S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s Miniature 4.59” x 2.4” x 0.5.” Size High Power Density up to 90.78W/ Inch ³ High Efficiency up to 90.5% at 230VAC (28V) Low Output Noise Metal Baseplate Thermal Protection Over Voltage Protection Current Limit/Short Circuit Protection Adjustable Output Voltage 60-120% of Vo, Set Remote Sense Power On Signal (ENA) Open Collector (10mA sink current). Low (ON) when output is present DESCRIPTION: AC-DC Converter SMV-xx-500 modules are high power density and high efficiency AC-DC converters designed for uses in telecom and other centralized modular and distributed power applications. All use metal baseplates, planar transformers, and surface mount construction to produce up to 500W maximum. Their surface-mount construction uses an insulated metal substrate baseplate construction, planar transformers and thermally conductive potting compound to produce up to 500W in a full brick package and is well suited for the most rigorous requirements of mil/aero COTS and other thermally challenging applications. Model Number Output Voltage Output Amps Input Range Max. Iin FL Efficiency (Tb=25°C) O/P Set Point SMV-12-500 SMV-28-500 SMV-48-500 12 VDC 28 VDC 48 VDC 42 18 10.5 85-264 VAC 85-265 VAC 85-265 VAC 6.2A 6.2A 6.2A 90.2% @ 230Vin 90.5% @ 230Vin 90.4% @ 230Vin 11.76-12.24VDC 27.44-28.56VDC 47.04-48.96VDC All specifications are typical at nominal input, full load, and 25DegC unless otherwise noted WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s ABSOLUTE MAXIMUM RATINGS (MIN TO MAX.) ISOLATION SPECIFICATIONS Input Power with No Damage Power Factor Correction Storage Temperature / Humidity Operating Temperature (Note 5) Operating Humidity Output Power Input-Output Input-Case Output-Case Input-Output Capacitance Isolation Resistance 312 VAC 0.95 min HL-LL and Full Load -55 to +125°C / 10 to 95% -40 to 100°C 20 to 95% 500 Watts 3000VAC, 60S 2500VAC, 60S 1500VDC, 60S 2000pF 100MΩ @ Tb=25°C & 70%RH Output to Baseplate-500VDC GENERAL SPECIFICATIONS INPUT SPECIFICATIONS Input Voltage (AC(L) to AC(N) Input Frequency Input Current FL @ 100 Vin, FL Inrush Current (Note 3) S M V- 5 0 0 85-265 VAC 47-440 Hz 6.2A max. 40A @ 265VAC OUTPUT SPECIFICATIONS O/P Voltage, Current & Set Point See Model Selection Chart PG. 1 Line/Load Regulation (Note 7) 12 V: 48mV, 28V: 56mV, 48V: 96mV Ripple/Noise p-p max. (Note 1) 10% of Vout Dynamic Response (Note 6) 25% - 50% - 75% Load Peak Deviation: 3% Vo, set Settling Time 300uS Current Limit (Note 2) 105-140% of Rated Load Over Voltage Protection 125-145% Vo, set, Io=0.5A, Inverter Shutdown Method Over Temperature Protection Shutdown: 110°C typ. Auto Recovery: 90°C min. Efficiency (Tb=25°C, FL) 12 Vout: 90.2% @ 110 Vin, 90.2% @ 230Vin 28 Vout: 90.5% @ 110 Vin, 90.4% @ 230Vin 48 Vout: 90.4% @ 110 Vin, 90.5% @ 230Vin See Figs. 4a, 4b & 4C EFFICIENCY CURVES MTBF (Tb=40°C, 80%L, 230 Vin) 12V: 1.6Mhrs, 28V: 1.47 Mhrs, 48V: 1.59 Mhrs Weight 7.2 oz (206g) Dimensions (inches / mm) 4.59 x 0.5 x2.4 / 116.8 x 12.7 x 61 Safety Approvals UL: UL 60950-1-07, 2nd Edition TUV: EN 60950-1:2006 CE: EN 60950-1:2006 CONTROL SPECIFICATIONS Turn-on Time Trim Adjustment Range Hold Up Time 3S max., 90% Vo, set, FL 60-120% w the following Caps. 2000uF/25V (12V); 940uF/35V (28V); 440uF/100V (48V) Tb=25°C See Fig. 1 TRIM CiRCUIT 20mSec. min. with Cap. 780uF (C10 & C11 in Fig.3) NOTES (SEE NEXT PAGE) STRUCTURAL DYNAMICS Vibration Shock (Note 4) 196.1mS² WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s S M V- 5 0 0 NOTES 1.Bandwidth 5Hz to 20MHz and with filter 4.7nF MLCC series 50Ω (12, 28V) 100Ω (48V) min. Output Capacitors: 12V: 1000uF*2, TC≥ -20°C, 1000uF*4 28V: 470uF*2, TC≥ -20°C, 470uF*4, TC≤ -20°C 48V: 220uF*2, TC≥ -20°C, 220uF*4, TC≤ -20°C 2. Current Limit inception point Vo=90% of Vo, set @ Tb-25°C; Auto recovery. 3. Turn on @ 265Vin, External Components are needed for operation Refer to Fig. 3 for application circuit. 4. Sine Wave, 10-55Hz (Sweep for 1 min.), Amplitude 0.825mm Constant (Max. 0.5g) X, Y. Z 1 Hour each, non operating . 5. Temperature measurement shall be taken from the baseplate (Tb). See Fig. 2 for location definition 6. 