VI BRICK® AC Front End FE175D480C033FP-00 Size: 3.75 x 1.91 x 0.38 in 95,3 x 48,6 x 9,55 mm S ® C US C NRTL US Complete AC-DC PCB-mounted solution Features • • • • • • • • • • • • • • • • • Typical Applications Complete AC-DC PCB-mounted solution Active Power Factor Correction (PFC) Rectification Filtering Transient protection Low profile package, 9.55mm height above board Power density: 121 W/in3, 330 W in 7.2 in2 footprint Consistent high efficiency over world-wide AC mains (85 – 264 Vac) Secondary-side energy storage SELV 48 V Output – Efficient power distribution to POL converters 3,000 Vac /4,242 Vdc isolation PFC (THD) exceeds EN61000-3-2 requirements Conducted emissions EN55022, Class B (with a few external components) Surge immunity EN61000-4-5 ZVS high frequency (MHz) switching Low profile, high-density filtering 100 °C baseplate operation • LED - Lighting, display, signage • Telecom (WiMAX, Power Amplifiers, Optical Switches) • Automatic Test Equipment (ATE) • High Efficiency Server Power • Office Equipment (Printers, Copiers, Projectors) • Industrial Equipment (Process Controllers, Material Handling, Factory Automation) Product Overview The VI BRICK® AC Front End is an AC-to-DC converter, operating from a universal AC input to generate an isolated and regulated 48 Vdc output with power factor correction. The module incorporates rectification, transient and surge suppression and AC to DC conversion to provide a complete AC to DC solution in a thin profile package. With its ZVS high frequency Adaptive CellTM topology, the VI BRICK AC Front End module consistently delivers high efficiency across worldwide AC mains. Downstream DC-DC converters support secondaryside energy storage and efficient power distribution, providing superior power system performance and connectivity from the wall plug to the point-of-load. Major Specifications 85 – 264 VAC VIN VOUT 48 VDC (isolated) POUT 330 W Nomenclature Function Input Voltage Designator F 1 E 7 5 Universal (85 – 264 Vac) Package Size D Output Voltage Vout (V) (x10) 4 Grade C= T= M= 8 Temperature Grade 0 Operating -20 to 100 °C -40 to 100 °C -55 to 100 °C C Output Power Pout (W) (–10) : 0 3 Storage -40 to 125 °C -40 to 125 °C -65 to 125 °C VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 1 of 20 11/2012 800 735.6200 3 Baseplate Pin Style F P Revision – F = Slotted Flange P = Through hole 0 0 FE175D480C033FP-00 Typical Application: Universal AC to 12 V and 1 V, total 300 W FUSE 85 264 Vac Gnd +OUT AC (L) VI BRICK® AC Front End MOV 12 V Load DC-DC Converter AC (N) Gnd +OUT –OUT PRMTM Regulator –OUT VTMTM Transformer 1.0 V Load Holdup Capacitor Absolute Maximum Ratings The ABSOLUTE MAXIMUM Ratings below are stress ratings only. Operation at or beyond these maximum ratings can cause permanent damage to device. Electrical specifications do not apply when operating beyond rated operating conditions. Positive pin current represents current flowing out of the pin. Parameter Comments Input voltage AC (L) to AC (N) Continuous Input voltage AC (L) to AC (N) 1 ms Min 0 Input voltage slew rate Max Unit 275 VAC 600 Vpk 25 V/µs RSV1 to –IN Do not connect to this pin -0.3 5.3 VDC EN to –IN 5 V tolerant 3.3 V logic -0.3 5.3 VDC RSV3 to –IN Do not connect to this pin -0.3 5.3 VDC Output voltage (+Out to -Out) -0.5 57.0 VDC Output current 0.0 10.2 A Temperature Operating junction Worst case semiconductor 0 125 °C Operating temperature C-Grade; baseplate -20 100 °C T-Grade; baseplate -40 100 °C M-Grade; baseplate -55 100 °C C-Grade -40 125 °C T-Grade -40 125 °C M-Grade -65 125 °C Storage temperature Dielectric Withstand Dielectric Withstand Input – Output 3000 VRMS Dielectric Withstand Input – Base 1500 VRMS Dielectric Withstand Output – Base 1500 VRMS VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 2 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Electrical Characteristics Specifications apply over all line and load conditions, 50 Hz and 60 Hz line frequencies, TC = 25 °C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. COUT is 6800uF +/- 20% unless otherwise specified. Attribute Power Input Specification Input voltage range, continuous operation Input voltage cell reconfiguration low-to-high threshold Input voltage cell reconfiguration high-to-low threshold Input current (peak) Source line frequency range Power factor Symbol Conditions / Notes Min VIN 85 VIN-CR+ 145 VIN-CR- 132 IINRP fline PF 47 0.9 1.1 LIN No Load Specification Input power – no load, maximum Input power – disabled, maximum PNL EN floating, see Figure 4 PQ EN pulled low, see Figure 5 Output voltage, no load VOUT VOUT-NL Output voltage range (transient) VOUT Output power POUT Efficiency h Vin = 230 Vrms, 10% Load Over all operating steady state line conditions Non-faulting abnormal line and load transient conditions See Figure 1, Safe Operating Area VIN = 230 V, full load 85 V < VIN < 264 V, full load, see Fig. 2 85 V < VIN < 264 V, 75% load Max Unit 264 VRMS 148 VRMS 135 Input power > 100 W Differential-mode inductance, commonmode inductance may be higher Input inductance, (external) Power Output Specification Output voltage set point Typ VRMS 12 63 A Hz - 1 mH 1.5 W 1.6 W 47.5 49 50.5 V 46 51.5 55 V 55 V 330 94 W % % % 30 91 88.5 89 Output voltage ripple, switching frequency VOUT-PP-HF Over all operating steady-state line and load conditions, 20 MHz BW, measured at C3, Fig 28. 