDC Input Current, 1 Max ADC Output Voltage VDC Output Rated Current I rated ADC Output Ripple/Noise, 2 mV p-p Typical Efficiency @ I rated % 36-75 7.9 53.7 4.85 150 92.5 (DC to 500 kHz) Page 1 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 1. Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long-term reliability, and cause permanent damage to the converter. Parameter Conditions/Description Min Max Units Input Voltage Continuous 36 75 VDC Operating Temperature Ambient 0 85 C Storage Temperature Ambient -55 125 C ON/OFF Control Voltage Referenced to -Vin 20 VDC 260 W Output Power 2. Environmental, Mechanical Specifications & Reliability Parameter Conditions/Description Operating Temperature Baseplate 1 Ambient Min Nom Max Units 0 110 C 0 85 C Operating Humidity Relative Humidity, Non-cond. 95 % Storage Humidity Relative Humidity, Non-cond. 95 % Water Washing Standard process Shock Half sinewave, 3 axes 50 Yes Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 Weight g 2.4 (68) 2.28 L (58.0 ) Dimensions (Overall) MTBF (calculated) per Bellcore TR-NWT-000332 Method I, Case 3, Quality level 2 Conditions: GB, TAMBIENT =30 C, O TBASEPLATE =40 C. Stress = measured. Assumptions: Additional "Limited Stress - Parts Count" g O 2.4 W (61.0) Oz(g) 0.42 H (10.67) In. (mm) 3.2 MHrs 1.8 MHrs 2.98 MHrs 7 Years adjustments made, based on measurements at full load conditions. MTBF (calculated) per Bellcore TR-NWT-000332 Method I, Case 3, Qual level 2 "Limited Stress - Parts Count" O Conditions: GB, TAMBIENT =50 C, O TBASEPLATE =70 C. Stress = measured. Assumptions: Additional adjustments made, based on measurements at full load conditions. 1 MTBF (calculated) per Bellcore TR-NWT-000332 Method I, Case 2, Quality level 2 "Parts Count" method, O Conditions: GB, TA=40 C, Stress @ 50% Service Life (calculated) TA=30 C O See Figures 12 - 13, "power derating curves". REV. OCT 13, 2004 Page 2 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 3. Isolation Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Insulation Safety Rating Isolation Voltage Min Nom Max Units Basic Input to Output 2250 VDC Input to Baseplate 1500 VDC Output to Baseplate 1500 VDC Isolation Resistance Input to Output 10 MOhm Capacitance Input to Output - - Input to Baseplate - Output to Baseplate - 5 nF - 1 nF - 12.5 nF 4. Safety Regulatory Compliance Safety Agency Standard Approved To: CSA UL60950- 3RD Marking cCSAs / CSA C22.2 60950-00 TUV product service TUV EN60950-1:2001 TUV PS Baurt mark CB report IEC60950-1:2001 N/A. May use CE mark Conducted Emissions (with external EMI filter) CISSPR 22 class B 5. Input Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Nom Input Voltage Continuous 36 48 Maximum Input Current Vin =36V, Iout=Irated Turn-On Input Voltage (UVLO) Turn-Off Input Voltage 1 2 3 1 1 Max Units 75 VDC 7.9 ADC Ramping Up 36 37 38 VDC Ramping Down 34.7 35.5 35.9 VDC Input Reflected Ripple Current Irated, 12H source inductance 2, 3 BW=20MHz 50 mA p-p Inrush Transient Vin=Vin.max 2 As 2 . See Figure 1 Vin = 48Vin. See Figure 7 for measurement method REV. OCT 13, 2004 Page 3 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 6. Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Combined Output Voltage Regulation Includes all below & Aging. (Vin=48V, Io=4.85A) Set-point Accuracy: 54.1 VDC 53.34 53.7 Load Regulation: (Io,min to Io,max) 100 mV 2, 3 O O (TAMB=0 C to 70 C) 6 VinNOM, Iout=4.85A 92.5 93.4 % VinNOM, > 50% Iout 91 92.5 % VinNOM, 10 to 50% Iout 83 87 % Fixed frequency 250 300 350 kHz 150 0.28 mVp-p % Vo (500kHz to 1MHz) 50 0.1 mVp-p % Vo (1MHz to 20MHz) 30 mVp-p 30 50 ms 20 30 ms 0 3 %Vout 0.2 200 3 500 %Vout 1,000 F Time from Vin=UVLO to regulation band From 10 to 90% of Vout.nom 4 Peak Deviation Settling Time 5 25% load step change (4.85A - 3.64A - 4.85A), di/dt=1A/s Admissible Load Capacitance 200 s See Figure 3 for efficiency at elevated temperatures. See Figure 6 for test setup Output ripple may exceed the specification for Io < 0.2 Amps. 4 Measured @ Remote Sense pins, CLOAD = 220F min, Settling Time (Vo, 1% of Vo) - refer to Figure 5. 