HIGH DENSITY DC/DC Converters International Power Sources, Inc. 260 Hopping Brook Road Holliston, Massachusetts 01746 Tel. (508) 429-4440 Fax (800) 226-2100 http://www.intlpower.com IBT Series: 200 & 400 Watts FEATURES • Patented Flat Transformer Technology • DC Input Range: 18 VDC to 400 VDC • DC Output Range: 2.1 VDC to 15 VDC • Switching Frequency: 300 kHz (fixed) • Output Trim and Remote Sense • Remote on/off Control TM • • • • • Industry standard Pin-Out Up to 70 W/in3 Over 80% Conversion Efficiency Less than 10°C Internal Temperature Rise Above Base Plate Temperature MTBF 700Khrs (MIL-HDBK-217E) MODELS CHART MODEL INPUT VOLTAGE IBT200-200 IBT200-201 IBT200-201-3 IBT200-202 IBT200-300 IBT200-301 IBT200-301-3 IBT200-302 IBT200-400 IBT200-401 IBT200-401-3 IBT200-402 IBT200-500 IBT200-501 IBT200-501-3 IBT200-502 IBT200-503 IBT200-600-1 IBT200-600 IBT200-601 IBT200-600-3 IBT200-602 IBT200-603 18-36 18-36 18-36 18-36 36-72 36-72 36-72 36-72 50-100 50-100 50-100 50-100 100-200 100-200 100-200 100-200 100-200 200-400 200-400 200-400 200-400 200-400 200-400 OUTPUT VOLTAGE (±1% w/o trimming) Nominal 3.3V 5V 10V 12V 3.3V 5V 10V 12V 3.3V 5V 10V 12V 3.3V 5V 10V 12V 15V 2.1V 3.3V 5V 10V 12V 15V OUTPUT CURRENT Min. 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A 0A NO LOAD OUTPUT VOLTAGE LONG TERM Power Trim Range Short Circuit %EFF (%Vnom) Current Consumption Max. Max. Typ. Max. (Watts) Max. * Min. 40A 0.6 -5 +8 0.10A 75 30A 0.6 -5 +8 0.10A 82 20A 0.8 -8 +8 0.10A 82 17A 0.8 -8 +8 0.10A 85 50A 0.8 -6 +9 0.10A 75 40A 0.8 -8 +8 0.10A 82 20A 0.8 -8 +10 0.10A 85 17A 0.9 -8 +10 0.10A 87 50A 0.8 -6 +9 0.05A 78 40A 0.8 -8 +10 0.05A 82 20A 0.9 -8 +10 0.05A 85 17A 0.9 -8 +10 0.05A 86 50A 0.9 -6 +9 0.02A 75 40A 0.9 -8 +10 0.02A 80 20A 0.9 -8 +10 0.02A 83 17A 1.2 -8 +10 0.02A 85 10A 1.2 -8 +10 0.02A 83 100A 1.8 -8 +10 0.01A 70 50A 1.5 -6 +9 0.01A 72 40A 1.5 -6 +9 0.01A 78 20A 1.5 -8 +10 0.01A 80 17A 1.5 -8 +10 0.01A 81 10A 1.5 -8 +10 0.01A 80 * Voltage adjustment down to -40% available as an option. 54 Electrical Specifications All specifications typical at nominal line, full load and 25°C Output Specifications Voltage/Current ........................................................ See Table Setpoint Accuracy ..................................................... ±1% max. Load Regulation ........................................................0.1% max. (10% to 100% load) Line Regulation ........................................................ 0.1% max. (Low line to high line) Output Ripple and Noise (p-p) ...................................... 2.0% max. (20MHz bandwidth) Output Temperature Drift ............................................. 0.02%/°C max. (Tbase = 30° to 90°C) Start-up Overshoot .................................................... 25mV max. (10% to 100% load) Transient Response Settling Time ................................................... 200µsec max. (75% to 100% load change, 2.5A/µsec) Over/under-shoot ..............................................500mV max. (75% to 100% load change, 2.5A/µsec) Remote Sense Compensation ...................................... 0.15V max. Overvoltage Protection ............................................... 120-140% Vout (Latching) Overcurrent Protection ............................................... 110-120% Full load (Latching) Overtemperature Protection.......................................... 90°-105°C Baseplate Input Specifications Voltage/Current ........................................................ See Table, Page 1 Reflected Ripple Current ............................................. 35mA (max.) Input Ripple Rejection (120 Hz/1kHz) ...............................30/25db (min.) General Specifications Isolation: Input-Output ................................................ 3750 VAC min. Input to Baseplate..........................................2500 VAC min. Output to Baseplate .......................................500 VAC min. Saftey Requirements – Compilance......................... UL 1950, EN60950 (Per TUV), CSA 22.2 # 950, CE (LVD) Environmental Specifications Storage Temperature ................................................. –40°C to +125°C Operating Temperature ............................................... –40°C to +105°C Baseplate Humidity ................................................................ 