AV45C

AV 4 5 C Q u a r t e r - b r i c k S e r i e s Te c h n i c a l R e f e r e n c e N o t e s 1.5V, 1.8V, 3.3V, 5V Single Output 48V Input, 100W DC-DC Converter (Rev01) TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -1Publishing Date: 20020621 AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Introduction The AV45C quarter-brick series comes in a industry standard quarter-brick package of 1.45" x 2.28" x 0.5" and footprint, and incorporates the super high efficiency up to Design Features ! ! ! ! ! ! ! ! High Efficiency High power density Low output noise Input under-voltage lockout CNT function Trim function Remote sense Output short circuit protection Output current limiting Output over-voltage protection Overtemperature protection High input-output isolation voltage 90%(@5Vout), and high power density up to 60.5W/in3. The input range is 36V-75V, and input is fully isolated from output and the isolation voltage is 1500Vdc. The typical efficiencies are 90% for the 5V output, 89% for the 3.3V output, 85% for the 1.8V and 1.5V output. ! ! ! Designed using a synchronous rectification topology, AV45C series incorporates simple structure, good electrical performance and high reliability. Standard features include input LVP, output OVP, OCP, short circuit protection, and over-temperature protection. ! Options ! ! Heat sink available for extended operation. Choice of CNT logic configuration. The AV45C quarter-brick series is designed to meet CISPR22, FCC Class A, UL, TUV, and CSA certifications. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -2www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Typical Application Fuse* +Vin CNT C1* Trim -Vo -Vin -S C3 C2 Load +S +Vo Vin Fuse*: Use external fuse ( fast blow type ) for each unit. 5V output 3.3V output 1.8V output 1.5V output 10A (Pout=100W) 8A (Pout=66W) 5A (Pout=36W) 5A (Pout=30W) C1*: Recommended input capacitor C1 -20 oC ~ +100 oC : 100µF/100V high frequency aluminum electrolytic capacitor for 1.5Vout & 1.8Vout 220µF/100V high frequency aluminum electrolytic capacitor for 3.3Vout & 5Vout -40 oC ~ +100 oC : 220µF/100V high frequency aluminum electrolytic capacitor for 1.5Vout & 1.8Vout 470µF/100V high frequency aluminum electrolytic capacitor for 3.3Vout & 5Vout C2*: Recommended output capacitor C2 -20 oC ~ +100 oC : 1000µF/10V (high frequency aluminum electrolytic capacitor) -40 oC ~ +100 oC : for this temperature, use two pieces of 1000µF/10V capacitor in parallel or one 2200µF high frequency aluminum electrolytic capacitor. C3: Recommended 1µF/10V ceramic type capacitor Note: The AV45C modules can not be used in parallel mode directly!! There is no minimum load requirement for the AV45C series modules. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -3www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Block Diagram +Vin +Vout -Vin -Vout +Sense Trim CNT -Sense Ordering Information Model Number Input Current Input Voltage CNT Logic Output Current Ripple (mV p-p) Noise (mV p-p) Efficiency typ Pin Length mm(inch) AV45C-048L-050F20HA AV45C-048L-050F20HAN AV45C-048L-033F20HA AV45C-048L-033F20HAN AV45C-048L-018F20HA AV45C-048L-018F20HAN AV45C-048L-015F20HA AV45C-048L-015F20HAN 3.3A 3.3A 2.05A 2.05A 1.25A 1.25A 1.0A 1.0A 36-75V 36-75V 36-75V 36-75V 36-75V 36-75V 36-75V 36-75V Positive Negative Positive Negative Positive Negative Positive Negative 20A 20A 20A 20A 20A 20A 20A 20A 70 70 70 70 70 70 70 70 150 150 150 150 150 150 150 150 90% 90% 89% 89% 86% 86% 85% 85% 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -4www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Absolute Maximum Rating Characteristic Input Voltage(continuous) Input Voltage(peak/surge) Operating case temperature storage temperature Min -0.3 -0.3 -40 -55 Typ Max 80 100 100 125 Units Vdc Vdc °C °C 100ms non-repetitive Notes Input Characteristics Characteristic Input Voltage Range Input Reflected Current Turn-off Input Voltage Turn-on Input Voltage Turn On Time 31 Min 36 Typ 48 10 33 34 20 36 35 Max 75 15 Units Vdc mAp-p V V ms Notes CNT Function Characteristic Logic High Logic Low Control Current Min 3.5 -0.7 Typ Max 15 1.8 2 Units Vdc Vdc mA Notes General Specifications Characteristic MTBF Isolation Pin solder temperature Hand Soldering Time Weight 60 1500 260 5 Min Typ 2000 Max Units k Hrs Vdc °C s grams wave solder < 10 s iron temperature 425°C Notes Bellcore TR332, Tcase=30°C TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -5www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output AV45C-048L-050F20HA(N) Output Characteristics Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 1 100 50-25% load 1 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 5.7 22 27 90 110 6.8 0.5 0.02 70 150 115 28 30 %Vo µs %Vo µs A A % %Vo V V %Vo/°C mV mV °C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs 4.90 20 5.00 0.02 0.03 5.10 0.2 0.5 Min Typ Max 100 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -6www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output AV45C-048L-033F20HA(N) Output Characteristics Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 2 100 50-25% load 2 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 3.9 22 27 89 110 5.0 0.5 0.02 70 150 115 28 30 %Vo µs %Vo µs A A % %Vo V V %Vo/°C mV mV °C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs 3.24 20 3.3 0.02 0.03 3.36 0.2 0.5 Min Typ Max 66 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -7www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s P o w e r C o n v e r t e r s 3 6 V D C t o 7 5 V D C I n p u t , 5 V a n d 1 . 8 V O u t p u t , 1 0 0 Wa t t O u t p u t AV45C-048L-018F20HA(N) Output Characteristics Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 3 100 50-25% load 3 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 2.2 22 27 86 110 2.8 10 0.02 70 150 115 28 30 %Vo µs %Vo µs A A % %Vo V %Vo %Vo/°C mV mV °C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs 1.77 20 1.80 0.02 0.1 1.83 0.2 0.5 Min Typ Max 36 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -8www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output AV45C-048L-015F20HA(N) Output Characteristics Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 3 100 50-25% load 3 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 1.9 22 27 85 110 2.5 10 0.02 70 150 115 28 30 %Vo µs %Vo µs A A % %Vo V %Vo %Vo/°C mV mV °C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs Ta=25°C, DI/Dt=1A/10µs 1.47 20 1.50 0.02 0.1 1.53 0.2 0.5 Min Typ Max 30 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -9www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Characteristic Curves Typical Efficiency AV45C-048L-050F20HAN 95 (at 25 ° C ) ( at Typical Efficiency AV45C-048L-033F20HAN 90 90 85 EFFICIENCY(%) EFFICIENCY (%) 80 75Vin 80 48Vin 75 70 70 36Vin 60 65 60 75Vin 48Vin 36Vin 50 2 4 6 8 10 12 14 16 18 20 0 4 8 12 16 20 OUTPUT CURRENT, Io(A) OUTPUT CURRENT(A) Typical Efficiency AV45C-048L-018F20HAN Typical Efficiency AV45C-048L-015F20HAN 90 85 80 90 85 Efficiency(%) 80 75 70 65 60 55 50 75Vin 48Vin 36Vin EFFICIENCY (%) 75 70 65 60 55 50 75Vin 48Vin 32Vin 2 4 6 8 10 12 14 16 18 20 0 4 8 12 16 20 OUTPUT CURRENT, Io(A) OUTPUT CURRENT(A) TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -10www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Characteristic Curves C haracteristic Typical Output Overcurrent Characteristics AV45C-048L-050F20HAN (at 25 ° C ) ( at Typical Output Overcurrent Characteristics AV45C-048L-018F20HAN 5.5 5 1.9 1.8 Output Voltage (volts) 4 3.5 3 2.5 2 1.5 0 5 10 15 20 25 30 Output Voltage (volts) 4.5 1.7 Vin=36V 1.6 Vin=48V Vin=72V 1.5 Vin=36V Vin=48V Vin=72V 1.4 0 5 10 15 20 25 Output Curent (amps) Output Curent (amps) TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -11www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output T ransient response (48V rated input voltage, full load, at 25 °C) ( 48V Typical Transient Response to Step Load Change from 50%-75%-50%Iomax,AV45C-048L-050F20HAN Typical Transient Response to Step Load Change from 75%-50%Iomax, AV45C-048L-050F20HAN Typical Transient Response to Step Load Change from 50%-75%Iomax, AV45C-048L-050F20HAN Typical Transient Response to Step Load Change from 50%-75%-50%Iomax, AV45C-048L-018F20HAN Typical Transient Response to Step Load Change from 75%-50%Iomax, AV45C-048L-018F20HAN Typical Transient Response to Step Load Change from 50%-75%Iomax, AV45C-048L-018F20HAN TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -12www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Characteristic Curves C haracteristic Typical Start-Up from Power On AV45C-048L-050F20HAN (48V rated input voltage, full load, at 25 °C) ( 48V Typical Start-Up from Power On AV45C-048L-018F20HAN Typical Shut-down from Power Off AV45C-048L-050F20HAN Typical Shut-down from Power Off AV45C-048L-018F20HAN TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -13www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Characteristic Curves C haracteristic Typical Start-Up Transient with CNT AV45C-048L-050F20HAN (48V rated input voltage, full load, at 25 °C) Typical Start-Up Transient with CNT AV45C-048L-018F20HAN Typical Shut-down Transient with CNT AV45C-048L-050F20HAN Typical Shut-down Transient with CNT AV45C-048L-018F20HAN TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -14www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Characteristic Curves C haracteristic Typical Output Ripple Voltage AV45C-048L-050F20HAN (48V rated