AC Front End FE175D480x033FP-00 (R) S US C C NRTL US Complete AC-DC PCB-Mounted Solution Features & Benefits Product Ratings * Complete AC-DC PCB-mounted solution VIN = 85 - 264VAC * Active Power Factor Correction (PFC) VOUT = 48VDC (Isolated) * Rectification * Filtering POUT = 330W Product Description * Transient protection * Low-profile package, 9.55mm height above board * Power density: 121W/in3, 330W in 7.2in2 footprint * Consistent high efficiency over world-wide AC mains (85 - 264VAC) * Secondary-side energy storage * SELV 48V Output Efficient power distribution to PoL converters * 3,000VAC / 4,242VDC isolation The AC Front End is an AC-to-DC converter, operating from a universal AC input to generate an isolated and regulated 48VDC output with power factor correction. The module incorporates rectification, transient and surge suppression and AC to DC conversion to provide a complete AC to DC solution in a thinprofile package. With its ZVS high-frequency Adaptive CellTM topology, the AC Front End module consistently delivers high efficiency across worldwide AC mains. Downstream DC-DC converters support secondary-side energy storage and efficient power distribution, providing superior power system performance and connectivity from the wall plug to the point-of-load. * PFC (THD) exceeds EN61000-3-2 requirements * Conducted emissions EN55022, Class B (with a few external components) * Surge immunity EN61000-4-5 * ZVS high-frequency (MHz) switching * Low-profile, high-density filtering * 100C baseplate operation Typical Applications * LED - Lighting, display, signage * Telecom (WiMAX, Power Amplifiers, Optical Switches) * Automatic Test Equipment (ATE) * High-Efficiency Server Power * Office Equipment (Printers, Copiers, Projectors) * Industrial Equipment (Process Controllers, Material Handling, Factory Automation) Part Ordering Information AC Front End Page 1 of 23 Part Number Temperature Grade FE175D480C033FP-00 C = -20 to 100C FE175D480T033FP-00 T = -40 to 100C Rev 2.1 03/2019 Revision 00 FE175D480x033FP-00 Typical Application FUSE Gnd +OUT AC (L) 85 - 264VAC AC Front End MOV AC (N) Gnd +OUT DCMTM -OUT 12V Load -OUT Hold-Up Capacitor Vicor recommends the following PRMTM modules: PRM48JF480T500A00, PRM48JH480T250A00, PR036A480x012xP, PR045A480X040xP AC Front End Page 2 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Pin Configuration RSV3 EN DC- OUT GND RSV1 DC+ OUT -IN DC- OUT AC (L) AC (N) DC+ OUT GND Top View AC Front End Pin Descriptions Signal Name Type GND PE Ground AC (N) AC Power Input AC Neutral Input AC (L) AC Power Input AC Line Input EN Signal Input -IN Signal Reference RSV3 No Connect Do not connect to this pin RSV1 No Connect Do not connect to this pin DC +OUT Power Output +48V Output DC -OUT Power Return +48V Return Pin AC Front End Page 3 of 23 Description Protective Earth Ground; two pins plus six grounded standoffs between PCB and baseplate Open drain with internal pullup. Leave open to enable, pull to -IN to disable EN pin reference pin Rev 2.1 03/2019 FE175D480x033FP-00 Absolute Maximum Ratings The absolute maximum ratings below are stress ratings only. Operation at or beyond these maximum ratings can cause permanent damage to device. Electrical specifications do not apply when operating beyond rated operating conditions. Positive pin current represents current flowing out of the pin Parameter Comments Input voltage AC (L) to AC (N) Continuous Input voltage AC (L) to AC (N) 1ms RSV1 to -IN Min Max Unit 275 VAC 0 600 VPK Do not connect to this pin -0.3 5.3 VDC EN to -IN 5V tolerant 3.3V logic -0.3 5.3 VDC RSV3 to -IN Do not connect to this pin -0.3 5.3 VDC Output voltage (+OUT to -OUT) -0.3 57.0 VDC Output Current 0.0 10.2 A C-Grade; baseplate -20 100 T-Grade; baseplate -40 100 M-Grade; baseplate -55 100 C-Grade -40 125 T-Grade -40 125 M-Grade -65 125 Operating Temperature Storage Temperature Dielectric Withstand Input - Output 3000 Input - Base 1500 Output - Base 1500 C C VRMS Electrical Specifications Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TC = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. COUT is 6800F 20% unless otherwise specified. Attribute Symbol Conditions / Notes Min Typ Max Unit 264 VRMS 148 VRMS Power Input Specification Input Voltage Range VIN Input Voltage Cell Reconfiguration Low-to-High Threshold VIN-CR+ Input Voltage Cell Reconfiguration High-to-Low Threshold VIN-CR- Input Current (Peak) IINRP Source Line Frequency Range FLINE Continuous operation 85 145 132 135 47 Power Factor PF Input power >100W Input Inductance (External) LIN Differential-mode inductance; common-mode inductance may be higher; see "Source Inductance Considerations" on page 19 Input Power - No Load, Maximum PNL EN floating, see Figure 3 Input Power - Disabled, Maximum PQ EN pulled low, see Figure 4 VRMS 12 A 63 Hz 0.9 - 1 mH 1.5 W 1.6 W No-Load Specification AC Front End Page 4 of 23 Rev 2.1 03/2019 1.1 FE175D480x033FP-00 Electrical Specifications (Cont.) Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TCASE = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. COUT is 6800F 20% unless otherwise specified. Attribute Symbol Conditions / Notes Min Typ Max Unit 47.5 49 50.5 V Over all operating stead-state line conditions 46 51.5 55 V 30 55 V 330 W Power Output Specification Output Voltage Set Point VOUT Output Voltage, No Load VOUT-NL VIN = 230VRMS, 10% load Output Voltage Range (Transient) VOUT Non-faulting abnormal line and load transient conditions Output Power POUT See Figure 1, safe operating area VIN = 230V, full load Efficiency 85V < VIN < 264V, full load, see Figure 2 85V < VIN < 264V, 75% load 91 94 88.5 % 89 Output Voltage Ripple, Switching Frequency VOUT-PP-HF Over all opearting steady-state line and load conditions, 20MHz BW, measured at C3, Figure 28 100 300 mV Output Voltage Ripple, Line Frequency VOUT-PP-LF Over all opearting steady-state line and load conditions, 20MHz BW 3.8 5 V Output Capacitance (External) COUT-EXT 12,000 F 400 1000 ms Output Turn-On Delay tON 6000 From VIN applied, EN floating From EN pin release, VIN applied Start-Up Set-Point Acquisition Time tSS Full load 400 500 ms Cell Reconfiguration Response Time tCR Full load 5.5 11 ms 8 % 250 500 ms 1 % Voltage Deviation (Load Transient) %VOUT-TRANS COUT = max Recovery Time tTRANS Line Regulation %VOUT-LINE Full load 0.5 Load Regulation %VOUT-LOAD 10 - 100% load 0.5 Output Current (Continuous) IOUT Output Current (Transient) IOUT-PK Output Switching Cycle Charge QTOT 1 % See Figure 1, SOA 6.9 A 20ms duration, max 10.2 A 13.5 C Output Inductance (Parasitic) LOUT-PAR Frequency at 1MHz 1 nH Output Capacitance (Internal) COUT-INT Effective value at nominal output voltage 7 F 0.5 m Output Cpacitance (Internal ESR) AC Front End Page 5 of 23 RCOUT Rev 2.1 03/2019 FE175D480x033FP-00 Electrical Specifications (Cont.) Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TCASE = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. COUT is 6800F 20% unless otherwise specified. Attribute Symbol Conditions / Notes Min Typ Max Unit 74 83 VRMS Powertrain Protections Input Undervoltage Turn-On VIN-UVLO+ Intput Undervoltage Turn-Off VIN-UVLO- Input Overvoltage Turn-On VIN-OVLO+ Input Overvoltage Turn-Off See timing diagram 65 71 VRMS See timing diagram 265 270 VRMS 273 283 VRMS Instantaneous, latched shut down 55.3 56.6 59.0 V VIN-OVLO- Output Overvoltage Threshold VOUT-OVLO+ Upper Start/Restart Temperature Threshold (Case) TCASE-OTP- 100 C Overtemperature Shut-Down Threshold (Junction) TJ-OTP+ 130 C Overtemperature Shut-Down Threshold (Case) TCASE-OTP+ Undertemperature Shut-Down Threshold (Case) TCASE-UTP- C-Grade -25 C Lower Start/Restart Temperature Threshold (Case) TCASE-UTP+ C-Grade -20 C ms Overcurrent Blanking Time tOC 110 C Based on line frequency 400 460 550 Input Overvoltage Response Time tPOVP 6 s Input Undervoltage Response Time tUVLO Based on line frequency 27 39 51 ms Output Overvoltage Response Time tSOVP Powertrain on 60 120 180 s 120 s Short-Circuit Response Time tSC Powertrain on, operational state 60 Fault Retry Delay Time tOFF See timing diagram 10 Output Power Limit 330 PPROT 6 360 5 300 4 240 3 180 2 120 1 60 0 0 80 100 120 140 160 180 200 220 240 260 95% 94% AC Front End Page 6 of 23 92% 91% 90% 88% 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (V) Power Figure 1 -- DC output safe opearating area 93% 89% Input Voltage (VRMS) Current W Full Load Efficiency vs. Line Voltage 25C Case Efficiency (%) 420 Output Power (W) Output Current (A) DC Output Safe Operating Area 7 s Figure 2 -- Full-load efficiency vs. line voltage Rev 2.1 03/2019 FE175D480x033FP-00 Signal Characteristics Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TCASE = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. Enable: EN * * * * The EN pin enables and disables the AC Front End; when held below 0.8V the unit will be disabled. The EN pin can reset the AC Front End after a latching OVP event. The EN pin voltage is 3.3V during normal operation. The EN pin is referenced to the -IN pin of the module. Signal Type State Start Up Digital Input Standby Attribute Symbol En Enable Threshold VEN_EN En Disable Time tEN_DIS En Disable Threshold VEN_DIS En Resistance To Disable REN_EXT Conditions / Notes Min From any point in line cycle Typ 9 Max 2.00 V 16 ms 0.80 Max allowable resistance to -IN required to disable the moducle V 14 Reserved: RSV1, RSV3 * No connections are required to these pins. In noisy environments, it is beneficial to add a 0.1F capacitor between each reserved pin and -IN. -IN * Warning: -IN and N are not at the same potential and must not be connected together. * The -IN pin is the signal reference ground for the EN pin. * The -IN pin also serves as an access point for the common mode bypass filter to comply with EN55022 Class B for Conducted Emissions. AC Front End Page 7 of 23 Rev 2.1 03/2019 Unit k FE175D480x033FP-00 High-Level Functional State Diagram Conditions that cause state transitions are shown along arrows. Sub-sequence activities are listed inside the state bubbles. Application of VIN VIN > VIN-UVLO+ EN = True and No Faults STARTUP SEQUENCE Line Frequency Acquisition tON Expiry Powertrain: Stopped RNG: Auto STANDBY EN = False or VIN Out of Range Powertrain: Stopped RNG: High No Faults NON LATCHED FAULT tOFF delay OPERATIONAL VOUT Ramp Up (tss) Regulates VOUT EN = False or VIN Out of Range Powertrain: Active RNG: Auto PFC: Auto Overtemp, Output Short, or Overload Powertrain: Stopped RNG: High Output OVP EN Falling Edge LATCHED FAULT Powertrain: Stopped RNG: High AC Front End Page 8 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Functional Block Diagram Module inputs are shown in blue; module outputs are shown in brown. Note: Negative current is externally forced and shown for the purpose of OVP protection scenario. 