45 24Vin / 15Vout / 200Watts Features See Page 8 for Part Numbers and Options • • • • • • • • • • • • • DC-DC Converter Module DC input range: 18 - 36V Input surge withstand: 50V for 100ms DC output: 15V Programmable output: 10 to 110% Regulation: ±0.2% no load to full load Efficiency: 85.6% Maximum operating temperature: 100°C at full load Power density: 80W/cubic inch Height above board: 0.43 in. (10,9 mm) Parallelable, with N+M fault tolerance Low noise ZCS/ZVS architecture Pin Style: See Page 6 Baseplate: See Page 7 Shown actual size: 2.28 x 2.2 x 0.5 in 57,9 x 55,9 x 12,7 mm (Product shown is for size only. Pin and baseplate style may vary. Pin style 1 and slotted baseplate are shown.) Product Overview This DC-DC converter module uses second generation power processing, control and packaging technologies to provide the performance, flexibility and cost effectiveness expected of a mature Power Component. For example, a plated-cavity core transformer couples widely separated primary and secondary windings, resulting in low in-toout parasitic capacitance and noise. High frequency ZCS/ZVS switching, advanced power semiconductor packaging and thermal management provide high power density with low temperature gradients. Extensive use of silicon integration results in 1/3 the part count of a first generation converter. This converter is manufactured in a state-of-the-art automated manufacturing facility on a short-cycle-time robotic line having a capacity of one module every ten seconds. In-line process controls are designed to achieve low defect rates and consistent quality. A comprehensive CIM system controls the dispatching, assembly and testing of each module, enabling small lots to be manufactured as efficiently as hundreds-of-thousands of units. Absolute Maximum Ratings Parameter Rating Unit -0.5 to +36 Vdc +In to –In voltage 50 Vdc PC to –In voltage -0.5 to +7.0 Vdc PR to –In voltage -0.5 to +7.0 Vdc +Out to –Out voltage -0.5 to +20 Vdc +Sense to –Out voltage -0.5 to +20 Vdc –Sense to –Out voltage 1.0 Vdc +In to –In voltage SC to –Out voltage Notes <100ms -0.5 to +1.5 Vdc Isolation voltage (in to out) 3000 Vrms Isolation voltage (in to base) 1550 Vrms Isolation voltage (out to base) 500 Vrms Storage temperature See Page 8 °C 125 Max Operating temperature See Page 8 °C Baseplate Pin soldering temperature 500 (260) °F (°C) <5 sec; wave solder Pin soldering temperature 750 (390) °F (°C) <7 sec; hand solder 5 (.57) in-lbs (N-m) Mounting torque 6 each, # 4-40 or M3 Thermal Resistance and Capacity Parameter Min Typ Max Unit Baseplate to sink; flat, greased surface 0.16 °C/Watt Baseplate to sink; thermal pad (P/N 20264) 0.14 °C/Watt Baseplate to ambient 8.0 °C/Watt Baseplate to ambient; 1000 LFM 1.9 °C/Watt Thermal capacity 83 Watt-sec/°C Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 1 of 9 ELECTRICAL CHARACTERISTICS Electrical characteristics apply over the full operating range of input voltage, output load (resistive) and baseplate temperature, unless otherwise specified. All temperatures refer to the operating temperature at the center of the baseplate. MODULE OPERATING SPECIFICATIONS Parameter Min Typ Max Unit Operating input voltage 18 24 36 Vdc 50 Vdc <100ms Input surge withstand Notes Output voltage setpoint 14.85 15.00 15.15 Vdc Nominal input; full load; 25°C Output OVP setpoint 17.1 17.8 18.5 Vdc 25°C; recycle input voltage to restart ( 1 minute off ) 200 Watts Output Power Efficiency 84.6 85.6 % At 100°C baseplate temp Nominal input; 75% of full load; 25°C MODULE INPUT SPECIFICATIONS Parameter Min Undervoltage turn-on Typ Max Unit 16.6 17.9 Vdc Notes Undervoltage turn-off 14.01 14.53 Overvoltage turn-off/on 36.3 37.8 39.6 Vdc 3.7 4.2 Watts No load Typ Max Unit Notes Line regulation ±0.02 ±0.20 % Low line to high line; full load Load regulation ±0.06 ±0.20 % No load to full load; nominal input Temperature regulation ±0.002 ±0.005 % / °C 200 250 mV Dissipation, standby Vdc MODULE OUTPUT SPECIFICATIONS Parameter Min Ripple and noise, p-p -20 to 100°C Nominal input; full load; 20 MHz Bandwidth Current limit 13.5 15.9 17.3 Amps Output voltage 95% of nominal Short circuit current 13.5 16.1 17.3 Amps Output voltage <250mV ±2 ±5 % 10 to 100% of full load 110 % Of nominal output voltage. For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required. Power sharing accuracy Programming range 10 Note: For important information relative to applications where the converter modules are subject to continuous dynamic loading, contact Vicor Applications Engineering at 800-927-9474. