PSA Series Extended Data Sheet Positive Switching Regulators (Benign) Input voltage up to 60 V DC Single output of 3.3...24 V DC No input to output isolation • High efficiency up to 93% • Wide input voltage range • Low input to output differential voltage • Very good dynamic properties • Input undervoltage lock-out • Parallel configurations possible 50 2.0" • Continuous no-load and short-circuit proof 25 1.0" 70 2.8" • No derating Safety according to IEC/EN 60950 Summary Modules with input voltages up to 60 V are specially designed for secondary switched and battery driven applications. The case design allows operation at nominal load up to 50°C without additional cooling. The PSA series of positive switching regulators is designed as power supply modules for electronic systems. Their major advantages include a high level of efficiency that remains virtually constant over the entire input range, high reliability, low ripple and excellent dynamic response. Type Survey and Key Data Table 1: Type survey 1 2 Output voltage Uo nom [V] Output current Io nom [A] Input voltage range Ui [V] 1 Input voltage Ui nom [V] Efficiency 2 5.1 2 8...40 20 75 5.1 5 7...35 20 83 PSA 5A5-2 12 3 15...40 20 89 PSA 123-2 Type designation Options package ηmin [%] PSA 5A2-2 15 3 19...40 30 90 PSA 153-2 24 2.5 29...60 40 93 PSA 242.5-2 iRY See also: Electrical Input Data: DUio min. Efficiency at Ui nom and Io nom. Table of Contents Page Page Summary ......................................................................... 1 Type Survey and Key Data .............................................. 1 Type Key .......................................................................... 2 Functional Description ..................................................... 2 Electrical Input Data ........................................................ 3 Electrical Output Data ..................................................... 4 Electromagnetic Compatibility (EMC) ............................. 6 Immunity to Environmental Conditions ........................... 6 Mechanical Data .............................................................. 7 Safety and Installation Instructions ................................. 7 Description of Options ..................................................... 9 Accessories ................................................................... 10 EC Declaration of Conformity ....................................... 11 REV. SEP 17, 2003 Page 1 of 11 PSA Series Extended Datasheet Positive Switching Regulators (Benign) Type Key PSA 12 3 -2 iRY Positive switching regulator in case A01 .................... PSA Nominal output voltage in volt (5 A for 5.1 V) ......... 5A...24 Nominal output current in ampere .............................. 2...5 Operational ambient temperature range TA –10...50°C ........................................................... -2 Options package: Inhibit input ............................................................ i Control input for output voltage adjustment ........ R PCB soldering pins 0.5 x 1.0 mm ......................... Y Example: PSA 123-2iPY = A positive switching regulator with a 12 V, 3 A output, ambient temperature range of –10…50°C, with options package: inhibit input, external output voltage adjustment and small soldering pins. Functional Description The switching regulators are using the buck converter topology. See also: Technical Information: Topologies. The input is not electrically isolated from the output. During the on period of the switching transistor, current is transferred to the output and energy is stored in the output choke in the form of flux. During the off period, this energy forces the current to continue flowing through the output, to the load and back through the freewheeling diode. Regulation is accomplished by varying the on to off duty ratio of the power switch. These regulators are ideal for a wide range of applications, where input to output isolation is not necessary, or where already provided by an external front end (e.g. a transformer with rectifier). To optimise customer’s needs, additional options and accessories are available. 