1 Input Power On & UV Turn-on 2 3 10% Full Load Load Applied Applied 6 Range Change LO to HI 4 5 EN EN Forced High Low 7 8 Input Input OV OV Turn-off Turn-on VIN-OVLO+ 9 Range Change HI to LO 10 Load Dump 11 12 Load Input Power Step Off & UV Turn-off VIN-OVLOVIN-CR- VIN-CR+ VIN-UVLO+ VIN-RMS Input VIN-UVLO- 30VRMS EN VOUT-NL tON VOUT tEN-DIS tCR tCR tPOVP tON tON VOUT tSS tSS Output tUVLO tTRANS (2 places) ILOAD 13 Input Power ON & UV Turn-on 14 Output OC Fault 15 Output OC Recovery 16 Output OVP Fault 18 Output OVP Fault )) VIN-UVLO+ Input 17 Toggle EN (Output OVP Recovery) 19 Recycle Input Power (Output OVP Recovery) )) 20 Output SC Fault 21 Output SC Recovery 22 23 24 OT Fault Line Input & Drop-Out Power Recovery Off & UV Turn-off VIN-UVLO+ VIN-UVLO- VIN-RMS )) )) )) )) )) )) EN tOC VOUT tON tSS Output tOC VOUT-OVLO+ tOFF+tON tON tON tOC tOFF+tON tOFF+tON )) )) tSOVP tSC ILOAD )) * AC Front End Page 9 of 23 )) * Rev 2.1 03/2019 tOFF+tON tOFF+tON FE175D480x033FP-00 Application Characteristics The following figures present typical performance at TCASE = 25C, unless otherwise noted. See associated figures for general trend data. No Load Power Dissipation vs. Line, Module Enabled - Nominal VOUT 2.50 Power Dissipation (W) Power Dissipation (W) 3.00 No Load Power Dissipation vs. Line, Module Disabled, EN Low 2.00 1.50 1.00 0.50 0.00 Input Voltage (V) 25C -55C 1.460 1.260 1.060 0.860 0.660 0.460 85 100 115 130 145 160 175 190 205 220 235 250 265 TCASE: 1.660 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (V) 100C Figure 3 -- Typical no-load power dissipation vs. VIN, module enabled Figure 4 -- No-load power dissipation trend vs. VIN, module disabled Figure 5 -- Typical switching frequency output voltage ripple waveform, TCASE = 30C, VIN = 230V, IOUT = 6.9A, no external ceramic capacitance Figure 6 -- Typical line frequency output voltage ripple waveform, TCASE = 30C, VIN = 230V, IOUT = 6.9A, COUT = 6,800F. Measured at C3, Figure 25 Figure 7 -- Typical output voltage transient response, TCASE = 30C, VIN = 230V, IOUT = 6.9A, COUT = 6,800F Figure 8 -- Typical start-up waveform, application of VIN , RLOAD = 7.1, COUT = 6,800F AC Front End Page 10 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Application Characteristics (Cont.) The following figures present typical performance at TCASE = 25C, unless otherwise noted. See associated figures for general trend data. Report No. TRFE175D480C033FP082912AR1 Figure 9 -- Typical start-up waveform, EN pin release, VIN = 230V, RLOAD = 7.1, COUT = 6,800F Compliance Engineering Figure 10 -- Line drop out, 50Hz, Output: 0 phase,90% Load (297W) Input: 230V/50Hz PLOAD = 330W, COUT = 6,800F Quasi-Peak Scan Red Lead (L1) Att 20 dB INPUT 2 100 Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit 1 MHz 55022RED dB V 10 MHz 90 SGL 80 22QPA 1QP 70 22QPB 60 50 40 30 Report No. TRFE175D480C033FP082912AR1 20 Compliance Engineering Input: 230V/50Hz 90% Load (297W) Figure 11 -- Line drop out, 50Hz,Output: 90 phase, VIN = 230V, PLOAD = 330W, COUT = 6,800F Average Scan Red Lead (L1) 29.Aug 2012 11:01 150 kHz Date: 30 MHz 29.AUG.2012 11:01:40 Quasi-Peak Scan Black Lead (L2/N) Figure 12 -- Typical EMI spectrum, quasi-peak scan, 90% load, 230VIN, COUT = 6,800F; test circuit - Figure 25 Att 20 dB INPUT 2 100 Att 20 dB INPUT 2 100 Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit 1 MHz Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit 1 MHz 55022RED 55022BLK dB V 10 MHz 90 dB V SGL 10 MHz 80 22QPA 90 1QP SGL 70 80 2AV 22QPB 60 70 22AVA 50 60 40 22AVB 50 30 40 20 30 29.Aug 2012 12:57 150 kHz Date: 20 30 MHz 12:57:35 29.Aug 2012 11:02 150 kHz Date: 30 MHz 29.AUG.2012 11:02:41 Average Scan Black Lead (L2/N) Figure 13 -- Typical EMI spectrum, average scan, 90% load, 230VIN, COUT = 6,800F; test circuit - Figure 28 Att 20 dB INPUT 2 100 AC Front End Page 11 of 23 90 29.AUG.2012 1 MHz Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit 55022BLK dB V Figure 14 -- Typical EMI spectrum, quasi-peak scan, 90% load, 115VIN, COUT = 6,800F; test circuit - Figure 25 8/29/2012 10 MHz SGL 80 2AV Rev 2.1 03/2019 Page 6 of 7 FE175D480x033FP-00 Report No. TRFE175D480C033FPR1 Compliance Engineering Application Characteristics (Cont.) Input : 115V/60Hz Output: 90% Load (297W) The following figures present typical performance at TCASE = 25C, unless otherwise noted. See associated figures for general trend data. Average Scan Red Lead (L1) Att 20 dB INPUT 2 Det MA/AV Trd ResBW 9 kHz Meas T 100 55022RED 1 s Unit 1 MHz dB V 10 MHz 90 SGL 80 2AV 70 22AVA 60 22AVB 50 40 30 20 26.Jul 2012 16:36 150 kHz Date: 30 MHz 26.JUL.2012 16:36:57 Average Scan Black Lead (L2/N) Figure 15 -- Typical EMI spectrum, average scan, 90% load, 115VIN, COUT = 6,800F; test circuit - Figure 25 Att 20 dB INPUT 2 300 200 1 s Unit dB V 10 MHz Power Factor vs. Load and VIN at 25C SGL 1.000 80 2AV .950 70 Power Factor Current [mA] 400 9 kHz Figure 16 -- Typical line current waveform, 60Hz, VIN = 120V, PLOAD = 330W; COUT = 6,800F 55022BLK Input Current Harmonics 600 500 ResBW 1 MHz 90 700 MA/AV Trd Meas T 100 800 Det 22AVA 60 22AVB 50 40 .900 .850 .800 30 100 20 26.Jul 2012 16:47 150 kHz .750 30 MHz 0 16:47:25 1 3 26.JUL.2012 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Date: 230 V, 50 Hz 1/3x EN61000-3-2, Class A 1 2 100 V VIN: Figure 17 -- Typical input current harmonics, full load vs. VIN 7/27/2012 Page 17 of 17 88% 86% 84% 82% 80% 78% 76% 48 44 40 36 32 28 24 20 16 12 8 4 0 90% 88% 86% 84% 82% 80% 78% 76% 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.18 5.52 6.21 6.90 Load Current (A) Load Current (A) 100 V Eff 100 V Power Diss 115 V Eff 115 V Power Diss VIN: 240 V Eff 100 V Eff 100 V