HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Data Sheet Features • • • • • • • • • • • Applications • • • • • Distributed power architectures Telecommunications equipment LAN/WAN applications Data processing applications • Low profile (-11mm) single board design 1500VDC input to output isolation meets basic insulation High efficiency - to 92% at full load Start-up into high capacitive load Low conducted and radiated EMI Output overcurrent protection Output overvoltage protection Overtemperature protection Remote sense Set point accuracy ± 1% Remote on/off (primary referenced), positive or negative logic Output voltage trim adjust, positive or negative UL 1950 Recognized, CSA 22.2 No. 950-95 certified, TUV IEC950 Description The new HLS30 series of high-density, single-output DC/DC converters, convert standard telecom and datacom voltages into isolated low voltage outputs. High efficiencies and a patent-pending board design create superior thermal transfer that enhances product reliability and eliminates the need for a heatsink. Selection Chart Model Input voltage VDC HLS30ZG HLS30ZE HLS30ZD 36-75 36-75 36-75 Input current, max ADC 4.8 3.3 2.5 Output voltage VDC Output rated current I rated ADC Output Ripple/Noise, mV p-p Typical Efficiency @ I rated % 5.0 3.3 2.5 30 30 30 100 75 50 91 89 88 This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment should be followed. Rev. 10/01 Page 1 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Data Sheet Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long-term reliability and cause permanent damage to the converter. Parameter Input voltage Operating Temperature Storage Temperature ON/OFF Control Voltage Conditions/Description Continuous Transient, 100mS At 100% load Min Max 75 100 100 125 50 -40 -40 Referenced to -Vin Units VDC VDC °C °C VDC Environmental and Mechanical Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Shock Sinusoidal Vibration Weight Water Washing MTBF Conditions/Description Halfsine wave, 3 axes GR-63-Core, Section 5.A.2 Min 50 1 Nom Max 1.6/46 Yes 1,780 Standard process Per Bellcore TR-NWT-000332 Units g Oz/g kHrs Isolation Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Insulation Safety Rating Isolation Voltage Isolation Resistance Isolation Capacitance Conditions/Description Min Nom Basic Max 1500 10 1100 Units VDC MOhm pF Input Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Input Voltage Turn-On Input Voltage Turn-Off Input Voltage Turn-On Time Input Reflected Ripple Current Inrush Transient Rev. 10/01 Conditions/Description Continuous Ramping Up Ramping Down To Output Regulation Band 100% Resistive Load Full Load, 12uH source inductance Vin=Vin.max Min 36 Nom 48 33 32 5 Max 75 Units VDC VDC VDC mS 80 mA p-p A2s 0.1 Page 2 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Data Sheet Output Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Output Voltage Setpoint Accuracy Output Current* Line Regulation Load Regulation Total output voltage regulation Remote Sense Headroom Dynamic Regulation Peak Deviation Settling Time Admissible Load Capacitance Output Current Limit Threshold** Switching Frequency Overvoltage Protection, Non Latching Trim Range Conditions/Description Vin=Vin.nom, Full Load Vin.min to Vin.max, Iout.max Vin=Vnom, Iout.min to Iout.max Over all input voltage, load, and temperature conditions Min -1 3 Nom -2 Max 1 30 0.2 0.2 Units %Vout ADC %Vout %Vout 2 %Vout 0.5 VDC 8 150 50-75% load step change to 1% error band Iout.max, Nom Vin Vout≤0.97Vout.nom 120 140 %Vout µS µF %Iout kHz %Vout 90 110 %Vout 30,000 110 140 270 Over all input voltage and load conditions Iout.max, Vin=Vnom * At Iout<Iout.min, the output may contain low frequency component that exceeds ripple specifications. ** Overcurrent protection is non-latching with auto recovery. Feature Specifications All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted. Parameter Shutdown (ON/OFF) Negative Logic - Converter ON - Source Current - Converter OFF -Open Circuit Voltage Positive Logic - Converter ON - Open Circuit Voltage - Converter OFF - Source Current Overtemperature Protection Rev. 10/01 Conditions/Description Min Nom Max Units 1.8 VDC mADC VDC VDC On/Off signal is low – converter is ON -1.0 ON/OFF pin is connected to -Vin 0.85 3.5 ON/OFF pin is floating On/Off signal is low –converter is OFF 50 2 3.5 ON/OFF pin is floating 50 3 -1.0 ON/OFF pin is connected to -Vin Average PCB Temp. – Shut