AV60C-048L-050F30NL - Emerson Network Power - Embedded Power

-1-

-b

48V Input, 5V Output

50-150W DC-DC Converter

(Rev01)

USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 Publishing Date: 20020607

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Introduction

The AV60C half-brick series of switching DC-

DC converters is one of the most cost effective

options available in component power. The

series uses an industry standard package size

of 2.4”x2.28”x0.5” and pinout configuration,

provides standard control, trim, and sense func-

tions, also features high power density up to

54.8W/in3which gives more selectivity to meet

small size requirement.

AV60C half-brick series comes in 48V input ver-

sion with a 2:1 ( 36-75V ) input range. This

series has input LVP, output OVP, OCP, short

circuit protection and over temperature protec-

tion. There are isolated single output 3.3V, 5V,

12V, 15V and the isolation voltage is 1500Vdc.

This series is designed to meet CISPR22, FCC

class A, UL and CSA certifications.

The design features of the AV60C half-brick

series set a new standard for high density

power converters. The unit employs an alu-

minum baseplate to carry all of the power com-

ponents, and conduct the dissipated heat to the

ambient. A conventional, multi-layer printed cir-

cuit board, over the top of the power substrate,

contains all of the small signal control circuitry,

all constructed with automated SMD technolo-

gy.

Feature

! High Efficiency

! High power density

! Low output noise

! Metal baseplate

! CNT function

! Remote sense

! Trim function

! Input under-voltage lockout

! Output short circuit protection

! Output current limiting

! Output over-voltage protection

! Overtemperature protection

! High input-output isolation voltage

Options

! Heat sink available for extended operation.

! Choice of CNT logic configuration.

-3-

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Fuse*

Trim

-Vout

-Sense

+Vout

+Sense

-Vin

CNT

+Vin

Load

C4 C2

Case

Vin



Fuse*: Use external fuse ( fast blow type ) for each unit.

50W output : 5A fuse

75W output : 7.5A fuse

100W output : 10A fuse

150W output : 20A fuse

C1*: Recommended input capacitor C1

-20 °C ~ +100 °C: m 47µF/100V electrolytic or ceramic type capacitor.

-40 ° C ~ +100 °C: m 47µF/100V ceramic type capacitor only.

C2*: Recommended output capacitor C2

-20 °C~ +100 °C: 1000µF/10V (electrolytic capacitor) for 50W-75W

2200µF/10V (electrolytic capacitor) for 100W-150W

-40 °C~ +100 °C: For this temperature range, use two pieces of the recommended capacitor

above.

C3: Recommended 4700pF/2000V

C4: Recommended 0.1µF/10V

Typical Application

ypical Application

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Block Diagram

Ordering Information

AV60C-048L-050F10 36-75V 5V 10A 40 150 83% 84%

AV60C-048L-050F10N 36-75V 5V 10A 40 150 83% 84%

AV60C-048L-050F15 36-75V 5V 15A 40 150 83% 85%

AV60C-048L-050F15N 36-75V 5V 15A 40 150 83% 85%

AV60C-048L-050F20 36-75V 5V 20A 40 150 83% 85%

AV60C-048L-050F20N 36-75V 5V 20A 40 150 83% 85%

AV60C-048L-050F30 36-75V 5V 30A 40 150 83% 85%

AV60C-048L-050F30N 36-75V 5V 30A 40 150 83% 85%

-4-

+Vout

-Vout

+Sense

-Sense

CNT

+Vin

-Vin

Trim

Model Input Output Output Ripple Noise Efficiency

Number Voltage Voltage Current (mV rms) (mV pp) min. typ.

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Absolute Maximum Rating

Input Voltage(continuous) -0.3 80 Vdc

Input Voltage(peak/surge) -0.3 100 Vdc 100ms non-repetitive

Case temperature -40 100 °C

storage temperature -55 125 °C

Input Characteristics

Input Voltage Range 36 48 75 Vdc

Input Reflected Current 30 50 mAp-p

T urn-of f Input Voltage 30 33 35 V

T urn-on Input Voltage 31 34 36 V

T urn On Time 20 35 ms

CNT Function

Logic High 3 15 Vdc

Logic Low 1.2 Vdc

Control Current 2 mA

General Specifications

MTBF 2000 k Hrs Bellcore TR332, Tc=40°C

Isolation 1500 Vdc

Pin solder temperature 260 °C wave solder < 10 s

Hand Soldering Time 5 s iron temperature 425°C

Weight 75 grams

Characteristic Min Typ Max Units Notes

AV60C-048L-050F10(N) Output Characteristics

Power 50 W

Output Current 1 10 A

Output Setpoint Voltage 4.95 5 5.05 Vdc V in=48V, Io=10A

Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=10A

Load Regulation 0.1 0.5 %Vo Io=0~10A, Vin=48V

Dynamic Response

50-75% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

50-25% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

Current Limit Threshold 11 13 14 A

Short Circuit Current 17 A

Efficiency 83 84 % Vin=48V, Io=10A

T rim Range 90 110 %Vo

Over Voltage Protection Setpoint 5.75 7 V

Sense Compensation 0.5 V 0.25V each leg

Temperature Regulation 0.02 %V o/°C

Ripple (rms) 20 40 mV ( 0 to 20MHz Bandwidth )

