AVE360-48S12 DC/DC Converter TRN AVE360-48S12 DC/DC Converter Technical Reference Note Industry Standard Half Brick: 36~75V Input, 12V Single Output Features Industry Standard Half Brick: 2.4” X 2.28’’ X 0.5’’ Options • • Choice of positive logic or negative logic for CNT function Choice of short pins or long pins • • • • • • • • • • • • • • Delivers up to 30A output current Basic isolation Ultra High efficiency Improved thermal performance: High power density Low output noise 2:1 wide input voltage of 36-75V CNT function Remote sense Trim function: +10%/-10% Input under-voltage lockout Output over-current protection Output over-voltage protection Over-temperature protection Description The AVE360-48S12 is a new DC/DC converter for optimum efficiency and power density. AVE360-48S12 provides up to 30A output current in an industry standard Half Brick, which makes it an ideal choice for small space and high power applications. AVE360-48S12 uses an industry standard half brick 61.0mm × 57.9mm × 12.7mm (2.4”x2.28”x0.5”), provides CNT and trim functions. AVE360-48S12 can provide 12V@30A, single output and output is isolated from input. TEL: (86) 755-86010808 BOM: 31020718 www.emersonnetworkpower.com.cn DATE: 2008-04-29 1/19 REV1.2 AVE360-48S12 DC/DC Converter TRN Module Numbering AVE 360 - 48 S 12 P - 4 Pin length: -4---4.80 mm ± 0.5mm -6---3.80 mm ± 0.5mm -8---2.80 mm + 0.5 mm/-0.3 mm Default is 5.80 mm ± 0.5mm CNT logic, P---positive, open frame, by default: negative, open frame Output rated voltage: 12---12V Output number: S ---single output, D---dual output Input rated voltage Output rated power Series name TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 2/19 AVE360-48S12 DC/DC Converter TRN Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage and temperature conditions. Standard test condition on a single unit is as following: Ta: 25°C +Vin: 48V ± 2% -Vin: return pin for +Vin CNT: connect to -Vin +Vout: connect to load -Vout: connect to load (return) +Sense: connect to +Vout -Sense: connect to -Vout Trim (Vadj): open Input Specifications Parameter Symbol Min Typ Max Unit Note Operating Input Voltage VI 36 48 75 VDC Inrush transient - - - 2 A2s - Input Reflected-ripple Current II - 50 80 mAp-p 5Hz to 20MHz: 12µH source impedance, TA = 25ºC. - CAUTION: This power module is not internally fused. An input line fuse must always be used. TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 3/19 AVE360-48S12 DC/DC Converter TRN Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operational sections of the IPS. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Typ Max Unit Note Continuous VI 0 - 80 Vdc - Transient VI, trans 0 - 100 Vdc 100ms Operating Ambient Temperature Ta -40 25 85 ºC See Thermal Consideration Operating Board Temperature Tc - 135 ºC Near temperature sensor Rt Storage Temperature TSTG -55 25 125 ºC - Operating Humidity - 5 - 95 % - Basic Input-Output Isolation - 1,500 - - Vdc 1mA for 5 sec, slew rate of 1,500V/10sec Output Power Po,max - - 360 W - Input Voltage TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 4/19 AVE360-48S12 DC/DC Converter TRN Output Specifications Parameter Symbol Min Typ Max Unit Conditions mVp-p Output Ripple& Noise - - - 300 External Load Capacitance - 680 2200 10000 μF (Ta: 25ºC, Vin: 48V, 30000μF can start-up) Output Voltage Setpoint Vo,set 11.8 12 12.2 Vdc Rating input@ Ionom - - - 0.3 %Vo - - - 0.5 %Vo - - - 0.02 %Vo/ºC Io 0 10 30 A - Io 31.5 - 45 A - Line (Vi,min to Vi,max) Whole range (f<20MHz) Load Output Regulation (Io = Io,min to Io,max) Temperature Regulation Whole range (Whole range) Rated Output Current Output Current-limit Inception (Hiccup) Efficiency Efficiency TEL: (86) 755-86010808 - - 93 93 94 94 - - % Ta: 25ºC, Air velocity: 300LFM, Vin: 48V, Load: Ionom; forced air direction: from Vin+ to Vin- % Ta: 25ºC, Air velocity: 300LFM, Vin: 48V, Load: 