FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Features Applications * * * * * Base station amplifiers Distributed power architectures Telecommunications equipment LAN/WAN applications Data processing applications * Low profile - 12.7 mm height * Input-to-output isolation: 1500VDC * Basic insulation * High efficiency - up to 93% at full load * Tight dynamic load response * Output overcurrent protection * Output overvoltage protection * Overtemperature protection * Remote sense * Remote on/off (primary referenced), positive or negative logic option * Output voltage trim adjust, positive or negative option * UL 1950 Recognition, CSA 22.2 No. 950-95 certification, TUV IEC950 Description The FHS Series power modules are dc-dc converters that operate over an input voltage range of 36 to 75VDC and provide a regulated DC output voltage at up to 18 amps of output current. The output is fully isolated from the input, which allows a positive or negative output configuration. The open-frame module is constructed with a two-board approach. The power devices are connected to an Insulated Metal Substrate (IMS) base plate, which provides very low thermal impedance. A separate PCB is populated with the control circuitry and is physically isolated from the hotter IMS board. This approach allows for lower component temperatures, hence increased reliability. The standard feature set includes remote on/off, 1 remote output voltage sensing, negative logic output trim (optional positive logic output trim available ), input under and overvoltage lockout and overtemperature shutdown with hysteresis. Model Selection Model FHS18Z28 Input voltage (VDC) 36-75 Input current, Max, (ADC) 16 Output voltage (VDC) 28 This product is intended for integration into end-use equipment. equipment should be followed. 1 Output rated current I rated, (ADC) 18 Output Ripple/Noise (mV p-p) 150 Typical Efficiency @ I rated, (%) 93 All the required procedures for CE marking of end-use Consult factory for availability. REV. JUN 09, 2004 Page 1 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect longterm reliability and cause permanent damage to the converter. Parameter Conditions/Description Input voltage Continuous Transient, 100ms Operating Temperature Baseplate Temperature Min Storage Temperature ON/OFF Control Voltage Max Units 75 100 VDC VDC -40 110 C -55 125 C 7 VDC 504 W Referenced to -Vin Output Power Environmental and Mechanical Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Shock Halfsine wave, 3 axes 50 g Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 g Weight Nom Max 5.4/152 Water Washing Standard process Yes MTBF Per Bellcore TR-NWT-000332 1,000 Units Oz/g kHrs Isolation Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Insulation Safety Rating Nom Max Units Basic Isolation Voltage Input to output, input to base plate 1500 VDC Isolation Voltage Output to base plate 1500 VDC 10 MOhm Isolation Resistance Isolation Capacitance 1000 pF Safety Regulatory Compliance Safety Agency Underwriters Laboratories TUV product Service CB report Standard Approved To: UL60950/CSA60950-00 TUV EN60950:2000 IEC60950:1999 Marking cULus TUV PS Baurt mark N/A. REV. JUN 09, 2004 Page 2 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter 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 32 34 36 VDC 30 32 34 VDC 80 84 VDC 1 Turn-On Input Voltage Ramping Up Turn-Off Input Voltage Ramping Down 1 Turn On/Off Hysteresis 1 2 1.5 76 VDC Input over voltage protection Turn-Off threshold Input Reflected Ripple Current Full Load, 12H source inductance 2 BW=20MHz 60 mAP-P Inrush Transient Vin=Vin.max 0.1 As 2 Refer to Fig. 2 for waveform. Refer to Fig. 10 for Test measurement circuit. Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Output Voltage Setpoint Accuracy Output Current Line Regulation Load Regulation Output Temperature Regulation 1,2 Ripple and Noise, DC to 20MHz Dynamic Regulation Peak Deviation Settling Time 3 Output Turn-On Time Admissible Load Capacitance Backdrive Protection Switching Frequency 1 2 3 Conditions/Description Vin=Vin.nom, Full Load Vin.min to Vin.max, IRATED-MAX Vin=Vin.nom, 10% to 100%Irated O O TBaseplate = -40 C to +110 C) Over line and load Tamb= 0C to 85C 50-75% load step change to 1% error band To 97% VoNOM IRATED, resistive load, VinNOM No damage to converter Min 27.44 1.8 Nom 28 0.2 0.5 Refer to fig. 3 REV. JUN 09, 2004 Page 3 of 11 Units Vdc A %Vout %Vout O %Vo/ C mVP-P mVRMS 800 750 25 100 mV s ms F/A 150 30 700 250 15 Yes 400 At Iout<Iout-min, the output may contain low frequency component that exceeds ripple specifications. See Figure 11 for test setup Max 28.56 18 0.5 1.0 0.02 kHz FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Protections Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Nom Max Units 29 A 15 ARMS 140 % Vout 130 C Overcurrent Protection Type Non-latching, auto-recovery Threshold 20 Short Circuit Hiccup-type Overvoltage Protection Type 23 1 2 Clamping / Hiccup, auto-recovery Threshold All Vin and Io conditions 115 Overtemperature