5 Aging < 7 years, Tamb. = 0OC to +70OC 6 mV ADC 0 Overall input voltage, load, and temperature conditions Turn-on Overshoot 100 4.85 Irated Over line and load, TAMB= 0C to 85C (DC to 500kHz) Rise Time 3 53.7 mV (via application of input voltage) 2 53.3 VDC Switching Frequency 1 Units 100 (TAMB=25C) Dynamic Regulation Max 54.04 1 Turn-On Time Nom (Vi = 36V to 75V) Temperature Regulation Output Ripple Min Line Regulation: Output Current Efficiency 5 See Figure 4 REV. OCT 13, 2004 Page 4 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 7. Protections Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Nom Max Units Overcurrent Protection Non-latching - Constant current mode, auto-recovery, may hiccup during short circuit. Type Threshold 5.7 Short Circuit 1 Hiccup Mode 9.0 ADC 9.0 ARMS Overvoltage Protection Type Latching, recycle input voltage or ON/OFF signal to unlatch Threshold 2 Vin = Vin.nom, Iout=IRATED 58 60 65 VDC 120 C Overtemperature Protection Type Non-latching, auto-recovery Threshold Baseplate temperature 112 Hysteresis C 10 1 See Figure 8 2 See Figure 9 8. Feature Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Nom Max Units 1.8 1 20 5 VDC mADC VDC VDC 20 5 1.8 1 VDC VDC VDC mADC ON/OFF Negative Logic (-N) Converter ON Source Current Converter OFF Open Circuit Voltage Positive Logic 1 Converter ON Open Circuit Voltage Converter OFF Source Current ON/OFF signal is low or the pin is connected to -Vin - converter is ON Von/off in reference to -Vin ON/OFF pin is connected to -Vin Von/off in reference to -Vin ON/OFF pin is floating On/Off signal is low or the pin is floating -converter is OFF Von/off in reference to -Vin ON/OFF pin is floating Von/off in reference to -Vin ON/OFF pin is connected to -Vin Remote Sense 0.5 2.5 2.5 -0.5 0.5 2 Remote Sense Headroom 0.5 Output Voltage Trim 1 -0.5 Trim Up Vin = Vin.nom, Iout=Irated Trim Down Vin = Vin.nom, Iout=Irated VDC 2 0.5 -2.5 VDC VDC Consult factory for availability of this option. 2 Combined output voltage positive adjustment cannot exceed 0.5Vdc. See section 10.3 "Output Voltage Trim" REV. OCT 13, 2004 Page 5 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 9. Performance Characteristics 9.1 UVLO Operation 96 94 92 ( % ) 90 88 86 48Vin@25DegC 84 0 1 2 3 4 5 Iout (A) Figure 3. HHS05Z55 operating at 25OC Ambient, 200LFM airflow (-Vin to +Vin) w/o heat sink. Unit temperature allowed to stabilize at each recorded datapoint. Figure 1. HHS05Z55 Input UVLO Characteristics 9.3 Startup Characteristics 9.2 Efficiency 96 94 92 % 90 88 86 42Vin 50Vin 84 0 1 2 3 4 5 Iout (A) Figure 2. HHS05Z55 operating at 70OC Ambient, 200LFM airflow (-Vin to + Vin) w/ CoolerMaster heat sink (4" X 2.4" X 0.3", P/N 700-17522-01 REV A) Figure 4. HHS05Z55 Startup Waveform Channel 1 - input voltage = 48V Channel 2 - output voltage Time: 20mS/div. This waveform demonstrates typical output voltage turn-on delay time and monotonic rise with no overshoot. REV. OCT 13, 2004 Page 6 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 9.6 Input Reflected Ripple 9.4 Dynamic Load Response TO OSCILLOSCOPE Vi(+) Ltest 12 uH BATTER Y Cs 220 uF ESR < 0.1 OHM @ 20 C, 100 kHz 22 uF ESR < 0.7 OHM @ 20 C, 100 kHz Vi(-) . Figure 7 Input Reflected Ripple Current Test Set-up Note: Measure input reflected-ripple current with a simulated inductance (Ltest) of 12 H. Capacitors offset possible battery impedance. Measure current as shown above 9.7 Overcurrent Protection Figure 5. HHS05Z55 Dynamic Regulation To provide protection from an output overload or short-circuit condition, the HHS05Z55 is equipped with current-limiting circuitry and can endure the fault condition for an