70% Ionom; forced air direction: from Vin+ to Vin- www.emersonnetworkpower.com.cn 5/19 AVE360-48S12 DC/DC Converter TRN Output Specifications (Cont) Parameter Peak Deviation Dynamic Response (all) Settling Time Symbol - Min - Typ - Max 600 Unit mV - - - 400 μsec Turn-On Time - - - 100 msec Output Voltage Overshoot - - - 5 %Vo Switching Frequency - - 280 - KHz (to Vo,nom) Note 25% Ionom step from 50%Ionom, 0.1A/μS Io = Ionom; Vo from 10% to 90% Io = Ionom; TEL: (86) 755-86010808 TA = 25C - www.emersonnetworkpower.com.cn 6/19 AVE360-48S12 DC/DC Converter TRN Feature Specifications Parameter Symbol Min Typ Max Unit Note Logic Low - -0.7 - 1.2 Vdc - Logic High - 3.5 - 5 Vdc - Logic Low - - - 1.0 mA Logic High - - - - μA Output Voltage Adjustment Range* - 90 - 110 %Vo - Output Over-voltage Protection (Static) Voclamp 14 - 16.5 V Hiccup Turn-on Point - 31 34 36 V Turn-off Point - 30 33 35 V Isolation Capacitance - - - - PF - Isolation Resistance - 10 - - MΩ - Enable pin voltage: Enable pin current: Under-voltage Lockout - - Vin: 48V, Calculated MTBF - - 2,000,000 - Hours Load: Ionom Board@25oC Weight - - 72 - g(oz.) - Vibration level: 3.5mm (2 ~ 9Hz), 10m/s2 (9 ~ 200HZ), 15m/s2 (200 ~ 500HZ) Vibration (Sine wave) Directions and time: 3 axes (X, Y, Z), 30 minutes each Sweep velocity: 1oct / min Peak acceleration: 300m/s2 Shock (Half-sine wave) Duration time: 6ms Continuous shock 3 times at each of 6 directions (±X, ±Y, ±Z) TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 7/19 AVE360-48S12 DC/DC Converter TRN Characteristic Curves 96 95 Efficiency (%) 94 93 36V 48V 75V 92 91 90 89 88 87 0 5 10 15 20 25 30 35 Output current (A) Fig. 1 AVE360-48S12 Typical Efficiency Fig. 2 AVE360-48S12-4 Typical Output Ripple Voltage o Ta: 25°C, Air velocity: 300LFM, Vin: 48V, Load: Ionom; Ta: 25 C, Air velocity: 300LFM, Vin: 48V, Vonom, Ionom, forced air direction: from Vin+ to Vin- 10μ tantalum (ESR≤100 mΩ)// 1μceramic capacitor Fig. 3 Fig. 4 AVE360-48S12-4 Typical Transient Response to Ta: 25℃, Air velocity: 300LFM, forced air direction: AVE360-48S12-4 Typical Transient Response to Ta: 25℃, Air velocity: 300LFM, forced air direction: from Vin+ to Vin-. Vin: 48V, Vonom, 25% Ionom step step from 50% Ionom, 0.1A/µs ”, the external capacitor from Vin+ to Vin-. Vin: 48V, Vonom, 50% Ionom from 75% Ionom, 0.1A/µs ”, the external capacitor should be “10µ tantalum (ESR≤100 mΩ) // 1µ ceramic should be “10µ tantalum (ESR≤100 mΩ) // 1µ ceramic capacitor capacitor TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 8/19 AVE360-48S12 DC/DC Converter TRN Performance Curves – Startup Characteristics Figure 5 Typical start-up from power on TEL: (86) 755-86010808 Figure 6 Typical start-up from CNT on www.emersonnetworkpower.com.cn 9/19 AVE360-48S12 DC/DC Converter TRN Feature Description CNT Function Two CNT logic options are available. The CNT logic, CNT voltage and the module working state are as the following table. L H OPEN N ON OFF OFF P OFF ON ON N--- means “Negative Logic” P--- means “Positive Logic” L--- means “Low Voltage”, -0.7V≤L≤1.2V H--- means “High Voltage”, 3.5V≤H≤5V ON--- means “Module is on”, OFF--- means “Module is off” Open--- means “CNT pin is left open “ Note: when CNT is left open, VCNT may reach 6V. Figure 7 shows a few simple CNT circuits. CNT CNT -Vin -Vin Simple control Transistor control CNT CNT -Vin -Vin Isolated control Figure 7 Relay control CNT circuits voltage of AVE360-48S12 in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. When the converter is supporting loads far away, or is used with undersized cabling, significant voltage drop can occur at the load. The best defense against such drops is to locate the load close to the converter and to ensure adequately sized cabling is used. When this is not possible, the converter can compensate for a drop of up to 10%Vo, through use of the sense leads. When