03050 Io Input Filter Ii Ui Vo+ Vi+ i (option package) Control circuit Ce Uo R (option package) Go– Gi– Fig. 1 Block diagram REV. SEP 17, 2003 Page 2 of 11 PSA Series Extended Datasheet Positive Switching Regulators (Benign) Electrical Input Data General Conditions: TA = 25°C, unless TC is specified Table 2a: Input data Input PSA 5A2 Characteristics Conditions Ui Io = 0...Io nom TC min...TC max Operating input voltage DUio min Min. diff. voltage Ui – Uo min typ 8 PSA 5A5 max min 40 7 typ 2.9 max Unit 35 V DC 1.9 Ui o Undervoltage lock-out 7.3 6.3 Ii 0 No load input current Io = 0, Ui min...Ui max I inr p Peak value of inrush current Ui nom 75 75 A t inr r Rise time 2.5 2.5 µs t inr h Time to half-value 15 ui RFI Input RFI level, EN 55011/22 Ui nom, Io nom 0.15...30 MHz 1 50 50 mA 15 A A Table 2b: Input data Input PSA 123 Characteristics Conditions min Ui Io = 0...Io nom TC min...TC max 15 Operating input voltage DUio min Min. diff. voltage Ui – Uo 1 typ PSA 153 max min 40 19 typ 3 7.3 PSA 242.5 max min 40 29 typ max Unit 60 V DC 4 5 Ui o Undervoltage lock-out Ii 0 No load input current Io = 0, Ui min...Ui max 7.3 Iinr p Peak value of inrush current Ui nom 75 150 150 A tinr r Rise time 2.5 2.5 2.5 µs tinr h Time to half-value 15 ui RFI Input RFI level, EN 55011/22 Ui nom, Io nom 0.15...30 MHz 1 50 12 50 50 15 A 15 A A Additional external input filter or capacitor necessary (see: Accessories). External Input Circuitry The sum of the lengths of the supply lines to the source or to the nearest capacitor ≥100 µF or to the nearest external input filter which includes such a capacitor (a + b) should not exceed 0.3 m (0.5 m twisted). An external input filter (FP 38 or FP 80, see Accessories) is recommended in order to prevent power line oscillations and reduce superimposed interference voltages. See also: Technical Information. REV. SEP 17, 2003 04016 + Vi+ Vo+ Gi– Go– a b Fig. 2 Switching regulator with long supply lines. Page 3 of 11 mA PSA Series Extended Datasheet Positive Switching Regulators (Benign) Electrical Output Data General Conditions: – TA = 25°C, unless TC is specified – With R option, output voltage Uo = Uo nom at Io nom Table 3a: Output data Output PSA 5A2 Characteristics Conditions min max min max Unit Uo Ui nom, Io nom 5.05 5.15 5.05 5.15 V 0 2.0 0 5.0 A 2.0 2.6 5.0 6.5 Output voltage 1 Io Output current IoL Output current limitation response 1 uo Output voltage noise Switching freq. Total Ui min...Ui max TC min...TC max 40 40 45 45 100 100 Static line regulation Ui min...Ui max, Io nom DUo l Static load regulation Ui nom, Io = 0...Io nom uo d Dynamic load regulation Ui nom Io nom ↔ 1/3 Io nom IEC/EN 61204 2 td aUo Recovery time Temperature coefficient ∆Uo/∆TC (TC min...TC max) typ Ui nom, Io nom IEC/EN 61204 2 BW = 20 MHz DUo U Voltage deviat. typ PSA 5A5 100 mV 100 300 300 100 100 Ui min...Ui max Io = 0...Io nom mVpp µs ±1 ±1 mV/K ±0.02 ±0.02 %/K Table 3b: Output data Output Conditions min max min max min max Unit Ui nom, Io nom 11.60 12.40 14.50 15.50 23.30 24.70 V 0 3.0 0 3.0 0 2.5 A 3.0 3.9 3.0 3.9 2.5 3.25 Io Output IoL Output current limitation response 1 uo Output voltage noise Switching freq. Total Ui min...Ui max TC min...TC max 150 200 300 160 210 310 240 300 480 Static line regulation Ui min...Ui max, Io nom DUo l Static load regulation Ui nom, Io = 0...Io nom uo d Dynamic load regulation Ui nom Io nom ↔ 1/3 Io nom IEC/EN 61204 2 Voltage deviat. Recovery time Temperature coefficient ∆Uo/∆TC (TC min...TC max) 180 200 450 720 120 120 160 Ui min...Ui max Io = 0...Io nom Page 4 