0.1A/uS; with cap 940uF/35V (28V); 440uF/100V (48V) Tb=25°C, Vin=200VAC 7. Line = LL-HL, Load = NL-FL, Measured in typical Milli Volts (mV) WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s Draft Rev.3a 07/07/2010 TRIM TRIMCIRCUIT: CIRCUIT: Output by using usingexternal externalresistor resistorand/or and/or variable resistor: OutputVoltage Voltage Adjusted Adjusted by variable resistor: Draft Rev.3a 07/07/2010 TRIM CIRCUIT: Output Voltage Adjusted by using external resistor and/or variable resistor: R=33Kohm and VR=20Kohm for 60% to 120% of Vo,set For 12Vout, R=12.7Kohm VR = 1.103 Votrim - 8.488 (UNIT:KΩ ) Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. For 28Vout, R=35.7Kohm R=33Kohm and VR=20Kohm 120% of Vo,set BASEPLATE MEASURE POINT: for 60% to Vo For 48Vout, R=42.2Kohm VR =( trim 1.472 ) - 19.532 (UNIT:KΩ ) Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. BASEPLATE MEASURE POINT: Fig2 Baseplate Temperature Measure Point. Fig2 Baseplate Temperature Measure Point. WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s S M V- 5 0 0 Rev.3.6 2014/02/26 ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 WWW.ASTRODYNE.COM 6 Web Site: http://www.acbel.com S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s Rev.3.6 2014/02/26 The Description For Each Region Of Time Sequence： ： Region I： (1) The input voltage is under 85Vrms, so the unit has no output and the ENA signal is high (open collector). (2) Input under voltage lockout (UVLO) action. The unit starts the turn on sequence. When the input voltage reaches 85Vac and it delays 300mS, the inrush signal changes from low to high. When the inrush signal is low, the internal transistor of the unit between R terminal and +BC terminal is open. Therefore, the inrush current can be suppressed by external resistor. When the inrush signal is high, the internal transistor of unit is short. Therefore, the external resistor is bypassed by internal transistor. The voltage of bulk capacitors (±BC) should be more than 95% of the rectification input voltage before inrush signal changes to high. If not, the unit could be damaged by inrush current. (3) When the inrush signal is high and then delays 100mS, the PFC_Ctrl signal changes from low to high. Which means the PFC converter turns on and the ±BC will be boosted to 385Vdc (Typ). (4) When the PFC_Ctrl is high as well as ±BC reaches 360V and then delays 300mS, the DC/DC_Ctrl signal will change from low to high. After the steps mentioned the output voltage of unit starts to increase to specified voltage level. (5) When the output voltage of DC9010-690G reaches 13.7V (Typ) at start up, the ENA signal is pulled low to indicate that unit finished the turn on sequence. The unit finished the turn on sequence through the steps above. Region II：The over temperature protection (OTP) action. When the baseplate temperature (refer to spec. figure 2) of the unit rises to 110℃(Typ), both PFC and DC/DC converters turns off and the output shuts down. When the baseplate temperature decreases to 90℃(Min), the output auto-recovers. Region III：PFC output over voltage protection (OVP) action. When ±BC is over 424V (Typ), the PFC converter turns off. The PFC output voltage auto-recovers if the failure is removed. Region IV：Output OVP action. The output OVP mode is clamped. ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 WWW.ASTRODYNE.COM 7 Web Site: http://www.acbel.com 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s S M V- 5 0 0 Rev.3.6 2014/02/26 Region V：Output over current protection (OCP) action. When the output current of the unit is over limitation, the output voltage steps down. If the failure mode is removed, the output voltage auto-recovers. Region VI： (1) Input UVLO action. When the input voltage is under 80Vac (Typ) , the PFC_Ctrl signal changes from high to low, which means that the PFC converter turns off. After ±BC reduces to 300V, the inrush signal changes from high to low at the same time. (2) When the inrush is low and delays 5mS, the DC/DC_Ctrl changes from high to low, which means the DC/DC converter turns off. (3) When the output voltage of DC9010-690G decreases to 13.7V (Typ), the ENA signal changes from low to high. The unit turns off through the steps of region VI. WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s C1,2,3 250V 1uF Film X Cap C16,17 0.033uF C4,5 C6,7 C8,9 C10,11 4700pf 1000pf 450V 1uF 390uF/450V L1,2 R1 TRF1 F1 6mH 470K 2W 10Ω 250V 15A C12 C13,14 1000pf 12V: 1000uF/50V 28V: 470uF/50V 48V: 220uF/50V 12V: 2.2uF/25V 28V, 48V: 2.2uF/100V Ceramic Y Caps Ceramic Y Caps Film Electrolytic Bulk Caps; max. 1200uF Ceramic Y Cap Electrolytic C15 S M V- 5 0 0 EMI; Ceramic or Film EMI Bleeder Thermal Fuse T FB F R 1 Ceramic Application Circuit Instructions F1: This power module has no internal fuse. Use an external fuse to acquire each Safety Standard and to further improve safety. Further, Fast-Blow type fuses must be used per one module. Also, In-rush Surge current flows during line throw-in. Be sure to check I²t rating of external switch and external fuse. Recommended External Fuse: 15A Select fuse based on rated voltage, rated current and surge capability. 