Protection Type Non-latching, auto-recovery Threshold Baseplate temperature 120 Recovery 1 C 90 Refer to Fig. 4 2 Refer to Fig. 5 Feature Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Nom Max Units 0.8 1 7 5 VDC mADC VDC VDC 7 5 0.8 1 VDC VDC VDC mADC 5 %Vout 1 Negative Logic (-N suffix) Converter ON Source Current Converter OFF Open Circuit Voltage Positive Logic (no suffix) Converter ON Open Circuit Voltage Converter OFF Source Current ON/OFF 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 0.5 2.5 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 Remote Sense 2 Remote Sense Headroom Output Voltage Trim 2 Trim Up Vin = Vin-nom, Iout=Irated 10 % Trim Down Vin = Vin-nom, Iout=Irated -10 % 1 Additional information located on page 6. 2 Vout can be increased up to 10% via the sense leads or up to 10% via the trim function, however total output voltage trim from all sources should not exceed 10% of Vout. REV. JUN 09, 2004 Page 4 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Efficiency Characteristics Turn-on Waveform FHS18Z28. EFF. VS. LOAD 100 95 90 EFFICIENCY % 85 80 75 70 65 60 55 50 45 EFF.(36V) EFF.(48V) EFF.(75V) 40 10 20 30 40 50 60 LOAD % 70 80 90 100 Figure 1. FHS18Z28 Efficiency vs. Output Load Figure 3. Output Voltage turn-on FHS18Z28 Conditions: Vin=48V, Load: full, , Co=none (Note: monotonic rise characteristic) Input Turn-On / Off Operation Input Current vs. Voltage Short Circuit Operation 17 16 15 14 13 Input Current (A) 12 11 10 9 8 7 6 Turn On Voltage Threshold 5 4 3 Turn Off Voltage Threshold 2 1 0 0 10 20 30 40 50 60 70 Input Voltage (V) Figure 2. FHS18Z28 Input UVLO Characteristics 80 Figure 4. Output Current with Shorted Output Pins, Vin = 75Vdc, Scale is 20Amp/Div. (Actual amplitude: 10.8ARMS) Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation. REV. JUN 09, 2004 Page 5 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter that the capacitors do not substitute the filtering required by the load. OVP Operation Shutdown Feature Description The ON/OFF pin in the FHS Series converters functions as a normal soft shutdown. It is referenced to the -Vin pin or signal ground (see Figure 6). With the positive logic, when the ON/OFF pin is pulled low, the output is turned off and the unit exhibits very low input current. 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. 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. Figure 5. Output Voltage Under OVP Condition, Vin = 75Vdc, Min Load. Scale is 10V/Div. (Actual amplitude: 34VPEAK) The user should avoid connecting a resistor between the ON/OFF pin and the +Vin pin. Typical Application Figure 6 shows the recommended connections for the FHS Series converter. FHSXXZX Fuse +Vi +Vo Note: If the ON/OFF pin is not used, it can be left floating (positive logic), or connected to the -Vin pin (negative logic). +Sense C1 On/Off Trim C2 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. C3 -Sense -Vi -Vo Remote Sense Figure 6. Typical Application of the FHS Series FHS Series converters do not require any external components for proper operation. However, if the distribution of the input voltage to the converter contains significant inductance, the capacitor C1 may be required to enhance performance of the converter. A minimum of a 100F 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 10F tantalum and a 1F ceramic capacitors connected directly across the output pins of the converter. Note The FHS Series converters have 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 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 Figures 6, 7 & 8. If the remote sense feature is not to be used, the sense pins should be connected locally. The +Sense (or Vsense) pin should be connected to the +Vout pin directly at the output of the converter and the -Sense (Vsense RTN) pin should be connected to the -Vout pin directly at the output of the converter. REV. JUN 09, 2004 Page 6 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter If sense pins are not connected to the load, or the respective output pins, the converter will not be damaged, but may not meet the output voltage regulation specifications. Output Voltage Trim The trim feature allows the user to adjust the output voltage from the nominal value. This can be used to compensate for distribution drops, perform margining in production, or accommodate other requirements when output voltage needs to be adjusted from the nominal value. There are two trim options available. Optional Positive Trim (suffix -T) 4.17Vonom(100 + %) 510 Radj - up = - - 42.2) k % % 510 Radj - down = - 42.2) k % where % is the output voltage change expressed in percent of the nominal output voltage, Vout. (example: to trim up or down by 5% of Vo nominal, % = 5) Negative Logic Trim (no P/N suffix) The negative logic trim unit trims down with a resistor from Trim to Vsense, and trims up with a resistor from Trim to VsenseRTN (see figure 8). The -T option units trim up with a resistor from the TRIM pin to the (+)Vsense pin and trim down with a resistor from the TRIM pin to the (-)Vsense RTN pin as shown in Figure 7. Figure 8. FHS Series Negative Trim Schematic The equations below determine the trim resistor value required to achieve a new output voltage. 