AEH30Y48(N) Half-brick Product Te c h n i c a l R e f e r e n c e N o t e s 48V Input, 1.8V@30A Output High Efficiency Half-brick DC-DC Converter (REV01) -1TEL: 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 Publishing Date: 20020703 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Introduction AEH30Y48(N) single output product Design Features comes ! High Efficiency ! High power density ! Low output noise age protection(OVP), over-current protec- ! Aluminum based plate tion(OCP), over-temperature protection(OTP), ! Input under-voltage lockout CNT, Trim, and remote sense functions. The ! CNT function ! Trim function ! Remote sense isolated DC/DC converters are built using the ! Output short circuit protection industry standard half-brick pin-out and pack- ! Output current limiting age: 61.0mm x 57.9mm x 12.7mm (2.4" x 2.28" ! Output over-voltage protection ! Overtemperature protection ! High input-output isolation voltage with a 2:1 input range of 36V-75V, isolated outputs 1.8V/30A. Standard features include input low voltage protection(LVP), output over-volt- input-output isolation is 1500Vdc, and it can operate up to 100C(base-plate temperature) without derating. AEH30Y48(N) single output x 0.5"). Typical efficiencies are 82% for the 1.8V@30A output. Designed using a synchronous rectification topology, AEH30Y48(N) incorporates simple structure, good electrical performance and high Options reliability. Using aluminum based plate, the maximum case temperature can reach 100 C ! Heat sink available for extended operation. ! Choice of CNT logic configuration. without derating. The AEH30Y48(N) 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Typical Application Fuse* +SEN Vin(+) K Vo(+) CNT power TRM CASE C1 C3 C4 C2 Load Vo(-) Vin(-) -SEN NOTE: The figure is Negative Logic Control, if the CNT pin is left open, the converter will default to 'control off' operation. Positive Logic Control is also available. Positive Logic Control: Low=Off, High=On. Negative Logic Control: Low=On, High=Off. Recommended External components: Fuse*: Recommended: 5A. C1: Recommended 100F/100V (use two parallel at -40 C). C2: Recommended electrolytic capacitor of 2200F /16V(LOW ESR). C3: Recommended 4700pF/2000V C4: Recommended metallic film capacitor of 1F /16V. 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Block Diagram +Vin +Vout -Vin -Vout +Sense Trim -Sense CNT Ordering Information (at 25 C) Model Input Output Output Ripple&Noise Efficiency Short-circuit Over-voltage (%) Current Lockout Voltage Voltage Current TEL: FAX: (V) (V) (A) (mV pp) Min Typ AEH30Y48N 36-75 1.8 30 60&100 80 AEH30Y48 36-75 1.8 30 60&100 80 USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 (A) (V) 82 33-42 2.2-3 82 33-42 2.2-3 Asia 852-2437-9662 852-2402-4426 -4www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Electrical Characteristic Absolute Maximum Rating Parameters Min. Typ. Max. Unit Note Input voltage (+Vin ~ -Vin) -0.3 - 80 Vdc Continuously CNT voltage (CNT ~ -Vin) - - 15 Vdc Continuously Isolated voltage - - 1500 Vdc Input-output Operating temperature -40 - +100* C *: case temperature Storage temperature -55 - +125 C Input characteristics Parameter Code Min. Typ. Max. Unit Input voltage range Vin 36 48 75 Vdc Maximum input current Iin - - 2.5 A 33 35 Vdc 30 mAp-p Input under-voltage shutdown - 30 Input reflected current - - Conditions (the lowest input voltage, rated output ) ( 5Hz-20MHz, 12H impedance, ambient temperature Ta=25C ) General Specification Parameter Code Min. MTBF - 2000000 Weight - Typ. Max. Unit Conditions hour 70 g CNT Function Parameter Code Min. Typ. Max. Unit Conditions Logic High - 3.5 - 15 V Logic Low - -0.7 - 1.2 V Control Current - - - 1 mA Logic Low Min. Typ. Max. Unit Conditions - 10 ms (80% rated load, ambient temperature On/OFF characteristics Parameter Code CNT is set on, input voltage Tdelay - sudden change (ON) TEL: FAX: 25 C) Output voltage rise time Trise - 10 20 ms Output voltage rush over Vrush - 0 - %Vo 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Output Characteristics Parameter Code Min. Typ. Max. Unit Conditions Output setpoint voltage Vo,set 1.782 1.800 1.818 Vdc 25 C ambient temperature,rated input, full load Output voltage Vo 1.782 1.800 1.818 Vdc Full input range, output range and ambient temperature range. 