down - Recover 1.8 0.46 90 Page 3 of 8 VDC VDC VDC mADC °C HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Data Sheet Characteristic curves Fig. 1 HLS30ZG (5V) Efficiency vs. Output Load Fig. 4 HLS30ZG (5V) Input Characteristic Fig. 2 HLS30ZE (3.3V) Efficiency vs. Output Load Fig. 5 HLS30ZE (3.3V) Input Characteristic Fig. 3 HLS30ZD (2.5V) Efficiency vs. Output Load Rev. 10/01 Fig. 6 HLS030ZD (2.5V) Input Characteristic Page 4 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Typical Application Figure 7 below shows the recommended connections for the HLS30 series converter. Fig.7 Typical application of HLS30 series The HLS30 series converters do not require any external components for proper operation. However, if the distribution of the input voltage to the converter contains significant inductance, the capacitor C1 may be required to enhance performance of the converter. A minimum of a 47μF electrolytic capacitor with the ESR<0.7Ω is recommended for the HLS30 series. If magnitude of the inrush current needs to be limited, see the “Inrush Current Control Application Note” on Power-One website www.power-one.com. For output decoupling we recommend to use a 10μF tantalum and a 1μF ceramic capacitors connected directly across the output pins of the converter. Note, that the capacitors do not substitute the filtering required by the load. Data Sheet resistor between the ON/OFF pin and the +Vin pin. When the ON/OFF pin is used to achieve remote control, the user must take care to insure that the pin reference for the control is really the -Vin pin. The control signal must not be referenced ahead of EMI filtering or remotely from the unit. Optically coupling the information and locating the optical coupler directly at the module will solve any of these problems. Note: If the ON/OFF pin is not used, it can be left floating (positive logic), or connected to the -Vin pin (negative logic). Output Voltage Trim The trim feature allows the user to adjust the output voltage from the nominal value. This can be used to compensate distribution drops, perform margining in production, or accommodate other requirements when output voltage needs to be adjusted from the nominal. There are two trim options available in the HLS30 series. Standard Negative Trim (No suffix) The negative trim method is the Power-One standard. The HLS30 standard trim units trim up with a resistor from the TRIM pin to the Sense pin and trim down with a resistor from the TRIM Fig.8 HLS30 series negative trim schematic pin to the +Sense pin as shown in Figure 8. Shutdown Feature Description The ON/OFF pin in the HLS30 series converters functions as a normal soft shutdown. It is referenced to the –Vin pin (see Figure 7). With positive logic, when the ON/OFF pin is pulled low, the output is turned off and the unit goes into a very low input power mode. With negative logic, when the ON/OFF pin is pulled low, the unit is turned on. An open collector switch is recommended to control the voltage between the ON/OFF pin and the -Vin pin of the converter. The ON/OFF pin is pulled up internally, so no external voltage source is required. The user should avoid connecting a Rev. 10/01 Fig. 8 HLS30 series negative trim schematic Page 5 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output The general equation (1) for changing the output voltage on the standard trim modules is invariant, but the constants in the equation change due to different internal design. RTRIM A − B × ∆V , KOhm = ∆V (1) where A and B are constants from the table below, and ΔV is the absolute value of the desired change in the output voltage in Volts. Model HLS30ZG HLS30ZE HLS30ZD Trim up A 3.77 2.07 1.27 B 6.81 3.92 3.92 Trim down A B 11.58 9.88 3.5 5.61 1.31 4.95 Optional Positive Trim (suffix –T) The -T option units trim up with a resistor from the TRIM pin to the +Sense pin and trim down with a resistor from the TRIM pin to the –Sense pin as shown in the Figure 9. Data Sheet where ΔV% is the output voltage change expressed in percents of the nominal output voltage, Vout. Notes: 1. When the output voltage is trimmed up, the output power from the converter must not exceed its maximum rating. This is determined by measuring the output voltage on the output pins, and multiplying it by the output current. 