Noise (p-p) 100 150 mV ( 0 to 20MHz Bandwidth )

Over Temperature Protection 105 °C

Switching Frequency 300 kHz

Maximum Capacitor Load 10000 µF

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Characteristic Min Typ Max Units Notes

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

AV60C-048L-050F15(N) Output Characteristics

Power 75 W

Output Current 1.5 15 A

Output Setpoint Voltage 4.95 5 5.05 Vdc Vin=48V, Io=15A

Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=15A

Load Regulation 0.1 0.5 %Vo Io=0~15A, Vin=48V

Dynamic Response

50-75% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

50-25% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

Current Limit Threshold 16.5 19 21 A

Short Circuit Current 25 A

Efficiency 83 85 % Vin=48V, Io=15A

T rim Range 90 110 %Vo

Over Voltage Protection Setpoint 5.75 7 V

Sense Compensation 0.5 V 0.25V each leg

Temperature Regulation 0.02 %V o/°C

Ripple (rms) 20 40 mV ( 0 to 20MHz Bandwidth )

Noise (p-p) 100 150 mV ( 0 to 20MHz Bandwidth )

Over Temperature Protection 105 °C

Switching Frequency 300 kHz

Maximum Capacitor Load 10000 µF

Characteristic Min Typ Max Units Notes

AV60C-048L-050F20(N) Output Characteristics

Power 100 W

Output Current 2 20 A

Output Setpoint Voltage 4.95 5 5.05 Vdc Vin=48V, Io=20A

Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=20A

Load Regulation 0.1 0.5 %Vo Io=0~20A, Vin=48V

Dynamic Response

50-75% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

50-25% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

Current Limit Threshold 22 25 28 A

Short Circuit Current 34 A

Efficiency 83 85 % Vin=48V, Io=20A

T rim Range 90 110 %Vo

Over Voltage Protection Setpoint 5.75 7 V

Sense Compensation 0.5 V 0.25V each leg

Temperature Regulation 0.02 %V o/°C

Ripple (rms) 20 40 mV ( 0 to 20MHz Bandwidth )

Noise (pp) 100 150 mV ( 0 to 20MHz Bandwidth )

Over Temperature Protection 105 °C

Switching Frequency 300 kHz

Maximum Capacitor Load 10000 µF

-8-

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Characteristic Min Typ Max Units Notes

-9-

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TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

AV60C-048L-050F30(N) Output Characteristics

Power 150 W

Output Current 3 30 A

Output Setpoint Voltage 4.95 5 5.05 Vdc V in=48V, Io=30A

Line Regulation 0.02 0.2 %Vo Vin=36~75V, Io=30A

Load Regulation 0.1 0.5 %Vo Io=0~30A, Vin=48V

Dynamic Response

50-75% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

50-25% load 2.5 5 %Vo Ta=25°C, DI/Dt=1A/10µs

100 250 µs Ta=25°C, DI/Dt=1A/10µs

Current Limit Threshold 32 36 40 A

Short Circuit Current 50 A

Efficiency 83 85 % Vin=48V, Io=30A

T rim Range 90 110 %Vo

Over Voltage Protection Setpoint 5.75 7 V

Sense Compensation 0.5 V 0.25V each leg

Temperature Regulation 0.02 %V o/°C

Ripple (rms) 20 40 mV ( 0 to 20MHz Bandwidth )

Noise (pp) 100 150 mV ( 0 to 20MHz Bandwidth )

Over Temperature Protection 105 °C

Switching Frequency 300 kHz

Maximum Capacitor Load 10000 µF

Characteristic Min Typ Max Units Notes

-10-

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Efficiency Characteristic Curves

ficiency Characteristic Curves (at 25

(at 25 °C)

°C)

0 20406080100

Vin=36V

Vin=48V

Vin=75V

Output Current (%Io)

Efficiency (%)

0 102030405060708090100

Vin=36V

Vin=48V

Vin=75V

Output Current (%Io)

Efficiency (%)

0 102030405060708090100

Vin=36V

Vin=48V

Vin=75V

Output Current (%Io)

Efficiency (%)

0 102030405060708090100

Vin=36V

Vin=48V

Vin=75V

Output Current (%Io)

Efficiency (%)

