Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Features • • • • • • • • • • • • Applications • • • • • • Distributed power architectures Telecommunications equipment LAN/WAN applications Data processing applications 75 Watts total output power Wide input range 18V – 60V Independent dual outputs Flexible load sharing Open-frame design with IMS board Low profile – 12.7mm height Start-up into high capacitive load Output overcurrent protection (self re-start) Output overvoltage protection (self re-start) Overtemperature protection (self re-start) Setpoint accuracy ± 2.0% Output voltage trim adjust, independent for each output Input/output isolation: 1500V UL 1950 Recognition, CSA 22.2 No. 950-95 certification Description The HWD series provides onboard conversion of standard telecom and datacom input voltages into two isolated low-voltage outputs. These products offer a unique combination of wide input range, low profile, and high current capability. High efficiency and advanced thermal management enable these half-brick products to deliver full rated power at 55°C ambient temperature, with 200 LFM airflow, without the addition of heatsinks. Selection Chart Model HWD075DGE-A Input voltage range, VDC 18-60 Input current, max, ADC 5.5 Output voltage, VDC 5.0/3.3 Output rated current, ADC 15/15 REV. 9/01 Output Ripple and Noise, mV p-p 100 Efficiency % 81% @ 24Vin 79% @ 48Vin Page 1 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Absolute Maximum Ratings Table 1. Parameter Symbol Input Voltage Continuous Transient (100 msec) Operating Baseplate Temperature Note 1 Storage Temperature Input to Output Isolation Output Short Circuit Duration Total Output Power No Load Power Dissipation Min Max Units Vi Vi Tb -40 60 100 +100 Vdc Vdc °C Tstg -55 +125 Pomax - 1500 Continuous 75 6 °C Vdc W W Electrical Specifications Unless otherwise indicated, specifications apply over all input voltages, resistive load, and Tbp=+40°C. Table 2. Input Specifications Parameter Symbol Min Typ Max Units Voltage Range Maximum Input Current Input Ripple Rejection (120Hz) Inrush Transient Input Reflected Ripple (see figure 1) 18* - 24/48 60 - 60 5.5 1 250 Vdc A dB A2s mAp-p Vi Ii * Module will operate within specification with an input voltage of 18 Vdc, but must be turned on with an input voltage > 19.5 Vdc. See Undervoltage Lockout Specification. Fusing considerations Caution: This DC-DC converter is not internally fused. An external input fuse must always be used. Table 3. Output Specifications Symbol Parameter Output Power Output Voltage Set Point (Vi=24Vdc or Vi=48Vdc, Io1,Io2=7.5A) Output Line Regulation: (Vi=Vi,min to Vi,max) (Io1, Io2=7.5A) Output Load Regulation: (Io,min to Io,max) Po1 Po2 Po1+Po2 Vo1 Vo2 Min 4.9 3.23 Typ 5.0 3.3 Max 75 50 75 5.1 3.37 Units W W W Vdc Vdc Vo1,Vo2 - 0.05 0.2 % Vo1,Vo2 - 0.5 1 % REV. 9/01 Page 2 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Output Temperature Regulation: (Tbase =-40°C to +100°C) Output Current (Maximum output power limited to 75W) Output Ripple (See Figure 2) (DC to 20MHz) (Io1,Io2 = 7.5A) Output Current Limit inception (Other outputs at no load) Transient Response (50% to 100% Load Step, ∆Io/∆t=0.1A/uSec) Peak Deviation Settling Time (Vo, 1% of Vo1) Overvoltage Limit All Outputs - 0.02 0.05 %/°C Io1 Io2 0.5 0.5 7.5 7.5 15 15 A A Vo1 Vo2 - 75 75 100 100 mVp-p mVp-p Io1 Io2 - 17 21 19 23 A A Vo1 Vo2 - 100 200 150 200 300 250 Vo1,clamp Vo2,clamp 5.9 3.6 - 6.5 4.7 mV mV µsec Vdc Vdc Min Typ Max Units - 3.5 350 1 7 2 5 - V V mA msec kHz 5.39 3.55 4.41 2.91 +105 5.5 3.63 4.5 2.97 5.61 3.71 4.59 3.03 +115 Vdc Vdc Vdc Vdc °C 16.5 19.2 16.8 19.5 - V V Table 4. Feature Specifications Parameter Symbol Remote On/Off, Primary side Vlow Vhigh Sink Current-Logic Low Turn-on time (Within 1% Vonom) Switching Frequency Output Voltage Adjust Adjust Up Adjust Down Vo1 Vo2 Vo1 Vo2 Thermal Shutdown Undervoltage Lockout Turn-on Turn-off Table 5. Environmental Parameter Operating Baseplate Temperature Operating Humidity (non-condensing) Storage Humidity (non-condensing) Min Typ Max -40 - +100 Units °C - - 95 95 % % REV. 9/01 Page 3 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Table 