used, the + Sense and - Sense leads should be connected from the converter to the point of load as shown in Figure 8, using twisted pair wire, or parallel pattern to reduce noise effect. The converter will then regulate its output voltage at the point where the leads are connected. Care should be taken not to reverse the sense leads. If reversed, the converter will trigger OVP protection and turn off. When not used, the +Sense lead must be connected with +Vo, and -Sense with -Vo. Although the output voltage can be increased by both the remote sense and trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. Remote Sense +Vo AVE360-48S12 converter can remotely sense both lines of its output which moves the effective output voltage regulation point from the output terminals of the unit to the point of connection of the remote sense pins. This feature automatically adjusts the real output TEL: (86) 755-86010808 +Sense +S Twisted pair Load -Sense -S -Vo Figure 8 Sense connection www.emersonnetworkpower.com.cn 10/19 AVE360-48S12 DC/DC Converter TRN Note that the trim-up function is valid only when the input is above 38V. Trim The +Vo output voltage of AVE360-48S12 can be trimmed using the trim pin provided. Applying a resistor to the trim pin through a voltage divider from the output will cause the +Vo output to increase by up to 10% or decrease by up to 20%. Trimming up by more than 10% of the nominal output may activate the OVP circuit or damage the converter. Trimming down more than 20% can cause the converter to regulate improperly. If the trim pin is not needed, it should be left open. Trim down With an external resistor between the TRIM and -SENSE pins, the output voltage set point decreases (see Figure 10). +Vin ON/OFF +Sense Load Trim -Vin Trim up +Vo R adj_down -Sense - Vo With an external resistor connected between the TRIM and +SENSE pins, the output voltage set point increases (see Figure 9). +Vin Figure 10 Trim down circuit The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. +Vo ON/OFF +Sense Load Trim R adj_ up - Vin Sense -Vo Figure 9 Trim up circuit The following equation determines the required external-resistor value to obtain a percentage output voltage change of %. Vtrim tolerance less than ±2%, Radj tolerance is ±1% Although the output voltage can be increased by both the remote sense and the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. Vtrim tolerance less than ±2%, Radj tolerance is ±1% TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 11/19 AVE360-48S12 DC/DC Converter TRN +Vo Minimum Load Requirements There is no minimum load requirement for the AVE360-48S12 module. Parameter Device Symbol Typ Unit Minimum Load 12V IMIN 0 A Output Over-current Protection AVE360-48S12 DC/DC converter feature foldback current limiting as part of their Over-current Protection (OCP) circuits. When output current exceeds 105 to 140% of rated current, such as during a short circuit condition, the module will work on intermittent mode, also can tolerate short circuit conditions indefinitely. When the over-current condition is removed, the converter will automatically restart. -Vo Figure 11 Output Capacitance Output ripple filter Extra care should be taken when long leads or traces are used to provide power to the load. Long lead lengths increase the chance for noise to appear on the lines. Under these conditions C2 can be added across the load, with a 1μF ceramic capacitor C2 in parallel generally as shown in Figure 12. +Vo C1 C2 Load -Vo Figure 12 Output ripple filter for a distant load Decoupling High output current transient rate of change (high di/dt) loads may require high values of output capacitance to supply the instantaneous energy requirement to the load. To minimize the output voltage transient drop during this transient, low Equivalent Series Resistance (ESR) capacitors may be required, since