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 2 of 9 ELECTRICAL CHARACTERISTICS, continued MODULE CONTROL SPECIFICATIONS Parameter Min Typ Max Unit Notes PRIMARY SIDE (PC = Primary Control; PR = Parallel) PC bias voltage current limit 5.50 1.5 5.75 2.1 6.00 3.0 Vdc mA PC current = 1.0 mA PC voltage = 5.5V PC module disable 2.3 2.6 2.9 Vdc Must be able to sink ≥4 mA. See Fig. 1 4 7 ms 0.5 Vavg UV, OV, OT, module fault. See Figs. 2, 4 6.1 Volts PR load >30 ohms, < 30 pF PC module enable delay PC module alarm PR emitter amplitude 5.7 5.9 PR emitter current 150 PR receiver impedance 375 500 625 ohms 25°C PR receiver threshold 2.4 2.5 2.6 Volts Minimum pulse width: 20ns 12 Modules Without PR buffer amplifier mA PR drive capability SECONDARY SIDE (SC = Secondary Control) SC bandgap voltage 1.21 1.23 1.25 Vdc SC resistance 990 1000 1010 ohms SC capacitance SC module alarm Referenced to –Sense 0.033 µF 0 Vdc With open trim; referenced to –Sense. See Fig. 6 Unit Notes MODULE GENERAL SPECIFICATIONS Parameter Min Typ Remote sense (total drop) Max Vdc 0.25V per leg (senses must be closed) Isolation voltage (in to out) 3000 0.5 Vrms Complies with reinforced insulation requirements Isolation voltage (in to base) 1550 Vrms Complies with basic insulation requirements Isolation voltage (out to base) 500 Vrms Complies with operational insulation requirements Isolation resistance (in to out) 10 Weight Temperature limiting Agency Approvals Available 3.7 (104) 100 Megohms 4 (112) 115 UL, CSA, TÜV, BABT, CE, VDE Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Ounces (grams) °C See Figs. 2, 4 UL1950, CSA950, EN60950, VDE0805, BS7002, IEC60950. With a fuse in series with the +Input 24Vin/15Vout/200w DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 3 of 9 CONTROL FUNCTIONS - PC PIN Module Enable/Disable Module Alarm The module may be disabled by pulling PC below 2.3V with respect to the –Input. This may be done with an open collector transistor, relay, or optocoupler. Multiple converters may be disabled with a single transistor or relay either directly or via “OR’ing” diodes. See Figure 1. The module contains “watchdog” circuitry which monitors input voltage, operating temperature and internal operating parameters. In the event that any of these parameters are outside of their allowable operating range, the module will shut down and PC will go low. PC will periodically go high and the module will check to see if the fault (as an example, overtemperature) has cleared. If the fault has not been cleared, PC will go low again and the cycle will restart. The SC pin will go low in the event of a fault and return to its normal state after the fault has been cleared. See Figures 2 and 4. Primary Auxiliary Supply At 5.7V, PC can source up to 1.5mA. In the example shown in Figure 3, PC powers a module enabled LED. +In +Out +In SW1 +S PC PR 2-20ms typ. f (VIN) SW3 1K SC –S 5.7Vdc (0-3mA) –In –Out SW2 +Out +S 50Ω SW1, 2, & 3 shown in "Fault" position PR –S –In Auto Restart PC SC Disable Input Undervoltage Input Overvoltage Overtemperature Module Faults 1.23 Vdc 6K –Out Disable = PC <2.3V Figure 1—Module enable/disable. Figure 2—PC/SC module alarm logic. +In +Out PC "Module Enabled" Fault +S PC 40µs typ. 5.7V SC 4kΩ PR –S –In –Out SC Figure 3—LED on-state indicator. Optocoupler 1.23V Figure 4—PC/SC module alarm timing. +In +Out +In PC +S PC +Out +S SC SC 4kW 2-20ms typ. PR –S PR –S –In –Out –In –Out Figure 5—Isolated on-state indicator. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Alarm 1.00V Figure 6—Secondary side on-state indicator. 