HHS05Z55-NT8 - Power-One - Datasheet.Directory

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48V Input, 53.7V @ 260W Half-Brick Converter

Applications

Next-generation IP Telephony &

Power Over Ethernet

(Unit is compliant to IEEE802.3af)

Benefits

• Simplifies power system design, reduces design

time and technical risk

• Reduces PCB area occupied by power conversion

and power management components

Features

• 260-Watt output power capability

• Standard ½-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)

• Safety: UL60950-3rd/ 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

Input

Voltage

VDC

Input

Current,

Max ADC 1

Output

Voltage

VDC

Output Rated

Current I rated

ADC

Output

Ripple/Noise,

mV p-p 2

Typical

Efficiency @

I rated %

HHS05Z55-NT 36-75 7.9 53.7 4.85 150 92.5

1 @ VIN min. 2 (DC to 500 kHz)

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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

Output Power 260 W

2. Environmental, Mechanical Specifications & Reliability

Parameter Conditions/Description Min Nom Max Units

Baseplate 0 110

°C

Operating Temperature

Ambient 1 0 85

°C

Operating Humidity Relative Humidity, Non-cond. 95 %

Storage Humidity Relative Humidity, Non-cond. 95 %

Water Washing Standard process Yes

Shock Half sinewave, 3 axes 50 g

Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 g

Weight 2.4 (68) Oz(g)

Dimensions (Overall)

2.28 L

(58.0 )

2.4 W

(61.0)

0.42 H

(10.67)

In.

(mm)

MTBF (calculated)

per Bellcore TR-NWT-000332

Method I, Case 3, Quality level 2

“Limited Stress - Parts Count”

Conditions: GB, TAMBIENT =30OC,

TBASEPLATE =40OC.

Stress = measured.

Assumptions: Additional

∆Τ adjustments made, based on

measurements at full load

conditions.

3.2 MHrs

MTBF (calculated)

per Bellcore TR-NWT-000332

Method I, Case 3, Qual level 2

“Limited Stress - Parts Count”

Conditions: GB, TAMBIENT =50OC,

TBASEPLATE =70OC.

Stress = measured.

Assumptions: Additional

∆Τ adjustments made, based on

measurements at full load

conditions.

1.8 MHrs

MTBF (calculated)

per Bellcore TR-NWT-000332

Method I, Case 2, Quality level 2

“Parts Count” method,

Conditions: GB, TA=40OC,

Stress @ 50%

2.98 MHrs

Service Life (calculated) TA=30OC 7 Years

1 See Figures 12 - 13, “power derating curves”.

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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 Min Nom Max Units

Insulation Safety Rating Basic

Input to Output 2250 VDC

Input to Baseplate 1500 VDC

Isolation Voltage

Output to Baseplate 1500 VDC

Isolation Resistance Input to Output 10 MOhm

Input to Output - - 5 nF

Input to Baseplate - - 1 nF

Capacitance

Output to Baseplate - - 12.5 nF

4. Safety Regulatory Compliance

Safety Agency Standard Approved To: Marking

CSA UL60950-3RD / CSA C22.2 60950-00 cCSAs

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 Max Units

Input Voltage Continuous 36 48 75 VDC

Maximum Input Current Vin =36V, Iout=Irated 7.9 ADC

Turn-On Input Voltage (UVLO) 1 Ramping Up 36 37 38 VDC

Turn-Off Input Voltage 1 Ramping Down 34.7 35.5 35.9 VDC

Input Reflected Ripple Current Irated, 12µH source inductance

BW=20MHz 2, 3

50 mA p-p

Inrush Transient Vin=Vin.max 2 A2s

1 . See Figure 1

2 Vin = 48Vin.

3 See Figure 7 for measurement method

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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 Min Nom Max Units

Combined Output Voltage Regulation

Includes all below & Aging. 5 53.3 53.7 54.1 VDC

Set-point Accuracy: (Vin=48V, Io=4.85A) 53.34 53.7 54.04 VDC

Line Regulation: (Vi = 36V to 75V) 100 mV

Load Regulation: (Io,min to Io,max) 100 mV

Temperature Regulation (TAMB=0OC to 70OC) 100 mV

Output Current Irated 0 4.85 ADC

VinNOM, Iout=4.85A 92.5 93.4 %

VinNOM, > 50% Iout 91 92.5 %

Efficiency 1

(TAMB=25°C)

VinNOM, 10 to 50% Iout 83 87 %

Switching Frequency Fixed frequency 250 300 350 kHz

Over line and load,

TAMB= 0°C to 85°C

(DC to 500kHz)

150

0.28

mVp-p

% Vo

(500kHz to 1MHz)

0.1

mVp-p

% Vo

Output Ripple 2, 3

(1MHz to 20MHz) 30 mVp-p

Turn-On Time 6

(via application of input voltage)

Time from Vin=UVLO to

regulation band

30 50 ms

Rise Time From 10 to 90% of Vout.nom 5 20 30 ms

Turn-on Overshoot Overall input voltage, load, and

temperature conditions

0 3 %Vout

Dynamic Regulation 4

Peak Deviation

Settling Time

25% load step change

(4.85A – 3.64A – 4.85A),

di/dt=1A/µs

±0.2

200

±3

500

%Vout

µs

Admissible Load Capacitance 200 1,000 µF

1 See Figure 3 for efficiency at elevated temperatures.

2 See Figure 6 for test setup

3 Output ripple may exceed the specification for Io < 0.2 Amps.

4 Measured @ Remote Sense pins, CLOAD = 220µF min, Settling Time (Vo, 1% of Vo) – refer to Figure 5.

5 Aging < 7 years, Tamb. = 0OC to +70OC

6 See Figure 4

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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

Type Non-latching – Constant current mode, auto-recovery,

may hiccup during short circuit.