a high ESR will produce a correspondingly higher voltage drop during the current transient. When the load is sensitive to ripple and noise, an output filter can be added to minimize the effects. A simple output filter to reduce output ripple and noise can be made by connecting a capacitor C1 across the output as shown in Figure 11. C1 ranges from 680μF to 10000μF , the recommended value for C1 is 2200μF. TEL: (86) 755-86010808 Load C1 The converter does not always create noise on the power distribution system. High-speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a 10μF ceramic capacitor in parallel with a 0.1μF ceramic capacitor across the load will decouple it. The capacitors should be connected as close to the load as possible. Ground Loops Ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in Figure 13. Multiple ground points can slightly different potential and cause www.emersonnetworkpower.com.cn 12/19 AVE360-48S12 DC/DC Converter TRN current flow through the circuit from one point to another. This can result in additional noise in all the circuits. To eliminate the problem, circuits should be designed with a single ground connection as shown in Figure 14. RLine RLine +Vo Design Consideration Load Load RLine -Vo mode when the maximum device reference temperature is exceeded. When the over-temperature condition is removed, the converter will automatically restart. Typical Application RLine RLine Ground Loop Fuse+ +Vin RLine Vin Figure 13 Ground loops + C1+ CNT RLine RLine Figure 15 Load -Vo RLine C3 + + C2 + Load -Vo +Vin -Vin +Vo Trim -Vin +Vo +Sense Load RLine -Sense Typical application F1: Fuse*: Use external fuse (fast blow type) for each unit. For 12V output: 30A (Pout=360W) RLine Figure 14 C1: Recommended input capacitor C1 ≥ 100μF/100V electrolytic or ceramic type capacitor. Single point ground Output Over-Voltage Protection The output over-voltage protection consists of circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals exceeds the over voltage protection threshold, then the module will work on hiccup mode. When the over-voltage condition is removed, the converter will automatically restart. The protection mechanism is such that the unit can continue in this condition until the fault is cleared. Over-Temperature Protection These modules feature an over-temperature protection circuit to safeguard against thermal damage. The module will work in intermittent TEL: (86) 755-86010808 C2: Recommended -40°C ~ 100°C uses: 2,200μF/25V (electrolytic capacitor) C3: Recommended 10μF/25V Fusing The AVE360-48S12 power module has no internal fuse. An external fuse must always be employed! To meet international safety requirements, a 250 Volt rated fuse should be used. If one of the input lines is connected to chassis ground, then the fuse must be placed in the other input line. Standard safety agency regulations require input fusing. Recommended fuse ratings for the AVE360-48S12 are shown as following list. For 12V output : 30A (Pout=360W) www.emersonnetworkpower.com.cn 13/19 AVE360-48S12 DC/DC Converter TRN Note: the fuse is fast blow type. Input Reverse Voltage Protection Under installation and cabling conditions where reverse polarity across the input may occur, reverse polarity protection is recommended. Protection can easily be provided as shown in Figure 16. In both cases the diode used is rated for 15A/100V. Placing the diode across the inputs rather than in-line with the input offers an advantage in that the diode only conducts in a reverse polarity condition, which increases circuit efficiency and thermal performance. Figure 16 + Vin + Vin - Vin - Vin are to be grounded or both the input and output pins are to be kept floating. Single fault testing in the power supply must be performed in combination with the DC/DC power module to demonstrate that the output meets the requirement