PKB 4418 PINB DC/DC Converter 48V Input, 1.8V at 25A Output Features * High Efficiency; 88.5% Typ. at 25A 91% at 12.5A * 1/8th brick pkg: low profile 58 x 19 mm2 (2.28 x 0.75 in2) * Pin compatible replacement for Industrystandard quarter brick * 2,250 V dc isolation and meets Isolation Requirements equivalent to Basic Insulation according to IEC/EN/UL 60 950 * Fast Dynamic Response, t tr = 50 us * More than 3.7million hours predicted MTBF * UL/ULC 60 950 Recognized and Certified in accordance with EN 60 950 Product shown is the PKB 4418 PINB The PKB 4000 Series of high efficiency DC/DC converters are designed to provide high quality on-board power solutions in distributed power architectures used in "Inter-networking" equipment in Wireless and Wired Communications and Datacom applications. The PKB 4000 Series has the same pinout as an industry standard quarter brick but only occupies approximately half the footprint. This makes it extremely well suited for limited board space applications. The PKB Series uses patented synchronous rectification technology and achieves an efficiency up to 88.5% at full load. The series is presently available in nonbaseplated versions and will be offered in baseplated and surface mount versions in the near future. Ericsson's PKB 4000 Series addresses the emerging telecom market for applications in the E multi-service network by specifying the input voltage range in accordance with ETSI specifications. Included as standard features are over-voltage protection, under-voltage protection, over temperature protection, soft-start, short circuit protection, remote sense, remote on/off, and industry standard output trim adjustment. The PKB 4000 Series also offers the flexibility of using a baseplate as well as an optional heatsink when needed, enabling reduced airflow, extended reliability, and higher ambient temperature operation. These converters are manufactured in highly automated manufacturing lines and meet worldclass quality levels. Ericsson Power Modules has been an ISO 9001 certified Supplier since 1991. PKB 4418 PINB General Safety Absolute Maximum Ratings Characteristics min max Unit TPcb Maximum Operating Pcb Temperature - 40 +110 TS Storage temperature - 55 +125 C VI Input voltage - 0.5 + 80 V dc VISO Isolation voltage (input to output test voltage) VTrans Input Voltage Transient C 2250 V dc 80 VRC Remote control voltage pin 2 Vadj Output adjust voltage pin 6 (measured from pin 5) (measured from pin 1) -0.5 V dc 15 -0.5 Vdc 2 x Vo Vdc Note: Stress in excess of Absolute Maximum Ratings may cause permanent damage. Absolute Maximum Ratings, sometimes referred to as "no destruction limits", are normally tested with one parameter at a time exceeding the limits of the Output data or Electrical Characteristics. Input TPcb < TPcb max Characteristics Conditions min typ max Unit 75 Vdc VI Input voltage range1) IO = 0...IOmax 38 V I off Turn-off input voltage Ramping from higher voltage 30 33.5 35 Vdc V Ion Turn-on input voltage Ramping from lower voltage, IO = 0...IOmax 32 34.5 36 Vdc CI Input capacitance IIac Reflected ripple current 5 Hz to 20 MHz II max Maximum input current VI = VImin, PIi Input idling power IO =0, VI = 53 V PRC Input stand-by power (turned off with RC) VI = 53V, RC open VTRIM Maximum input voltage on trim pin 2.18 uF 10 mAp-p 66 W 1.55 A 1.6 W 0.055 W 6.6 Vdc Note: 1) The input voltage range 38...75 V meets the requirements in the European Telecom Standard prETS 300 132-2 for Normal input voltage range in 48 V and 60 V DC power systems, - 40.5...-57.0 V and -50.0...