2. In order to avoid creating apparent load regulation degradation, it is important that the trim resistors are connected directly to the remote sense pins, and not to the load or to traces going to the load. 3. The HLS30 series converters will trim down further than the 10% limit. In general, this is permissible. The user must confirm that the results are acceptable in his application. Safety Considerations The HLS30 series converters feature 1500 Volt DC isolation from input to output. The input to output DC resistance is greater than 10MOhm. These converters are provided with Basic insulation between input and output circuits according to all IEC60950 based standards. Nevertheless, if the system using the converter needs to receive safety agency approval, certain rules must be followed in the design of the system. In particular, all of the creepage and clearance requirements of the end-use safety requirements must be observed. These documents include UL60950, CSA60950-00 and EN60950, although other additional requirements may be needed for user’s specific applications. Fig.9 HLS30 series positive trim schematic The equations below determine the trim resistor value required to achieve a ΔV change in the output voltage. Vout× (100+ ∆V %) 100+ 2× ∆V % − ,kOhm 1.225× ∆V % ∆V % 100 RDOWN = − 2 , kOhm ∆V % RUP = Rev. 10/01 The HLS30 series converters have no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in Figure 7. The fuse with a rating not greater than 10A is recommended. The user can select a lower rating fuse based upon the highest inrush transient at the maximum input voltage and the maximum input current of the converter at the minimum input voltage. Both input traces and the chassis ground trace (if applicable) must be capable of conducting a current of 1.5 times the Page 6 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output value of the fuse without opening. The fuse must not be placed in the grounded input line, if any. Data Sheet air, while up to 28A reliably with 200LFM forced air. In order for the output of the HLS30 series converter to be considered as SELV (Safety Extra Low Voltage) or TNV-1, according to all IEC60950 based standards, one of the following requirements must be met in the system design: • • • If the voltage source feeding the module is SELV or TNV-2, the output of the converter may be grounded or ungrounded. If the voltage source feeding the module is ELV, the output of the converter may be considered SELV only if the output is grounded per the requirements of the standard. If the voltage source feeding the module is a Hazardous Voltage Secondary Circuit, the voltage source feeding the module must be provided with at least Basic insulation between the source to the converter and any hazardous voltages. The entire system, including the HLS30 converter, must pass a dielectric withstand test for Reinforced insulation. Design of this type of systems requires expert engineering and understanding of the overall safety requirements and should be performed by qualified personnel. Fig.10 HLS30ZG (5V) derating curves Thermal Considerations The HLS30 series converters are designed for natural or forced convection cooling. The maximum allowable output power of the converters is determined by meeting the derating criteria of all electronic components used in the power supplies. An example of the derating criteria for the semiconductor junction temperature is not to exceed 120C to provide reliable long-term operation of the converters. Note: Please contact Power-One for more derating criteria for other components. The graphs in Figures 10-12 show the maximum output current of the HLS30 series converters at different ambient temperatures under both natural and forced (longitudinal airflow direction, from pin 1 to pin 4) convection. As an example, from Figure 10, the HLS30ZG operating at 55C can deliver up to 25.5A reliably with 100LFM forced Rev. 10/01 Fig.11 HLS30ZE (3.3V) derating curves Fig.12 HLS30ZD (2.5V) derating curves . Page 7 of 8 HLS30 Series – 30A Half-Brick DC/DC Converter 48V Input 5.0V, 3.3V, 2.5V Output Data Sheet Mechanical Drawing PIN 1 FUNCTION -Vin 2 No Pin 3 On/Off 4 +Vin 5 -Vout 6 -Sense 7 Trim 8 +Sense 9 +Vout Tolerances: .xx + .020 (.5) .xxx + .010 (.25) Pin Diameter + 0.002 (.05) Ordering Information Options Remote ON/OFF Trim Pin Length Suffixes to add to part number Positive- no suffix required Negative- Add “N” suffix Negative- no suffix required Positive - Add “T” suffix 0.18”- 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. 10/01 Page 8 of 8