HHS60 DC/DC Series Data Sheet 48V Input, 60-Amp Half-Brick Converter Features * * * * * * * * * * * * * * * Applications * * * * Distributed Power Architectures Telecommunications Equipment LAN/WAN Data Processing * * Standard 1/2-brick footprint and pinout 100V/100ms input voltage surge Low Profile (12.7mm) Input-to-output isolation: 1500VDC Basic insulation High efficiency - to 90% at full load Start-up into high capacitive load Start-up into pre-biased loads Back-drive protection Remote sense Low conducted and radiated EMI Output overcurrent protection Output overvoltage protection Overtemperature protection Remote On/Off (primary referenced), positive or negative logic Output voltage trim adjust, positive or negative UL 1950 Recognized, CSA 22.2 No. 950-95 certification, TUV IEC95 Description The HHS60 series of high-density, single-output DC/DC converters is ideal for telecom and datacom systems that require low voltage at high current in an industry-standard, half-brick footprint. Highly efficient topology and thermally-optimized construction allow the units to provide high output current in the system over a wide operating temperature range while still maintaining a safe guardband for component electrical and thermal ratings. The addition of an external heatsink increases the capacity of the unit. The HHS60 employs 100% surface-mount components for consistency and reliability in our production process, and is available in four standard output voltages from 1.5 V to 3.3 V. Model Selection Model HHS60ZE HHS60ZD HHS60ZB HHS60ZA Input Voltage VDC 36-75 36-75 36-75 36-75 Input Current, 1 Max ADC 6.5 4.9 3.6 3.1 Output Voltage VDC 3.3 2.5 1.8 1.5 Output Rated Current I rated ADC 60 60 60 60 Output Ripple/Noise, mV p-p 150 150 150 150 Typical Efficiency @ I rated % 90 89 86 85 This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. 1 specified @ VIN min. REV. OCT 24, 2003 Page 1 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-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 Min Max Units Input voltage Continuous 75 VDC Operating Temperature Transient, 100ms Baseplate -40 100 100 VDC C -55 125 C VDC Storage Temperature ON/OFF Control Voltage Referenced to -Vin 50 Environmental, Mechanical, & Reliability Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Min Operating Temperature Operating Humidity Storage Humidity Shock Sinusoidal Vibration Weight Water Washing MTBF (Calculated) Baseplate Relative humidity, non-condensing Relative humidity, non-condensing 1/2 Sine, 6ms, 3 axes GR-63-CORE, Section 5.4.2 -40 Dimensions (overall) Nom Max Units 100 95 95 C % % g 50 1 3.3/92 Yes 1,200 Oz/g 2.28 (57.9) x 2.4 (61) x 0.5 (12.7) in (mm) Standard process Per Bellcore TR-NWT-000332 O (50% stress, 40 C) kHrs Isolation Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Insulation Safety Rating Isolation Voltage Isolation Resistance Isolation Capacitance Conditions/Description Min Input/Output Input to Baseplate Output to Baseplate 1500 1500 1500 10 Input to Output Nom Basic Max Units VDC VDC VDC M pF 500 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. OCT 24, 2003 Page 2 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Input Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. 1 2 Parameter Input Voltage Turn-On Input Voltage Turn-Off Input Voltage Input Reflected Ripple Current Conditions/Description Continuous 1 Ramping Up 1 Ramping Down Full Load, 12H source inductance 2 BW=20MHz Inrush Transient Vin=Vin.max Min 36 33 31 Nom 48 34 32 Max 75 35 33 2.6 50 Units VDC VDC VDC mA p-p 0.1 1 As 2 Refer to Fig. 9 for waveform. Refer to Fig. 18 for Test circuit. / measurement method? Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Output Voltage Set-point Accuracy: Output Current Line Regulation: Load Regulation: Output Temperature Regulation 1,2 Ripple and Noise, DC to 20MHz Dynamic Regulation Peak Deviation Settling Time Peak Deviation Settling Time Turn-On Time (turn-on via application of Vin) Turn-On Time (turn-on via ON/OFF signal) Rise Time Turn-on Overshoot Admissible Load Capacitance Backdrive Protection Switching Frequency 1 2 Conditions/Description Vin=48Vdc, Full Load Min -1.2 Irated (Vin= 36V to 75V) 3* Max 1.2 Units %Vout 60 0.2 ADC %Vout Vin=Vnom, Io,min to Io,max 0.2 %Vout (TBaseplate) = -40 C to +100 C) Over line and load Tamb= 0C to 85C 75-100-75% load step change, to 1% error band di/dt=0.1A/s 75 15 0.03 150 40 %/ C mV p-p mVRMS 6 200 8 500 6 125 15 8 400 20 %Vout s %Vout s 12 15 ms 1 10 5 ms %Vout 15,000 F di/dt=1A/s Time from Vin=UVLO to regulation band Time from ON/OFF signal to regulation band from 10 to 90% of Vout.nom Over all input voltage, load, and temperature conditions Irated, Nom Vin No damage to converter Nom Yes 400 At Iout<Iout.min, the output may contain low frequency component that exceeds ripple specifications. See Figure 12 for test setup REV. OCT 