-72.0 V respectively. Environmental Characteristics Characteristics Random Vibration 2 Test procedure & conditions IEC 68-2-34ED Frequency Spectral density Duration Frequency Amplitude Acceleration Number of cycles 10...500 Hz 0.025 g2/Hz 10 min each direction Sinusoidal Vibration IEC 68-2-6 Fc 10...500 Hz 0.75mm 10g 10 in each axis Shock (Half sinus) IEC 68-2-27 Ea Peak acceleration Duration 100g 3ms Temperature change IEC 68-2-14 Na Temperature Number of cycles -40C... +125C 300 Accelerated damp heat IEC 68-2-3 Ca with bias Temperature Humidity Duration 85C 85% RH 1000 hours Solder resistability IEC 68-2-20 Tb 1A Temperature, solder Duration 260C 10...13 s Resistance to cleaning solvents IEC 68-2-45 XA Method 1 Water Isopropyl alcohol Method +55 5C +35 5C with rubbing The PKB 4000 PI Series DC/DC converters are designed in accordance with Safety Standards IEC/EN/UL 60 950, Safety of Information Technology Equipment. The PKB 4000 Series DC/DC converters are ULC 60 950 recognized and certified in accordance with EN 60 950. The DC/DC converters should be installed in end-use equipment, in accordance with the requirements of the ultimate application. The input source must be isolated by minimum Basic Insulation from the primary circuit in accordance with IEC/EN/UL 60 950. If the input voltage to the DC/DC converter is 75Vdc or less, then the output remains SELV (Safety Extra Low Voltage) under normal and abnormal operating conditions. Single fault testing in the input power source circuit should be performed with the DC/DC converter connected to demonstrate that the input voltage does not exceed 75Vdc. If the input power source circuit is a DC power system, the source maybe treated as a TNV2 circuit and testing has demonstrated compliance with SELV limits and isolation requirements equivalent to Basic Insulation in accordance with IEC/ EN/UL 60 950. It is recommended that a fast blow fuse with a rating of 5A be used at the input of each DC/ DC converter. The PKB series DC/DC converters are approved for a maximum fuse rating of 15A. If a fault occurs in the DC/DC converter that imposes a short circuit on the input power source, this fuse will provide the following functions: * Isolate the faulty DC/DC converter from the input source so as not to affect the operation of other parts of the system. * Protect the distribution wiring from excessive current and power loss thus preventing hazardous overheating. The galvanic isolation is verified in an electric strength test. The test voltage (V ISO) between input and output is 2250 Vdc for 60 seconds. Leakage current is less than 1uA at nominal input voltage. The flammability rating for all construction parts of the DC/DC converter meets UL 94V-0. EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 PKB 4418 PINB Mechanical Data Connections Pin Designation 1 - INPUT 2 Function Weight Negative input RC PKB 4418 PI Maximum 25 g (est.) PKB 4418 PINB Maximum 20 g Remote on/off (primary) to turn-on and turn-off the output 3 + INPUT Positive input. 4 - OUTPUT Negative output 5 - SENSE Negative remote sense 6 TRIM Output voltage adjust 7 + SENSE Positive remote sense 8 + OUTPUT Positive output Pins Material: Brass Alloy Plating: Tin over Nickel Electrical Data Fundatmental Circuit Diagram Primary Secondary Choke Resistor Capacitor 3 8 Control 2 4 Control 1 Isolated Feedback 5 7 6 Note: * If the remote sense is not needed the "-Sense" should be connected to "-Out" and the "+Sense" should be connected to "+Out." * If the remote control is not needed the RC pin must be connected to -V in for negative logic. For positive logic the pin should be left open or floating. Class B External Input EMI Filter Circuit Diagram The following external input filter is required to meet EN55022 Class B EMI requirements. Please refer to Design Note 19 for further information. CY4 L2 CY2 + L1 CD1 Vin 36-75Vdc Cin CD3 CD2 CY3 PKB Module - CY1 EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 + CYS2 Output CYS1 Filter Schematic Legend: Cin: 100uF/100V, Electrolytic capacitor CY1, CY2, CYS1, CYS2: 2700pF/ 2000V Ceramic capacitors CY3, CY4: 2 x 2700pF/2000V Ceramic capacitors CD1, CD2: 4 x 1uF/100V Ceramic CD3: 2 x 1uF/100V Ceramic L1, L2: common mode inductor, 1.5mH, each winding consists of 13 turns of AWG #21wire on the T18-10-10E HS72 core from TDK 3 PKB 4418 PINB Output TPcb = -40...+100C, VI = 38 ...75V unless otherwise specified. Characteristics typ max Output Conditions Unit min typ max 1.764 1.80 1.836 V Output voltage initial setting and accuracy TPcb =+25 C, VI = 53 V, IO =IOmax Output adjust range IO =IOmax 1.44 1.98 V Output voltage tolerance band IO =0 to IO max 1.746 1.854 V Line regulation IO =IO m a x 3 10 mV Load regulation VI = 53V, IO =0 to IO max, 3 10 mV Vt r Load transient voltage deviation Load step = 12.5A IO = 6.25... 