of 11 mVpp mV 300 360 See also: Thermal Considerations. See: Technical Information: Measuring and Testing. REV. SEP 17, 2003 typ Ui nom, Io nom IEC/EN 61204 2 BW = 20 MHz DUo U aUo 2 current 1 typ PSA 242.5 Uo Output voltage typ PSA 153 Characteristics td 1 PSA 123 µs ±2 ±3 ±5 mV/K ±0.02 ±0.02 ±0.02 %/K PSA Series Extended Datasheet Positive Switching Regulators (Benign) Uo 05010 uod Parallel and Series Connection DU o I Outputs of equal nominal voltages can be parallel-connected. However, the use of a single unit with higher output power, because of its power dissipation, is always a better solution. t In parallel-connected operation, one or several outputs may operate continuously at their current limit knee-point, which will cause an increase of the heat generation. Consequently, the max. ambient temperature should be reduced by 10 K. t Fig. 3 Dynamic load regulation. Outputs can be series-connected with any other module. In series-connection the maximum output current is limited by the lowest current limitation. Electrically separated source voltages are needed for each module! Thermal Considerations Short Circuit Behaviour When a switching regulator is located in free, quasi-stationary air (convection cooling) at a temperature TA = 50°C and is operated at its nominal output current Io nom, the case temperature TC will not exceed 80°C after the warmup phase, measured at the Measuring point of case temperature TC (see: Mechanical Data). A constant current limitation circuit holds the output current almost constant whenever an overload or a short circuit is applied to the regulator's output. It acts self-protecting and recovers – in contrary to the fold back method – automatically after removal of the overload or short circuit condition. uod td td I o/I o nom 1 0 ≥10 µs ≥10 µs Under practical operating conditions, the ambient temperature TA may exceed 50°C, provided additional measures (heat sink, fan, etc.) are taken to ensure that the case temperature TC does not exceed its maximum value of 80°C. Example: Sufficient forced cooling allows TA max = 65°C. A simple check of the case temperature TC (TC ≤ 80°C) at full load ensures correct operation of the system. Io /Io nom 1.2 1.0 0.8 0.4 0.2 TC max 40 50 60 70 80 TA [ C] Fig. 4 Output current derating versus temperature Output Protection A voltage suppressor diode which in worst case conditions fails into a short circuit, protects the output against an internally generated overvoltage. Such an overvoltage could occur due to a failure of either the control circuit or the switching transistor. The output protection is not designed to withstand externally applied overvoltages. The user should ensure that systems with Power-One power supplies, in the event of a failure, do not result in an unsafe condition (fail-safe). REV. SEP 17, 2003 Io L 0.6 Convection cooling TA min 05033 0.2 0.4 0.6 0.8 1.0 1.2 Fig. 5 Overload, short-circuit behaviour Uo versus Io. 05032 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Uo /Uo nom 0 Forced cooling Io nom DU o I Page 5 of 11 1.4 Io /Io nom PSA Series Extended Datasheet Positive Switching Regulators (Benign) Electromagnetic Compatibility (EMC) Electromagnetic Immunity General condition: Case not earthed. Table 4: Immunity type tests Phenomenon Standard 1 Class Level Coupling mode 2 Value applied Waveform Source Imped. Test procedure Electrostatic discharge IEC/EN 61000-4-2 2 contact discharge to case 4000 Vp 1/50 ns 330 Ω 10 positive and 10 negative discharges yes B4 Electromagnetic IEC/EN field 61000-4-3 2 antenna 3 V/m AM 80% 1 kHz 26…1000 MHz yes A Electrical fast transient/burst IEC/EN 61000-4-4 2 i/c, +i/–i 1000 Vp bursts of 5/50 ns 5 kHz rep. rate transients with 15 ms burst duration and a 300 ms period 50 Ω 1 min positive 1 min negative bursts per coupling mode yes A4 Surge IEC/EN 61000-4-5 1 