Power Diss 240 V Power Diss Figure 19 -- VIN to VOUT efficiency and power dissipation vs. VIN and IOUT, TCASE = -55C AC Front End Page 12 of 23 7 240 V 92% 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.18 5.52 6.21 6.90 VIN: 115 V 94% Efficiency (%) 90% 6 96% Power Dissipation (W) Efficiency (%) 92% 5 Efficiency & Power Dissipation 25C Case 48 44 40 36 32 28 24 20 16 12 8 4 0 94% 4 Figure 18 -- Typical power factor vs. VIN and IOUT Efficiency & Power Dissipation -55C Case 96% 3 Load Current (A) EN61000-3-2, Class D 115 V Eff 115 V Power Diss 240 V Eff 240 V Power Diss Figure 20 -- VIN to VOUT efficiency and power dissipation vs. VIN and IOUT, TCASE = 25C Rev 2.1 03/2019 Power Dissipation (W) 0 FE175D480x033FP-00 Application Characteristics (Cont.) The following figures present typical performance at TCASE = 25C, unless otherwise noted. See associated figures for general trend data. Efficiency & Power Dissipation 100C Case Efficiency (%) 92% 90% 88% 86% 84% 82% 80% 78% 76% 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.52 6.21 VIN: 100 V Eff 115 V Eff 115 V Power Diss 4 3 2 1 0 200 400 600 800 1000 Air Flow (LFM) 240 V Eff INSULATED 240 V Power Diss Figure 21 -- VIN to VOUT efficiency and power dissipation vs. VIN and IOUT, TCASE = 100C AC Front End Page 13 of 23 5 0 6.90 Load Current (A) 100 V Power Diss Thermal Resistance (Baseplate to Air) vs. Air Flow 6 Thermal Resistance (C/W) 94% Power Dissipation (W) 48 44 40 36 32 28 24 20 16 12 8 4 0 96% UNINSULATED Figure 22 -- Baseplate-to-air thermal resistance; Insulated: minimal thermal dissipation through pins to PCB; Uninsulated: thermal dissipation to typical PCB Rev 2.1 03/2019 FE175D480x033FP-00 General Characteristics Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TC = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified product grade. Attribute Symbol Conditions / Notes Min Typ Max Unit Mechanical Length L 95.3 [3.75] mm [in] Width W 48.6 [1.91] mm [in] Height H 9.55 [0.38] mm [in] Volume Vol 44.2 [2.69] cm3 [in3] Weight W 111 [3.9] g [oz] Pin Material C10200 copper, full hard Underplate Nickel 100 150 Pin Finish Pure matte tin, whisker-resistant chemistry 200 300 C-Grade -20 100 T-Grade -40 100 M-Grade -55 100 in Thermal Operating Baseplate (Case) Temperature TC Thermal Resistance Any operating condition Baseplatetosink, flat greased surface 0.13 Baseplatetosink, thermal pad (PN 36967) 0.17 Thermal Capacity C C / W 84.5 Ws / C Assembly ESD Rating ESDHBM Human Body Model, (JEDEC JESD 22-A114C.01) ESDMM Machine Model, (JEDEC JESD 22-A115B) N/A ESDCDM Charged Device Model, (JEDEC JESD 22-C101D) 200 1000 V Soldering See Application Note: Soldering Methods and Procedure for Vicor Power Modules Safety & Reliability Touch Current Measured in accordance with IEC 60990 using measuring network Figure 28 cURus UL/CSA 60950-1 Agency Approvals / Standards cTUVus EN 60950-1 CE, Low Voltage Directive 2006/95/EC AC Front End Page 14 of 23 Rev 2.1 03/2019 0.56 0.68 mA FE175D480x033FP-00 General Characteristics (Cont.) Specifications apply over all line and load conditions, 50Hz and 60Hz line frequencies, TC = 25C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified product grade. Attribute Symbol Conditions / Notes EMI/EMC Compliance FCC Part 15, EN55022, CISPR22: 2006 + A1: 2007, Conducted Emissions Class B Limits - with components connected as shown in Figure 28 EN61000-3-2: 2009, Harmonic Current Emissions Class A EN61000-3-3: 2005, Voltage Changes & Flicker PST < 1.0; PLT < 0.65; dc < 3.3%; dmax < 6% EN61000-4-4: 2004, Electrical Fast Transients Level 2, Performance criteria A EN61000-4-5: 2006, Surge Immunity Level 3, Immunity Criteria B, external TMOV required EN61000-4-6: 2009, Conducted RF Immunity Level 2, 130dBV (3.0VRMS) EN61000-4-8: 1993 + A1 2001, Power Frequency H-Field 10A/m, continuous field Level 3, Performance Criteria A EN61000-4-11: 2004, Voltage Dips & Interrupts Class 2, Performance Criteria A Dips, Performance Criteria B Interrupts AC Front End Page 15 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Product Details and Design Guidelines Power Factor Correction The module provides power factor correction over worldwide AC mains. For most static loads, PFC approaches unity, see Figure 18. Load transients that approach the line frequency should be filtered or avoided as these may reduce PFC. Building Blocks and System Designs Approximately 48VDC Input Fuse Selection +OUT AC (L) MOV* AC (N) 85 - 264VAC +OUT -OUT DC-DC Converter The AC Front End is not internally fused in order to provide flexibility in configuring power systems. Input line fusing is recommended at system level, in order to provide thermal protection in case of catastrophic failure. The fuse shall be selected by closely matching system requirements with the following characteristics: LOAD AC Front End -OUT (Optional) Hold-Up Capacitor Figure 23 -- 300W universal AC-to-DC supply The AC Front End is a high efficiency AC-to-DC converter, operating from a universal AC input to generate an isolated SELV 48VDC output bus with power factor correction. It is the key component of an AC-to-DC power supply system such as the one shown in Figure 23 above. The input to the AC Front End is a sinusoidal AC source with a power factor maintained by the module with harmonics conforming to IEC 61000-3-2. Internal filtering enables compliance with the standards relevant to the application (Surge, EMI, etc.). See EMI/EMC Compliance standards on page 16. The module uses secondary-side