unlimited duration. At the point of current-limit inception, the converter enters constant current mode, causing the output current to be limited. Heavy overload or short circuit will result in a hiccup current limit mode and restrict current both in peak and duration. Because of a lower duty cycle, the RMS value of output current is also low. The load is switched from 4.85A to 3.65A at di/dt=1A/s. Cext=200F. (Above performance: 158mV / 200s) Top waveform - output voltage, 200mV/div. Bottom waveform - output current Time: 2ms/div 9.5 Ripple and Noise To improve accuracy and repeatability of ripple and noise measurements, Power-One utilizes the test setup shown in Figure 6. DUT +Vin +Vo1 0.1uf ceramic LOAD1 -Vo1 10uF @ 35V ESR=0.3 Tantalum SCOPE Shielded Cable (3 to 4 inches) +Vin Figure 6. Output Ripple & Noise Measurement Test Setup A BNC connector is used for the measurements to eliminate noise pickup associated with long ground leads of conventional scope probes. The connector, a 0.1F ceramic a 10F tantalum capacitors and the load are located 2-3" away from the converter. REV. OCT 13, 2004 Figure 8. HHS05Z55 Output Current With Output Shorted and Vin=36V. Scale is 5A Per Division Measurement: 6.83ARMS Once the output current is brought back into its specified range, the converter automatically exits the protection mode and continues normal operation. Page 7 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 9.8 Overvoltage Protection The output overvoltage protection consists of a separate control loop, independent of the primary control loop. This control loop has a higher voltage set point than the primary loop. In a fault condition the converter limits its output voltage and latches off. Figure 9 shows operation of the converter under an overvoltage condition. When the ON/OFF pin is used to achieve remote control, the user must take care to insure that the pin reference for the control is really the -Vin pin. The control signal must not be referenced ahead of EMI filtering, or remotely from the unit. Optically coupling the information and locating the optical coupler directly at the module will solve any of these problems. Note: If the ON/OFF pin is not used, it can be left floating (positive logic), or connected to the -Vin pin (negative logic). 10.2 Remote Sense The HHS05Z55 converter has the capability to remotely sense both lines of the output. This feature moves the effective output voltage regulation point from the output of the unit to the point of connection of the remote sense pins. This feature automatically adjusts the real output voltage of the converter in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. This is shown in Figure 10. Figure 9. Output Voltage of an HHS05Z55 Under a Forced Overvoltage Condition. Vin=75V, No Load, Co=220F 10. Feature Descriptions 10.1 ON/OFF The ON/OFF (#3) pin in the HHS05Z55 converter is referenced to the -Vin (#1) pin. With negative logic (which is denoted by the suffix "- N" in the part number), when the ON/OFF pin is pulled low, the unit is turned on. With the positive logic, when the ON/OFF pin is pulled low, the output is turned off and the unit goes into a very low input power mode. (Consult factory for availability of this option) If the remote sense feature is not to be used, the sense pins should be connected locally. The +Sense (# 8) pin should be connected to the +Vout (# 9) pin directly at the output of the converter and the -Sense (# 6) pin should be connected to the -Vout (# 5) pin directly at the output of the converter. If sense pins are not connected to load, or the respective output pins, the converter will not be damaged, may not meet the output voltage regulation specifications and the output voltage will be approximately 0.75 volts higher than nominal. 