BK60C-048L-018F40H-8 - Emerson Network Power - Embedded Power

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 1 of 14

REV Description Date Approved

PR-A Preliminary Release 4/30/00

PR-B Preliminary Release 9/05/00

PR-C Remove 1.5, 2, 5V unit – misc.

updates 3/28/01 KTF

TECHNICAL REFERENCE

NOTES (TRN)

BK60C-H SERIES

HIGH EFFICIENCY

DC-DC CO NVERTER

ASTEC POWER

ANDOVER, MA

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 2 of 14

Electrical Spec if ications

Absolute Maximum Ratings

Stresses in excess of the absolute maximum ratings can cause permanent damage to the device.

These are absolute stress ratings only. Functional operation of the device in not implied at these

or any other conditions in excess of those given in the operational sections of the TRN. Exposure

to absolute maximum ratings for extended periods can adversely affect device reliability.

Table 1. Absolute Maximum Ratings

Parameter Device Symbol Min Typ Max Unit

Input Voltage:

Continuous:

Transient (100ms) All

All VI

VI, trans

-80

100 Vdc

Vdc

Operating Case Temperature All Tc -40 - 100 ºC

Storage Temperature All Tstg -55 - 125 ºC

Operating Humidity All - - - 95 %

I/O Isolation All - - - 1500 Vdc

Input Specifications

Table 2. Input Specifications

Parameter Device Symbol Min Typ Max Unit

Operating Input Voltage All VI36 48 75 Vdc

Maximum Input Current

(VI = 0 to VI,max: Io = Io,max) 018FX

025FX

033FX

II,max

3.0

4.0

5.0

Input Reflected-ripple Current

(5Hz to 20MHz: 12uH source

impedance: TA = 25 ºC.) See Figure 9.

All II-10 -mAp-p

No Load Input Power

(VI = VI,nom ) All - - - 7.5 W

Internal Input Capacitance All - - - 3.7 uF

Output Specifications

Table 3. Output Specifications

Parameter Device Symbol Min Typ Max Unit

Output Volta ge Set poi nt

(VI = VI,min to VI,max: Io = Io,max ;

TA = 25 ºC )

018FX

025FX

033FX

Vo,set

1.77

2.46

3.25

1.8

2.5

3.3

1.83

2.54

3.35

Vdc

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 3 of 14

Output Specifications (continued)

Table 3. Output Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Output Regulation:

Line (VI = VI,min to VI,max)

Load(Io = Io,min to Io,max)

Temperature (Tc = -40 ºC to +100 ºC)

All -

0.05

0.1

0.2

0.3

%Vo

Output Ripple and Noise

(Across 0. 1uF ceramic and 10uF

tantalum capacitors ) See Figure 10.

All - - - 150 mVp-p

External Load Capacitance All -

-10,000 uF

Output Current 018FX

025FX

033FX

0.5

Output Current- limit Inceptio n

(Vo = 90% Vo,set) All Io 45 - 55 A

Output Shor t-c irc uit Cur rent

(Vo = 250mV) All - - - 190 %Io,max

Efficiency

(VI = VI,nom ; Io = Io,max;

Tc = 25°C)

018FX

025FX

033FX

Switching Frequency 018FX

025FX

033FX

330

400

kHz

Dynamic Response:

(∆Io/∆t = 1A/10us; VI = VI,nom ; Tc =

70 ºC )

Load Change from Io = 50% to

75% of Io, max:

Peak Deviation

Settling Time

Load Change from Io = 50% to

25% of Io, max:

Peak Deviation

Settling Time

All

300

%Vo

usec

%Vo

usec

Turn-on Time

(Io = Io,max; Vo within 1%) All - - 2 5 msec

Output Volta ge O vers hoo t

(Io = Io,max; Tc = 70 ºC) All - - - 5 %Vo

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 4 of 14

Isolation Specifications

Table 4. Isolation Specifications

Parameter Device Symbol Min Typ Max Unit

Isolation Capacitance All - - 2300 - pF

Isolation Resistance All - - 1000 - Mohm

General Specifications

Table 5. General Specifications

Parameter Device Symbol Min Typ Max Unit

Calculated MTBF

(Io = Io,max; TA = 25 ºC)All - - TBD - hours

Weight All - - - 100(3.5) g (oz.)

Feature Specifications

Table 6. Feature Specifications

Parameter Device Symbol Min Typ Max Unit

Remote On/Off Signal Interface:

(VI = 0 to VI,max ; Open collector or

equivalent co mpatible; Signal

referenced to VI (-) terminal.)