2.49 Radj - up = - 20 k 2 . 49 /( 1 . 225 * 54 . 4 /( Voadj - 1 . 225 )) - 1 Figure 7. FHS Series Positive Trim Schematic (-T) The equations below determine the trim resistor value required to achieve a % change in the output voltage. 54.4 Radj - down = - 20 k 54 . 4 /( 2 . 03 ( Voadj - 1 . 225 )) - 1 where Voadj is the desired output voltage REV. JUN 09, 2004 Page 7 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter 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 FHS Series converters will trim down further than the 10% limit. In general, this is permissible. The user must confirm that the results are acceptable in the application. 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 FHS 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. * Safety Considerations Thermal Considerations FHS Series converters are designed for natural or 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 long-term operation of the converters. Contact Power-One for the complete list of the derating criteria. Figure 9 shows the maximum output current of the FHS Series at different ambient temperatures under both natural and forced (longitudinal airflow direction, from pin 1 to pin 4) convection. The FHS Series converters have no internal fuse. The external fuse must be provided to protect the system from catastrophic failure as shown in Figure 6. The fuse with a rating not greater than 20A is recommended. The user can select a lower rating fuse based upon the highest inrush transient at the maximum input voltage and the maximum input current of the converter, which occurs at the minimum input voltage. 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 FHS Series 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 REV. JUN 09, 2004 Page 8 of 11 THERMAL DERATING CURVE FHS18Z28 Vin = 54V, Orientation : Vin- to Vin + Data Rev: 01 20 15 Load Current (A) The FHS Series converters feature 1500 Volt DC isolation from input to output. The input-to-output resistance is greater than 10M. 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. 10 5 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM 0 25 40 55 70 Ambient Temperature (Deg C) Figure 9. FHS18Z28 Derating Curves 85 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Test Configurations To improve accuracy and repeatability of output ripple and noise measurements, Power-One utilizes the test setup shown in Figure 11. TO OSCILLOSCOPE COPPER STRIPS (2 to 3 inches) Cs 220 uF ESR < 0.1 OHM @ 20 C, 100 kHz BATTER Y DUT Vi(+) Ltest 12 uH +Vo1 22 uF ESR < 0.7 OHM @ 20 C, 100 kHz 0.1uf ceramic 10uF Tantalum SCOPE LOAD1 -Vo1 Vi(-) . Figure 11. Output Ripple and Noise Measurement Test Setup Figure 10. Input Reflected Ripple Current Test Setup Note: Measure input reflected-ripple current with a simulated inductance (Ltest) of 12 H. Capacitors offset possible battery impedance. Measure current as shown above. 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 and a 10F tantalum capacitors, and the load are located 2-3" away from the converter. REV. JUN 09, 2004 Page 9 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Conducted EMI (Line) + FC100V20A FHS18Z28 Vin+ Vo1 LOAD1 VIN C1 C2 C3 C4 -Vo1 - VinGND CASE C5 Ref. Des C1, 2 C3 C4 C5, 6 F1 C6 Description 0.47F @100V MLC Capacitor (1812) 100F @ 100V Alum. Electrolytic Capacitor 22F@ 100V Alum. Electrolytic Capacitor 0.01F MLC Capacitor FC100V20A Input Filter Module Manufacture AVX or Equivalent (Equiv.) Nichicon NRSZ Series or Equiv. United Chemicon KMG Series or Equiv. AVX or Equiv. Power-One Figure 12. Recommended Filter Configuration (to meet CISPR 22 Class A for Conducted Emissions) The above circuit and component values are offered as a guide. Performance results vary depending on circuit layout techniques, proximity to noise emitting components and conductor traces and other variables of the specific application. Verification of compliance must be performed. Figure 13. Measured Performance Characteristics CISPR 22 Class A for Conducted Emissions Vin=48Vdc, Io=18Amps REV. JUN 09, 2004 Page 10 of 11 FHS DC-DC Series Data Sheet 500-Watt, Full-Brick Converter Mechanical Drawing Mechanical Tolerances Pin Inches X.XX 0.020 X.XXX 0.010 Millimeters X.X 0.5 X.XX 0.25 0.002 0.05 Ordering Information Options Suffixes to add to part number Remote ON/OFF Positive- Standard, no suffix required Negative- Add "N" suffix Trim Negative- No suffix required Positive - Add "T" suffix Pin Length 1 0.18"- Standard, no suffix required 0.11"- Add "8" suffix 1 0.15"- Add "9" suffix 1 Pin 1 2 3 4 5, 6, 7 8,9,10 11 12 13 14 15 Function -Vin +Vin Sgnd On/off Vout -Vout -Sense +Sense Trim NU IOG Notes: 1 Consult factory for availability. NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not 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. JUN 09, 2004 Page 11 of 11