24, 2003 Page 3 of 12 ms kHz HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Protection Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Parameter Conditions/Description Overcurrent Protection Type Min Nom Max Units 1 Non-latching - Hiccup mode, auto-recovery Threshold 64 Short Circuit Overvoltage Protection Type 78 Adc 30 ARMS 140 Vdc 115 C 2 Clamping, auto-recovery Threshold Vin = Vin.nom, Iout=Irated 120 Overtemperature Protection Type Non-latching, auto-recovery Threshold Baseplate temperature 105 Recovery 1 110 C 90 See Fig. 13 2 See Fig. 14 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 10 5 1.8 1 VDC VDC VDC mADC 10 %Vout ON/OFF Negative Logic (-N suffix) ON/OFF signal is low or the pin is connected to -Vin - converter is ON Von/off in reference to -Vin Converter ON Source Current Converter OFF Open Circuit Voltage Positive Logic (no suffix) ON/OFF pin is connected to -Vin Von/off in reference to -Vin ON/OFF pin is floating Converter ON Open Circuit Voltage Converter OFF Source Current -0.5 0.5 3.5 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 3.5 -0.5 0.5 Remote Sense 1 Remote Sense Headroom Output Voltage Trim 1 Trim Up Vin = Vin.nom, Iout=Irated 10 Vdc Trim Down Vin = Vin.nom, Iout=Irated -10 Vdc 1 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. OCT 24, 2003 Page 4 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter 95 95 90 90 85 85 Efficiency,% Efficiency,% Efficiency Characteristics 80 75 70 36V 48V 75V 36V 48V 75V 65 0 10 20 30 40 50 60 0 Output current, A 95 90 85 80 75 70 36V 48V 75V 65 0 10 20 30 40 Output current, A 50 60 Figure 2. HHS60ZD (2.5V) Efficiency Curves 95 90 85 80 75 70 36V 48V 75V 65 0 10 20 30 40 50 10 20 30 40 Output current, A 50 Figure 4. HHS60ZA (1.5V) Efficiency Curves Figure 1. HHS60ZE (3.3V) Efficiency Curves Efficiency, % 75 70 65 Efficiency,% 80 60 Output current, A Figure 3. HHS60ZB (1.8V) Efficiency Curves REV. OCT 24, 2003 Page 5 of 12 60 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Power Derating Characteristics THERMAL DERATING CURVE THERMAL DERATING CURVE HHS60ZE HHS60ZB Vin = 54V, Orientation : Vin- to Vin + Data Rev: 01 Vin = 54V, Orientation : Vin- to Vin + 60 Data Rev: 01 60 50 50 30 Load Current (A) Load Current (A) 40 40 30 20 20 10 10 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM NC (25 - 35 LFM) 0 100 LFM 200 LFM 300 LFM 40 55 70 85 25 40 Ambient Temperature (Deg C) 55 70 85 Ambient Temperature (Deg C) Figure 5. HHS60ZE (3.3V) Derating Curves Figure 7. HHS60ZB (1.8V) Derating Curves THERMAL DERATING CURVE THERMAL DERATING CURVE HHS60ZD HHS60ZA Vin = 54V, Orientation : Vin- to Vin + Data Rev: 01 Vin = 54V, Orientation : Vin- to Vin + 70 70 60 60 50 50 Load Current (A) Load Current (A) 400 LFM 0 25 40 30 20 Data Rev: 01 40 30 20 10 10 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM NC (25 - 35 LFM) 0 100 LFM 200 LFM 300 LFM 400 LFM 0 25 40 55 70 85 Ambient Temperature (Deg C) 25 40 55 70 Ambient Temperature (Deg C) Figure 6. HHS60ZD (2.5V) Derating Curves Figure 8. HHS60ZA (1.5V) Derating Curves REV. OCT 24, 2003 Page 6 of 12 85 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Output Ripple and Noise UVLO Operation Input Current vs. Voltage 7 6.5 6 5.5 Input Current (A) 5 4.5 4 Turn On Voltage Threshold 3.5 3 2.5 Turn Off Voltage Threshold 2 1.5 1 Figure 11. HHS60ZE Output Ripple Characteristics 0.5 Vin=48V and Iout=3A 0 0 10 20 30 40 50 60 70 80 Input Voltage (Vdc) Figure 9. HHS60 Input UVLO Characteristics To improve accuracy and repeatability of ripple and noise measurements, Power-One utilizes the test setup shown in Figure 12. COPPER STRIPS (2 to 3 inches) DUT Turn-on Characteristics +Vo1 0.1uf ceramic 10uF Tantalum SCOPE LOAD1 -Vo1 Figure 12 Output ripple and 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 and a 10F tantalum capacitors, and the load are located 2-3" away from the converter. Figure 10. Output Voltage turn-on HHS60ZE Conditions: Vin=48V, Load: full, , Co=none (Note: monotonic rise characteristic) REV. OCT 24, 2003 Page 7 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Typical Application Short Circuit Operation Figure 15 shows the recommended connections for the HHS60 Series converter. HHS60ZX Fuse +Vi +Vo +Sense C1 On/Off Trim C2 C3 -Sense -Vi -Vo Figure 15. Typical Application of the HHS60 Series Figure 13 Output current with shorted output pins, Vin = 48Vdc, Scale is 20Amp/Div. Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation. 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 14 shows operation of the converter under an overvoltage condition. The HHS60 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 for the HHS60 series. If the magnitude of the inrush current needs to be limited, for suggestions see the "Inrush Current Control Application Note" on the Power-One website at www.power-one.com. For output decoupling we recommend using one 10F tantalum and one 1F ceramic capacitors connected directly across the output pins of the converter. Note, that the capacitors do not substitute the filtering required by the load. Shutdown Feature Description The ON/OFF (# 3) pin of the HHS60 Series converters are referenced to the -Vin (# 1) pin (see Figure 5). Both negative and positive logic models are available. 