0%~100% load Line regulation - - 0.1 0.2 % Low-high Load regulation - - 0.1 0.5 % 0%~100% rated load Temperature coefficient Tcoeff - - 0.02% / C Output ripple peak-peak value - - - 60 mVp-p Output noise peak-peak value - - - 100 mVp-p f<20MHz Output current Io - - 30 A (when Io>Iomax, the module can operate normally, but the ripple&noise may exceed the standards.) Output current-limiting setpoint - 33 - 42 A (Vo=90%Vo) Efficiency 80 82 - - (rated input voltage, rated load, ambient Dynamic response Voltage inrush Vo,set - - 80 mV 25% Inom step, Io/t=1A/10s 25% Inom step, Io/t=1A/10s temperature 25 C) - - 200 S Switching frequency - - 180 - KHz Output voltage adjustable range - 90% - 110% Vo,set Output over-voltage shutdown - 2.2 - 3 V Code Min. Typ. Max. Unit Input - output - 1500 - - Vdc Input -case - 1500 - - Vdc Output - case - 1500 - - Vdc - 10 - - M Response time - Safety Characteristics Parameter Isolation voltage: Isolation resistance 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Characteristic Curves (at 25 C ) H Reflected noise current testing With 12 impedance, test point in the input line Output ripple & noise testing method to grounding loop To oscilloscope Current Probe 12H +Vin Battery LTest + + Cs 220F Ci 100F -Vin Typical Input-Output Characteristics AEH30Y48N Typical Efficiency AEH30Y48N 90 2 85 1.5 Iin(A) Efficiency (%) 80 75 70 36Vin 1 0.5 48Vin 65 75Vin 60 0 0 55 0 5 10 15 20 25 20 40 60 80 Vin(V) 30 %Io Typical OCP AEH30Y48N 1.8 Output Voltage (V) 1.7 36Vin 1.6 48Vin 75Vin 1.5 1.4 0 5 10 15 20 25 30 35 40 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 -7www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output T ransient response (48V rated input voltage, full load, at 25 C) Typical Start-Up Transient with Remote On/Off AEH30Y48N Typical Shut-down Transient with Remote On/Off AEH30Y48N Typical Start-up from Power On AEH30Y48N Typical Shut-down from Power Off AEH30Y48N 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output T ransient response TEL: FAX: (48V rated input voltage, full load, at 25 C) Typical Transient Response to Step Load Change from 25%-50%-25%Iomax AEH30Y48N Typical Transient Response to Step Load Change from 50%-75%-50%Iomax AEH30Y48N Typical Output Ripple Voltage AEH30Y48N Typical Overvoltage Protection AEH30Y48N 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Pin Location The +Vin and -Vin input connection pins are located as shown in Figure 1. AEH30Y48(N) converter has a 2:1 input voltage range and can accept input voltage range of 36-75 Vdc. Care should be taken to avoid applying reverse polarity to the input which can damage the converter. -Vin -Vout Case -Sense CNT +Sense +Vin +Vout Input Reverse Voltage 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. Diodes should be rated at 5A/100V for AEH30Y48(N). 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. +Vin +Vin -Vin -Vin Trim Fig.2 Reverse Polarity Protection Circuits Component-side footprint (component-side view) Fig.1 Pin Location Input Characteristic Fusing The AEH30Y48(N) 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 AEH30Y48(N) is 5A. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Input Undervoltage Protection The module has input under voltage protection. The AEH30Y48(N) 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 under-voltage condition is removed. When the input voltage is below LVP point, the input under-voltage protection active, output is cut off. There is a 1-2V hysteresis between the under-voltage shutdown point and restart up point. 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 AEH30Y48(N) has an internal switching frequency of 180 kHz so a high frequency capacitor mounted close to the input terminals pro- Asia 852-2437-9662 852-2402-4426 -10www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output +Vin C1 -Vin Fig.3 Ripple Rejection Input Filter duces the best results. To reduce reflected noise, a capacitor can be added across the input as shown in Figure 3, forming a filter. A 100F/100V electrolytic capacitor is recommended for C1. 