Typical Efficiency AV60C-048L-050F10N

Typical Efficiency AV60C-048L-050F20N

Typical Efficiency AV60C-048L-050F15N

Typical Efficiency AV60C-048L-050F30N

-11-

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TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Overcurrent Protection (OCP)

Overcurrent Protection (OCP)(at 25

(at 25 °C)

°C)

0 5 10 15 20

Vin=36V

Vin=48V

Vin=75V

Output Voltage (volts)

Output Current (amps)

0102030

Vin=36V

Vin=48V

Vin=75V

Output Voltage (volts)

Output Current (amps)

0 5 10 15 20 25 30 35

Vin=36V

Vin=48V

Vin=75V

Output Voltage (volts)

Output Current (amps)

0 9 18 27 36 45

Vin=36V

Vin=48V

Vin=75V

Output Voltage (volts)

Output Current (amps)

Typical Output Overcurrent Performance

AV60C-048L-050F10N

Typical Output Overcurrent Performance

AV60C-048L-050F20N

Typical Output Overcurrent Performance

AV60C-048L-050F15N

Typical Output Overcurrent Performance

AV60C-048L-050F30N

-12-

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Transient response

ransient response (at 25

(at 25 °C)

°C)

Typical Transient Response Load Increased

from 50%Iomax to 75%Iomax

AV60C-048L-050F30N

Typical Transient Response Load Decreased

from 50%Iomax to 25%Iomax

AV60C-048L-050F30N

Typical Start-Up from CNT Control

AV60C-048L-050F30N Typical Shut-down from CNT Control

AV60C-048L-050F30N

Vin Falling

Vin Rising

20 40 60 80

Input Voltage (volts)

Input Current (amps)

Typical Output Voltage Start-up From Power On Typical Input Current AV60C-048L-050F30N

-13-

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USA Europe Asia

TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Pins

The +Vin and -Vin input connection pins are

located as shown in figure 1. AV60C half-brick

converters have a 2:1 input voltage range and

48 Vin converters can accept 36-75Vdc. Care

should be taken to avoid applying reverse

polarity to the input which can damage the con-

verter.

Input Characteristic

Fusing

The AV60C half-brick 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

AV60C half-brick series are shown in Table 1.

Input Reverse V

Input Reverse Voltage Protection

oltage 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 deter-

mined by the power of the converter. Diodes

should be rated as shown in Table1.

Placing the diode across the inputs rather

than in-line with the input offers an advan-

tage in that the diode only conducts in a

reverse polarity condition, which increases

circuit efficiency and thermal performance.

Input Undervoltage Protection

The AV60C half-brick is protected against

undervoltage on the input. If the input voltage

drops below the acceptable range, the convert-

er will shut down. It will automatically restart

when the undervoltage condition is removed.

Input Filter

Input filters are included in the converters to

help achieve standard system emissions certifi-

cations. Some users however, may find that

additional input filtering is necessary. The

series has an internal switching frequency of

300 kHz so a high frequency capacitor mount-

ed close to the input terminals produces the

-Vin

Case

CNT

-Vout

-Sense

Trim

+Sense

+Vout

+Vin

Component-side footprint

Fig.1 Pin Location

Table 1

Series Fuse Rating(48Vin)

50W 5A

75W 7.5A

100W 10A

150W 20A

+Vin

-Vin

+Vin

-Vin

Fig.2 Reverse Polarity Protection Circuits

-14-

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best results. To reduce reflected noise, a

capacitor can be added across the input as

shown in figure 3, forming a πfilter. A

47µF/100V electrolytic capacitor is recom-

mended for C1.

For conditions where EMI is a concern, a differ-

ent input filter can be used. Figure 4 shows an

input filter designed to reduce EMI effects. C1is

a 47µF/100V electrolytic capacitor, and C2is a

1µF/100V metal film or ceramic high frequency

capacitor, Cy1 and Cy2 are each

1000pF/1500Vdc high frequency ceramic

capacitors, and L1 is a 1mH common mode

choke.

When a filter inductor is connected in series

with the power converter input, an input capac-

itor C1should be added. An input capacitor C1

should also be used when the input wiring is

long, since the wiring can act as an inductor.

Failure to use an input capacitor under these

conditions can produce large input voltage

spikes and an unstable output.

CNT Function

Two CNT logic options are available.

Negative logic applying a voltage less than

1.2V to the CNT pin will enable the output, and

applying a voltage greater than 3V will disable

it.

Positive logic applying a voltage larger than

3V to the CNT pin will enable the output, and

applying a voltage less than 1.2V will disable it.

Negative logic, device code suffix “ N “ .

Positive 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 nega-

tive logic, but default to “ control on ” in

positive logic.

The maximum voltage that can be applied to

the control pin is 15V.