100 300 mV Output voltage ripple line frequency VOUT-PP-LF Over all operating steady-state line and load conditions, 20 MHz BW 3.8 5 V Output capacitance (external) COUT-EXT 12,000 µF 400 1000 ms 400 5.5 500 11 8 500 1 1 6.9 ms ms % ms % % A Output turn-on delay TON Start-up setpoint acquisition time Cell reconfiguration response time Voltage deviation (load transient) Recovery time Line regulation Load regulation Output current (continuous) Tss TCR %VOUT-TRANS TTRANS %VOUT-LINE %VOUT-LOAD IOUT 6,000 From VIN applied, EN floating From EN pin release, VIN applied Full load Full load COUT = Max 250 0.5 0.5 Full load 10% to 100% load See Figure 1, SOA VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 3 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Electrical Characteristics (cont.) Attribute Symbol Conditions / Notes Min Output current (transient) Output switching cycle charge IOUT-PK QTOT 20ms duration, max Output inductance (parasitic) LOUT-PAR Frequency @ 1 MHz Output capacitance (internal) Output capacitance (internal ESR) COUT-INT RCOUT Effective value at nominal output voltage Typ Max Unit 10.2 13.5 A µC Power Output Specification (cont.) Powertrain Protections Input undervoltage turn-on Input undervoltage turn-off Output overvoltage threshold Upper start / restart temperature threshold (case) Overtemperature shutdown threshold (junction) Overtemperature shutdown threshold (case) Undertemperature shutdown threshold (case) Lower start / restart temperature threshold (case) Overcurrent blanking time Input overvoltage response time Input undervoltage response time Output overvoltage response time Short circuit response time Fault retry delay time Output power limit 1 See Timing Diagram VIN-UVLO+ VIN-UVLOVOUT-OVLO+ Instantaneous, latched shutdown °C 110 TCASE-OTP+ C Grade -25 °C TCASE-UTP+ C Grade -20 °C 550 6 51 180 120 ms µs ms µs µs s W Based on line frequency 400 460 Based on line frequency Powertrain on Powertrain on, operational state See Timing Diagram 27 60 39 120 60 10 330 300 4 240 3 180 2 120 1 60 0 0 200 220 240 Input Voltage (VRMS) Current 260 95% 94% Efficiency (%) 5 Full Load Efficiency vs. Line Voltage 25 °C Case Output Power (W) Output Current (A) °C TCASE-UTP- TOC TPOVP TUVLO TSOVP TSC TOFF PPROT 180 59.0 VRMS VRMS V 130 360 160 83 TJ-OTP+ 6 140 74 71 56.6 °C 420 120 µF mΩ 100 DC Output Safe Operating Area 100 7 0.5 TCASE-OTP- 7 80 65 55.3 nH 93% 92% 91% 90% 89% 88% 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (V) Power Figure 1 — DC output safe operating area Figure 2 — Full load efficiency vs. line voltage VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 4 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Signal Characteristics Specifications apply over all line and load conditions, 50 Hz and 60 Hz line frequencies, TC = 25 °C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. ENABLE : EN • The EN pin enables and disables the VI BRICK® AC Front End; when held below 0.8 V the unit will be disabled. • The EN pin can reset the VI BRICK AC Front End after a latching OVP event. • The EN pin voltage is 3.3 V during normal operation. • The EN pin is referenced to the –IN pin of the module. Signal Type Digital Input State Startup Standby Attribute EN enable threshold EN disable time EN disable threshold Symbol VEN_EN TEN_DIS VEN_DIS EN resistance to disable REN_EXT Conditions / Notes Min From any point in line cycle Typ 9 Max 2.00 16 Unit V ms V 14 kΩ 0.80 Max allowable resistance to -IN required to disable the module RESERVED : RSV1, RSV3 No connections should be made to these pins -IN • Warning: -IN and N are not at the same potential and must not be connected together. • The -IN pin is the signal reference ground for the EN pin • The -IN pin also serves as an access point for the common mode bypass filter to comply with EN55022 Class B for Conducted Emissions. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 5 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Functional Block Diagram Adaptive Cell™ Topology Primary & Secondary Powertrain Q1T Q3T CIN-T Cell Configuation Controller Top Cell Q2T Q4T S1 +OUT VIN-B S3 COUT-INT -OUT L AC N Rectifier + Filter + Transient Supression Q1B S2 Q3B CIN-B Bottom Cell Q2B Q4B -IN 3.3 V Primary-side Voltage Sense VIN-B RSV1 49.9 kΩ Modulator EN RSV3 Powertrain Enable -IN -IN Micro controller VEAO Auto Ranger Control Fault Latch & Reset Logic Enable Microcontroller: Fault monitoring Error Amplifier Output OVP Fault Monitoring Output and OCP/SCP PFC Input UVP & OVP Internal OTP / UTP -IN VEAO Output Voltage with Offset PFC Control VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 6 of 20 11/2012 800 735.6200 -IN Reference Voltage with Ripple Twice the Supply Frequency FE175D480C033FP-00 High Level Functional State Diagram Conditions that cause state transitions are shown along arrows. Sub-sequence activities listed inside the state bubbles. Application of VIN VIN > VIN-UVLO+ EN = True and No Faults STARTUP SEQUENCE Line Frequency Acquisition tON Expiry Powertrain: Stopped RNG: Auto STANDBY OPERATIONAL VOUT Ramp Up (tss) Regulates VOUT EN = False or VIN Out of Range Powertrain: Stopped RNG: High EN = False or VIN Out of Range No Faults NON LATCHED FAULT tOFF delay Powertrain: Active RNG: Auto PFC: Auto Overtemp, Output Short, or Overload Powertrain: Stopped RNG: High Output OVP EN Falling Edge LATCHED FAULT Powertrain: Stopped RNG: High VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 7 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Timing Diagrams Module Inputs are shown in blue; Module Outputs are shown in brown. 