input voltage, full load, at 25 °C) Typical Output Ripple Voltage AV45C-048L-018F20HAN Overvoltage Protection AV45C-048L-050F20HAN Overvoltage Protection AV45C-048L-018F20HAN TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -15www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output Pin Location The +Vin and -Vin input connection pins are located as shown in Figure 1. AV45C series converters have a 2:1 input voltage range and can accept 36-75 Vdc input. Care should be taken to avoid applying reverse polarity to the input which can damage the converter. Note: the fuse is normal blow type. Input Reverse Voltage Protection Under installation and cabling conditions where reverse polarity across the input may occur, reverse polarity protection is recommended. Protection can easily be provided as shown in Figure 2. In both cases the diode rating is determined by the power of the converter. +Vin +Vin -Vin -Vin CNT +Vin -Vo -Sense TRIM +Sense +Vo -Vin Fig.2 Reverse Polarity Protection Circuits Placing the diode across the inputs rather than in-line with the input offers an advantage in that the diode only conducts in a reverse polarity condition, which increases circuit efficiency and thermal performance. Input Undervoltage Protection The AV45C quarter-brick series is protected against undervoltage on the input. If the input voltage drops below the acceptable range, the converter will shut down. It will automatically restart when the undervoltage condition is removed. Input Filter Input filters are included in the converters to help achieve standard system emissions certifications. Some users however, may find that additional input filtering is necessary. The AV45C quarter-brick series has an internal switching frequency of 250 kHz so a high frequency capacitor mounted close to the input terminals produces the best results. To reduce reflected noise, a capacitor can be added across the input as shown in Figure 3, forming Fig.1 Pins Location ( Pin-side View ) Input Characteristic Fusing The AV45C power module has no internal fuse. An external fuse must always be employed! To meet international safety requirements, a 250 Volt rated fuse should be used. If one of the input lines is connected to chassis ground, then the fuse must be placed in the other input line. Standard safety agency regulations require input fusing. Recommended fuse ratings for the AV45C quarter-brick are shown in Table 1. Table 1 Series AV45C 5Vout AV45C 3.3Vout AV45C 1.8Vout AV45C 1.5Vout Fuse Rating(48Vin) 10A (Pout=100W) 8A 5A 5A (Pout=66W) (Pout=36W) (Pout=30W) TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -16www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output a π filter. The recommended value of the capacitor C1 can refer to the Typical Application on page 3. Table 2 L N ON OFF H OFF ON Open OFF ON +Vin C1 -Vin P Fig.3 Ripple Rejection Input Filter Also when a filter inductor is connected in series with the power converter input or when the input wiring is long (since the wiring can act as an inductor), an input capacitor C1 should be added. Failure to use an input capacitor under these conditions can produce large input voltage spikes and an unstable output. For conditions where EMI is a concern, Figure 4 shows an input filter designed to reduce EMI effects. C1 2200P C2 2200P N--- means “Negative Logic” P--- means “Positive Logic” L--- means “Low Voltage”, -0.7V [ L [ 1.8V H--- means “High Voltage”, 3.5V [ H [ 15V ON--- means “module is on” OFF--- means “module is off” Open--- means “ CNT pin is left open ” Note: The VCNT [ 15V The following figure 5 to 8 are a few simple CNT circuits. CNT -Vin Fig.5 Simple CNT Control CNT -Vin +Vin C3 2200P C6 100µ C10 2200P C11 2200P C12 2200P L1 2.5mH C4 2200P C7 100µ +Vo C5 2200P C9 4700P C8 1000µ Fig.6 Transistor CNT Control CNT -Vin C13 2200P -Vo C14 2200P -Vin Fig.7 Isolated CNT Control CNT Fig.4 EMI Reduction Input Filter -Vin CNT Function C NT Two CNT logic options are available. The CNT logic, CNT voltage and the module working state is as the following Table 2. Fig.8 Relay CNT Control Safety Consideration For safety-agency approval of the system in which the power module is used, the power TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Asia 852-2437-9662 852-2402-4426 -17www.astec.com AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL1950, CSA C22.2 No. 950-95, and EN60950. The input-to-output 1500VDC isolation is an operational insulation. The DC/DC power module should be installed in end-use equipment, in compliance with the requirements of the ultimate application, and is intended to be supplied by an isolated secondary circuit. When the supply to the DC/DC power module meets all the requirements for SELV(4mm