+Vin

-Vin

Fig.3 Ripple Rejection Input Filter

+Vin

-Vin

C2Cy1

Cy2 L1

Fig.4 EMI Reduction Input Filter

-Vin

CNT

-Vin

CNT

-Vin

CNT

-Vin

CNT

Fig.8 Relay Control

Fig.5 Simple Control

Fig.6 Transistor Control

Fig.7 Isolated Control

-15-

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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 mod-

ule should be installed in end-use equipment, in

compliance with the requirements of the ulti-

mate 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 Vin pin and one Vout 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 com-

bination with the DC/DC power module to

demonstrate that the output meets the require-

ment 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 AV60C half-brick module does

not require a connection to a chassis ground.

Whether to ground the case must be decided

by safety considerations, and entirely deter-

mined by the final application. If the AV60C

half-brick module is not in a metallic enclosure

in a system, it may be advisable to directly

ground the case to reduce electric field emis-

sions. 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 induc-

tor 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. In general, the inductor maintains a

DC resistance from the case to chassis ground

of no more than 0.1 S during the safely con-

ducting of all the available input current. All the

available input current refer to the value of the

input fuse to the module. IEC 950 requires test-

ing the DC resistance at 1.5 times that value.

Specific safety requirements may dictate some-

thing different.

Output Characteristics

Minimum Load Requirements

There is a 10% (of full load) minimum load

required in the main output.

The series modules will maintain regulation and

operate properly with a NO LOAD condition.

However, the transient response is altered

below a minimum output load condition. When

the module is operating below the minimum

load, the transient amplitude and recovery time

are both increased when the load is stepped

higher, the output ripple continues to meet the

peak to peak requirements. For the AV60C half-

brick modules, the 10% minimum load require-

ment is strictly in order to meet all performance

specifications.

-16-

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Remote Sensing

The AV60C half-brick converter 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 automat-

ically adjusts the real output voltage of the

series 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, sig-

nificant 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 ade-

quately sized cabling is used. When this is not

possible, the converter can compensate for a

drop of up to 0.25V per lead, or a total of 0.5V,

through use of the sense leads.

When used, the + and - Sense leads should be

connected from the converter to the point of

load as shown in figure 9 using twisted pair

wire. The converter will then regulate its output

voltage at the point where the leads are con-

nected. Care should be taken not to reverse the

sense leads. If reversed, the converter will trig-

ger OVP protection and turn off. When not

used, the +Sense lead must be connected with

+Vo, and -Sense with -Vo. Also note that the

output voltage and the remote sense voltage

offset must be less than the minimum overvolt-

age 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.

Output T

Output Trimming

rimming

Users can increase or decrease the output volt-

age set point of a module by connecting an

external resistor between the TRIM pin and

either the SENSE (+ ) or SENSE ( - ) 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. 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 10 and figure 11.

Note that at elevated output voltages the

maximum power rating of the module

remains the same, and the output current

capability will decrease correspondingly.

The circuits and test results for the trim up and

trim down configurations are displayed as fol-

lowing:

Output Over-Current Protection

AV60C half-brick series DC/DC converters fea-

ture foldback current limiting as part of their

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.

When the overcurrent condition is removed, the

converter will automatically restart.

+Vout

-Vout

Load

+Sense

-Sense

Twisted Pair +S

-S

Fig.9 Sense Connections

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Output Over-V

Output Over-Voltage Protection

oltage Protection

The over-voltage protection has a separate

feedback loop which activates when the output

voltage is between 5.75V-7V. When an over-

voltage condition occurs, a “ turn off “ signal

was sent to the input of the module, and shut off

the output. The module will restart after power

on again.

-17-

Adjusting Percentage of Output Voltage ( % )

Trim Up Resistor Value (ohm)

0 2 4 6 8 10

100 M

10 M

1 M

100 K

10 K

Radj-down =

where y is the adjusting percentage of the voltage.

0 < y < 10

Radj-down is in kΩ.



adj-down

LOAD

100

y- 2

+Vin

-Vin

CNT

Case

+Vout

-Vout

Sense(+)

Trim

Sense(–)

100

100k

Adjusting Percentage of Output Voltage ( % )

10k

0 10 20 30 40

Trim Down Resistor Value (ohm)

Fig.11. Trimming Down Circuit and Curves

Vo(100+y)



Radj-up = (100+2y)

1.26y



y



+Vin

-Vin

CNT

Case

+Vout

-Vout

Sense(+)

Trim

Sense(–)

adj-up

LOAD

Where y is the adjusting percentage of the voltage.

0 < y < 10

Radj-up is in kΩ.



Fig.10. Trim Up Circuit and Curves

-18-

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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 is 2200µF/10V.

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 con-

ditions C2 can be added across the load as

shown in figure 13. The recommended compo-

nent for C2 is 2200µF/10V capacitor and con-

necting a 0.1µF ceramic capacitor in parallel

generally.