10.3 Output Voltage Trim The trim feature allows the user to adjust the output voltage from its nominal value. The HHS05Z55 (-T suffix) trims up with a resistor from the Trim (# 7) pin to the +Sense (# 8) pin and trims down with a resistor from the Trim pin to the - Sense (# 6) pin as shown in Figure 10. An open collector switch is recommended to control the voltage between the ON/OFF pin and the -Vin pin of the converter. The ON/OFF pin is pulled up internally, so no external voltage source is required. The user should avoid connecting a resistor between the ON/OFF pin and the +Vin (# 4) pin. REV. OCT 13, 2004 Page 8 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 11. Application Information 11.1 Typical Input and Output Connections Figure 10 shows the recommended connections for the HHS05Z55 converter. HHS04Z52 Fuse +Vi +Vo +Sense C1 On/Off Trim C2 C3 -Sense -Vi -Vo Figure 10. HHS05Z55 ["T" suffix] Converter Trim Schematic The equations below determine the trim resistor value required to achieve a V change in the output voltage. Vo (100 + %) (100 + 2 %) Rup = - k % 1.225 % 100 Rdown = - 2) k % where V% is the output voltage change expressed in percent of the nominal output voltage, Vo. Notes: 1. When the output voltage is trimmed up, the output power from the converter must not exceed its maximum rating. The power is determined by measuring the output voltage on the output pins, and multiplying it by the output current. 2. In order to avoid creating apparent load regulation degradation, it is important that the trim resistors are connected directly to the remote sense pins, and not to the load or to traces going to the load. 3. The output voltage increase can be accomplished by either the trim or by the remote sense or by the combination of both. In any case the absolute maximum output voltage increase shall not exceed the limits defined in table 8 above. 4. Either Rup or Rdown should be used to adjust the output voltage according to the equations above. If both Rup and Rdown are used simultaneously, they will form a resistive divider and the equations above will not apply. REV. OCT 13, 2004 Figure 11. Typical Application of the HHS05Z55 The HHS05Z55 converter does require an external output capacitor for optimum operation. A 200uF low impedance capacitor is recommended. If the distribution of the input voltage to the converter contains significant inductance, capacitor C1 may be required to enhance performance of the converter. A minimum of a 68F electrolytic capacitor with the ESR<0.7 is recommended. Refer to the "Inrush Current Control Application Note" on www.power-one.com for suggestions on how to limit the magnitude of the inrush current. For output decoupling we recommend to use a low ESR 10F, and 0.1F ceramic capacitors. Note that the capacitors do not substitute for the filtering required by the load. Page 9 of 12 www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter The graph in Figure 13 shows the maximum output current of the HHS05Z55 converter with the available POWER-ONE 0.45" height heatsink attached. (option # "-2V") at various ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4) 11.2 Thermal Considerations The HHS05Z55 converters are designed for both natural and forced convection cooling. The maximum allowable output current of the converters is determined by meeting the derating criteria for all components used in the converters. For example, the maximum semiconductor junction temperature is not allowed to exceed 125C to ensure reliable longterm operation of the converters. Contact PowerOne for the complete list of the derating criteria. THERMAL DERATING CURVE HHS05Z55-NT Vin = 48V, Orientation : Vin- to Vin + Tested with attached (fin-type) heatsink, 0.45" height. Data Rev: 01 5.0 4.5 4.0 3.5 Load Current (A) The graph in Figure 12 shows the maximum output current of the HHS05Z55 converter (with no attached heatsink) at various ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4). 