i/c 1.2/50 µs 12 Ω yes A4 2 +i/–i 2Ω 5 pos. and 5 neg. surges per coupling mode 2 i, o, signal wires 150 Ω 0.15...80 MHz yes A Conducted disturbances 1 3 4 IEC/EN 61000-4-6 3 2000 Vp 500 Vp 130 dBµV (3 Vrms) AM 80% 1 kHz In Peroper. form. 3 B4 For related and previous standards see Technical Information: Safety & EMC. 2 i = input, o = output, c = case. A = Normal operation, no deviation from specifications, B = Normal operation, temporary deviation from specs possible. External input filter FP 38 or FP 80 necessary. For emission levels refer to Electrical Input Data. Immunity to Environmental Conditions Table 5: Mechanical stress Test Method Standard Test Conditions Status Damp heat steady state IEC/DIN IEC 60068-2-3 MIL-STD-810D section 507.2 Temperature: Relative humidity: Duration: 40 ±2 °C Ea Shock (half-sinusoidal) IEC/EN/DIN EN 60068-2-27 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 15 gn = 147 m/s2 11 ms 18 (3 each direction) Unit operating Eb Bump (half-sinusoidal) IEC/EN/DIN EN 60068-2-29 MIL-STD-810D section 516.3 Acceleration amplitude: Bump duration: Number of bumps: 10 gn = 392 m/s2 16 ms 6000 (1000 each direction) Unit operating Fc Vibration (sinusoidal) IEC/EN/DIN EN 60068-2-6 MIL-STD-810D section 514.3 Acceleration amplitude: 0.15 mm (10...60 Hz) 2 gn = 20 m/s2 (60...150 Hz) 10...150 Hz 3.75 h (1.25 h each axis) Unit operating Ca 93 +2/-3 % 21 days Frequency (1 Oct/min): Test duration: Table 6: Temperature specifications, valid for air pressure of 800...1200 hPa (800...1200 mbar) Temperature 1 Standard Characteristics Conditions min max Unit TA Ambient temperature Operational 1 –10 50 °C TC Case temperature TS Storage temperature Non operational –10 80 –25 100 See: Thermal Considerations REV. SEP 17, 2003 Page 6 of 11 Unit not operating PSA Series Extended Datasheet Positive Switching Regulators (Benign) Table 7: MTBF MTBF Ground Benign TC = 40°C MTBF acc. to MIL-HDBK-217F 580 000 h Mechanical Data European Projection Dimensions in mm. Tolerances ±0.3 mm unless otherwise specified. 20.5 8.75 18.7 6.3 Vo+ i Gi– Vi+ R 70.2 ±0.5 Go– 47.5 ±0.2 65 09017 1.2 2.7 ±0.2 50.2 ±0.2 09016 71.4 Fig. 7 Case A01 hole locations for circuit board layout (component side view of PCB): - - - = Space reserved for switching regulator a = 3.0 mm x 0.7 mm slot or Ø 3.0 mm, through plated for hand or machine soldering (fast on) a = Ø 1.3...1.5 mm with option Y pins REV. SEP 17, 2003 Page 7 of 11 51.4 65 Distance between M 2.5 mounting screws a Fig. 6 Case A01, weight 100 g Aluminium, black finish and self cooling 8.75 18.7 1.2 47.5 ±0.1 2.8 x 0.5 (1.0 x 0.5 option Y) 20.5 6.3 6.5 ±1 7 ±0.5 25.2 ±0.5 min. 5 Measuring point of case temperature PSA Series Extended Datasheet Positive Switching Regulators (Benign) Safety and Installation Instructions Installation Instruction Cleaning Agents Installation of the switching regulators must strictly follow the national safety regulations in compliance with the enclosure, mounting, creepage, clearance, casualty, markings and segregation requirements of the end-use application. In order to avoid possible damage, any penetration of cleaning fluids is to be prevented, since the power supplies are not hermetically sealed. Check for hazardous voltages before altering any connections. Connections can be made using fast-on or soldering technique. The input and the output circuit are not separated, i.e. the negative path is internally interconnected! Only functional insulation to the case. The units should be connected to a secondary circuit. Do not open the module. Ensure that a unit failure (e.g. by an internal short-circuit) does not result in a hazardous condition. See also: Safety of operator accessible output circuit. Protection Degree The protection degree is IP 40. Isolation Electric strength test voltage between input interconnected with output and