energy storage (at the SELV 48V bus) and optional PRMTM regulators to maintain output hold up through line dropouts and brownouts. Downstream regulators also provide tighter voltage regulation, if required. The FE175D480C033FP-00 is designed for standalone operation; however, it may be part of a system that is paralleled by downstream DC-DC converters. Contact Vicor Sales or refer to our www.vicorpower.com, regarding new models that can be paralleled directly for higher power applications. Traditional PFC Topology nn Recommended fuse: 5A, 216 Series Littelfuse nn Current rating (usually greater than the AC Front End maximum current) nn Maximum voltage rating (usually greater than the maximum possible input voltage) nn Ambient temperature nn Breaking capacity per application requirements nn Nominal melting I2t Fault Handling Input Undervoltage (UV) Fault Protection The AC Front End's input voltage is monitored by the microcontroller to detect an input undervoltage condition. When the input voltage is less than the VIN-UVLO-, a fault is detected, the fault latch and reset logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the unit falls. After a time tUVLO, the unit shuts down. Faults lasting less than tUVLO may not be detected. Such a fault does not go through an auto-restart cycle. Once the input voltage rises above VIN-UVLO+, the unit recovers from the input UV fault, the powertrain resumes normal switching after a time tON and the output voltage of the unit reaches the set-point voltage within a time tSS. Overcurrent (OC) Fault Protection Full-Wave Rectifier EMI/TVS Filter Isolated 12V Bus DC-DC Converter Figure 24 -- Traditional PFC AC-to-DC supply To cope with input voltages across worldwide AC mains (85 - 264VAC), traditional AC-DC power supplies (Figure 24) use two power conversion stages: 1) a PFC boost stage to step up from a rectified input as low as 85VAC to ~380VDC; and 2) a DCDC down converter from 380VDC to a 12V bus. The efficiency of the boost stage and of traditional power supplies is significantly compromised operating from worldwide AC lines as low as 85VAC. Adaptive CellTM Topology With its single-stage Adaptive Cell topology, the AC Front End enables consistently high-efficiency conversion from worldwide AC mains to a 48V bus and efficient secondary-side power distribution. AC Front End Page 16 of 23 The unit's output current, determined by VEAO, VIN-B and the primary-side-sensed output voltage is monitored by the microcontroller to detect an output OC condition. If the output current exceeds its current limit, a fault is detected, the reset logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the module falls after a time tOC. As long as the fault persists, the module goes through an auto-restart cycle with off time equal to tOFF + tON and on time equal to tOC. Faults shorter than a time tOC may not be detected. Once the fault is cleared, the module follows its normal start up sequence after a time tOFF. Short Circuit (SC) Fault Protection The microcontroller determines a short circuit on the output of the unit by measuring its primary sensed output voltage. Most commonly, a drop in the primary-sensed output voltage triggers a short circuit event. The module responds to a short circuit event within a time tSC. The module then goes through an auto restart cycle, with an off time equal to tOFF + tON and an on time equal to tSC, for as long as the short circuit fault condition persists. Once the fault is cleared, the unit follows its normal start up sequence after a time toff. Faults shorter than a time tSC may not be detected. Rev 2.1 03/2019 FE175D480x033FP-00 Temperature Fault Protection Output Filtering The microcontroller monitors the temperature within the AC Front End. If this temperature exceeds TJ-OTP+, an overtemperature fault is detected, the reset logic block disables the modulator, the modulator stops the powertrain switching and the output voltage of the AC Front End falls. Once the case temperature falls below TCASE-OTP-, after a time greater than or equal to toff, the converter recovers and undergoes a normal restart. For the C-Grade version of the converter, this temperature is 75C. Faults shorter than a time totp may not be detected. If the temperature falls below TCASE-UTP-, an undertemperature fault is detected, the reset logic disables the modulator, the modulator stops powertrain switching and the output voltage of the unit falls. Once the case temperature rises above TCASE-UTP, after a time greater than or equal to tOFF, the unit recovers and undergoes a normal restart. The AC Front End module requires an output bulk capacitor in the range of 6,000 - 12,000F for proper operation of the PFC front end. The output voltage has the following two components of voltage ripple: 1) Line frequency voltage ripple: 2 * fLINE Hz component 2) Switching frequency voltage ripple: 1MHz module switching frequency component C2 GND F1 AC (L) 85 - 264VAC Output Overvoltage Protection (OVP) AC Front End MOV RSV1 EN RSV3 -IN AC (N) The microcontroller monitors the primary sensed output voltage to detect output OVP. If the primary sensed output voltage exceeds VOUT-OVLO+, a fault is latched, the logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the module falls after a time tsovp. Faults shorter than a time tSOVP may not be detected. This type of fault is a latched fault and requires that 1) the EN pin be toggled or 2) the input power be recycled to recover from the fault. R2 +OUT GND L1 +OUT +OUT C5 CM C3 C4 -OUT -OUT -OUT R1 C1 Figure 25 -- Typical application for EN55022 Class B EMI Where, in the schematic: Hold-Up Capacitance C1 = 2.2nF (Murata GA355DR7GF222KW01L) C2 = 4.7nF (Murata GA355DR7GF472KW01L) C3 = 3.3F (TDK C4532X7R1H335MT) C4 = 6800F 63V (Panasonic UVR1J682MRD) Hold-up time depends upon the output power drawn from the ACFront-End-based AC-to-DC front end and the input voltage range of downstream DC-to-DC converters. C5 = 100F 63V (Nichicon UVY1J101MPD) F1 = 5A, 216 Series Littlefuse The following formula can be used to calculate hold-up capacitance L1 = 15H (TDK MLF2012C150KT) L2 = 600H (Vicor 37052-601) The AC Front End uses secondary-side energy storage (at the SELV 48V bus) and optional PRMTM regulators to maintain output hold up through line dropouts and brownouts. The module's output bulk capacitance can be sized to achieve the required hold up functionality. (0.005 + td) C = 2 * POUT * (V22 - V12) L2 (1) MOV = 300V, 10kA, 20mm dia (Littlefuse TMOV20RP300E) for a system comprised of AC Front End and a PRM regulator: Where: R1 = 6.8 R2 = 2.2 Line Frequency Filtering C = AC Front End's output bulk capacitance in farads td = Hold-up time in seconds POUT = AC Front End's output power in watts V2 Output voltage of AC Front end's converter in volts = Output line frequency ripple depends upon output bulk capacitance. Output bulk capacitor values should be calculated based on line frequency voltage ripple. High-grade electrolytic capacitors with adequate ripple current ratings, low ESR and a minimum voltage rating of 63V are recommended. V1 = PRM regulator undervoltage turn off (volts) or POUT/IOUT-PK, whichever is greater lPK lPK/2 loutDC lfLINE Figure 26 -- Output current waveform AC Front End Page 17 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 EMI Filtering and Transient Voltage Suppression Based on the output current waveform, as seen in Figure 26, the following formula can be used to determine peak-to-peak line frequency output voltage ripple: VPPLINE = 0.2 * POUT (VOUT * fLINE * C) EMI Filtering The AC Front End with PFC is designed such that it will comply with EN55022 Class B for Conducted Emissions with the filter connected across -IN and GND as shown in Figure 25. The emissions spectrum is shown in Figures 12 - 15. If one of the outputs is connected to earth ground, a small (single turn) output common mode choke is also required. (2) Where: VPPLINE = Output voltage ripple peak-to-peak line frequency POUT = Average output power VOUT = Output voltage set point, nominally 48V EMI performance is subject to a wide variety of external influences such as PCB construction, circuit layout etc. As such, external components in addition to those listed herein may be required in specific instances to gain full compliance to the standards specified. fLINE = Frequency of line voltage Transient Voltage Suppression C = Output bulk capacitance IDC = Maximum average output current The AC Front End contains line transient suppression circuitry to meet specifications for surge (i.e., EN61000-4-5) and fast transient conditions (i.e., EN61000-4-4 fast transient/"burst"). IPK = Peak-to-peak line frequency output current ripple In certain applications, the choice of bulk capacitance may be determined by hold-up requirements and low frequency output voltage filtering requirements. Such applications may use the greater capacitance value determined from these requirements. The ripple current rating for the bulk capacitors can be determined from the following equation: IRIPPLE 0.8 * POUT VOUT (3) Thermal management of internally dissipated heat should maximize heat removed from the baseplate surface, since the baseplate represents the lowest aggregate thermal impedance to internal components. The baseplate temperature should be maintained below 100C. Cooling of the system PCB should be provided to keep the leads below 100C, and to control maximum PCB temperatures in the area of the module. Powering a Constant Power Load Switching Frequency Filtering Some applications require the output filtering shown in Figure 25 to meet radiated emissions limits. In such a situation, the output switching ripple shown in Figure 5 should be expected at the output of the filter. In cases where other means are used to control radiated emissions, and more ripple can be tolerated, the output filter can be simplified by removal of the common mode inductor, and C5, which is used to reduce the Q of the LC resonant tank. Output switching frequency voltage ripple is the function of the output bypass ceramic capacitor. Output bypass ceramic capacitor values should be calculated based on switching frequency voltage ripple. Normally bypass capacitors with low ESR are used with a sufficient voltageQrating. TOT C3 = Thermal Design (4) When the output voltage of the AC Front End module is applied to the input of the PRMTM regulator, the regulator turns on and acts as a constant-power load. When the module's output voltage reaches the input undervoltage turn on of the regulator, the regulator will attempt to start. However, the current demand of the PRM regulator at the undervoltage turn-on point and the hold-up capacitor charging current may force the AC Front End into current limit. In this case, the unit may shut down and restart repeatedly. In order to prevent this multiple restart scenario, it is necessary to delay enabling a constant-power load when powered up by the upstream AC to 48V front end until