2200uF/16V 0.33uF 1uF 1uF 1000p Case 470u 1u L1 0.33uF -Vin 1000p 100pF Negative logic, device code suffix nothing is the factory-preferred. If the CNT pin is left open, the converter will default to " control off " operation in negative logic, but default to " control on " in positive logic. The maximum voltage that can be applied to the CNT pin is 15V. If the CNT function is not used: negative logic --- connect CNT pin to Vin(-), positive logic --- leave CNT pin open. During operation, the working current of CNT is related to its input voltage, and is lower than 1mA. In the non-isolated application, CNT control can be realized through mechanical switcher or transistor as Figure 5. In the isolated application, CNT control can be realized through optoisolator or relay as Fig. 6. It is recommended to parallel a 0.1F capacitor to remove the interference when the CNT line is too long. Fig.4 EMI Reduction Input Filter CNT For conditions where EMI is a concern, a different input filter can be used. Figure 4 shows an typical application circuit special designed to reduce EMI effects. Users can choose different capacitor value according to actual applications. CNT Control Signal -Vin -Vin Transistor Mechanical Switcher CNT Function Two remote CNT options are available. For Negative logic: applying a voltage less than 1.2V to the CNT pin will enable the output, and applying a voltage greater than 3.5V will disable it. For Positive logic: applying a voltage larger than 3.5V to the CNT pin will enable the output, and applying a voltage less than 1.2V will disable it. Positive logic, device code suffix " P " . TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Fig.5 Non-isolated CNT Control CNT CNT Control signal Control signal -Vin Optoisolator -Vin Relay Fig.6 Isolated CNT Control Asia 852-2437-9662 852-2402-4426 -11www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Input-Output Characteristic Safety Consideration For safety-agency approval of the system in which the power module is used, the power 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(<60Vdc), the output is considered to remain within SELV limits (level 3). If connected to a 60Vdc power system, double or reinforced insulation must be provided in the power supply that isolates the input from any hazardous voltages, including the ac mains. One Vi pin and one Vo pin are to be grounded or both the input and output pins are to be kept floating. Single fault testing in the power supply must be performed in combination with the DC/DC power module to demonstrate that the output meets the requirement for SELV. The input pins of the module are not operator accessible. Note: Do not ground either of the input pins of the module, without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. Case Grounding For proper operation of the module, the case or baseplate of the AEH30Y48(N) does not TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 require a connection to a chassis ground. If the AEH30Y48(N) is not in a metallic enclosure in a system, it may be advisable to directly ground the case to reduce electric field emissions. Leaving the case floating can help to reduce magnetic field radiation from common mode noise currents. If the case has to be grounded for safety or other reasons, an inductor can be connected to chassis at DC and AC line frequencies, but be left floating at switching frequencies. Under this condition, the safety requirements are met and the emissions are minimized. Output Characteristics Minimum Load Requirement There is no minimum load requirement for the AEH30Y48(N). Remote Sensing The AEH30Y48(N) can remotely sense both lines of its output which 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 AEH30Y48(N) in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. When the converter is supporting loads far away, or is used with undersized cabling, significant voltage drop can occur at the load. The best defense against such drops is to locate the load close to the converter and to ensure adequately sized cabling is used. When this is not possible, the converter can compensate for a drop of up to 0.5V, through use of the sense Asia 852-2437-9662 852-2402-4426 -12www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output +Vout +Sense Vin(+) +S Twisted Pair Load -Sense VO(+) CNT +SEN Radj-up -S CASE TRM Vin(-) -SEN VO(-) -Vout Fig.7 Sense Connections Output Trimming Trimming Users can increase or decrease the output voltage set point of a module by connecting an external resistor between the TRIM pin and either the +SEN or -SEN pins. The trim resistor should be positioned close to the module. If not using the trim feature, leave the TRIM pin open. Trimming up by more than 10% of the nominal output may damage the converter or trig the OVP protection. Trimming down more than 10% can cause the converter to regulate improperly. Trim down and trim up circuits and the corresponding configuration are shown in Figure 8 to Figure 11. USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Radj-up = 10x[Vo(100+y)-122.5] 1.225y - 11 y is the adjusting percentage of the voltage. 0 < y < 10 Radj-up is in k. Vo is rated output voltage. Fig.8 Equation to Trim Up Output Voltage 500 Adjustment Resistor Value (k) leads. When used, the +SEN and -SEN leads should be connected from the converter to the point of load as shown in Figure 7 using twisted pair wire. The converter will then regulate its output voltage at the point where the leads are connected. Care should be taken not to reverse the sense leads. If reversed, the converter will trigger OVP protection and turn off. When not used, the +SEN lead must be connected with +Vo, and -SEN with -Vo. Also note that the output voltage and the remote sense voltage offset must be less than the minimum overvoltage trip point. Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. TEL: FAX: RLOAD 450 400 350 300 250 200 150 100 50 0 0 1 2 3 4 5 6 7 8 9 10 y ( % Change In Output Voltage ) Fig.9 Resistor Selection for Trimming Up Vin(+) VO(+) CNT +SEN CASE TRM Vin(-) -SEN RLOAD Radj-down VO(-) Radj-down = 1000 - 11 y y is the adjusting percentage of the voltage. 0 < y < 10 Radj-up is in k. Vo is rated output voltage. Fig.10 Equation to Trim Down Output Voltage Asia 852-2437-9662 852-2402-4426 -13www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Adjustment Resistor Value (k) 1000 +Vout C1 900 Load 800 -Vout 700 600 500 Fig.12 Output Ripple Filter 400 300 200 100 0 0 1 2 3 4 5 6 7 8 9 10 y ( % change in output voltage ) Fig.11 Resistor Selection for Trimming Down Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. Trimming up the output voltage, the output power should not exceed its rated output power. When not use trim function, please leave Trim pin in the midair. Output Over-Current Protection: AEH30Y48(N) DC/DC converters feature Overcurrent Protection (OCP) circuits. When output current exceeds 110% to 140% of rated current, such as during a short circuit condition, the output will shutdown immediately, and can tolerate short circuit conditions indefinitely. Output Filters When the load is sensitive to ripple and noise, an output filter can be added to minimize the effects. A simple output filter to reduce output ripple and noise can be made by connecting a capacitor across the output as shown in Figure 12. The recommended value for the output capacitor C1 is 2200F/16V(low ESR). TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Extra care should be taken when long leads or traces are used to provide power to the load. Long lead lengths increase the chance for noise to appear on the lines. Under these conditions C2 can be added across the load as shown in Figure 13. The recommended component for C2 is 2200F/16V(low ESR) capacitor and connecting a 0.1F ceramic capacitor C1 in parallel generally. +Vout C1 C2 Load -Vout Fig.13 Output Ripple Filter For a Distant Load Decoupling Noise on the power distribution system is not always created by the converter. High speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a 10 F tantalum capacitor in parallel with a 0.1F ceramic capacitor across the load will decouple it. The capacitors should be connected as close to the load as possible. Ground Loops Ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in Figure 14. Multiple ground points can slightly different potential and cause Asia 852-2437-9662 852-2402-4426 -14www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output current flow through the circuit from one point to another. This can result in additional noise in all the circuits. To