case: 500 V DC, 1 s. This test is performed as factory test in accordance with IEC/EN 60950 and UL 1950 and should not be repeated in the field. Power-One will not honour any guarantee claims resulting from electric strength field tests. Standards and Approvals Safety of Operator Accessible Output Circuit All switching regulators are UL recognized according to UL 1950 and EN 60950 and UL recognized for Canada to CAN/CSA C22.2 No. 234-M90. If the output circuit of a switching regulator is operator-accessible, it shall be an SELV circuit according to IEC/EN 60950 related safety standards The units have been evaluated for: • Building in, • Functional insulation from input to output and input/output to case, • The use in an overvoltage category II environment, • The use in a pollution degree 2 environment. The following table shows some possible installation configurations, compliance with which causes the output circuit of the switching regulator to be an SELV circuit according to IEC/EN 60950 up to a nominal output voltage of 30 V. The switching regulators are subject to manufacturing surveillance in accordance with the above mentioned UL and CSA and with ISO 9001 standards. However, it is the sole responsibility of the installer or user to assure the compliance with the relevant and applicable safety regulations. More information is given in: Technical Information: Safety & EMC. Table 8: Safety concept leading to an SELV output circuit Conditions Front end Supply voltage Minimum required grade of isolation, to be provided by the AC-DC frontend including mainssupplied battery charger 2 3 4 Result Safety status of the switching regulator output circuit Battery Double or Reinforced supply, considered as secondary circuit ≤60 V SELV circuit None SELV circuit Mains Basic ≤250 V AC ≤60 V Earthed SELV circuit 2 None Double or reinforced 1 Switching regulator Maximum Minimum required safety Measures to achieve the DC output status of the front end specified safety status of the voltage output circuit output circuit from the front end 1 ≤60 V 3 ELV circuit Input fuse and earthed output circuit 2 and non accessible case 4 SELV circuit None Earthed SELV circuit SELV circuit The front end output voltage should match the specified input voltage range of the switching regulator. The earth connection has to be provided by the installer according to the relevant safety standard, e.g. IEC/EN 60950. The installer shall provide an approved fuse (slow blow type with the lowest current rating suitable for the application, max. 12.5 A) in a non-earthed input conductor directly at the input of the switching regulator. If Vo+ is earthed, insert the fuse in the Gi- line. For UL’s purpose, the fuse needs to be UL-listed. If option C is fitted, a suitable fuse is already built-in in the Vi+ line. Has to be insulated from earth by double or reinforced insulation according to the relevant safety standard, based on the maximum output voltage from the front end. REV. SEP 17, 2003 Page 8 of 11 PSA Series Extended Datasheet Positive Switching Regulators (Benign) Description of Options With this series, the options i (inhibit), R (control input for output voltage adjustment) and Y (small soldering pins) are defined as a package. Other combinations or parts of this package are not available. i Inhibit for Remote On and Off The inhibit input allows the switching regulator output to be disabled via a control signal. In systems with several units, this feature can be used, for example, to control the activation sequence of the regulators by a logic signal (TTL, CMOS, etc.). An output voltage overshoot will not occur when switching on or off. 06010 3 2 10 20 30 40 50 t tf tr Inhibit 1 0 0 06001 0.1 0 Uo off -50 -40 -30 -20 -10 Go– Gi– Uo /Uo nom 1 Uo on 1 U inh Uinh = 2.4 V Uinh = 0.8 V 4 I inh i Fig. 9 Definition of Iinh and