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 4 of 9 CONTROL FUNCTIONS - SC PIN Output Voltage Programming The output voltage of the converter can be adjusted or programmed via fixed resistors, potentiometers or voltage DACs. See Figures 7 & 8. +Out +Out +S +S Error Amp SC –S 1kΩ 0.033 µF RD Trim Down Load Error Amp RU Trim Up SC Load –S 1kΩ 0.033 µF –Out –Out 1.23V 1.23V RD (ohms) = 1,000 Vout Vnom - Vout RU (ohms) = 1,000 (Vout-1.23) Vnom 1.23 (Vout-Vnom) - 1,000 Figure 7—Output voltage trim down circuit. Figure 8—Output voltage trim up circuit. Trim Down Trim Up 1. This converter is not a constant power device – it has a constant current limit. Hence, available output power is reduced by the same percentage that output voltage is trimmed down. Do not exceed maximum rated output current. 1. The converter is rated for a maximum delivered power. To ensure that maximum rated power is not exceeded, reduce maximum output current by the same percentage increase in output voltage. 2. The trim down resistor must be connected to the –Sense pin. 2. The trim up resistor must be connected to the +Sense pin. 3. Do not trim the converter above maximum trim range (typically +10%) or the output over voltage protection circuitry may be periodically activated. Trim values calculated automatically: Resistor trim calculators are available on Vicor’s web site at URL: www.vicr.com/tools.html or by requesting a copy of Vicor’s Applications Manual on a CD ROM. Resistor values can be calculated for fixed trim up, fixed trim down and for variable trim up or down cases for both 1st and 2nd Generation DC-DC converters. In addition to trimming information, the web site and the applications manual on CD ROM also include design tips, applications circuits, EMC suggestions, thermal design guidelines and PDF data sheets for all available Vicor products. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/15Vout/200w DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 5 of 9 CONTROL FUNCTIONS - PR PIN Parallel Operation sharing but is not fault tolerant. Minus In pins must be tied to the same electric potential. See Figure 9. The PR pin supports paralleling for increased power with N+1 (N+M) redundancy and phased array capability. Modules of the same input voltage, output voltage, and power level will current share if all PR pins are suitably interfaced. AC coupled single-wire interface. All PR pins are connected to a single communication bus through 0.001µF (500V) capacitors. This interface supports current sharing and is fault tolerant except for the communication bus. See Figure 10. Compatible interface architectures include the following: DC coupled single-wire interface. All PR pins are directly connected to one another. This interface supports current +In +Out +In PC +S PC Module 1 –S PR –In –Out +In +Out +In +Out +S PC Module 2 (up to 12) PR –In Module 2 PR –In +In Module N+1 PC PR –In +Out +S SC –S –Out SC –S PR –S –Out –In –Out Ground plane Figure 10—AC coupled single-wire interface. • The +Out and –Out power buses should be designed to minimize and balance parasitic impedance from each module output to the load. +S –S +S +In PC +S Module 2 (up to 12) –In Figure 9—DC coupled single-wire interface. PC 0.001µF SC –S PR Ground plane Module 1 SC –Out PC +Out +S SC –S –Out +S Module 1 –In PR +In 0.001µF SC +Out +S Load –S –S +Out +S SC –S –Out +In • The +Sense pins should be tied to the same point on the +Out power bus; the –Sense pins should be tied to the same point on the –Out power bus. PC +Out +S SC PR • At the discretion of the power system designer, a subset of all modules within an array may be configured as slaves by shorting SC to –S. –In –S –Out • OR’ing diodes may be inserted in series with the +Out pins of each module to provide module output fault tolerance. Figure 11—N+1 module array output connections. +Sense from other modules in the array Figure 12—OR’ing diodes connections. PIN STYLES Description Notes Short solder Requires