for SELV. The input pins of the module are not operator accessible. Note: Do not ground either of the input pins of the module, without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. The circuit cannot withstand transient over-voltage. Thermal Consideration Technologies Reverse polarity protection circuit Safety Consideration For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL60950, CSA C22.2, and EN60950. AVE360-48S12 input-to-output isolation is a basic insulation. The DC/DC power module should be installed in end-use equipment, in compliance with the requirements of the ultimate application, and is intended to be supplied by an isolated secondary circuit. When the supply to the DC/DC power module meets all the requirements for SELV (<60Vdc), the output is considered to remain within SELV limits (level 3). If connected to a 60Vdc power system, double or reinforced insulation must be provided in the power supply that isolates the input from any hazardous voltages, including the ac mains. One input pin and one output pin TEL: (86) 755-86010808 AVE360-48S12 modules have ultra high efficiency at full load. With less heat dissipation and temperature-resistant components such as ceramic capacitors, these modules exhibit good behavior during pro-longed exposure to high temperatures. Maintaining the operating board temperature within the specified range helps keep internal component temperatures within their specifications which in turn help keep MTBF from falling below the specified rating. Proper cooling of the power modules is also necessary for reliable and consistent operation. Basic Thermal Management Measuring the board temperature of the module is shown in Figure 17. www.emersonnetworkpower.com.cn 14/19 AVE360-48S12 DC/DC Converter TRN Because each power module output voltage has a different power dissipation curve, a plot of power dissipation versus output current over three different line voltages are given in Figure 19. MEASURE CASE TEMPERATURE HERE Vin (+) CNT Vo (+) +SENSE TRIM Module Derating -SENSE Vin (-) Vo (-) Experiment Setup DIMENSIONS: milimeters (inches) Figure 17 Temperature measurement location The module should work under 85°C ambient for the reliability of operation and the board temperature must not exceed 112°C while operating in the final system configuration. The measurement can be made with a surface probe after the module has reached thermal equilibrium. No heatsink is mounted, make the measurement as close as possible to the indicated position. It makes the assumption that the final system configuration exists and can be used for a test environment. Note that the board temperature of module must always be checked in the final system configuration to verify proper operational due to the variation in test conditions. Thermal management acts to transfer the heat dissipated by the module to the surrounding environment. The amount of power dissipated by the module as heat (PD) is got by the equation: PD = PI-PO Where PI is input power; PO is output power; PD is dissipated power. Also, module efficiency () is defined as the following equation: = PO / PI If eliminating the input power term, from two above equations can yield the equation below: PD = PO (1-) / The module power dissipation then can be calculated through the equation. TEL: (86) 755-86010808 From the experiment setup shown in Figure 18, the derating curves shown in Figure 19 can be drawn. Note that the Printed Wiring Board (PWB) and the module must be mounted vertically. The Passage has a rectangular cross-section. The clearance between the facing PWB and the top of the module is kept 13 mm (0.5 in.) constantly. 