after the output set point of the AC Front End is reached. This can be achieved by VOUT-PP-HF - COUT-INT Output bypass ceramic capacitor value for allowable peak-to-peak switching frequency voltage ripple can be determined by: C3 = QTOT VOUT-PP-HF - COUT-INT and (4) 2) Turning the downstream constant-power load on after the output voltage of the module reaches 48V steady state. Where: VOUT-PP-HF = Allowable peak-to-peak output switching frequency voltage ripple in volts QTOT = The total output charge per switching cycle at full load, maximum 13.5C COUT-INT = The module internal effective capacitance C3 = Required output bypass ceramic capacitor AC Front End Page 18 of 23 1) Keeping the downstream constant-power load off during power up sequence After the initial start up, the output of the AC Front End can be allowed to fall to 30V during a line dropout at full load. In this case, the circuit should not disable the PRM regulator if the input voltage falls after it is turned on; therefore, some form of hysteresis or latching is needed on the enable signal for the constant power load. The output capacitance of the AC Front End should also be sized appropriately for a constant power load to prevent collapse of the output voltage of the module during line dropout (see Hold-Up Capacitance on page 18). A constant-power load can be turned off after completion of the required hold up time during the powerdown sequence or can be allowed to turn off when it reaches its own undervoltage shut-down point. Rev 2.1 03/2019 FE175D480x033FP-00 Source Inductance Considerations The timing diagram in Figure 27 shows the output voltage of the AC Front End module and the PRMTM PC pin voltage and output voltage of the PRM regulator for the power up and power down sequence. It is recommended to keep the time delay approximately 10 - 20ms. AC Front End VOUT The AC Front End powertrain uses a unique Adaptive Cell Topology that dynamically matches the powertrain architecture to the AC line voltage. In addition the AC Front End uses a unique control algorithm to reduce the AC line harmonics yet still achieve rapid response to dynamic load conditions presented to it at the DC output terminals. Given these unique power processing features, the AC Front End can expose deficiencies in the AC line source impedance that may result in unstable operation if ignored. 49V - 3% PRM UV Turn on PRMTM Regulator It is recommended that for a single AC Front End, the line source inductance should be no greater than 1mH for a universal AC input of 100 - 240V. If the AC Front End will be operated at 240V nominal only, the source impedance may be increased to 2mH. For either of the preceding operating conditions it is best to be conservative and stay below the maximum source inductance values. When multiple AC Front End's are used on a single AC line, the inductance should be no greater than 1mH/N, where N is the number of AC Front End's on the AC branch circuit, or 2mH/N for 240VAC operation. It is important to consider all potential sources of series inductance including and not limited to, AC power distribution transformers, structure wiring inductance, AC line reactors, and additional line filters. Non-linear behavior of power distribution devices ahead of the AC Front End may further reduce the maximum inductance and require testing to ensure optimal performance. tDELAY PC PRMTM Regulator VOUT tHOLD-UP Figure 27 -- PRM enable hold-off waveforms Special care should be taken when enabling the constant-power load near the auto-ranger threshold, especially with an inductive source upstream of the AC Front End. A load current spike may cause a large input voltage transient, resulting in a range change which could temporarily reduce the available power (see Adaptive CellTM Topology below). Adaptive CellTM Topology The Adaptive Cell topology utilizes magnetically coupled "top" and "bottom" primary cells that are adaptively configured in series or parallel by a configuration controller comprised of an array of switches. A microcontroller monitors operating conditions and defines the configuration of the top and bottom cells through a range control signal. If the AC Front End is to be utilized in large arrays, the AC Front Ends should be spread across multiple phases or sources thereby minimizing the source inductance requirements, or be operated at a line voltage close to 240VAC. Vicor Applications should be contacted to assist in the review of the application when multiple devices are to be used in arrays. A comparator inside the microcontroller monitors the line voltage and compares it to an internal voltage reference. If the input voltage of the AC Front End crosses above the positive going cell reconfiguration threshold voltage, the output of the comparator transitions, causing switches S1 and S2 to open and switch S3 to close (see Functional Block Diagram on page 8). With the top cell and bottom cell configured in series, the unit operates in "high" range and input capacitances CIN-T and CIN-B are in series. If the peak of input voltage of the unit falls below the negativegoing range threshold voltage for two line cycles, the cell configuration controller opens switch S3 and closes switches S1 and S2. With the top cell and bottom cells configured in parallel, the unit operates in "low" range and input capacitances CIN-T and CIN-B are in parallel. Power processing is held off while transitioning between ranges and the output voltage of the unit may