Threshold 5.7 9.0 ADC

Short Circuit 1 Hiccup Mode 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

Overtemperature Protection

Type Non-latching, auto-recovery

Threshold Baseplate temperature 112 120

°C

Hysteresis 10 °C

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

ON/OFF

Negative Logic (-N)

Converter ON

Source Current

Converter OFF

Open Circuit Voltage

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

-0.5

2.5

0.5

1.8

VDC

mADC

VDC

Positive Logic 1

Converter ON

Open Circuit Voltage

Converter OFF

Source Current

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

2.5

-0.5

0.5

1.8

VDC

mADC

Remote Sense 2

Remote Sense Headroom 0.5 VDC

Output Voltage Trim 2

Trim Up Vin = Vin.nom, Iout=Irated 0.5 VDC

Trim Down Vin = Vin.nom, Iout=Irated -2.5 VDC

1 Consult factory for availability of this option.

2 Combined output voltage positive adjustment cannot exceed

0.5Vdc. See section 10.3 “Output Voltage Trim”

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9. Performance Characteristics

9.1 UVLO Operation

Figure 1. HHS05Z55 Input UVLO Characteristics

9.2 Efficiency

012345

Iout (A)

42Vin 50Vin

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)

012345

Iout (A)

( % )

48Vin@25DegC

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.

9.3 Startup Characteristics

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.

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9.4 Dynamic Load Response

Figure 5. HHS05Z55 Dynamic Regulation

The load is switched from 4.85A to 3.65A at

di/dt=1A/µs. Cext=200µF. (Above performance:

158mV / 200µs)

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

0.1uf

ceramic SCOPE

+Vo1

-Vo1

10uF @ 35V

ESR=0.3Ω

Tantalum

LOAD1

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 0.1µF ceramic a 10µF tantalum capacitors and the

load are located 2-3” away from the converter.

9.6 Input Reflected Ripple

. Figure 7 Input Reflected Ripple Current Test Set-up

Note: Measure input reflected-ripple current with a simulated

inductance (Ltest) of 12 µH. Capacitors offset possible battery

impedance. Measure current as shown above

9.7 Overcurrent Protection

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.

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.

BATTER

Cs 220 uF

ESR < 0.1 OHM

@ 20 ºC, 100

kHz

Ltest

12 uH

22 uF

ESR < 0.7 OHM

@ 20 ºC, 100 kHz

Vi(+)

Vi(-)

TO OSCILLOSCOPE

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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.

Figure 9. Output Voltage of an HHS05Z55 Under a Forced

Overvoltage Condition. Vin=75V, No Load, Co=220µF

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)

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.

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.

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.

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48V Input, 53.7V @ 260W Half-Brick Converter

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.

Ω

⎟

⎠

⎞

⎜

⎝

⎛

∆

∆+

−

∆

∆+

Rup %

%)2100(

%225.1

%)100(

Ω

⎟

⎠

⎞

⎜

⎝

⎛−

∆

=kRdown )2

100

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.

11. Application Information

11.1 Typical Input and Output Connections

Figure 10 shows the recommended connections for

the HHS05Z55 converter.

+Vo

+Sense

Trim

-Sense

-Vo-Vi

+Vi

On/Off

Fuse

C1 C2 C3

HHS04Z52

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 68µF electrolytic capacitor with the

ESR<0.7Ω 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 10µF, and 0.1µF ceramic capacitors. Note that

the capacitors do not substitute for the filtering

required by the load.

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48V Input, 53.7V @ 260W Half-Brick Converter

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 125°C to ensure reliable long-

term operation of the converters. Contact Power-

One for the complete list of the derating criteria.

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).

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

25 40 55 70 85

Ambient Temperature (Deg C)

Load Current (A)

NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM

Figure 12. HHS05Z55 Derating Curves

(@ Vin = 48Vdc, w/o supplemental heat sink)

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)

THERMAL DERATING CURVE

Vin = 48V, Orientation : Vin- to Vin +

Tested with attached (fin-type) heatsink, 0.45" height.

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

25 40 55 70 85

Ambient Temperature (Deg C)

Load Current (A)

NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM

HHS05Z55-NT

Data Rev: 01

Figure 13. HHS05Z55 Derating Curves

(@ Vin = 48Vdc, w/ supplemental 0.45” height heat sink)

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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.

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.

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:

• 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.

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48V Input, 53.7V @ 260W Half-Brick Converter

12. Mechanical Drawing

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 Millimeters

X.XX ± 0.02 X.X ± 0.5

X.XXX ± 0.010 X.XX ± 0.25

± 0.002 ± 0.05

13. Ordering Information

Options Suffixes to add to part number

Positive- no suffix required (note 1)

Remote ON/OFF

Negative - Add “N” suffix

Trim Positive - “T” suffix (required)

0.18”- Standard, no suffix required

0.145”- Add “7” suffix

Pin Length

0.110”- Add “8” suffix (note 1)

Host board Insulator Standard, no suffix required (see drawing note above)

1 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.

Pin Function

1 -Vin

2 Case

3 On/Off

4 +Vin

5 -Vo

6 -Sense

7 Trim

8 +Sense

9 +Vo