in-board, mounting Long solder On-board mounting for 0.65" boards Short ModuMate SurfMate or in-board socket mounting Long ModuMate On-board socket mounting Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 2 Page 6 of 9 MECHANICAL DRAWINGS MODULE OUTLINE Converter Pins Function Label +In + Primary PC Control 3 Parallel PR 4 –In – 5 –Out – 0.50 ±0.02 12,7 ±0,5 No. 1 2 –Sense –S 7 Secondary Control +Sense +Out SC 8 9 0.01 style 2 & 3 baseplates only (4X)*** 0.300 ±0.015 7,62 ±0,38 1 0.300 ±0.015 7,62 ±0,38 2 3 +S + 0.10 2,5 0.10 X 45˚ 2,5 CHAMFER 0.35 (2X) 8,8 1.900 48,26 2.000 50,80 0.49 12,4 0.12* 0.20** 3,1 5,1 4 (ALL MARKINGS THIS SURFACE) 6 2.20 55,9 1.74 44,2 0.23 (REF) 5,8 ALUMINUM BASEPLATE 2.28 1.30 57,9 33,0 0.65 16,5 FULL R (6X) 0.130 3,30 9 PINS: TIN/LEAD HOT SOLDER DIP 8 7 6 0.150 DIA,(2X) 3,81 0.080 DIA,(7X) 2,03 0.400 10,16 0.43 10,9 or 0.06 R (3X) 1,5 0.54 (9X) Pin Style 1&S 13,7 (Short Pin) 0.700 17,78 1.000 25,40 1.400 35,56 Slotted (Style 1) (6X) 5 Use a 4-40 Screw (6X) Torque to: 5 in-lbs .57 N-m 2.20 55,9 (REF.) 0.62 (9X) Pin Style 2&N 15,7 (Long Pin) Threaded (Style 2) 4-40 UNC-2B (6X) or Thru Hole (Style 3) * Style 1 baseplate only ** Style 2 & 3 baseplates *** Reserved for Vicor accessories Not for mo nting #30 Drill Thru (6X) (0.1285) ALL MARKINGS THIS SURFACE PCB MOUNTING SPECIFICATIONS PCB THICKNESS R 0.062 ±0.010 1,57 ±0,25 PLATED THRU HOLE DIA 1.790 45,47 0.06 (4X) 1,5 ONBOARD SOLDER MOUNT PIN STYLE 1&S PIN STYLE 2&N (7X) 0.094 ±0.003 2,39 ±0,08 0.094 ±0.003 2,39 ±0,08 (2X) 0.164 ±0.003 4,16 ±0,08 0.164 ±0.003 4,16 ±0,08 ALUMINUM BASEPLATE PINS STYLES STYLE 1 & 2: TIN/LEAD HOT SOLDER DIPPED STYLE S & N: GOLD PLATED COPPER 0.158 4,01 1 2 3 4 1.584* 40,23 1.900* 48.26 48,26 9 8 7 6 5 0.400* 10,16 0.43 10,9 0.700* 17,78 0.195 4,95 INBOARD SOLDER MOUNT 0.53 13,5 Unless otherwise specified, dimensions are in inches mm Decimals 1.000* 25,40 1.400* 35,56 0.XX * DENOTES ±0.003 TOL = ±0,08 Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Tol. ±0.25 0.XXX Angles ±0.01 ±1° ±0.005 ±0.127 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 7 of 9 PART NUMBERS & OPTIONS 24Vin / 15Vout / 200Watts Part Number Pins Base VI-882545 VI-882546 VI-882547 VI-882548 VI-882549 VI-882550 VI-882551 VI-882552 VI-882553 VI-882554 VI-882555 VI-882556 VI-882557 VI-882558 VI-882559 VI-882560 VI-882561 VI-882562 VI-882563 VI-882564 VI-882565 VI-882566 VI-882567 VI-882568 VI-882569 VI-882570 VI-882571 VI-882572 VI-882573 VI-882574 VI-882575 VI-882576 VI-882577 VI-882578 VI-882579 VI-882580 Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Minimum Grade Operating Temp C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C C -20°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C T -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C H -40°C Max Operating Temp 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 100°C 24Vin/15Vout/200W DC-DC Converter Set your site on VICOR at www.vicorpower.com Minimum Storage Temp -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -40°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C -55°C Rev. 5.2 Page 8 of 9 Vicor’s comprehensive line of power solutions includes modular, high density DC-DC converters and accessory components, configurable power supplies, and custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. No license is granted by implication or otherwise under any patent or patent rights of Vicor. Vicor components are not designed to be used in applications, such as life support systems, wherein a failure or malfunction could result in injury or death. All sales are subject to Vicor’s Terms and Conditions of Sale, which are available upon request. Specifications are subject to change without notice. 45 Component Solutions for Your Power System Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 Email Vicor Express: [email protected] Technical Support: [email protected] Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/15Vout/200W DC-DC Converter Rev. 5.2 Set your site on VICOR at www.vicorpower.com 01/03