eliminate the problem, circuits should be designed with a single ground connection as shown in Figure 15. RLine RLine +Vout Load Load RLine -Vout RLine RLine Ground Loop Parallel Power Distribution Figure 16 shows a typical parallel power distribution design. Such designs, sometimes called daisy chains, can be used for very low output currents, but are not normally recommended. The voltage across loads far from the source can vary greatly depending on the IR drops along the leads and changes in the loads closer to the source. Dynamic load conditions increase the potential problems. RLine I1 + I2 + I3 I2 + I3 I3 RL2 RL1 RL3 +Vout Fig.14 Ground Loops Load 1 Load 2 Load 3 -Vout RG2 RG1 RLine RG3 RL = Lead Resistance RG = Ground Lead Resistance RLine +Vout Fig.16 Parallel Power Distribution Load Load RLine -Vout RLine RLine Fig.15 Single Point Ground Output Over-Voltage Over-Voltage Protection The over-voltage protection has a separate feedback loop which activates when the output voltage is between 2.2~3.0V. When an overvoltage condition occurs, a "turn off" signal is sent to the input of the module which will shut down the output. The module will restart after power on again. If the module is trimmed up to the voltage, which exceeds the 110% rated output voltage, the output over-voltage protection will be probably triggered off. Radial Power Distribution Radial power distribution is the preferred method of providing power to the load. Figure 17 shows how individual loads are connected directly to the power source. This arrangement requires additional power leads, but it avoids the voltage variation problems associated with the parallel power distribution technique. +Vout RL3 RL1 RL2 Load 1 RG1 Load 2 Load 3 RG2 RG3 -Vout RL = Lead Resistance RG = Ground Lead Resistance Fig.17 Radial Power Distribution Mixed Distribution In the real world a combination of parallel and radial power distribution is often used. Dynamic and high current loads are connected using a radial design, while static and low current loads can be connected in parallel. This combined approach minimizes the drawbacks of a parallel design when a purely radial design is not feasible. 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output +Vout Thermal Management RL3 RL1 RL2 Load 1 RG1 RL4 Load 2 Load 3 Load 4 RG2 RG3 -Vout RG4 RL = Lead Resistance RG = Ground Lead Resistance Fig.18 Mixed Power Distribution Redundant Operation A common requirement in high reliability systems is to provide redundant power supplies. The easiest way to do this is to place two converters in parallel, providing fault tolerance but not load sharing. Oring diodes should be used to ensure that failure of one converter will not cause failure of the second. Figure 19 shows such an arrangement. Upon application of power, one of the converters will provide a slightly higher output voltage and will support the full load demand. The second converter will see a zero load condition and will "idle". If the first converter should fail, the second converter will support the full load. When designing redundant converter circuits, Shottky diodes should be used to minimize the forward voltage drop. The voltage drop across the Shottky diodes must also be considered when determining load voltage requirements. Technologies AEH30Y48(N) modules feature high efficiency, it have typical efficiency of 82% at full load. With less heat dissipation and temperature-resistant components such as ceramic capacitors, these modules exhibit good behavior during prolonged exposure to high temperatures. Maintaining the operating board temperature (Tc) within the specified range help keep internal-component temperatures within their specifications which in turn help keep MTBF from falling below the specified rating. Proper cooling of the power modules is also necessary for reliable and consistent operation. Basic Thermal Management Measuring the case temperature of the module (Tc) as the method shown in Figure 20 can verify the proper cooling. Figure 20 shows the metal surface of the module and the pin locations. The module should work under 100C for the reliability of operation and TC must not exceed 100 C while operating in the final system configuration. The measurement