1 Input Power On & UV Turn-on 2 3 Full 10% Load Load Applied Applied 6 Range Change LO to HI 5 4 EN EN Forced High Low 7 Range Change HI to LO 8 Load Dump 10 9 Load Input Power Off & UV Step Turn-off VIN-CR- VIN-CR+ VIN-UVLO+ Input VIN-RMS VIN-UVLO- ≈30VRMS EN VOUT-NL tON tEN-DIS VOUT tCR tCR tON tUVLO tTRANS (2 places) VOUT tSS Output ILOAD 11 Input Power ON & UV Turn-on 12 Output OC Fault 13 Output OC Recovery 14 Output OVP Fault 15 Toggle EN (Output OVP Recovery) 16 Output OVP Fault 17 Recycle Input Power (Output OVP Recovery) 19 Output SC Recovery 20 21 22 OT Fault Line Input & Drop-Out Power Recovery Off & UV Turn-off )) )) VIN-UVLO+ Input 18 Output SC Fault VIN-UVLO+ VIN-UVLO- VIN-RMS )) )) )) )) )) )) EN tOC VOUT tON tSS Output tOC VOUT-OVLO+ tOFF+tON tON tON tOC tOFF+tON tOFF+tON )) )) tSOVP tSC tOFF+tON ≥tOFF+tON ILOAD )) * )) * Figure 3 — Timing diagram - * Negative current is externally forced and shown for the purpose of OVP protection scenario. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 8 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Application Characteristics The following figures present typical performance at TC = 25 ºC, unless otherwise noted. See associated figures for general trend data. 2.50 2.00 1.50 1.00 0.50 0.00 No Load Power Dissipation vs. Line, Module Disabled, EN Low Power Dissipation (W) Power Dissipation (W) 3.00 No Load Power Dissipation vs. Line, Module Enabled - Nominal VOUT 85 100 115 130 145 160 175 190 205 220 235 250 265 1.660 1.460 1.260 1.060 0.860 0.660 0.460 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (V) TCASE: 25 °C -55 °C Input Voltage (V) 100 °C Figure 4 – Typical no load power dissipation vs. VIN , module enabled. Figure 5 – No load power dissipation trend vs. VIN , module disabled. Figure 6 – Typical switching frequency output voltage ripple waveform, TCASE = 30 ºC, VIN = 230 V, IOUT = 6.9 A, no external ceramic capacitance. Figure 7 – Typical line frequency output voltage ripple waveform, TCASE = 30 ºC, VIN = 230 V, IOUT = 6.9 A, COUT = 6,800 µF. Measured at C3, Fig. 28. Figure 8 – Typical output voltage transient response, TCASE = 30 ºC, VIN = 230 V, IOUT = 6.9 A, COUT = 6,800 µF. Figure 9 – Typical startup waveform, application of VIN , RLOAD = 7.1 Ω, COUT = 6,800 µF. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 9 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Application Characteristics (cont.) The following figures present typical performance at TC = 25 ºC, unless otherwise noted. See associated figures for general trend data. C Figure 10 – Typical startup waveform, EN pin release, VIN = 230 V, RLOAD = 7.1 Ω, COUT = 6,800 µF. Output: Figure 11 – Line drop out, 50 Hz, 0° phase, 90% Load (297W) PLOAD = 330 W, COUT = 6,800 µF. Att 20 dB INPUT 2 100 1 MHz Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit 55022RED dB Ì V 10 MHz 90 SGL 80 22QPA 1QP 70 22QPB 60 50 40 30 29.Aug 2012 11:01 20 150 kHz Date: 29.AUG.2012 30 MHz 11:01:40 C Figure 12 – Line drop out, 50 Hz, 90° phase, VIN = 230 V, Output: 90% Load (297W) PLOAD = 330 W, COUT = 6,800 µF. Att 20 dB INPUT 2 100 1 MHz Det QP/AV Trd ResBW 9 kHz Meas T 20 ms Unit Figure 13 – Typical EMI spectrum, Quasi-Peak Scan, 90% load, 230 VIN, COUT = 6,800 µF. Test circuit - Figure 28. 55022RED dB Ì V 10 MHz 90 SGL 80 2AV 70 22AVA 60 22AVB 50 40 30 29.Aug 2012 11:02 20 150 kHz Date: 29.AUG.2012 30 MHz 11:02:41 Figure 14 – Typical EMI spectrum, Average Scan, 90% load, 230 VIN, COUT = 6,800 µF. Test circuit - Figure 28. Figure 15 – Typical EMI spectrum, Quasi-Peak Scan, 90% load, 115 VIN, COUT = 6,800 µF. Test circuit - Figure 28. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 10 of 20 11/2012 800 735.6200 FE175D480C033FP-00 C Application CharacteristicsO (cont.) The following figures present typical performance at TC = 25 ºC, unless otherwise noted. See associated figures for general trend data. Att 20 dB INPUT 2 Det MA/AV Trd ResBW 9 kHz Meas T 100 55022RED 1 s Unit 1 MHz dB Ì V 10 MHz 90 SGL 80 2AV 70 22AVA 60 22AVB 50 40 30 26.Jul 2012 16:36 20 150 kHz Date: 30 MHz 26.JUL.2012 16:36:57 / Figure 16 – Typical EMI spectrum, Average Scan, 90% load, 115 VIN, COUT = 6,800 µF. Test circuit - Figure 28. Figure 17 – Typical line current waveform, 60 Hz, VIN = 120 V, PLOAD = 330 W. COUT = 6,800 µF. Input Current Harmonics vs. Input Voltage 800 .950 600 Power Factor Current [mA] 700 500 400 300 .900 .850 .800 200 100 .750 0 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 230 V, 50 Hz 1/3x EN61000-3-2, Class A 1 EN61000-3-2, Class D 90% 88% 86% 84% 82% 80% 78% 76% 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.18 5.52 6.21 6.90 96% 100 V Eff 100 V Power Diss 115 V Eff 115 V Power Diss 6 115 V 7 240 V Efficiency & Power Dissipation 25 °C Case 92% 90% 88% 86% 84% 82% 80% 78% 76% 48 44 40 36 32 28 24 20 16 12 8 4 0 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.18 5.52 6.21 6.90 Load Current (A) Load Current (A) VIN: 5 94% Efficiency (%) 92% 4 Figure 19 – Typical power factor vs. VIN and IOUT. 48 44 40 36 32 28 24 20 16 12 8 4 0 94% 3 100 V VIN: Efficiency & Power Dissipation -55 °C Case 96% 2 Load Current (A) Figure 18 – Typical input current harmonics, full load vs. VIN. Efficiency (%) Power Factor vs. Load and VIN at 25 °C 1.000 240 V Eff 240 V Power Diss Figure 20 – VIN to VOUT efficiency and power dissipation vs. VIN and IOUT, TCASE = -55 ºC. VIN: 100 V Eff 100 V Power Diss 115 V Eff 115 V Power Diss 240 V Eff 240 V Power Diss Figure 21 – VIN to VOUT efficiency and power dissipation vs. VIN and IOUT , TCASE = 25 ºC. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 11 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Application Characteristics (cont.) The following figures present typical performance at TC = 25 ºC, unless otherwise noted. See associated figures for general trend data. Thermal Resistance (Baseplate to Air) vs. Air Flow Efficiency & Power Dissipation 100 °C Case Efficiency (%) 92% 90% 88% 86% 84% 82% 80% 78% 76% 0.69 1.38 2.07 2.76 3.45 4.14 4.83 5.52 6.21 6.90 VIN: 100 V Eff 115 V Eff 115 V Power Diss 5 4 3 2 1 0 0 Load Current (A) 100 V Power Diss 6 Thermal Resistance (°C/W) 94% Power Dissipation (W) 48 44 40 36 32 28 24 20 16 12 8 4 0 96% 200 600 800 1000 Air Flow (LFM) 240 V Eff INSULATED 240 V Power Diss Figure 22 – VIN to VOUT efficiency and power dissipation vs. VIN and IOUT , TCASE = 100 ºC. 400 UNINSULATED Figure 23 – Baseplate to air thermal resistance Insulated – no thermal dissipation through pins to pcb; Uninsulated – thermal dissipation to typical pcb. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 12 of 20 11/2012 800 735.6200 FE175D480C033FP-00 General Characteristics Specifications apply over all line and load conditions, 50 Hz and 60 Hz line frequencies, TC = 25 °C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. Attribute Mechanical Length Width Height Volume Weight Pin material Underplate Symbol Conditions / Notes Min L W H Vol W Typ Max 95.3 / [3.75] 48.6 / [1.91] 9.55 / [0.38] 44.2 / [2.69] 111 / [3.9] C10200 copper, full hard Nickel Pure matte tin, whisker resistant chemistry Pin finish Unit mm / [in] mm / [in] mm / [in] cm3 / [in3] g / [oz] 100 150 200 300 -20 -40 -55 100 100 100 µin Thermal Operating baseplate (case) temperature Any operating condition TC Thermal resistance, baseplateto-sink, flat greased surface Thermal resistance, baseplateto-sink, thermal pad (PN 36967) Thermal capacity Thermal design C - Grade T - Grade M - Grade °C °C °C 0.13 °C / W 0.17 °C / W 84.5 Ws / °C See Thermal Design on page 18 Assembly ESDHBM ESD rating ESDMM ESDCDM Human Body Model, “JEDEC JESD 22-A114C.01” Machine Model, “JEDEC JESD 22-A115B” Charged Device Model, “JEDEC JESD 22-C101D” 1,000 N/A V 200 Soldering See application note Soldering Methods and Procedure for Vicor Power Modules » Safety & Reliability Agency approvals / standards EMI/EMC Compliance FCC Part 15, EN55022, CISPR22: 2006 + A1: 2007, Conducted Emissions EN61000-3-2: 2009, Harmonic Current Emissions EN61000-3-3: 2005, Voltage Changes & Flicker cTÜVus (EN60950-1) cURus (UL/CSA 60950-1) CE, Low Voltage Directive 2006/95/EC Touch Current measured in accordance with IEC 60990 using measuring network Fig. 4 Class B Limits - with components connected as shown in Figure 28 Class A PST<1.0; PLT<0.65; dc<3.3%; dmax<6% VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 13 of 20 11/2012 800 735.6200 0.56 0.68 mA FE175D480C033FP-00 General Characteristics (cont.) Specifications apply over all line and load conditions, 50 Hz and 60 Hz line frequencies, TC = 25 °C, unless otherwise noted. Boldface specifications apply over the temperature range of the specified Product Grade. Attribute EMI/EMC Compliance (cont.) EN61000-4-4: 2004, Electrical Fast Transients EN61000-4-5: 2006, Surge Immunity EN61000-4-6: 2009, Conducted RF Immunity EN61000-4-8: 1993 + A1 2001, Power Frequency H-Field 10A/m, continuous field EN61000-4-11: 2004, Voltage Dips & Interrupts Symbol Conditions / Notes Min Typ Level 3, Performance Criteria A Level 3, Immunity Criteria A, external TMOV required, limit input transient to 750 V Level 2, 130 dBµV (3.0 VRMS) Level 3, Performance Criteria A Class 2, Performance Criteria A Dips, Performance Criteria B Interrupts Product Outline Drawing and Recommended PCB Footprint Module Outline Figure 24 — Product outline drawing; Product outline drawings are available in .pdf and .dxf formats. 3D mechanical models are available in .pdf and .step formats. See http://www.vicorpower.com/cms/home/technical_resources/Mechanical_Drawings/Modules for more details. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 14 of 20 11/2012 800 735.6200 Max Unit FE175D480C033FP-00 Product Outline Drawing and Recommended PCB Footprint (cont.) Mounting Specifications Figure 25— Recommended PCB pattern; Product outline drawings are available in .pdf and .dxf formats. 3D mechanical models are available in .pdf and .step formats. See http://www.vicorpower.com/cms/home/technical_resources/Mechanical_Drawings/Modules for more details. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 15 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Product Details and Design Guidelines End enables consistently high efficiency conversion from worldwide AC mains to a 48 V bus and efficient secondary-side power distribution. Building Blocks and System Designs Power Factor Correction Approximately 48 Vdc +OUT AC (L) MOV* AC (N) 85 V – 264 Vac +OUT –OUT DC/DC Converter LOAD VI BRICK® AC Front End –OUT The module provides power factor correction over worldwide AC mains. For most static loads, PFC approaches unity, see Figure 19. Load transients that approach the line frequency should be filtered or avoided as these may reduce PFC. Input Fuse Selection (Optional) Holdup Capacitor Figure 26 – 300 W Universal AC-to-DC Supply VI BRICK products are not internally fused in order to provide flexibility in configuring power systems. Input line fusing is recommended at system level, in order to provide thermal protection in case of catastrophic failure. The fuse shall be selected by closely matching system requirements with the following characteristics: The VI BRICK® AC Front End is a high efficiency AC-to-DC converter, operating from a universal AC input to generate an isolated SELV 48 VDC output bus with power factor correction. It is the key component of an AC-to-DC power supply system such as the one shown in Figure 26 above. – Recommended fuse: 5 A, 216 Series Littelfuse – Current rating (usually greater than the VI BRICK AC Front End maximum current) The input to the VI BRICK AC Front End is a sinusoidal AC source with a power factor maintained by the module with harmonics conforming to IEC 61000-3-2. Internal filtering enables compliance with the standards relevant to the application (Surge, EMI, etc.). See EMI/EMC Compliance standards on page 13. – Ambient temperature – Breaking capacity per application requirements – Nominal melting I2t The module uses secondary-side energy storage (at the SELV 48 V bus) and optional PRM™ regulators to maintain output hold up through line dropouts and brownouts. Downstream regulators also provide tighter voltage regulation, if required. The FE175D480C033FP-00 is designed for standalone operation; however, it may be part of a system that is paralleled by downstream DC-DC converters. Contact Vicor Sales or refer to our website, www.vicorpower.com, regarding new models that can be paralleled directly for higher power applications. Traditional PFC Topology Full Wave Rectifier EMI/TVS Filter – Maximum voltage rating (usually greater than the maximum possible input voltage) Fault Handling Input Undervoltage (UV) Fault Protection The VI BRICK AC Front End’s input voltage (proportional to VIn-B as shown on page 6) is monitored by the micro-controller to detect an input under voltage condition. When the input voltage is less than the VIn-uVLo-, a fault is detected, the fault latch and reset logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the unit falls. Aer a time tuVLo, the unit shuts down. Faults lasting less than tuVLo may not be detected. Such a fault does not go through an auto-restart cycle. once the input voltage rises above VInuVLo+, the unit recovers from the input uV fault, the powertrain resumes normal switching aer a time ton and the output voltage of the unit reaches the set-point voltage within a time tSS. Overcurrent (OC) Fault Protection Isolated DC / DC 12 V Bus Converter Figure 27 – Traditional PFC AC-to-DC supply To cope with input voltages across worldwide AC mains (85 – 264 Vac), traditional AC-DC power supplies (Figure 27) use two power conversion stages: 1) a PFC boost stage to step up from a rectified input as low as 85 Vac to ~380 Vdc; and 2) a DC-DC down converter from 380 Vdc to a 12 V bus. The efficiency of the boost stage and of traditional power supplies is significantly compromised operating from worldwide AC lines as low as 85 Vac. Adaptive Cell™ Topology With its single stage Adaptive Cell™ topology, the VI BRICK AC Front The unit’s output current, determined by VEAo, VIn_B and the primaryside sensed output voltage, (as shown on page 6) is monitored by the microcontroller to detect an output oC condition. If the output current exceeds its current limit, a fault is detected, the reset logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the module falls aer a time toC. As long as the fault persists, the module goes through an auto-restart cycle with off time equal to toFF + ton and on time equal to toC. Faults shorter than a time toC may not be detected. once the fault is cleared, the module follows its normal start up sequence aer a time toFF. Short Circuit (SC) Fault Protection The microcontroller determines a short circuit on the output of the unit by measuring its primary sensed output voltage and EAo (as shown on page 6). Most commonly, a drop in the primary-sensed output voltage triggers a short circuit event. The module responds to a short circuit event within a time tSC. The module then goes through an auto restart cycle, with an off time equal to toFF + ton and an on time equal to tSC, for as long as the short circuit fault condition persists. once the fault is cleared, the unit follows its normal start up sequence aer a time toFF. Faults shorter than a time tSC may not be detected. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 16 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Product Details and Design Guidelines (cont.) Temperature Fault Protection The output voltage has the following two components of voltage ripple: The microcontroller monitors the temperature within the VI BRICK AC Front End. If this temperature exceeds Tj-oTP+, an overtemperature fault is detected, the reset logic block disables the modulator, the modulator stops the powertrain switching and the output voltage of the VI BRICK AC Front End falls. once the case temperature falls below TCASE-oTP-, aer a time greater than or equal to toFF, the converter recovers and undergoes a normal restart. For the Cgrade version of the converter, this temperature is 75 °C. Faults shorter than a time toTP may not be detected. If the temperature falls below TCASE-uTP-, an undertemperature fault is detected, the reset logic disables the modulator, the modulator stops powertrain switching and the output voltage of the unit falls. once the case temperature rises above TCASE-uTP, aer a time greater than or equal to toFF, the unit recovers and undergoes a normal restart. 1) Line frequency voltage ripple: 2*fLInE Hz component 2) Switching frequency voltage ripple: 1 MHz module switching frequency component C2 Gnd ® F1 85 – 264 Vac AC (L) +OUT +OUT C5 L2 C3 C4 MOV RSV1 AC (N) EN RSV3 -In Gnd -OUT -OUT -OUT L1 R1 Output Overvoltage Protection (OVP) C1 The microcontroller monitors the primary sensed output voltage (as shown on page 6) to detect output oVP. If the primary sensed output voltage exceeds VouT-oVLo+, a fault is latched, the logic disables the modulator, the modulator stops powertrain switching, and the output voltage of the module falls aer a time tSoVP. Faults shorter than a time tSoVP may not be detected. This type of fault is a latched fault and requires that 1) the En pin be toggled or 2) the input power be recycled to recover from the fault. Hold-up Capacitance The VI BRICK AC Front End uses secondary-side energy storage (at the SELV 48 V bus) and optional PRM™ regulators to maintain output hold up through line dropouts and brownouts. The module’s output bulk capacitance can be sized to achieve the required hold up functionality. Hold-up time depends upon the output power drawn from the VI BRICK AC Front End based AC-to-DC front end and the input voltage range of downstream DC-to-DC converters. The following formula can be used to calculate hold-up capacitance for a system comprised of VI BRICK AC Front End and a PRM™ regulator: 2 2 C = 2*POUT*(0.005+td) / (V2 – V1 ) Figure 28 – Typical Application for EN55022 Class B EMI Where, in the schematic: C1 C2 2.2nF (Murata GA355DR7GF222KW01L) 4.7nF (Murata GA355DR7GF472KW01L) C3 C4 3.3µF (TDK C4532X7R1H335MT) 6800uF 63V (Panasonic UVR1J682MRD) C5 F1 100uF 63V (Nichicon UVY1J101MPD) 5A, 216 Series Littlefuse L1 15µH (TDK MLF2012C150KT) L2 MOV 300V, 10KA, 20mm dia 600µH (Vicor 37052-601) (Littlefuse TMOV20RP300E) R1 R2 6.8Ω 2.2Ω Line Frequency Filtering output line frequency ripple depends upon output bulk capacitance. output bulk capacitor values should be calculated based on line frequency voltage ripple. High-grade electrolytic capacitors with adequate ripple current ratings, low ESR and a minimum voltage rating of 63 V are recommended. where: C VI BRICK AC Front End’s output bulk capacitance in farads td Hold-up time in seconds POUT VI BRICK AC Front End’s output power in watts V2 Output voltage of VI BRICK AC Front End’s converter in volts V1 PRM TM VI BRICK AC Front End R2 +OUT lPK lPK/2 regulator undervoltage turn off (volts) loutDC –OR– POUT / IOUT-PK, whichever is greater. lfLINE Output Filtering The VI BRICK AC Front End module requires an output bulk capacitor in the range of 6,000 µF to 12,000 µF for proper operation of the PFC front-end. Figure 29 – Output current waveform VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 17 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Product Details and Design Guidelines (cont.) Based on the output current waveform, as seen in Figure 29, the following formula can be used to determine peak-to-peak line frequency output voltage ripple: VPPl ~ = 0.2 * POUT / (VOUT * fLINE * C) where: VPPl Output voltage ripple Peak-to-peak line frequency POUT Average output power VOUT Output voltage set point, nominally 48 V fLINE Frequency of line voltage C Output bulk capacitance IDC Maximum average output current IPK Peak-to-peak line frequency output current ripple EMI Filtering and Transient Voltage Suppression EMI Filtering The VI BRICK AC Front End with PFC is designed such that it will comply with En55022 Class B for Conducted Emissions with the filter connected across -In and GnD as shown in Figure 28. The emissions spectrum is shown in Figures 13-16. If one of the outputs is connected to earth ground, a small (single turn) output common mode choke is also required. EMI performance is subject to a wide variety of external influences such as PCB construction, circuit layout etc. As such, external components in addition to those listed herein may be required in specific instances to gain full compliance to the standards specified. Transient Voltage Suppression The VI Brick AC Front End contains line transient suppression circuitry to meet specifications for surge (i.e. En61000-4-5) and fast transient conditions (i.e. En61000-4-4 fast transient/“burst”). Thermal Design In certain applications, the choice of bulk capacitance may be determined by hold-up requirements and low frequency output voltage filtering requirements. Such applications may use the