18.75A VI = 53V, di/dt = 8A/us tt r Load transient recovery time ts Start-up time IO Output current POmax Max output power At VO = VOnom 45 Ilim Current limit threshold VO = 0.96 VOnom 28 30 32 A Isc Short circuit current 32 33.5 35 A VOac Output ripple & noise IO =IO max, f < 20 MHz 80 mVp-p SVR Supply voltage rejection (ac) f < 1kHz OVP Over voltage protection VI= 53V, IO = 0 ...25A VOi VO +/-100 mV s 50 From VI connection to VO = 0.9 x VOnom 45 55 0 75 ms 25 A W 70 dB 2.1 3.3 V Miscellaneous Characteristics Conditions Efficiency - 50% Load IO = IOmax, VI = 53V, TPcb = +25oC Efficiency - 100% Load Pd fS typ 88.5 91 % IO = IOmax, VI = 53V, TPcb = +25 C 88.5 % Power dissipation IO = IOmax, VI = 53V, TPcb = +25oC 5.77 6.93 W Switching frequency IO = 0...1.0 x IOmax 160 168 kHz o 152 Efficiency TA = +25oC 25 91 36V 20 90 48V 89 53V Output Current (A) Efficiency ( %) max Output Current Derating VI = 53V 92 88 75V 87 86 85 15 3.0 mps 2.5 mps 2.0 mps 10 1.5 mps 1.0 mps 5 84 0.5 mps Nat Conv 83 0 82 0 5 10 15 Current (A) 4 Unit min 20 25 0 10 20 30 40 50 60 70 80 90 100 110 120 Ambient Temperature (C) EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 PKB 4418 PINB Power Dissipation TA = +25oC 2 10 1.8 9 1.6 8 1.4 7 Vin36V 6 Vin48V Power Loss (W) Voltage (Vo) Output Characteristic (typ) 1.2 1 0.8 Uin 36V 0.6 Uin 48V 0.4 Uin 53V Vin53V 4 Vin75V 3 2 Uin 75V 0.2 5 1 0 25 27 29 31 33 Current (A) Start-up 35 0 0 TA = +25oC, IO = 25A, Vin = 53V EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 10 15 20 25 Current (A) Turn-Off TA = +25oC, IO = 25A, Vin = 53V (Load >2A or a capcitor > 220uF) Output Ripple 5 TA = +25oC, IO = 25A, Vin = 53V Transient TA = +25oC, IO = 6.25-18.75-6.25A, V in = 53V 5 PKB 4418 PINB Operating Information Current Limiting Input Voltage The input voltage range 36...75Vdc meets the requirements of the European Telecom Standard ETS 300 132-2 for normal input voltage range in -48V and -60V DC power systems, -40.5...-57.0V and -50.0...-72V respectively. At input voltages exceeding 75V, the power loss will be higher than at normal input voltage and TC must be limited to absolute max +110 oC. The absolute maximum continuous input voltage is 80V DC. All PKB 4000 series DC/DC converters include current limiting circuitry that allows them to withstand continuous overloads or short circuit conditions on the output. The output voltage will decrease towards zero for output currents in excess of max output current (I Omax). The converter will resume normal operation after removal of the overload. The load distribution system should be designed to carry the maximum short circuit output current specified. Remote ON/OFF (RC) Over Voltage Protection (OVP) The PKB 4000 series DC/DC converters have two remote on/off options available. The standard converter is provided with "negative logic" remote on/off. The negative logic remote on/off turns the converter off during a logic high voltage on the on/off pin and on during a logic low state. The second option is "positive Logic" remote on/off which can be ordered by adding the suffix "P" to the end of the part number such as PKB 4418 PIP. "Positive logic" remote on/off turns the converter on during a logic high and off during a logic low state. The PKB 4000 series DC/DC converters have latching output overvoltage protection. In the event of an overvoltage condition, the converter will shut down. The converter can be restarted by cycling the input voltage. Optional (P) Remote Control RC (primary) Module RC (primary) Low Open/High ON OFF Low Open/High Module OFF ON The remote on/off is referenced to the primary side. A mechanical switch or an open collector transistor or FET must be provided between the -V in and the remote on/off inputs to drive the RC inputs to turn the module on and off. In situations where it is desired to have the converter power up automatically without the need for control signals or a switch, the RC pin can be wired directly to the -Input circuit on the application board. Remote Sense The remote sense circuitry will compensate for moderate amounts of resistance in the distribution system and allow for voltage regulation at the load or other selected point. The remote sense lines will carry very little current and do not need a large cross sectional area. However, the sense lines on a pcb should be located close to a ground trace or ground plane. In a discrete wiring situation, the use of twisted pair wires or other technique to reduce noise susceptibility is highly recommended. The converter will compensate for up to 0.5V voltage drop between the sense voltage and the voltage at the power module output pins. The output voltage and the remote sense voltage offset must be less than the minimum over voltage trip point. 