can be made with a surface probe after the module has +Vout -Vin -Vout Case -Sense +Vout CNT +Sense -Vout +Vin +Vout -Vout Load Trim Component-side footprint Fig.19 Redundant Operation Fig.20 Case Temperature Measurement 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output tion below: PD = PI PO where : PI is input power; PO is output power; PD is dissipated power. Also, module efficiency () is defined as the following equation: = PO / PI From two above equations can yield the equation below: PD = PO (1- )/ 12 10 Power Dissipation (W) reached thermal equilibrium. If a heat sink is mounted to the case, make the measurement as close as possible to the indicated position. It makes the assumption that the final system configuration exists and can be used for a test environment. The following text and graphs show guidelines to predict the thermal performance of the module for typical configurations that include heat sinks in natural or forced airflow environments. Note that Tc of module must always be checked in the final system configuration to verify proper operational due to the variation in test conditions. Thermal management acts to transfer the heat dissipated by the module to the surrounding environment. The amount of power dissipated by the module as heat (PD) is got by the equa- 8 6 36Vin 48Vin 4 75Vin 2 0 0 10 20 30 40 Output Current (A) Fig.21 AEH30Y48N Power Dissipation Curves Module Derating Experiment Setup From the experimental set up shown in figure 22, the derating curves as figure 23 can be drawn. Note that the PWB ( printed-wiring board ) and the module must be mounted vertically. The passage has a rectangular crosssection. The clearance between the facing PWB and the top of the module is kept 13 mm (0.5 in.) constantly. FACING PWB The module power dissipation then can be calculated through the equation. Because each power module output voltage has a different power dissipation curve, a plot of power dissipation versus output current over three different line voltages is given in each module-specific data sheet. The typical power dissipation curve of AEH30Y48(N) is shown in figure21. PWB MODULE AIR VELOCITY AND AMBIENT TEMPERATURE MEASURED BELOW THE MODULE 76 (3.00) AIRFLOW 19 (0.75) Dimensions: millimeters (inches). Fig.22 Experiment Set Up 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 AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Convection Without Without Heat Sinks Heat transfer can be enhanced by increasing the airflow over the module. Figure 23 shows the maximum power that can be dissipated by the module. In the test, natural convection airflow was measured at 0.05 m/s to 0.1 m/s (10 ft./min. to 20 ft./min.). The 0.5 m/s to 4.0 m/s (100 ft./min. to 800 ft./min.) curves are tested with externally adjustable fans. The appropriate airflow for a given operating condition can be determined through figure 23. 57.0 (2.24) 4.9(0.193) 4.0 m/s (800 ft./min.) 3.0 m/s (600 ft./min.) 2.0 m/s (400 ft./min.) 1.5 m/s (300 ft./min.) 1.0 m/s (200 ft./min.) 18 15 11.8 (0.465) Dimensions: millimeters (inches). 89.1(3.51) 21 Power Dissipation , PD (W) where: x = fin orientation: longitudinal (L) or trans verse (T) yyy = heat sink height (in 100ths of inch) For example, WDT5040 is a heat sink that is transverse mounted (see Figure 31) for a 61 mm x 57.9 mm (2.4 in.x 2.28 in.) module with a heat sink height of 0.5 in. Fig.24 Non Standard Heatsink WDL02540 1/4 IN. WDL05040 1/2 IN. 12 9 0.5 m/s (100 ft./min.) 6 61 (2.4) 0.1 m/s (20 ft./min.) Natural Convection 3 WDL10040 1 IN. 0 0 10 20 30 40 50 60 70 80 90 100 57.9 (2.28) Local Ambient Temperature, T A (C) Dimensions: millimeters (inches). Fig.23 Forced Convection Power Derating without Heat Sink Heat Sink Configuration Several standard heat sinks available for the AEH30Y48(N) is shown in Figure 24 to Figure 36. The heat sinks mount to the top surface of the module with screws torqued to 0.56 N-m (5 in.lb). A thermally conductive dry pad or thermal grease is placed between the case and the heat sink to minimize contact resistance (typically 0.1 C/W to 0.3 C/W) and temperature differential. Nomenclature for heat sink configurations is as follows: WDxyyy40 TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Fig.25 