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 µF tantalum capacitor in paral-

lel with a 0.1µF 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

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 con-

nection as shown in figure 15.

Parallel Power Distribution

figure 16 shows a typical parallel power distrib-

ution 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 clos-

er to the source. Dynamic load conditions

increase the potential problems.

+Vout

-Vout

Load

C1C2

Fig.13 Output Ripple Filter For a Distant

Load

+Vout

-Vout

Load

Fig.12 Output Ripple Filter

+Vout

-Vout

Load Load

RLine

RLine RLine

RLine

Ground

Loop

Fig.14 Ground Loops

Fig.15 Single Point Ground

+Vout

-Vout

Load Load

RLine

RLine RLine

RLine

Load 1 Load 2 Load 3

+Vout

-Vout

RL1 RL2 RL3

RG1 RG2 RG3

I1 + I2 + I3I2 + I3I3

RL = Lead Resistance

RG = Ground Lead Resistance

Fig.16 Parallel Power Distribution

-19-

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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.

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 feasi-

ble.

Redundant Operation

A common requirement in high reliability sys-

tems is to provide redundant power supplies.

The easiest way to do this is to place two con-

verters 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 deter-

mining load voltage requirements.

Load 1 Load 2 Load 3

+Vout

-Vout

RL1 RL2

RL3

RG1 RG2

RG3

RL = Lead Resistance

RG = Ground Lead Resistance

Fig.17 Radial Power Distribution

Load 1 Load 2 Load 3

+Vout

-Vout

RL1 RL2

RL3

RG1 RG2

RG3

RL = Lead Resistance

RG = Ground Lead Resistance

Load 4

RL4

RG4

Fig.18 Mixed Power Distribution

+Vout

-Vout

+Vout

-Vout

Load

Fig.19 Redundant Operation

-20-

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Thermal Management

Technologies

echnologies

AV60C Half-brick series 50 W to 150 W mod-

ules feature high efficiency and the 5V output

units have typical efficiency of 85% at full load.

With less heat dissipation and temperature-

resistant components such as ceramic capaci-

tors, these modules exhibit good behavior dur-

ing prolonged exposure to high temperatures.

Maintaining the operating case temperature

(Tc) within the specified range help keep inter-

nal-component temperatures within their speci-

fications which in turn help keep MTBF from

falling below the specified rating. Proper cool-

ing 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 ver-

ify the proper cooling. Figure 20 shows the

metal surface of the module and the pin loca-

tions. The module should work under 90°C for

the reliability of operation and TCmust not

exceed 100 °C while operating in the final sys-

tem configuration. The measurement can be

made with a surface probe after the module has

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 mod-

ule 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 condi-

tions.

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-

tion below:

PD= PI˘ PO

where : PIis input power;

POis output power;

PD is dissipated power.

Also, module efficiency (η) is defined as the fol-

lowing equation:

η= PO / PI

If eliminating the input power term, from two

above equations can yield the equation below:

PD = PO(1-η )/η

The module power dissipation then can be cal-

culated 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 AV60C half-brick series 5V

output are shown as figure 21 to figure 24.

29.0 (1.14)

30.5 (1.2)

CNT

Case

+Sense

Trim

– Sense

+Vin

MEASURE CASE

TEMPERATURE HERE

Base-plate side View

Dimensions: millimeters (inches)

-Vin

+Vout

-Vout

Fig.20 Case Temperature Measurement

-21-

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Module Derating

Experiment Setup

From the experimental set up shown in figure

25, the derating curves as figure 26 can be

drawn. Note that the PWB ( printed-wiring

board ) and the module must be mounted verti-

cally. The passage has a rectangular cross-

section. The clearance between the facing

PWB and the top of the module is kept 13 mm

(0.5 in.) constantly.

Convection W

Convection Without Heat Sinks

ithout Heat Sinks

Heat transfer can be enhanced by increasing

the airflow over the module. Figure 26 shows

the maximum power that can be dissipated by

the module.

In the test, natural convection airflow was mea-

sured 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 26.

02468101214161820

Vin=36V

Vin=48V

Vin=75V

Power Dissipation ( W )

Output Current ( A )

0123456789101112131415

Vin=36V

Vin=48V

Vin=75V

Power Dissipation ( W )

Output Current ( A )

0 3 6 9 12 15 18 21 24 27 30

Vin=36V

Vin=48V

Vin=75V

Power Dissipation ( W )

Output Current ( A )

Fig.22 AV60C-048L-050F15N Power Dissipation

Fig.23 AV60C-048L-050F20N Power Dissipation

Fig.24 AV60C-048L-050F30N Power Dissipation

Dimensions: millimeters (inches).

facing PWB

PWB

Module

50.8(2.0)

Air velocity and

Ambient Temperature

Testing Point

Air flow

13(0.5)

Fig.25 Experiment Set Up

2.4

3.6

4.2

4.8

5.4

6.6

7.2

7.8

8.4

012345678910

Vin=36V

Vin=48V

Vin=75V

Power Dissipation ( W )

Output Current ( A )

Fig.21 AV60C-048L-050F10N Power Dissipation

-22-

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TEL: 1-760-930-4600 44-(0)1384-842-211 852-2437-9662

FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Example 1. How to calculate the minimum

airflow required to maintain a desired Tc?