6. Isolation Specifications Parameter Min Input to Each Output Input to Baseplate Output to Output Resistance, Input - Output Capacitance, Input - Output Typ Max Units 1500 1500 10 - - - 2200 - Vdc Vdc Vdc MΩ pF Table 7. EMI & Regulatory Agency Compliance Conducted Emissions (With input filter configuration in Figure 3.) Safety Table 8. General Specifications Parameter Efficiency η (Vi=24Vdc, Io1,Io2 = 7.5A) (Vi=48Vdc, Io1,Io2 = 7.5A) Calculated MTBF (Po=60W, Tbp=40°C) Table 7. Physical Parameter Dimensions Weight Markings & labeling CISPR 22 class A UL60950 Recognized, CAN/CSA C22.2 No. 60950-00 Recognized Min Typ Max Units 79 77 81 79 - % - 900 - kHrs Units 2.30(58.4) 2.40(60.9 ) 0.50(12.70 ) In. (mm) 2.4(68) oz(g) Includes Part Number, Power-One Logo, Date Code and Country of Manufacture REV. 9/01 Page 4 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Mechanical Diagram Pin 1 2 3 4 5 6 7 8 9 10 Function -Vin Case On/Off +Vin +Vo2 +Vo2 Rtn Trim 2 +Vo1 +Vo1 Rtn Trim 1 Ordering Information Options Remote On/Off Trim Pin Length Suffixes to add to part number Positive- Standard, no suffix required Negative- Add “N” suffix Negative- Standard, no suffix required 0.18”- Standard, no suffix required 0.11”- Add “8” suffix 0.15”- Add “9” suffix Notes 1. 2. 3. Consult factory for the complete list of available options. 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 President of Power-One, Inc. Specifications are subject to change without notice. REV. 9/01 Page 5 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Test Setup TO CURRENT PROBE Vi(+) Ltest 12 uH BATTERY Cs 220 uF ESR < 0.1 OHM @ 20 ºC, 100 kHz 22uF ESR < 0.7 OHM @ 20 ºC, 100 kHz Vi(-) Figure 1 Input Reflected Ripple Current Test Set-up: Note: Measure input reflected-ripple current with a simulated inductance (Ltest) of 12 uH. Capacitor Cs offsets possible battery impedance. Measure current as shown above. COPPER STRIPS (2 to 3 inches) DUT +Vo1 0.1uf ceramic 22uF Tantalum 0.1uf ceramic 22uf Tantalum SCOPE LOAD1 -Vo1 +Vo2 SCOPE LOAD2 -Vo2 Figure 2: Output Ripple Measurement Test Set-up: Note: Use a 0.1uf ceramic and 22uF tantalum capacitor. Scope measurement should be made using a BNC socket. Position loads between 51 mm and 76 mm (2 in. and 3 in.) from module. REV. 9/01 Page 6 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output FC100V10 + HWD15DGE Vin+ Vo1 LOAD1 -Vo1 VIN C1 C2 C3 C4 - Vin- GND Vo2 LOAD2 -Vo2 C5 C6 CASE Figure 3: Input filter configuration required to meet CISPR 22 Class A for Conducted Emissions. Part List for Input Filter Ref. Des C1, 2 C3 C4 C5, 6 F1 Description 0.47uF @100V MLC Capacitor (1812) 100uF @ 100V Alum. Electrolytic Capacitor 22uF@ 100V Alum. Electrolytic Capacitor 0.01uF MLC Capacitor FC100V10 Input Filter Module Manufacture AVX or Equivalent (Equiv.) Nichicon NRSZ Series or Equiv. United Chemicon KMG Series or Equiv. AVX or Equiv. Power-One Feature Descriptions Output Overvoltage Clamp The output overvoltage clamp consists of a separate control loop, independent of the primary control loop. This control loop has a higher voltage setpoint than the primary loop. In a fault condition the converter goes into “Hiccup Mode”, and the output overvoltage clamp ensures that the output voltage does not exceed Vo,clamp,max. This secondary control loop provides a redundant voltage-control that reduces the risk of output overvoltage. REV. 9/01 Page 7 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Output Current Protection To provide protection in an output overload or short circuit condition, the converter is equipped with current limiting circuitry and can endure the fault condition for an unlimited duration. At the point of current-limit inception, the converter goes into “Hiccup Mode”, causing the output current to be limited both in peak and duration. The converter operates normally once the output current is brought back into its specified range. Enable Two enable options are available. Positive Logic Enable and Negative Logic Enable. Positive Logic Enable turns the converter on during a logic-high voltage on the enable pin, and off during a logic-low. Negative Logic Enable turns the