greater capacitance value determined from these requirements. The ripple current rating for the bulk capacitors can be determined from the following equation: Iripple Thermal management of internally dissipated heat should maximize heat removed from the baseplate surface, since the baseplate represents the lowest aggregate thermal impedance to internal components. The baseplate temperature should be maintained below 100 °C. Cooling of the system PCB should be provided to keep the leads below 100 °C, and to control maximum PCB temperatures in the area of the module. Powering a Constant Power Load ~ = 0.8 * POUT / VOUT Switching Frequency Filtering Some applications require the output filtering shown in figure 28 to meet radiated emissions limits. In such a situation, the output switching ripple shown in figure 6 should be expected at the output of the filter. In cases where other means are used to control radiated emissions, and more ripple can be tolerated, the output filter can be simplified by removal of the common mode inductor, and C5, which is used to reduce the Q of the LC resonant tank. output switching frequency voltage ripple is the function of the output bypass ceramic capacitor. output bypass ceramic capacitor values should be calculated based on switching frequency voltage ripple. normally bypass capacitors with low ESR are used with a sufficient voltage rating. output bypass ceramic capacitor value for allowable peak-to-peak switching frequency voltage ripple can be determined by: When the output voltage of the VI BRICK AC Front End module is applied to the input of the PRM™ regulator, the regulator turns on and acts as a constant-power load. When the module’s output voltage reaches the input undervoltage turn on of the regulator, the regulator will attempt to start. However, the current demand of the PRM regulator at the undervoltage turn-on point and the hold-up capacitor charging current may force the VI BRICK AC Front End into current limit. In this case, the unit may shut down and restart repeatedly. In order to prevent this multiple restart scenario, it is necessary to delay enabling a constant-power load when powered up by the upstream AC to 48 V front end until aer the output set point of the VI BRICK AC Front End is reached. This can be achieved by 1) keeping the downstream constant-power load off during power up sequence and 2) turning the downstream constant-power load on aer the output voltage of the module reaches 48 V steady state. C3 = QTOT / VOUT-PP-HF – COUT-INT where: VOUT-PP-HF Allowable peak-to-peak output switching frequency voltage ripple in volts QTOT The total output charge per switching cycle at full load, maximum 13.5 µC COUT_INT The module internal effective capacitance C3 Required output bypass ceramic capacitor Aer the initial startup, the output of the VI BRICK AC Front End can be allowed to fall to 30 V during a line dropout at full load. In this case, the circuit should not disable the PRM™ regulator if the input voltage falls aer it is turned on; therefore, some form of hysteresis or latching is needed on the enable signal for the constant power load. The output capacitance of the VI BRICK AC Front End should also be sized appropriately for a constant power load to prevent collapse of the output voltage of the module during line dropout (see Hold up Capacitance on page 17). A constant-power load can be turned off aer completion of the required hold up time during the power-down sequence or can be allowed to turn off when it reaches its own undervoltage shutdown point. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 18 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Product Details and Design Guidelines (cont.) The timing diagram in Figure 30 shows the output voltage of the VI BRICK AC Front End module and the PRM PC pin voltage and output voltage of the PRM regulator for the power up and power down sequence. It is recommended to keep the time delay approximately 10 to 20 ms. VI BRICK™ AC Front End VOUT 49V – 3% PRM UV Turn on PRM™ Regulator tDELAY PC PRM™ Regulator VOUT tHOLD-UP Figure 30 – PRM Enable Hold off Waveforms Special care should be taken when enabling the constant-power load near the auto-ranger threshold, especially with an inductive source upstream of the VI BRICK AC Front End. A load current spike may cause a large input voltage transient, resulting in a range change which could temporarily reduce the available power (see Adaptive Cell™ Topology below). Adaptive Cell™ Topology The Adaptive Cell™ topology utilizes magnetically coupled “top” and “bottom” primary cells that are adaptively configured in series or parallel by a configuration controller comprised of an array of switches. A microcontroller monitors operating conditions and defines the configuration of the top and bottom cells through a range control signal. A comparator inside the microcontroller monitors the line voltage and compares it to an internal voltage reference. If the input voltage of the VI BRICK AC Front End crosses above the positive going cell reconfiguration threshold voltage, the output of the comparator transitions, causing switches S1 and S2 to open and switch S3 to close (see Functional Block Diagram on page 6). With the top cell and bottom cell configured in series, the unit operates in “high” range and input capacitances CIn-T and CIn-B are in series. If the peak of input voltage of the unit falls below the negative-going range threshold voltage for two line cycles, the cell configuration controller opens switch S3 and closes switches S1 and S2. With the top cell and bottom cells configured in parallel, the unit operates in “low” range and input capacitances CIn-T and CIn-B are in parallel. Power processing is held off while transitioning between ranges and the output voltage of the unit may temporarily droop. External output hold up capacitance should be sized to support power delivery to the load during cell reconfiguration. The minimum specified external output capacitance of 6,000 µF is sufficient to provide adequate ridethrough during cell reconfiguration for typical applications. VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 19 of 20 11/2012 800 735.6200 FE175D480C033FP-00 Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. Vicor makes no representations or warranties with respect to the accuracy or completeness of the contents of this publication. Vicor reserves the right to make changes to any products, specifications, and product descriptions at any time without notice. Information published by Vicor has been checked and is believed to be accurate at the time it was printed; however, Vicor assumes no responsibility for inaccuracies. Testing and other quality controls are used to the extent Vicor deems necessary to support Vicor’s product warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. Specifications are subject to change without notice. Vicor’s Standard Terms and Conditions All sales are subject to Vicor’s Standard Terms and Conditions of Sale, which are available on Vicor’s webpage or upon request. Product Warranty In Vicor’s standard terms and conditions of sale, Vicor warrants that its products are free from non-conformity to its Standard Specifications (the “Express Limited Warranty”). This warranty is extended only to the original Buyer for the period expiring two (2) years after the date of shipment and is not transferable. UNLESS OTHERWISE EXPRESSLY STATED IN A WRITTEN SALES AGREEMENT SIGNED BY A DULY AUTHORIZED VICOR SIGNATORY, VICOR DISCLAIMS ALL REPRESENTATIONS, LIABILITIES, AND WARRANTIES OF ANY KIND (WHETHER ARISING BY IMPLICATION OR BY OPERATION OF LAW) WITH RESPECT TO THE PRODUCTS, INCLUDING, WITHOUT LIMITATION, ANY WARRANTIES OR REPRESENTATIONS AS TO MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE, INFRINGEMENT OF ANY PATENT, COPYRIGHT, OR OTHER INTELLECTUAL PROPERTY RIGHT, OR ANY OTHER MATTER. This warranty does not extend to products subjected to misuse, accident, or improper application, maintenance, or storage. Vicor shall not be liable for collateral or consequential damage. Vicor disclaims any and all liability arising out of the application or use of any product or circuit and assumes no liability for applications assistance or buyer product design. Buyers are responsible for their products and applications using Vicor products and components. Prior to using or distributing any products that include Vicor components, buyers should provide adequate design, testing and operating safeguards. Vicor will repair or replace defective products in accordance with its own best judgment. For service under this warranty, the buyer must contact Vicor to obtain a Return Material Authorization (RMA) number and shipping instructions. Products returned without prior authorization will be returned to the buyer. The buyer will pay all charges incurred in returning the product to the factory. Vicor will pay all reshipment charges if the product was defective within the terms of this warranty. Life Support Policy VICOR’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF THE CHIEF EXECUTIVE OFFICER AND GENERAL COUNSEL OF VICOR CORPORATION. As used herein, life support devices or systems are devices which (a) are intended for surgical implant into the body, or (b) support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in a significant injury to the user. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system or to affect its safety or effectiveness. Per Vicor Terms and Conditions of Sale, the user of Vicor products and components in life support applications assumes all risks of such use and indemnifies Vicor against all liability and damages. Intellectual Property Notice Vicor and its subsidiaries own Intellectual Property (including issued U.S. and Foreign Patents and pending patent applications) relating to the products described in this data sheet. No license, whether express, implied, or arising by estoppel or otherwise, to any intellectual property rights is granted by this document. Interested parties should contact Vicor's Intellectual Property Department. The products described on this data sheet are protected by the following U.S. Patents Numbers: 5,945,130; 6,403,009; 6,710,257; 6,911,848; 6,930,893; 6,934,166; 6,940,013; 6,969,909; 7,038,917; 7,166,898; 7,187,263; 7,361,844; D496,906; D505,114; D506,438; D509,472; and for use under 6,975,098 and 6,984,965. Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 email Customer Service: [email protected] Technical Support: [email protected] VI BRICK® AC Front End Rev 1.1 vicorpower.com Page 20 of 20 11/2012 800 735.6200