13(0.5) PWB Facing PWB Converter Air velocity and ambient temperature testing point 50.8(2.0) Air flow Dimensions: millimeters (inches) Figure 18 Experiment setup Forced Convection Figure 19 shows the change of the module output current with the change of ambient temperature. In the test, the airflow was www.emersonnetworkpower.com.cn 15/19 AVE360-48S12 DC/DC Converter TRN created with externally adjustable fans. A heatsink should be fitted in the case the input voltage is 36V or 75V. 35 Power dissipation (W) 30 25 20 36V 48V 75V 15 Dimensions: milimeters (inches) Figure 20 Non-standard heatsink 10 5 0 0 5 10 15 20 25 30 35 Output current (A) Figure 19 Forced convection power derating Airflow direction from Vin(+) to Vin(-): Vin=36,48,75V; Heatsink Configuration Dimensions: milimeters (inches) Several standard heatsinks available for the AVE360-48S12 are shown in Figure 20 to 22. Figure 21 Longitudinal fins heatsink The heatsinks mounted to the top surface of the module with screws torqued to 0.56 N-m (5 in.-Ib). A thermally conductive dry pad or thermal grease is placed between the case and the heatsink to minimize contact resistance (typically 0.1°C/W to 0.3°C /W) and temperature differential. Nomenclature for heatsink configurations is as follows: WDxyyy40 Figure 22 Transverse fins heatsink Heatsink Mounting x = fin orientation: longitudinal (L) or transverse (T) yyy = heatsink height (in 100ths of inch) For example, WDT5040 is a heatsink that is transverse mounted for a 61mm × 57.9mm (2.4in × 2.28in) module with a heatsink height of 0.5 in. TEL: (86) 755-86010808 Dimensions: milimeters (inches) A crucial part of the thermal design strategy is the thermal interface between the baseplate of the module and the heatsink. Inadequate measures taken will quickly negate any other attempts to control the baseplate temperature. For example, using a conventional dry insulator can result in a case-heatsink thermal impedance of >0.5oC/W, while use one of the recommended interface methods (using silicon grease or thermal pads) can result in a www.emersonnetworkpower.com.cn 16/19 AVE360-48S12 DC/DC Converter TRN case-heatsink 0.1oC/W. thermal impedance around have separate airflow paths. This can keep other system equipment cooler and increase component life spans. Soldering Figure 23 Heatsink mounting Installation Although AVE360-48S12 converters can be mounted in any orientation, free air-flowing must be taken. Normally power components are always put at the end of the airflow path or TEL: (86) 755-86010808 AVE360-48S12 converter is compatible with standard wave soldering techniques. When wave soldering, the converter pins should be preheated for 20-30 seconds at 110oC, and wave soldered at 260oC for less than 10 seconds. When hand soldering, the iron temperature should be maintained at 425oC and applied to the converter pins for less than 5 seconds. Longer exposure can cause internal damage to the converter. Cleaning can be performed with cleaning solvent IPA or with water. www.emersonnetworkpower.com.cn 17/19 AVE360-48S12 DC/DC Converter TRN Mechanical Chart Device Code Suffix -4 -6 -8 NONE L 4.8mm+/-0.5mm 3.8mm+/-0.5mm 2.8mm+0.5/-0.3mm 5.8mm+/-0.5mm TOLERANCES: X.Xmm= +/-0.5mm X.XXmm=+/-0.25mm Pins Definition Pin Number P1 P2 P3 P4 TEL: (86) 755-86010808 Function +Vin CNT -Vin +Vout Pin Number P5 P6 P7 P8 www.emersonnetworkpower.com.cn Function +SENSE TRIM -SENSE -Vout 18/19 AVE360-48S12 DC/DC Converter TRN Ordering Information Input Voltage (V) Output Voltage (V) Output Current (A) Ripple &Noise (mV pp, Max.) Efficiency (%) Typ. AVE360-48S12-4 36~75 12 30 300 94 AVE360-48S12P-4 36~75 12 30 300 94 Model Number 有毒有害物质或元素标识表 部件 名称 制成板 有毒有害物质或元素 铅 汞 镉 Pb Hg Cd × ○ ○ 六价铬 C 多溴联苯 多溴联苯醚 PBB PBDE ○ ○ 6＋ ○ ○：表示该有毒有害物质在该部件所有均质材料中的含量在 SJ/T-11363-2006 规定的限量要求以下。 ×：表示该有毒有害物质至少在该部件的某一均质材料中的含量超出 SJ/T-11363-2006 规定的限量要求 艾默生网络能源有限公司一直致力于设计和制造环保的产品，我们会通过持续的研究来减少和消除产品中的有毒有害 物质。以下部件或应用中含有有毒有害物质是限于目前的技术水平无法实现可靠的替代或者没有成熟的解决方案： 1．器件的高温焊料中含有铅。 2．电子器件的玻璃中含有铅。 3．插针的铜合金中含有铅 适用范围：AVE360-48S12 TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 19/19