6 All PKB 4000 series DC/DC converters have an Output Voltage Adjust pin (Trim). This pin can be used to adjust the output voltage above or below V Oi. When increasing the output voltage, the voltage at the output pins (including any remote sensing offset) must be kept below the overvoltage trip point. Also note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. These converters trim according to the industry standard method. To decrease V O connect R TRIM-DOWN from -SENSE to TRIM RTRIM-DOWN =5.11 100 - 2 k ( % ) To increase V O connect RTRIM-UP from +SENSE to TRIM ( RTRIM-UP =5.11 VO (100+%) 1.225 % ) (100+2%) k % Output Voltage Trim for 1.8V 100000 Adjust Resistor Value (KOhm) Standard Remote Control Output Voltage Adjust (Trim) 10000 Decrease Increase 1000 100 10 1 0 2 4 6 8 10 12 14 16 18 20 C h a n g e I n O u t p u t V o l t a g e ( %) EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 PKB 4418 PINB Circuit Configuration for Output Voltage Adjustment (Trim) +VOUT +VOUT +SENSE D TRIM +SENSE D RTRIM-DOWN Load Load TRIM RTRIM-UP -SENSE -SENSE -VOUT -V OUT TRIM DOWN converters have been designed to be completely stable without the need for external capacitors on the input or the output circuits. The performance in some applications can be enhanced by the addition of external capacitance as described below. If the distribution of the input voltage source to the converter contains significant inductance, the addition of a 100uF capacitor across the input of the converter will help insure stability. This capacitor is not required when powering the converter from a low impedence source with a short, low inductance, input power lead. TRIM UP Output Ripple & Noise (VOac) Output Capacitance Output ripple is measured as the peak to peak voltage from 0 to 20MHz which includes the noise voltage and the fundamental ripple. When powering loads with significant dynamic current requirements, the voltage regulation at the load can be improved by the addition of decoupling capacitance at the load. The most effective technique is to locate low ESR ceramic capacitors as close to the load as possible, using several capacitors to lower the effective ESR. These ceramic capacitors will handle short duration high frequency components of dynamic load changes. In addition, higher values of electrolytic capacitors should be used to handle the mid-frequency components. It is equally important to use good design practices when configuring the DC distribution system. Low resistance and low inductance Pcb (printed circuit board) layouts and cabling should be used. Remember that when using remote sensing, all the resistance, inductance, and capacitance of the distribution system is within the feedback loop of the converter. This can have an affect on the converter's compensation and the resulting stability and dynamic response performance. As a "rule of thumb", 100uF/A of output current can be used without any additional analysis. For example, with a 20A converter, values of decoupling capacitance up to 2000uF can be used without regard to stability. With larger values of capacitance, the load transient recovery time can exceed the specified value. As much of the capacitance as possible should be outside of the remote sensing loop and close to the load. The absolute maximum value of output capacitance is 10,000uF. For values larger than this, please contact your local Ericsson Power Modules representative. Over Temperature Protection (OTP) The PKB 4000 series DC/DC converters are protected from thermal overload by an internal over temperature shutdown circuit. When the Pcb