temporarily droop. External output hold up capacitance should be sized to support power delivery to the load during cell reconfiguration. The minimum specified external output capacitance of 6,000F is sufficient to provide adequate ride-through during cell reconfiguration for typical applications. AC Front End Page 19 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Product Outline Drawing - Top View IWI 47.63 1.875 9.8 .386 95.3 3.75 7.01 .276 74.52 2.934 37.26 1.467 2.0 .080 2.54 .100 3.18 .125 (6) PL. 5.2 .204 5.8 .227 9.3 .364 44.55 1.754 26.05 1.026 17.28 .680 8.00 .315 8.78 .345 24.30 .957 7.03 .277 38.2 1.505 IWI IWI 4.00 .157 2.86 .113 12.00 .472 48.6 1.91 IWI 50.25 1.978 80.25 3.159 3.99 .157 2.06 .081 (12) PL. 13.54.64 .533.025 9.55.25 .376.010 .6 .022 SEATING PLANE 94.1 3.706 NOTES: 1- RoHS COMPLIANT PER CST-0001 LATEST REVISION. 2- PLATED THROUGH HOLES SHALL BE USED WITH VIBRICK STANDOFF KITS TO GROUND THE BASEPLATE TO THE CUSTOMERS PCB AND/OR COLD PLATE. Product outline drawings are available in .pdf and .dxf formats. 3D mechanical models are available in .pdf and .step formats. See the AC Front End family page for more details. AC Front End Page 20 of 23 Rev 2.1 03/2019 37.1 1.46 FE175D480x033FP-00 Recommended PCB Footprint 40.13.08 1.580.003 TOP LAYER COPPER KEEP OUT AREA 37.26.08 1.467.003 10.13.08 .399.003 3.86.08 .152.003 37.26.08 1.467.003 3.81.08 .150.003 PLATED THRU 1.02 [.040] ANNULAR RING (O5.84 [.230]) (4) PL. SEE NOTE 2 40.13.08 1.580.003 47.63 1.875 15.39.08 .606.003 .00 .000 95.3 3.75 R4.64 .182 (3) PL. 22.28.08 .877.003 13.03.08 .513.003 48.6 1.91 4.25.08 .167.003 .00 .000 4.25.08 .167.003 24.30 .957 13.03.08 .513.003 DC+ OUT GND AC(L) DC+ OUT RSV1 EN -IN DCOUT DCOUT 0 .000 22.28.08 .877.003 2.36.08 .093.003 PLATED THRU .73 [.029] ANNULAR RING (O3.81 [.150]) (8) PL. 7.74.08 .305.003 6.00.08 .236.003 2.00.08 .079.003 RSV3 AC(N) GND 18.28.08 .720.003 3.81.08 .150.003 PLATED THRU .06 [.023] ANNULAR RING (O5.00 [.197]) (2) PL. SEE NOTE 2 .00 .000 2.00.08 .079.003 6.00.08 .236.003 2.36.08 .093.003 PLATED THRU .54 [.021] ANNULAR RING (O3.43 [.135]) (4) PL. yljvttluklkGwjiGwh{{lyu (COMPONENT SIDE SHOWN) Product outline drawings are available in .pdf and .dxf formats. 3D mechanical models are available in .pdf and .step formats. See the AC Front End family page for more details. AC Front End Page 21 of 23 Rev 2.1 03/2019 FE175D480x033FP-00 Revision History Revision Date 2.1 03/19/19 AC Front End Page 22 of 23 Description First release with updated formatting Rev 2.1 03/2019 Page Number(s) n/a FE175D480x033FP-00 Vicor's comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. Vicor makes no representations or warranties with respect to the accuracy or completeness of the contents of this publication. Vicor reserves the right to make changes to any products, specifications, and product descriptions at any time without notice. Information published by Vicor has been checked and is believed to be accurate at the time it was printed; however, Vicor assumes no responsibility for inaccuracies. Testing and other quality controls are used to the extent Vicor deems necessary to support Vicor's product warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. Specifications are subject to change without notice. Visit http://www.vicorpower.com/ac-dc/converters/ac-front-end-module for the latest product information. Vicor's Standard Terms and Conditions and Product Warranty All sales are subject to Vicor's Standard Terms and Conditions of Sale, and Product Warranty which are available on Vicor's webpage (http://www.vicorpower.com/termsconditionswarranty) or upon request. Life Support Policy VICOR'S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF THE CHIEF EXECUTIVE OFFICER AND GENERAL COUNSEL OF VICOR CORPORATION. As used herein, life support devices or systems are devices which (a) are intended for surgical implant into the body, or (b) support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in a significant injury to the user. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system or to affect its safety or effectiveness. Per Vicor Terms and Conditions of Sale, the user of Vicor products and components in life support applications assumes all risks of such use and indemnifies Vicor against all liability and damages. Intellectual Property Notice Vicor and its subsidiaries own Intellectual Property (including issued U.S. and Foreign Patents and pending patent applications) relating to the products described in this data sheet. No license, whether express, implied, or arising by estoppel or otherwise, to any intellectual property rights is granted by this document. Interested parties should contact Vicor's Intellectual Property Department. The products described on this data sheet are protected by the following U.S. Patents Numbers: 5,945,130; 6,403,009; 6,710,257; 6,911,848; 6,930,893; 6,934,166; 6,940,013; 6,969,909; 7,038,917; 7,166,898; 7,187,263; 7,361,844; D496,906; D505,114; D506,438; D509,472; and for use under 6,975,098 and 6,984,965. Contact Us: http://www.vicorpower.com/contact-us Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 www.vicorpower.com email Customer Service: custserv@vicorpower.com Technical Support: apps@vicorpower.com (c)2019 Vicor Corporation. All rights reserved. The Vicor name is a registered trademark of Vicor Corporation. All other trademarks, product names, logos and brands are property of their respective owners. AC Front End Page 23 of 23 Rev 2.1 03/2019