1. Voltage Ratings: 100VAC Line: AC125V 200VAC Line: AC250V 2. Current Ratings: Rated current is determined by the maximum input current based on operating conditions and can be calculated using the following formula: Pout Iin (max.) = (Arms) Iin (max.): Maximum Input Current Vin x Eff x PF Pout: Maximum Output Power Vin: Minimum Input Voltage Eff: Efficiency PF: Power Factor C1,2,3: 1uF (Safety Approved “X” Film Capacitor): Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating: 250VAC Note: Connect C3 as near as possible to the input terminals of the power module. C4,5: 4,700pF (Ceramic “Y” Capacitor): Add ceramic capacitor as an EMI/EMS counter measure. Be sure to consider leakage current of your equipment when adding this capacitor. High withstand voltages are applied across this capacitor depending on the application. Select capacitors with high withstand voltage ratings. C6,7: 1,000pF (Ceramic “Y” Capacitor): Add ceramic capacitor as an EMI/EMS counter measure. Be sure to consider leakage current of your equipment when adding this capacitor. High withstand voltages are applied across this capacitor depending on the application. Select capacitors with high withstand voltage ratings. C8,9: 1uF (Film Capacitor): Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating: 450VAC Note: Select capacitor with more than 3A (rms) rating. Connect C8,9 as near as possible to the input terminals of the power module. WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s Rev.3.6 2014/02/26 Fig. 4 Bulk cap ripple current requirement vs. Output load R2: R2 Inrush current limit. Resistance can be calculated by formula below. Suggest to choose resistance >10ohm. R= Vin rms * 2 . Ir , pk Vinrms: Input voltage Ir,pk: Inrush current peak value. Sufficient inrush energy withstand capacity is required. Required energy capacity can be calculated below and suggest having some design margin. 1 Cbulk * ( 2Vin rms ) 2 2 Cbulk: Bulk capacitance (C10&C11) Vinrms: Input voltage. The selected inrush resistor R2 have to meet the formula below, if the resistor value over the limitation may cause the brick damage. R< 300 mS 20 * C bulk Cbulk: Bulk capacitance (C10&C11) C12: C12 Part of EMI filter. Choose safety approved Y-cap. C13 C14 C14: E-cap to reduce output ripple and ensure stability. Choose low ESR part and check the ripple current rating higher than application. Suggest at least 470uF*2 if Tb>-20℃ and 470uF*4 if -40℃<Tb<-20℃. C15: C15 Connect ceramic capacitor near output terminal to reduce output noise. C16 C17 C17: Ceramic or film capacitor for EMI filtering. High voltage rating is required for isolation requirement. WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s S M V- 5 0 0 C10,11 (390uF x 2 PCs in parallel; Electrolytic Bulk Capacitors) Boost voltage bulk capacitor is determined by boost voltage ripple voltage, ripple current and hold-up time. Select capacitor value such that boost voltage ripple voltage does not exceed 15Vp-p. Recommended Voltage Rating: 450VDC Recommended Total Capacitor: 390uF to 1,200uF Notes: 1) When ambient temperature is -20ºC or less, AC ripple of boost voltage, output ripple voltage and start-up characteristics might increase or be affected due to ESR characteristics of the bulk capacitors. Therefore, verify above characteristics by actual evaluation. 