If a AV60C-048L-050F30N module operates

with a 48V line voltage, a 25 A output current,

and a 40 °C maximum ambient temperature,

what is the minimum airflow necessary for the

operating?

Determine PD( referenced Fig.24 ) with con-

dition:

Vin = 48 V

lO= 25 A

Get: PD= 20 W

And with TA= 40 °C

Determine airflow ( Fig.26 ):

v = 3 m/s (600 ft./min.)

Example 2. How to calculate the maximum

output power of a module in a certain con-

vection and a max. TA?

What is the maximum power output for a

AV60C-048L-050F30N operating at following

conditions:

Vin = 48 V

v = 3.0 m/s (600 ft./min.)

TA= 40 °C

Determine PD( Fig.26 )

PD= 21 W

Determine IO(Fig.24):

IO= 26 A

Calculate PO:

PO= (VO) x (IO) = 5 x 26 = 130 W

Although the two examples above use 100 ° C

as the maximum case temperature, for

extremely high reliability applications, one may

design to a lower case temperature as shown in

Example 4 on page 24.

Heat Sink Configuration

Several standard heat sinks are available for

the AV60C half-brick 50 W to 150 W modules

as shown in figure 27 to figure 29.

Dimensions: millimeters (inches).

57.9 (2.28)

(2.4)

WDL10040

WDL02540

WDL05040

1/4 IN.

1/2 IN.

1 IN.

Fig.28 Longitudinal Fins Heat Sink

Dimensions: millimeters (inches).

WDT10040

61 (2.4)

WDT02540

WDT05040

57.9

(2.28)

1/4 IN.

1/2 IN.

1 IN.

Fig.29 Transverse Fins Heat Sink

89.1(3.51)

57.0

(2.24) 11.8

(0.465)

4.9(0.193)

Dimensions: millimeters (inches).

Fig.27 Non Standard Heatsink

010203040 100

Ambient Temperature, TA (°C)

Power Dissipation P

(W)

80706050

4.0 m/s

(800 ft./min.)

1.0 m/s

(200 ft./min.)

2.0 m/s

(400 ft./min.)

3.0 m/s

(600 ft./min.)

0.5 m/s

(100 ft./min.)

Natural Convection

(10-20 ft./min.)

Fig.26 Forced Convection Power Derating

without Heat Sink

-23-

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FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

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 (typi-

cally 0.1°C/W to 0.3°C/W) and temperature dif-

ferential.

Nomenclature for heat sink configurations is as

follows:

WDxyyy40

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 29) 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.

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-

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 imped-

ance of >0.5°C/W, while use one of the rec-

ommended interface methods (silicon grease

or thermal pads available from Astec) can

result in a case-heatsink thermal impedance

around 0.1°C/W.

Natural Convection with Heat Sink

The power derating for a module with the heat

sinks ( shown as figure 27 to figure 29) in nat-

ural convection is shown in figure 31. In this

test, natural convection generates airflow about

0.05 m/s to 0.1 m/s ( 10ft./min to 20ft./min ).

Figure 31 can be used for heat-sink selection in

natural convection environment.

Example 3. How to select a heat sink?

What heat sink would be appropriate for a

AV60C-048L-050F30N in a natural convection

environment at nominal line, 3/4 load, and max-

imum ambient temperature of 40°C?

Determine PD( referenced Fig.24 ) with con-

dition:

Vin = 48 V

IO= 3/4 (30) = 23 A

TA= 40 °C

Get: PD= 19 W

Determine Heat Sink ( Fig.31 ):

1 in. allows up to TA = 45 °C

Fig.30 Heat Sink Mounting

010203040 90100

Ambient Temperature, TA (°C)

Power dissipation P

(W)

50 60 70 80

1 in. heat sink

1/2 in. heat sink

1/4 in. heat sink

NO heat sink

Fig.31 Heat Sink Power Derating Curves,

Natural Convection

-24-

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FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Basic Thermal Model

There is another approach to analyze module

thermal performance, to model the overall ther-

mal 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 32. Also, ∆TC, max is defined as

the difference between the module case tem-

perature (TC) and the inlet ambient temperature

(TA).

∆TC, max = TC˘ TA

Where TCis the module case temperature;

TA is the inlet ambient temperature.