temperature adjacent to the primary mosfet exceeds +120 oC (+5oC, -5oC), the power module will automatically shut down. It will restart when the temperature drops to +100 oC (+5oC, -5oC). Paralleling for Redundancy The figure below illustrates how n + 1 redundancy can be achieved. The customer provided diodes on the converter outputs allow a failed converter to remove itself from the shared group without pulling down the common output bus. This configuration can be extended to additional numbers of converters. Based on the desired circuit, the converters can be controlled individually or in groups by means of signals to the primary Remote On/Off inputs. Input and Output Impedence The impedence of both the power source and the load will interact with the impedence of the DC/DC converter. It is most important to have the ratio between L and C as low as possible, i.e. a low characteristic impedence, both at the input and output, as the conveters have a low energy storage capability. The PKB 4000 series DC/DC EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002 7 PKB 4418 PINB Quality Reliability The Mean Time Between Failure (MTBF) of the PKB 4000 series DC/DC converter family is calculated to be greater than (>) 3.72 million hours at full output power and a pcb temperature of +90 oC using the Ericsson reliability database (TILDA/Preditool) which is based on field failure rates and is continuously updated. The data corresponds to actual failure rates of components used in Information Technology and Telecom equipment in temperature controlled environments (T A= -5...+65 oC). The data is considered to have a confidence level of 90%. For more information please refer to Design Note 002. Product Options Option Positive Remote on/off logic Non-baseplated Suffix Ordering No. P PKB 4418 PIP NB PKB 4418 PINB Lead length 0 .145" +/-0.010" LA PKB 4418 PINBLA Note: As an example a positive logic, no baseplate, short pin product would be PKB 4418 PIPNBLA Please check with the factory for availability. Quality Statement The PKB 4000 series DC/DC converters are designed and manufactured in an industrial environment where quality systems and methods like ISO 9000, 6 (sigma), and SPC are intensively in use to boost the continuous improvememts strategy. Infant mortality or early failures in the products are screened out and they are subjected to an ATE-based final test. Conservative design rules, design reviews and product qualifications, plus the high competence of an engaged work force, contribute to the high quality of our products. Warranty Ericsson Inc., Power Modules warrants to the original purchaser or end user that the products conform to this Data Sheet and are free from material and workmanship defects for a period of five (5) years from the date of manufacture, provided the product is used within specified conditions and not modified in any way. In case the product is discontinued, claims will be accepted up to three (3) years from the date of the discontinuation. For additional details on this limited warranty we refer to Ericsson Inc., Power Modules "General Terms and Conditions of Sales", or individual contract documents. Limitation of Liability Ericsson Inc., Power Modules does not make any other warranties, expressed or implied including any warranty of merchantability or fitness for a particular purpose (including, but not limited to, use in life support applications, where malfunctions of product can cause injury to a person's health or life). Ericsson Inc. Power Modules 1700 International Pkwy. Richardson, Texas 75081 Phone: 877-374-2642 www.ericsson.com/powermodules 8 Information given is believed to be accurate and reliable. No responsibility is assumed for the consequences of its use for any infringement of patents or other rights of third parties that may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Ericsson Inc.,Power Modules. These products are sold only according to Ericsson Inc., Power Modules' general conditions of sale, unless otherwise confirmed in writing. Specifications are subject to change without notice. Preliminary Advanced Data Sheet EN/LZT 108 6072 P1A (c)Ericsson Inc., Power Modules , November 2002