Longitudinal Fins Heat Sink WDT02540 1/4 IN. WDT05040 1/2 IN. 57.9 (2.28) WDT10040 1 IN. 61 (2.4) Dimensions: millimeters (inches). Fig.26. Transverse Fins Heat Sink Heatsink Mounting Advice A crucial part of the thermal design strategy is the thermal interface between the baseplate of the module and the heatsink. Inadequate mea- Asia 852-2437-9662 852-2402-4426 -18www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output sures taken here will quickly negate any other attempts to control the baseplate temperature. For example, using a conventional dry insulator can result in a case-heatsink thermal impedance of >0.5 C/W, while use one of the recommended interface methods (silicon grease or thermal pads available from Avansys) can result in a case-heatsink thermal impedance around 0.1C/W. 0.1 m/s ( 10ft./min to 20ft./min ). Figure 28 can be used for heat-sink selection in natural convection environment. Basic Thermal Model There is another approach to analyze module thermal performance, to model the overall thermal resistance of the module. This presentation method is especially useful when considering heat sinks. The following equation can be used to calculate the total thermal resistance . RCA = TC, max / PD Where RCA is the module thermal resistance; TC, max is the maximum case temperature rise; PD is the module power dissipation. In this model, PD, TC, max, and RCA are equals to current flow, voltage drop, and electrical resistance, respectively, in Ohm's law, as shown in Figure 29. Also, TC, max is defined as Fig.27 Heat Sink Mounting Natural Convection with Heat Sink The power derating for a module with the heat sinks ( shown as figure 21) in natural convection is shown in figure 28. In this test, natural convection generates airflow about 0.05 m/s to POWER DISSIPATION, PD (W) TA is the inlet ambient temperature. = BMPM THERMAL RESISTANCE BMPM PD 35 30 1 1/2 in. 1 in. 1/2 in. 1/4 in. 25 20 Fig.29 Basic Thermal Resistance Model NONE 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 LOCAL AMBIENT TEMPERATURE, TA (C) Fig.28 Heat Sink Power Derating Curves, Natural Convection TEL: FAX: the difference between the module case temperature (TC) and the inlet ambient temperature (TA). TC, max = TC TA Where TC is the module case temperature; USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 For AEH30Y48(N), the module's thermal resistance values versus air velocity have been determined experimentally and shown in figure 30. The highest values on each curve represents the point of natural convection. Asia 852-2437-9662 852-2402-4426 -19www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Figure 30 is used for determining thermal performance under various conditions of airflow and heat sink configurations. Case-Ambient Thermal Resistance R CA (C/W) 8 MTBF 7 1 in. HEAT SINK 1/2 in. HEAT SINK 1/4 in. HEAT SINK NO HEAT SINK 6 5 4 3 2 1 0 the converter. Cleaning can be performed with cleaning solvent IPA or with water. 0 0.5 (100) 1.0 (200) 1.5 (300) 2.0 (400) 2.5 (500) 3.0 (600) The MTBF, calculated in accordance with Bellcore TR-NWT-000332 is 2,000,000 hours. Obtaining this MTBF in practice is entirely possible. If the ambient air temperature is expected to exceed +25C, then we also advise a heatsink on the AEH30Y48(N), oriented for the best possible cooling in the air stream. Air Velocity m/s (ft./min.) Fig.30 Case-to-Ambient Thermal Resistance Curves; Either Orientation ASTEC can supply replacements for converters from other manufacturers, or offer custom solutions. Please contact the factory for details. Mechanical Considerations Installation Although AEH30Y48(N) converters can be mounted in any orientation, free air-flowing must be taken. Normally power components are always put at the end of the airflow path or have the separate airflow paths. This can keep other system equipment cooler and increase component life spans. Soldering AEH30Y48(N) is compatible with standard wave soldering techniques. When wave soldering, the converter pins should be preheated for 20-30 seconds at 110 C, and wave soldered at 260C for less than 10 seconds. When hand soldering, the iron temperature should be maintained at 425C and applied to the converter pins for less than 5 seconds. Longer exposure can cause internal damage to 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 -20www.astec.com AEH 48V Input Half-Brick Series Power Converters 1.8V@30A Output Recommend Hole Pattern Base-plate side view Dimensions are in millimeters and (inches). 