For AV60C half-brick series 50W to 150W 5V

output converters, the module's thermal resis-

tance values versus air velocity have been

determined experimentally and shown in figure

33. The highest values on each curve repre-

sents the point of natural convection.

Figure 33 is used for determining thermal per-

formance under various conditions of airflow

and heat sink configurations.

Example 4. How to determine the allowable

minimum airflow to heat sink combinations

necessary for a module under a desired Tc

and a certain condition?

Although the maximum case temperature for

the AV60C half-brick series converters is

100°C, you can improve module reliability by

limiting Tc,max to a lower value. How to

decide? For example, what is the allowable

minimum airflow for AV60C-048L-050F30N

heat sink combinations at desired Tc of 80 °C?

The working condition is as following:

Vin = 48 V, IO= 25A, TA= 40 °C

Determine PD( Fig.24 )

PD= 20 W

Then solve RCA::

RCA = ∆TC, max / PD

RCA = (TC− TA)/ PD

RCA = (80 − 40)/ 20 = 2°C/W

Determine air velocity from Fig.33:

If no heat sink:

v > 3.0 m/s (600 ft./min.)

If 1/4 in. heat sink:

v = 3.0 m/s (600 ft./min.)

If 1/2 in. heat sink:

v = 2.0 m/s (400 ft./min.)

If 1 in. heat sink:

v = 1.2 m/s (240 ft./min.)

Thermal

RCA:

Resistance

Fig.32 Basic Thermal Resistance Model

0 0.5(100) 1.0(200) 1.5(300) 2.0(400) 2.5(500) 3.0(600)

Air Velocity m/s (ft./min.)

Case-Ambient Thermal Resistance

(°C/W)

1 in. heat sink

1/2 in. heat sink

1/4 in. heat sink

NO heat sink

Fig.33 Case-to-Ambient Thermal

Resistance Curves; Either Orientation

-25-

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FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Example 5. How to determine case tempera-

ture ( Tc ) for the various heat sink configu-

rations at certain air velocity?

What is the allowable Tc for AV60C-048L-

050F30N heat sink configurations at desired air

velocity of 2.0 m/s, and it is operating at a 48 V

line voltage, a 25 A output current, a 40 °C

maximum ambient temperature?

Determine PD( Fig.24 ) with condition:

Vin = 48 V

IO= 25 A

TA= 40 °C

v = 2.0 m/s (400 ft./min.)

Get: PD= 20 W

Determine TC:TC= (RCA x PD) + TA

Determine the corresponding thermal resis-

tances ( RCA ) from Fig.33:

No heat sink: RCA = 3.8 °C/W

TC= (3.8 x 20) + 40 = 116 °C

1/4 in. heat sink: RCA = 2.8 °C/W

TC= (2.8 x 20) + 40 = 96 °C

1/2 in. heat sink: RCA = 2.0 °C/W

TC= (2.0 x 20) + 40 = 80 °C

1 in. heat sink: RCA = 1.2 °C/W

TC= (1.2 x 20) + 40 = 64 °C

In this configuration, the heat sink would have

to be at least 1/4 in. high so that the power

module does not exceed the maximum case

temperature of 100°C.

AV60C Half-brick Series

V60C Half-brick Series

Mechanical Considerations

Installation

Although AV60C half-brick series converters

can be mounted in any orientation, free air-flow-

ing 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

AV60C half-brick series converters are compat-

ible 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 260°C for less

than 10 seconds.

When hand soldering, the iron temperature

should be maintained at 425°C and applied to

the converter pins for less than 5 seconds.

Longer exposure can cause internal damage to

the converter. Cleaning can be performed with

cleaning solvent IPA or with water.

MTBF

The MTBF, calculated in accordance with

Bellcore TR-NWT-000332 is 2,000,000 hours.

Obtaining this MTBF in practice is entirely pos-

sible. If the ambient air temperature is expected

to exceed +25°C, then we also advise a

heatsink on the AV60C half-brick series, orient-

ed for the best possible cooling in the air

stream.

ASTEC can supply replacements for converters

from other manufacturers, or offer custom solu-

tions. Please contact the factory for details.

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FAX: 1-760-930-0698 44-(0)1384-843-355 852-2402-4426 www.astec.com

Recommend Hole Pattern

Mechanical Chart

-26-

Base-plate side view

Dimensions are in millimeters and (inches).