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. Figure 14 Output Voltage of an HHS60ZE Under a Forced Overvoltage Condition, Vin=75V, Min Load, Co=none 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. REV. OCT 24, 2003 Page 8 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter 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. Negative Trim (No P/N suffix) All HHS60 negative-trim models trim up with a resistor connected from the TRIM (#7) pin to the (-) Sense (#6) pin and trim down with a resistor from the TRIM pin to the (+) Sense (#8) pin as shown in Figure 16. 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 actually 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). Remote Sense The HHS60 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 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 Figures 16 & 17. Figure 16. HHS60 Series Negative Trim Schematic The following equation determines the required external resistor value to obtain an output voltage change of %. Vo*(100-%)-122.5 Rtrim-dn = R1*(--------------------------- ) - R2 K Vo*% 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, but may not meet the output voltage regulation specifications. 122.5*R1 Rtrim-up = (------------- - R2) K Vo*% Where R1 and R2 are constants from the table below 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 in the HHS60 Series. REV. OCT 24, 2003 Page 9 of 12 Model HHS60ZA HHS60ZB HHS60ZD HHS60ZE R1 (k) 0. 223 0.474 1.039 4.220 R2 (k) 0.15 1 3.92 5.11 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter increase shall not exceed the limits defined within the "Features" section above. Optional Positive-Trim (-T, P/N suffix) The trim feature allows the user to adjust the output voltage from its nominal value. The HHS60 positive-trim (-T) models trim 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 the Figure 17. 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 Safety Considerations The HHS60 Series converters feature 1500 Volt DC isolation from 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. Figure 17. HHS60 Series Positive Trim Schematic The equations below determine the trim resistor value required to achieve a V change in the output voltage. 100 Rtrim-dn = (-------- - 2) k % In order for the output of the HHS60 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: Vo*(100+%) (100+2*%) Rtrim-up = (-------------------- - ------------------) k 1.225*% % where V% is the output voltage change expressed in percent of the nominal output voltage, Vout. 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. The HHS60 Series converters have no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 15. Refer to the "Input Fuse Selection for DC/DC converters" application note on www.powerone.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 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. * 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 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 REV. OCT 24, 2003 Page 10 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter voltages. The entire system, including the HHS60 converter, must pass a dielectric withstand test for Reinforced insulation. Design of this type of systems requires expert engineering and under-standing of the overall safety requirements and should be performed by qualified personnel. Test Setup 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 Thermal Considerations Vi(-) The HHS60 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 120C to ensure reliable longterm operation of the converters. Figure 18. 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 The graphs in Figures 5 thru 8 show the maximum output current of the HHS60 Series converters at different ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4). REV. OCT 24, 2003 Page 11 of 12 HHS60 DC/DC Series Data Sheet 48Vdc Input, 60-Amp Half-Brick Converter Mechanical Drawing PIN 1 FUNCTION -Vin 2 Case Pin 3 On/Off 4 +Vin 5 -Vo 6 -Sense 7 Trim 8 +Sense 9 +Vo Tolerances: .xx + .020 (.5) .xxx + .010 (.25) Pin Diameter + 0.002 (.05) Ordering Information Options Trim P/N Suffixes Positive (Industry std) - Add "T" suffix Negative - no suffix required Positive - no suffix required Negative - Add "N" suffix 0.18"- Standard - no suffix required 1 0.11"- Add "8" suffix 1 0.15"- Add "9" suffix Remote ON/OFF Pin Length Notes 1 Consult factory for available options. 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. OCT 24, 2003 Page 12 of 12