3.0 2.5 2.0 1.5 1.0 0.5 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM 0.0 5.0 25 40 55 70 Ambient Temperature (Deg C) 4.5 4.0 Figure 13. HHS05Z55 Derating Curves (@ Vin = 48Vdc, w/ supplemental 0.45" height heat sink) Load Current (A) 3.5 3.0 2.5 2.0 1.5 1.0 0.5 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM 0.0 25 40 55 70 85 Ambient Temperature (Deg C) Figure 12. HHS05Z55 Derating Curves (@ Vin = 48Vdc, w/o supplemental heat sink) REV. OCT 13, 2004 Page 10 of 12 www.power-one.com 85 HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 11.3 Safety Considerations The HHS05Z55 converter features 2,250VDC isolation from the input to output. The input to output resistance is greater than 10MOhm. These converters are provided with Basic insulation between input and output circuits according to all IEC60950 based standards. Nevertheless, if the system using the converter needs to receive safety agency approval, certain rules must be followed in the design of the system. In particular, all of the creepage and clearance requirements of the end-use safety requirements must be observed. These documents include UL60950 - CSA60950-00 and EN60950, although other or additional requirements may be needed for specific applications. In order for the output of the HHS05Z55 converter to be considered as SELV (Safety Extra Low Voltage) or TNV-1, according to all IEC60950 based standards, one of the following requirements must be met in the system design: * * * The HHS05Z55 converter has no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 11. Refer to the "Input Fuse Selection for DC/DC converters" application note on www.power-one.com for proper selection of the input fuse. Both input traces and the chassis ground trace (if applicable) must be capable of conducting a current of 1.5 times the value of the fuse without opening. The fuse must not be placed in the grounded input line, if any. REV. OCT 13, 2004 Page 11 of 12 If the voltage source feeding the module is SELV or TNV-2, the output of the converter may be grounded or ungrounded. If the voltage source feeding the module is ELV, the output of the converter may be considered SELV only if the output is grounded per the requirements of the standard. If the voltage source feeding the module is a Hazardous Voltage Secondary Circuit, the voltage source feeding the module must be provided with at least Basic insulation between the source to the converter and any hazardous voltages. The entire system, including the HHS05Z55 converter, must pass a dielectric withstand test for Reinforced insulation. Design of this type of systems requires expert engineering and understanding of the overall safety requirements and should be performed by qualified personnel. www.power-one.com HHS05Z55 DC-DC Converter Data Sheet 48V Input, 53.7V @ 260W Half-Brick Converter 12. Mechanical Drawing Pin 1 2 3 4 5 6 7 8 9 Note: Kapton HN, a non-porous, highly puncture-resistant plastic film (0.002" thickness) with 6KV/mil dielectric strength is secured to the module (pin side) as a standard feature on each unit. This adds a protective insulative barrier layer between the converter and the host board. Mechanical Tolerances Inches X.XX 0.02 X.XXX 0.010 Millimeters X.X 0.5 X.XX 0.25 Pin 0.002 Function -Vin Case On/Off +Vin -Vo -Sense Trim +Sense +Vo 0.05 13. Ordering Information Options Remote ON/OFF Suffixes to add to part number 1 Positive- no suffix required (note ) Negative - Add "N" suffix Trim Positive - "T" suffix (required) Pin Length 0.18"- Standard, no suffix required 0.145"- Add "7" suffix 1 0.110"- Add "8" suffix (note ) Host board Insulator 1 Standard, no suffix required (see drawing note above) Consult factory for availability of this option. NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. REV. OCT 13, 2004 Page 12 of 12 www.power-one.com