2) Do not connect capacitors with more than the above capacitance value as this would result in power module damage. C12: 1,000pF (Ceramic “Y” Capacitor): Part of EMI filter. Choose safety approved “Y” capacitor. C13,14: 470uF/50V x 2 PCs in parallel; (220uF/100V for 48V Output) Electrolytic Capacitor: Take note of the maximum allowable ripple current of the electrolytic capacitor used. Especially for sudden load current changes, verify actual ripple current and make sure that allowable maximum ripple current is not to be exceeded. Note: Connect capacitors within 50mm from the output terminals +V and -V of the power module. C15: 2.2uF/100V (Ceramic Capacitor): Connect chip ceramic capacitor within 50mm from the output terminals +V and -V of the power module to reduce output spike noise. Also, note that output spike voltage may vary depending on the wiring pattern of the printed circuit board. C16,17: 0.033uF (Ceramic or Film Capacitor): Connect ceramic or film capacitor as EMI/EMS counter measure and to reduce spike noise. Note: High Voltage is applied across this capacitor during withstand voltage test depending on the applicatiion. Connect these capacitors as near as possible to the output terminals of the power module. L1,2: 6mH: Add common mode choke coil as EMI/EMS counter measure. When using multiple modules, connect coil to each module. Note: Depending on the input filter used, noise might increase or power module might malfunction due to filter resonance. R1: 470KΩ (Bleeder Resistor): Connect bleeder resistor across ACL and ACN terminals. TFR1: 10 to 100Ω: By connecting a thermal fuse resistor across R and +BC terminals as shown in fig. 3, in-rush current during line throw-in can be suppressed. Failures due to in-rush current such as melting of external fuse, welding of relay or switch connecting joints or shutdown of No Fuse Breakers (NFB) can occur. Therefore, be sure to connect this external thermal fuse resistor. Note: This module will not operate without this external resistor. Selection Method of External Resistor TFR1: 1) Calculating Resistance Value for TFR1: Resistance can be calculated by the following formula: Vin R= (Ω) R: Resistance Value for External TFR1 Irush Vin: Input Voltage converted to DC value = Input Voltage (rms) x √2 Irush: Input surge current value 2) Required Surge Current Rating: Sufficient surge current withstand capability is required for external TFR1. Required Surge Current Rating can be selected by I²t. (Current squared multiplied by time) Co x Vin² (A²s) 2xR I²t = WWW.ASTRODYNE.COM I²t: Current squared multiplied by time Co: Booster Voltage Bulk Capacitance Vin: Input Voltage converted to DC value = Input Voltage (rms) x √2 R: Resistance Value for External TFR1 ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s Draft Rev:3.3 2013/07/31 INPUT VOLTAGE DROPOUT TRANSIENT IMMUNITY: The output voltage should immune input voltage dropout. The allowable dropout time is related to output power and bulk capacitance (C10&C11) and Vo. Dropout time is longer with higher capacitance or lower output power. But the maximum allowable dropout time is 60mS regardless of capacitance and output power. The formula of allowable dropout time is shown below. Cbulk = C bulk = Cbulk: Bulk capacitance (uF) 2( Po * Tholdup ) * 1000 For Vo≦ 12V (385 2 − 320 2 ) * 0.92 Po: Output power (W) Tholdup: Allowable dropout time (mS) 2( Po * Tholdup ) * 1000 (385 − (320 * Vo / 12) ) * 0.92 For Vo>12V 2 2 For example, if required dropout time is 20mS at Po=500W, Vo=12V, the Cbulk capacitance must higher than 475uF, Note that capacitance tolerance need to take into account and must fulfill the minimum capacitance 390*2uF requirement for -40degC operation. Note that the maximum allowable dropout time is 60mS even the calculation result over 60mS. Draft Rev:3.3 2013/07/31 EFFICIENCY CURVE: (12V): SMV-12-500 EFFICIENCY CURVE DC9011-000G Efficiency Curve @ 12Vo, Tb=25degC 92 230V 110V 90 Efficiency 88 86 84 82 80 0 10 20 30 40 50 60 70 80 90 100 Fig.5 Fig. 4aEfficiency Efficiencycurve curve OUTLINE DRAWING: WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 S M V- 5 0 0 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s (28V): SMV-28-500 Efficiency Curve Efficiency (%) @ Vo = 28V, Tb = 25˚C 91 110Vac 230Vac 90 89 88 87 86 85 84 83 82 81 80 0 10 20 30 40 50 60 Output Load(%) 70 80 70 80 90 100 Fig. 4b Efficiency curve EFFICIENCY CURVE: (48V): SMV-48-500 Efficiency Curve At 48Vo, Tb=25degC 92 110 Vin 230 Vin 90 E ciency 88 86 84 82 80 78 0 10 20 30 40 50 60 Output Load % 90 100 Fig.Fig. 4c4bEfficiency curve E ciency curve WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 500 Wa t t , H i g h E ff ic i enc y, A C / D C P ow er Mo d u le s S M V- 5 0 0 MECHANICAL DIMENSIONS WWW.ASTRODYNE.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458