57.9 (2.28) Max 4.8 (0.19) 48.3 (1.90) 48.26 (1.900) +Vin 35.56 (1.400) 50.8 (2.00) +Vout 35.56 (1.400) +Sense CNT 25.40 (1.000) Trim 25.40 (1.000) 10.16 (0.400) -Sense Case 17.78 10.16 (0.700) (0.400) 61.0 (2.40) Max -Vout -Vin 5.1 (0.20) 12.7 (0.50) Mounting Inserts Module Outline Mechanical Chart 5.1 (0.2) 61.0 (2.4) 7.62 (0.3) +Vin +Vout CNT +Sense 10.16 (0.4) 10.16 (0.4) 7.62 (0.3) 15.24 (0.6) Trim 7.62 (0.3) Case -Sense -Vin -Vout 10.16 (0.4) 10.16 (0.4) Mounting Inserts M3 thru hole x4 4.8 (0.19) 48.26 (1.9) mm (inches) 57.9 (2.28) Length optional 5.8 (0.228) default 12.7 (0.5) 7- 1.0 (0.04) all pins except +Vo and -Vo Pin Length Option 4.80mm ! 0.5mm 0.189in. ! 0.020in. 3.80mm ! 0.25mm 0.150in. ! 0.010in. 2.80mm ! 0.25mm 0.110in. ! 0.010in. 5.8mm ! 0.5mm 0.228in. ! 0.02in. TEL: FAX: USA 1-760-930-4600 1-760-930-0698 Europe 44-(0)1384-842-211 44-(0)1384-843-355 Device Code Suffix -4 -6 -8 none 2- 2.0 (0.08) only +Vo and -Vo Base-plate side view Tolerances: Inches .xx !0.020 .xxx !0.010 Pins >4mm <4mm Asia 852-2437-9662 852-2402-4426 Millimeters .x !0.5 .xx !0.25 !0.02inch ( !0.5mm) !0.01inch ( !0.25mm) -21www.astec.com PART NUMBER DESCRIPTION ss pp c - 0 iv L - iv = Input Voltage 05 = Range centered on 5V 12 = Range centered on 12V 24 = 18 to 36(2:1), 9 to 36V(4:1) 36 = 20 to 60V 46 = 18V to 75V (4:1) 48 = Typ 36 to 75V xxx f - yy h n p - mx-Options p = Pin Length Omit this digit for Standard 5mm 6 = 3.8mm, 7= 5.8mm 8 = 2.8mm Enable Logic Polarity Omit for Positive Enable Logic N = Negative Enable Except: AK60C-20H, BK60C-30H Omit for Negative Logice P = Positive Logic c = Pinout compatability A= Astec Footprint or "non Lucent" footprint C= Ind Std, Exact Lucent drop in pp = Package Type 40 = 1" x 2" SMD 42 = 1.5" x 2" SMD 45 = 1.45" X 2.3" (1/4 Brk) 60 = 2.4" X 2.3" (1/2 Brk) 80 = Full size 4.6" x 2.4" 72= 2.35" X 3.3 (3/4 Brk) H = High Efficiency (Synch rect.) Omit H if Conventional Diode (low Eff) yy = Output Current ie. 08 = 8 Amps f = # of Outputs F = Single Output D = Dual Output xxx = Output Voltage Format is XX.X (ie 1.8V = 018) ss = Series AA = 1/2brick Dual (Old designator) mx = Options M1,M2 = .25" Height Heatsink M3,M4 = .5" height Heatsink M5.M6 = 1.0" Height Heatsink AK = Ind Std sizes (1/4, 1/2, full) <150W AM/BM = Full size, astec pin out AL = Half size, astec pin-out BK = Ind Std size =>150W or feature rich AV = Avansys Product Note: For some products, they may not conform with the PART NUMBER DESCRIPTION above absolutely. REVISION Q ATTACHMENT I Page 1 of 2 NEW PART NUMBER DESCRIPTION A c s ii V1 V2 V3 Output Voltage A = 5.0V F = 3.3V G = 2.5V D = 2.0V / 2.1V Y = 1.8V M = 1.5V K = 1.2V J = 0.9V Vin - e t p Mx E = 7.5V B = 12V, C = 15V L = 8V, H = 24V, R = 28V Omit V2 and V3 if Single Output Omit V3 if Dual Output ie for Dual Output 5 and 3.3V V1 =A, V2 = F, V3 =Omit V1 =A, V2 = F, V3 =Omit ii = Output Current Max ie 60 = 60 Amps Vin = Input Voltage range 300 = 250V to 450V 48 = 36V to 75V 24 = 18V to 36V 03 = 1.8V to 5.0V 08 = 5.0V to 13.0V PFC: Power Factor Corrected S = Size F = Full Brick H = Half Brick Q = Quarter Brick S = 1 X 2 18 Pin SMT E = 1 X 2 Thru Hole C = (.53X1.3X.33) SMT (Austin Lite drop in) V = Conventional Package (2X2.56") or ( A = SIP W = Convent pkg (Wide 2.5X3) R = 1 X 1 Thru Hole A = SIP T = 1.6 X 2 E = Enable Logic for > 15W Omit this digit for Positive enable N = Negative Logic E = Enable Logic for < 15W Omit this digit for no enable option 1 = Negative Logic 4 = Positive Logic c = Construction E = Enhanced Thermals (Baseplate or adapter plate) I = Integrated (Full Featured) Hong Kong models L = Low Profile (Open Frame, No case - Isolated) P = Open Frame (SIP or SMT) non-isolated Trim for 1W to 15W 9 = Trim Added P = Pin Length Omit this digit for Standard 5mm 6 = 3.8mm 8 = 2.8mm 7 = 5.8 mm Mx - Factory Options customer Specific Note: For some products, they may not conform with the NEW PART NUMBER DESCRIPTION above absolutely. REVISION Q ATTACHMENT I Page 2 of 2