IBC Module IB054E096T48N1-00 5:1 Intermediate Bus Converter Module: Up to 500 W Output Features • Input: 36 – 60 Vdc • 98% peak efficiency • Output: 9.6 Vdc at 48 Vin • Low profile: 0.38” height above board • Output current up to 48 A • Industry standard 1/8 Brick pinout • Output power: up to 500 W Size: 2.30 x 0.9 x 0.38 in 58,4 x 22,9 x 9,5 mm [A] • 2,250 Vdc isolation • Sine Amplitude Converter • Low noise 1 MHz ZVS/ZCS [A] For lower power applications see 300 W model IB054E096T40N1-00 Product Overview Applications The Intermediate Bus Converter (IBC) Module is a very efficient, low profile, isolated, fixed • Enterprise networks ratio converter for power system applications in enterprise and optical access networks. • Optical access networks Rated at up to 345 W from 36 Vin and up to 500 W from 54 to 60 Vin, the IBC • Storage networks conforms to an industry standard eighth brick footprint while supplying the power of • Automated test equipment a quarter brick. Its leading efficiency enables full load operation at 55 °C with only 200 LFM airflow. Its small cross section facilitates unimpeded airflow — above and below its thin body — to minimize the temperature rise of downstream components. Absolute Maximum Ratings Min Max Unit Notes 36 60 Vdc Continuous 75 Vdc <100 mS 5 V/μs Input voltage (+In to –In) Operating Input voltage slew rate EN to –IN -0.5 20 Vdc Output voltage (+Out to –Out) -0.5 13.8 Vdc 15 V for 100 mS 48 A Pout ≤ 500 W Vdc 1 min. Hottest Semiconductor Output current Dielectric withstand (input to output) 2,250 Temperature Operating junction Storage -40 125 °C -55 125 °C IBC MODULE Rev 1.1 vicorpower.com Page 1 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS All specifications valid at 48 VIN , 100% rated load and 25 °C ambient, unless otherwise indicated. Electrical Characteristics Attribute Symbol Conditions / Notes Min Typ Max Unit 36 48 60 75 5 Vdc Vdc V/us 36 34 7 200 Vdc Vdc Vdc µs µs 79.5 78 4 Vdc Vdc µs 30 ms 50 µs 50 µs 250 ms 2.5 0.21 9.8 13.5 W W A A 500 mArms 40 25 A A μF nH INPUT (Operating from DC input source) Operating input voltage Non-operating input surge withstand Operating input dV/dt <100 mS 0.003 Undervoltage protection Turn-on Turn-off Turn-on/ Turn-off hysteresis Time constant Undervoltage blanking time 31 29 2 UV blanking time is enabled after start up Overvoltage protection Turn-off Turn-on Time constant 50 100 76 75 Turn ON delay VIN reaching turn-on voltage to enable function operational, see Figure 6 Enable to 90% VOUT; pre-applied VIN, see Figure 7, 0 load capacitance From 10% to 90% Vout, 10% load, 0 load capacitance. See page 10 for resart after EN pin disable Start up inhibit Turn-on delay Output voltage rise time Restart turn-on delay No Load power dissipation Enabled Disabled Input current Inrush current overshoot 20 25 1.9 0.18 Low line, full load Using test circuit in Figure 21 At max power; Using test circuit in Figure 22 Input reflected ripple current Peak short circuit input current Repetitive short circuit peak current Internal input capacitance Internal input inductance Recommended external input capacitance 8.8 5 470 μF 12.0 V 0 0 345 450 W W 0 500 48 W A 15 % mΩ 200 nH maximum source inductance 47 No load, over Vin range 7.2 OUTPUT DC Output voltage band Output power [a] 36-60 VIN 48-60 VIN 54-60 VIN Output current P ≤ 500 W of Iout max, maximum output capacitance Output start up load Effective output resistance Line regulation (K factor) [a] 9.6 VOUT = K • VIN @ no load 0.198 4.7 0.200 0.2020 Does not exceed IPC-9592 derating guidelines. At 70 °C ambient, full power operation may exceed IPC-9592 guidelines, but does not exceed component ratings, does not activate OTP and does not compromise reliability. IBC MODULE Rev 1.1 vicorpower.com Page 2 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS (CONT.) All specifications valid at 48 VIN , 100% rated load and 25 °C ambient, unless otherwise indicated. Electrical Characteristics (Continued) Attribute Symbol Conditions / Notes Min Typ Max Unit 10 % 4500 15.9 % % nH μF μF Vdc 150 mVp-p 150 % 5 1.5 ms µs MHz 100 mV 1.25 µs V 12 Vdc OUTPUT (Continued) Full power operation; See Parallel Operation on page 11; up to 3 units Current share accuracy Efficiency 50% load Full load Internal output inductance Internal output capacitance Load capacitance Output OVP set point Output voltage ripple Output