converter of during a logic-high and on during a logic-low. Output Voltage Adjustment Output voltage adjustment is accomplished by connecting an external resistor between the Trim Pin and either the +Vo1 or –Vo1 Pins. With an external resistor between the Trim Pin and +Vo1 Pin (Radj-down) the output voltage set point (Vo,adj) decreases. The following equation determines the required external resistor value to obtain an adjusted output voltage: Radj, dn ( Vo, adj − D) ⋅ A − B ⋅ ohm Vo, nom − Vo, adj Where Radj-down is the resistance value and A, B, and D are defined in Table 7. With an external resistor between the Trim Pin and –Vo1 Pin (Radj-up) the output voltage set point (Vo,adj) increases. The following equation determines the required external resistor value to obtain an adjusted output voltage: Raj, up A⋅D − B ⋅ ohm ( Vo, adj − D) − C Where Radj-up is the resistance value and A, B, C, and D are defined in Table 7: Table 8 Output Adjustment Variables. Output Vo1 Vo2 A 4990 4990 B 2000 2000 REV. 9/01 C 2.5 0.8 D 2.5 2.5 Page 8 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Thermal Considerations The power converter operates in a variety of thermal environments: however, sufficient cooling should be provided to help ensure reliable operation of the converter. Heat-dissipating components are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Proper cooling can be verified by measuring the case temperature. Heat Transfer Characteristics Increasing airflow over the converter enhances the heat transfer via convection. Figure 3 shows the maximum power that can be dissipated by the converter without exceeding the maximum case temperature versus local ambient temperature (TA) for natural convection through 400 ft/min. Systems in which these converters are used generate airflow rates of 50 ft/min due to other heat dissipating components in the system. Therefore, the natural convection condition represents airflow rates of approximately 50 ft/min. Use of Figure 3 is shown in the following example. Example What is the minimum airflow required for the device operating at 24 V, an output power of 60 W, and maximum ambient temperature of 60 ºC. Solution: Given: Vi = 24 V, Po = 60 W, TA = 60 ºC. Determine PD (Figure 4): PD = 13 W. Determine airflow (Figure 3): v = 200 ft/min Natural 100 LFM 200 LFM 300 LFM 400 LFM HWD15DGE - Power Derating 22 20 18 Power Dissipation (W) 16 14 12 10 8 6 4 2 0 0 10 20 30 40 50 60 70 80 90 100 Ambient Temperature (C) Figure 3. Power Derating Curve REV. 9/01 Page 9 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Thermal Considerations (continued) Vinmin Vinnom1 Vinnom2 Vinmax HWD15DGE Power Dissipation vs Output Power 20 18 16 14 Po we r 12 Di ss ip 10 ati on (W 8 ) 6 4 2 0 0 10 20 30 40 50 60 70 Output Power (W) Figure 4. Power Dissipation vs Output Power REV. 9/01 Page 10 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Vinmin Vinnom1 Vinnom2 Vinmax HWD15DGE Power Dissipation vs Full Load Power Distribution 20 18 16 14 Po we r 12 Di ss ip 10 ati on (W 8 ) 6 4 2 0 15/0.5 7.5/7.5 0.5/15 Output Load, Io1/Io2 (A) Figure 5. Power Dissipation vs Full Load Distribution REV. 9/01 Page 11 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Characteristic Curves Tb = 40 ºC, nominal input voltage, and rated load unless otherwise specified. Vinmin Vinnom1 Vinnom2 Vinmax HWD15DGE Efficiency vs Output Power 90 85 80 Eff ici 75 en cy (% ) 70 65 60 55 0 10 20 30 40 50 60 70 Output Power (W) Figure 6. Efficiency vs Output Power REV. 9/01 Page 12 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Vinmin Vinnom1 Vinnom2 Vinmax HWD15DGE Efficiency vs Full Load Power Distribution 90 88 86 84 Eff 82 ici en cy 80 (% ) 78 76 74 72 70 15/0.5 7.5/7.5 0.5/15 Output Load, Io1/Io2 (A) Figure 7. Efficiency vs Full Load Power Distribution REV. 9/01 Page 13 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Characteristic Curves (con’t) Figure 8. Typical Turn-on Characteristics REV. 9/01 Page 14 of 15 www.power-one.com Datasheet HWD Series – 75 Watt, Half-Brick DC/DC Converter Wide Input Range Dual Output Figure 9. Typical Turn-off Characteristics REV. 9/01 Page 15 of 15 www.power-one.com