Positive Logic – No Suffix

Low Logic – Module Off

High Logic – Module On

Negative Logic –Suffix “N”

Low Logic – Module On

High Logic – Module Off

Module Sp ecifications :

On/Off Current – Logic Low

On/Off Voltage:

Logic Low

Logic High (Ion/off = 0)

Open Collector Switch

Specifications:

Leakage Current – Logic High

(Von/off = 10V)

Output Voltage – Logic Low

(Ion/off = 1mA)

All

Ion/off

Von/off

Ion/off

Von/off

-0.7

1.0

1.2

Output Volta ge Adj us tment

Remote Sense Range

Voltage Adjustment Range All

All -

90 -

-0.5

110 V

%Vo

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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Feature Specifications (continued)

Table 6. Feature Specifications (continued)

Parameter Device Symbol Min Typ Max Unit

Output Overvoltage Clamp 018FX

025FX

033FX

Vo,clamp

2.4

3.1

3.9

2.7

3.5

4.6

Overtem per ature Shu t do wn All T c 105 110 120 ºC

Undervoltage Lockout

Turn-on Point

Turn-off Point All

All -

32 34.5

32.5 35

-V

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 6 of 14

Characteristic Curves

Figure 1. Typical Input Current vs Input Voltage.

Figure 2. 018F Efficiency vs Load Current. Figure 3. 025F Efficiency vs Load Current.

Figure 4. 033F Efficiency vs Load Current.

BK60C-048L-033F40H

Effici ency vs Outp ut Current

Tc = 25 Deg Celsius

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36 Vdc

Vin = 48 Vdc

Vin = 75 Vdc

BK60C-048L-033F40H

Input Current (Worst Case)

Tc = 25 C, Iout = 40A

0 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72

Vin (Volts)

BK60C-048L-018F40H

Effici ency vs Outp ut Current

Tc = 25 Deg Celsius

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36V dc

Vin = 48V dc

Vin = 75V dc

BK60C-048L-025F40H

Effici ency vs Outp ut Current

Tc = 25 Deg Celsius

50%

55%

60%

65%

70%

75%

80%

85%

90%

95%

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36V dc

Vin = 48V dc

Vin = 75V dc

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 7 of 14

Characteristic Curves (continued)

Figure 5. Typical Output Voltage Startup Figure 6. Typical Output Ripple (033F)

Vi = Vi,nom, Io = Io,max. Vi = Vi,nom, Io = Io,max.

Figure 7. Typical Dynamic Response (033F) Figure 8. Typical Dynamic Response (033F)

Step Load Change from 50% to 75% Io,max Step Load Change from 50% to 25% Io,max

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 8 of 14

Test Configurations

Note: Measure input reflected-ripple current with a simulated source inductance (Ltest) of 12 uH. Capacitor

Cs offsets possible battery impedance. Measure current as shown above.

Figure 9. Input Reflecte d-ripple Test Setup.

Note: Use a 0.1 uF ceramic capacitor and a 10 uF tantalum capacitor. Scope measurement should be made

using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in. ) from module.

Figure 10. Peak-to-Peak Output Noise Measurement Test Setup.

BATTERY Cs 220 uF

ESR < 0.1 OHM

@ 20 ºC, 100 kHz

Ltest

12 uH

33 uF

ESR < 0.7 OHM

@ 20 ºC, 100 kHz

Vi(+)

Vi(-)

TO OSCILLOSCOPE

Vo(+)

Vo(-)

RESISTIVE

LOAD

10 uF0.1 uF SCOPE

COPPER STRIP

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 9 of 14

Feature Descriptions

Output Overvoltage Clamp

The output overvoltage clamp consists of a separate control loop, independent of the primary

control loop. This control loop has a higher voltage setpoint than the primary loop. In a fault

condition the converter goes into “Hiccup Mode”, and the output overvoltage clamp ensures that

the output voltage does not exceed Vo,clamp,max. This secondary control loop provides a

redundant voltage-control that reduces the risk of output overvoltage.

Output Current P rotection

To provide protection in an output overload or short circuit condition, the converter 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 goes into “Hiccup Mode”, causing the output current

to be limited both in peak and duration. The converter operates normally once the output current

is brought back into its specified range.

Enable (Optional)

Two enable option are available. Positive Logic Enable, no suffix, and Negative Logic Enable,

suffix “N”. Positive Logic Enable turns the converter on during a logic-high voltage on the enable

pin, and off during a logic-low. Negative Logic Enable turns the converter off during a logic-high

and on during a logic-low.

Output Voltage Adjustment

Output voltage adjustment is accomplished by connecting an external resistor between the Vadj

Pin and either the +Sense or –Sense Pins.