Uinh Iinh [mA] 5 06009 Vo+ Vi+ Note: With open i-input, output is enabled (Uo = on) Uinh [V] t 0 Fig. 8 Typical inhibit current Iinh versus inhibit voltage Uinh Fig. 10 Output response as a function of inhibit signal Table 9: Inhibit characteristics Characteristics Uinh Inhibit input voltage to keep regulator output voltage... Uo = on Uo = off Conditions min Ui min...Ui max TC min...TC max typ max Unit –10 +0.8 V DC +2.4 +50 tr Switch-on time after inhibit command Switch-off time after inhibit command Ui = Ui nom RL = Uo nom /Io nom 2 tf ms Ii inh Input current when inhibited Ui = Ui nom 10 4 mA R Control for Output Voltage Adjustment Note: With open R input, Uo ≈ Uo nom. The output voltage Uo can either be adjusted with an external reference voltage (Uext) or with an external resistor (Rext). The adjustment range is 0...100% of Uo nom. The Vo+ R minimum differential voltage DUio min between input and output (see: Electrical Input Data) should be maintained. Undervoltage look-out = minimum input voltage. Vo + 06035 Uref 4000 Ω + Uext R + – + – G Go – Fig. 11 Voltage adjustment with Uext between R and Go– Fig. 12 Voltage adjustment with external resistor Rext 4000 Ω • Uo Rext ≈ ––––––––––– Uo nom – Uo Uext Uo ≈ Uo nom • ––––– 2.5 V Caution: To prevent damage Uext must neither exceed 2.7 V, nor be negative! REV. SEP 17, 2003 4000 Ω Rext G Go – Uo Uext ≈ 2.5 V • ––––– Uo nom 06040 Uref Page 9 of 11 Uo nom • Rext Uo ≈ –––––––––––– Rext + 4000 Ω PSA Series Extended Datasheet Positive Switching Regulators (Benign) Y PCB Soldering Pins This option defines soldering pins of 1.0 x 0.5 x 6.5 mm, instead of the standard fast-on terminals of 2.8 x 0.5 x 6.5 mm. Regulators with this option can be mounted onto printed circuit boards (through-plated finished hole size of Ø 1.3...1.5 mm). Accessories A variety of electrical and mechanical accessories are available including: – Isolation pads for easy and safe PCB-mounting. – Filters and ring core chockes for ripple and interference reduction. – Adaptor kit for DIN-rail and chassis mounting. For detailed information see: Accessories on the PowerOne homepage. NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. REV. SEP 17, 2003 Page 10 of 11 PSA Series Extended Datasheet Positive Switching Regulators (Benign) EC Declaration of Conformity We Power-One AG Ackerstrasse 56 CH-8610 Uster declare under our sole responsibility that all PSx Series switching regulators carrying the CE-mark are in conformity with the provisions of the Low Voltage Directive (LVD) 73/23/ EEC of the European Communities. Conformity with the directive is presumed by conformity wih the following harmonized standards: • EN 61204: 1995 (= IEC 61204: 1993, modified) Low-voltage power supply devices, d.c. output - Perfomance characteristics and safety requirements • EN 60950: 1992 + A1: 1993 + A2 (= IEC 950 second edition 1991 + A1: 1992 + A2: 1993) Safety of information technology equipment The installation instructions given in the corresponding data sheet describe correct installation leading to the presumption of conformity of the end product with the LVD. All PSx Series Switching Regulators are components, intended exclusively for inclusion within other equipment by an industrial assembly operation or by professional installers. They must not be operated as stand alone products. Hence conformity with the Electromagnetic Compatibility Directive 89/336/EEC (EMC Directive) needs not to be declared. Nevertheless, guidance is provided in most product application notes on how conformity of the end product with the indicated EMC standards under the responsibility of the installer can be achieved, from which conformity with the EMC directive can be presumed. Uster, 1 Sep. 2003 Power-One AG Rolf Baldauf Director Engineering REV. SEP 17, 2003 Page 11 of 11 Johann Milavec Director Products and IP