10.16

(0.400)

10.16

(0.400)

12.7 (0.50)

48.3 (1.90)

48.26

(1.900)

4.8

(0.19)

Mounting Inserts

Module Outline

5.1 (0.20)

28)

Max

17.78

(0.700)

25.40

(1.000)

35.56

(1.400)

25.40

(1.000)

50.8

(2.00)

35.56

(1.400)

61.0

(2.40)

-Vout

 -Vin

–Sense

Trim

+Sense

Case

CNT

+Vin +Vout

Max

-Vin

Case

CNT

+Vin +Vout



+Sense

Trim

-Sense

-Vout

5.1 (0.2)

10.16 (0.4)

15.24 (0.6)

4.8 (0.19) 48.26 (1.9)

10.16 (0.4)

7.62 (0.3)

57.9 (2.28)

61.0 (2.4)

mm (inches)

7-

12.7 (0.5)

Mounting Inserts

M3 thru hole x4



2-

φ2.0 (0.08)



only +Vo and -Vo

φ1.0 (0.04)

all pins except +Vo and -Vo

Length optional

4.8 (0.189) default

Base-plate side view

Tolerances:

Inches Millimeters

.xx !0.020 .x !0.5

.xxx !0.010 .xx !0.25



Pins

>4mm !0.02inch ( !0.5mm)

<4mm !0.01inch ( !0.25mm)



Pin Length Option

4.80mm ! 0.5mm

0.189in. ! 0.020in.

3.80mm ! 0.25mm

0.150in. ! 0.010in.

5.80mm ! 0.5mm

0.228in. ! 0.02in.

2.80mm ! 0.25mm

0.110in. ! 0.010in.



Device Code Suffix

none (default) 

-6

-7

-8

PART NUMBER DESCRIPTION

ss pp

-0 iv L- xxx f yy h n -p-mx-Options

p = Pin Length

Omit this digit for Standard 5mm

6 = 3.8mm, 7= 5.8mm

iv = Input Voltage 8 = 2.8mm

05 = Range centered on 5V

12 = Range centered on 12V Enable Logic Polarity

24 = 18 to 36(2:1), 9 to 36V(4:1) Omit for Positive Enable Logic

36 = 20 to 60V N = Negative Enable

46 = 18V to 75V (4:1) Except: AK60C-20H, BK60C-30H

48 = Typ 36 to 75V Omit for Negative Logice

P = Positive Logic

c = Pinout compatability

A= Astec Footprint or "non Lucent" footprint H = High Efficiency (Synch rect.)

C= Ind Std, Exact Lucent drop in Omit H if Conventional Diode (low Eff)

yy = Output Current

pp = Package Type ie. 08 = 8 Amps

40 = 1" x 2" SMD

42 = 1.5" x 2" SMD f = # of Outputs

45 = 1.45" X 2.3" (1/4 Brk) F = Single Output

60 = 2.4" X 2.3" (1/2 Brk) D = Dual Output

80 = Full size 4.6" x 2.4"

72= 2.35" X 3.3 (3/4 Brk) xxx = Output Voltage

Format is XX.X (ie 1.8V = 018)

ss = Series

AA = 1/2brick Dual (Old designator)

AK = Ind Std sizes (1/4, 1/2, full) <150W mx = Options

AM/BM = Full size, astec pin out M1,M2 = .25" Height Heatsink

AL = Half size, astec pin-out M3,M4 = .5" height Heatsink

BK = Ind Std size =>150W or feature rich M5.M6 = 1.0" Height Heatsink

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

Acs ii V1 V2 V3Vin -e t p Mx

Output Voltage

A = 5.0V E = 7.5V

F = 3.3V B = 12V, C = 15V

G = 2.5V L = 8V, H = 24V, R = 28V

D = 2.0V / 2.1V Omit V2 and V3 if Single Output

Y = 1.8V Omit V3 if Dual Output

M = 1.5V ie for Dual Output 5 and 3.3V

K = 1.2V V1 =A, V2 = F, V3 =Omit

J = 0.9V V1 =A, V2 = F, V3 =Omit

ii = Output Current Max

ie 60 = 60 Amps Vin = Input Voltage range

300 = 250V to 450V

S = Size 48 = 36V to 75V

F = Full Brick 24 = 18V to 36V

H = Half Brick 03 = 1.8V to 5.0V

Q = Quarter Brick 08 = 5.0V to 13.0V

S = 1 X 2 18 Pin SMT PFC: Power Factor Corrected

E = 1 X 2 Thru Hole

C = (.53X1.3X.33) SMT (Austin Lite drop in) E = Enable Logic for > 15W

V = Conventional Package (2X2.56") or ( Omit this digit for Positive enable

A = SIP N = Negative Logic

W = Convent pkg (Wide 2.5X3) E = Enable Logic for < 15W

R = 1 X 1 Thru Hole Omit this digit for no enable option

A = SIP 1 = Negative Logic

T = 1.6 X 2 4 = Positive Logic

c = Construction Trim for 1W to 15W

E = Enhanced Thermals (Baseplate or adapter plate) 9 = Trim Added

I = Integrated (Full Featured) Hong Kong models

L = Low Profile (Open Frame, No case - Isolated)

P = Open Frame (SIP or SMT) non-isolated 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