With an external resistor between the Vadj Pin and -Sense Pin (Radj-down) the output voltage set

point (Vo,adj) decreases (see Figure 11). The following equation determines the required external

resistor value to obtain an adjusted output voltage:

Where Radj-down is the resistance value and %Vo,adj is the percent change in the output voltage.

With an external resistor between the Vadj Pin and +Sense Pin (Radj-up) the output voltage set

point (Vo,adj) increases (see Figure 12). The following equation determines the required external

resistor value to obtain an adjusted output voltage:

Where Radj-up is the resistance value and %Vo,adj is the percent change in the output voltage.

Radj_down .

100

,%Vo adj 2 koh

Radj_up .

Vo ( ),

100 %Vo adj

1.225%Vo adj

,100 .

2 %Vo adj

,%Vo adj koh

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 10 of 14

Figure 11 . Circuit Configuration to Decrease Output Voltage.

Figure 12 . Circuit Configuration to Increase Output Voltage.

+Vin

-Vin

Case

Enable

-Vout

+Vout

-Sense

+Sense

Vadj

Rload

Radj-down

+Vin

-Vin

Case

Enable

-Vout

+Vout

-Sense

+Sense

Vadj

Rload

Radj-up

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 11 of 14

Thermal Considerations

The power converter operates in a variety of thermal environments: however, sufficient cooling

should be provided to help ensure reliable operation of the converter. Heat-dissipating

components are thermally coupled to the case. Heat is removed by conduction, convection and

radiation to the surrounding environment. Proper cooling can be verified by measuring the case

temperature.

Heat Transfer Characteristics

Increasing airflow over the converter enhances the heat transfer via convection. Figure 13 shows

the maximum power that can be dissipated by the converter without exceeding the maximum

case temperature versus local ambient temperature (TA) for natural convection through 2.0 m/s

(400 ft/min).

Systems in which these converters are used generate airflow rates of 0.25 m/s (50 ft/min) due to

other heat dissipating components in the system. Therefore, the natural convection condition

represents airflow rates of approximately 0.25 m/s (50 ft/min). Use of Figure 13 is shown in the

follo wing ex ample.

Example

What is the minimum airflow required for an 033F40H operating at 48 V, an output current of 25

A, and maximum ambient temperature of 55 ºC.

Solution:

Given: Vi = 48 V, Io = 25 A, TA = 55 ºC.

Determine PD (Figure 16): PD = 13 W.

Determine airflow (Figure 16): v = 1.0 m/s (200 ft/min)

Figure 13. Forced Convection Power Derating

BK60C SERIES

Power Derating Curve

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110

Ambient Temperature (ºC)

Nat. Conv.

0.5 m/s (100 ft/min)

1.0 m/s (200 ft/min)

2.0 m/s (400 ft/min)

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 12 of 14

Thermal Considerations (continued)

Figure 14. 018F Pwr. Diss. vs Load Current. Figure 15. 025F Pwr. Diss. vs Load Current.

Figure 16. 033F Pwr. Diss. vs Load Current.

BK60C-048L-018F40H

Dissipation vs Output Current

Tc = 100 Deg Cel sius

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36 Vd c

Vin = 48 Vd c

Vin = 75 Vd c

BK60C-048L-033F40H

Dissipation vs Output Current

Tc = 100 Deg Cel sius

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36 Vd c

Vin = 48 Vd c

Vin = 75 Vd c

BK60C-048L-025F40H

Dissipation vs Output Current

Tc = 100 Deg Cel sius

0 5 10 15 20 25 30 35 40

Output Current (Amps)

Vin = 36 Vd c

Vin = 48 Vd c

Vin = 75 Vd c

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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Outline Drawing

Tolerances: x.xx +/- 0.02 in (x.x +/- 0.5mm)

x.xxx +/- 0.010 in (x.xx +/- 0.25mm

Pin Assignment

1. -Vin

2. Case

3. Enable (on/off)

4. + Vin

5. - Output

6. - Sense

7. Trim

8. + Sense

9. + Output

All pins are 0.040 diameter except pins 5 & 9 which are 0.080 diameter.

Technical Reference Notes (TRN) BK60C-H Series

36 Vdc to 75 Vdc Inputs, 150 W

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ASTEC POWER - Andover 14 of 14

Table 8 Part Numbers.

Model Designation Part Number

018FN BK60C-048L-018F40HN

025FN BK60C-048L-025F40HN

033FN BK60C-048L-033F40HN

018F BK60C-048L-018F40H

025F BK60C-048L-025F40H

033F BK60C-048L-033F40H

Table 9. Options

Suffix Option

N Negative Logic Enable

No Suffix Positive Logic Enable

-6 3.7 mm Pin Length

-8 2.8 mm Pin Length