0 to 95% Mechanical Specifications NOTES: Weight: 226 grams/0.5 lbs. Mounting Screw Type: M3 Suggested Screw Torque: 8.0m-Kg 55 Product Overview The unique transformer technology is the basis of International Power Sources low cost, high performance, high reliability DC/DC converter line. These converters are designed for telecommunication and industrial applications. The converter design utilizes a push-pull topology operating at a fixed switching frequency of 300 kHz. By using a fixed switching frequency, EMI filtering is made easier and less expensive. The core technology is a patented, modular, and very low noise Flat TransformerTM which generates extremely low leakage inductance and inter-winding capacitance, a combination not available in conventional transformers. In addition, the Flat Transformer does not create hot spots, making the converters more reliable. The use of direct bond aluminum base plates, forced current sharing in parallel rectifiers and the absence of hot spots in the transformers allow the converter to have very low temperature gradients. The converter’s internal temperature rise is less than 10°C above the base plate temperature, allowing base plate temperature to be raised to 105°C. The converters are manufactured in an ISO9001 approved facility utilizing advanced automated surface mount technology and state of the art in-process test procedures. IBT200 Features Output Inductor L3 Flat Transformer T1 Input Filter choke L1 TM Thermal Clad Aluminium Baseplate TM Input choke L2 Direct bond MOSFETS Q6, Q8 Direct bond parallel Rectifiers are used D10 (Forced equal current sharing due to use of Flat Transformer ) TM Competitive Advantages International Power Sources’ DC/DC converters are low cost, and can be delivered in a timely manner because readily available standard off the shelf components are used. No custom parts are used. International Power Sources’ DC/DC converters are extremely reliable because of the lower temperature gradient and even thermal loading: • The highly derated multiple parallel rectifiers receive the exact same shared currents from the use of Flat Transformer technology. This ensures even thermal loading on the rectifiers. • The Flat Transformer technology uses multiple cores. This coupled with the absence of many turns eliminates hot spots in the transformer windings. • All heat generating components such as the Flat Transformers, inductors, rectifiers, and MOSFETS are directly solder-bonded onto the aluminum base plate for maximum transfer of heat out of the converter International Power Sources’ DC/DC converters utilize simple push-pull topology with fewer components. The fixed switching frequency ensures easier and less expensive EMI filtering. In addition, negligible leakage inductance of Flat TransformersTM reduces the switching losses. High Power Units We are also pleased to offer new 400 watt modules in an industry standard 200 watt footprint. Input Voltage 200-400 VDC 200-400 VDC 200-400 VDC Output Voltage 5.0 VDC 12.0 VDC 15.0 VDC Output Current 80 Amps 34 Amps 27 Amps Output Power 400 Watts 400 Watts 400 Watts 36-72 VDC 5.0 VDC 12.0 VDC 15.0 VDC 80 Amps 34 Amps 27 Amps 400 Watts 400 Watts 400 Watts 36-72 VDC 36-72 VDC 56 Application Notes Thermal Consideration Graph A shows the output power derating (in watts) with heat sink and without heat sink at various ambient temperatures in still air conditions. If appropriate forced air is used with or without a heat sink, there is no power deration as illustrated in Graph B. In such a case, the converter can be operated at its full output power rating. Graph A: Output Power Derating in Still Air Graph B: Output Power With Forced Air Conversion Efficiency The graph below shows load current vs. conversion efficiency specific to IBT200-301 only. Graphs for other models available upon request. Heat Sink The converter can be operated at full-load with appropriate forced air cooling or by using a lower thermal resistance heat sink. Load Current vs Efficiency Gate Control A remote on-off control pin is provided to enable or disable the converter. When the Gate-In Pin 2 is at logic high (2.8 to 7V) or open circuited, the converter is enabled. At logic low (<2.8V) the converter is then disabled. If the control signal has a common return with the primary side, one can use a NPN transistor circuit to enable/disable the converter. If the control signal is from the secondary, or anywhere else, an opto-coupler circuit can be used. 57 Material: Aluminum Extrusion Dimensions: 2.44 “ x 0.78” x 4.6” Weight: 135 grams(0.3 lbs) Thermal Impedance: 3.0°C/W Output Trimming Approximately ±10% output voltage trimming can be achieved by adding a potentiometer. The recommended circuit connection technique is shown below. The suggested minimum resistance value is 5.1K .