Overload protection threshold See Figure 1,2 and 3 See Figure 1,2 and 3 97.5 96.9 Nominal load Module will shutdown 20 MHz bandwidth, using test circuit in Figure 23 Of Iout max., will not shutdown when started into max Cout and 15% load Auto restart with duty cycle <10% 0 15.2 98.0 97.1 1.6 55 60 105 Over current protection time constant Short circuit current response time Switching frequency Transient Response 1.0 25% load step; See Figures 11 - 14 using test set up in Figure 24 See Figures 11 - 14 using test set up in Figure 24 5 V step in 1 µs within Vin operating range Unit will start up into pre-bias voltage on output Voltage overshoot Response time VIN step Pre-bias voltage 1 0 General Characteristics Conditions: 25 °C case, 75% rated load and specified input voltage range unless otherwise specified. Attribute Symbol MTBF Service life Conditions / Notes Calculated per Telcordia SR-332, 40 °C Calculated at 30 °C TJ ; Converter will reset when over temperature condition is removed Input to output Input to output Over temperature shut down Dielectric withstand Insulation resistance Mechanical Weight Length Width Height above customer board Clearance to customer board From lowest component on IBC UL/cUL 60950-1, EN 60950-1, IEC 60950-1 Low voltage directive (CE Mark) Derate operating temp 1 °C per 1,000 feet above sea level Non condensing Compatible with RoHS directive 2002/95/EC Agency approvals Altitude, operating Relative humidity, Operating RoHS compliance IBC MODULE Rev 1.1 vicorpower.com Page 3 of 13 10/2012 800 735.6200 Min Typ Max 1.0 7 125 Unit Mhrs Years 130 135 2,250 °C Vdc MΩ 30 0.71 / 20.3 2.30 /58.4 0.9/22.9 0.38 /9.5 0.12/3.0 oz/g in/mm in/mm in/mm in/mm cTUVus CE -500 10,000 Feet 10 90 % IB054E096T48N1-00 SPECIFICATIONS (CONT.) Control & Interface Specifications Attribute Symbol Enable (negative logic)* Module enable threshold Module enable current Module disable threshold Module disable current Disable hysteresis Enable pin open circuit voltage Conditions / Notes Min Typ Max 130 200 2.4 10 Unit Referenced to –IN 0.8 VEN = 0.8 V VEN = 2.4 V 500 2.5 EN to –IN resistance Enable (positive logic)* Module enable threshold Module disable threshold EN source current (operating) EN voltage (operating) Open circuit, 10 V applied between EN and -IN Referenced to –IN Vdc µA Vdc µA mV Vdc 3.0 35 2.0 2.5 4.7 5 VEN = 5 V kΩ 3.0 1.45 2 5.3 Vdc Vdc mA Vdc *See part numbering on page 11 IPC-9592A, Based on Class II Category 2 the following detail is applicable. – Pre-conditioning required Environmental Qualification Test Description 5.2.3 HALT (Highly Accelerated Life testing) Test Detail Low Temp High Temp Rapid Thermal Cycling 6 DOF Random Vibration Test Input Voltage Test Output Load Test Combined Stresses Test Quantity Tested 3 3 3 3 3 3 3 5.2.4 THB (Temp. Humidity Bias) (72 hr presoak required) 1000 hrs – Continuous Bias 5.2.5 HTOB (High Temp. Operating Bias) Power cycle - On 42 minutes Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 10 minutes. Alternating between maximum and minimum operating Voltage every hour. 5.2.6 TC (Temp. Cycling) 700 cycles , 30 minute dwell at each extreme – 20C minimum ramp rate. 30 5.2.7 Power Cycling Reference IPC-9592A 3 5.2.8 – 5.2.13 Shock and Vibration Random Vibration – Operating IEC 60068-2-64 (normal operation vibration) Random Vibration Non-operating (transportation) IEC 60068-2-64 Shock Operating - normal operation shock IEC 60068-2-27 Free fall - IEC 60068-2-32 Drop Test 1 full shipping container (box) 3 3 3 3 12 5.2.14 Other Environmental Tests 5.2.14.1 Corrosion Resistance – Not required 5.2.14.2 Dust Resistance – Unpotted class II GR-1274-CORE 5.2.14.3 SMT Attachment Reliability IPC-9701 - J-STD-002 5.2.14.4 Through Hole solderability – J-STD-002 N/A 3 3 5 ESD Classification Testing Sample size assumes CDM testing 12 Total Quantity 30 30 161 IBC MODULE Rev 1.1 vicorpower.com Page 4 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS (CONT.) WAVEFORMS Efficiency TAMB 25 °C Efficiency TAMB 55 °C 99 98 98 97 97 Efficiency (%) Efficiency (%) 99 96 95 94 93 96 95 94 93 92 92 10 0 VIN : 19 Iout (A) 38 V 29 38 48 V 48 0 55 V 10 VIN : 19 38 V Iout (A) 29 48 V 38 48 55 V Figure 2 — Efficiency vs. output current, 55°C ambient Figure 1 — Efficiency vs. output current, 25°C ambient Efficiency TAMB 70 °C 99 Efficiency (%) 98 97 96 95 94 93 92 0 10 VIN : 19 38 V Iout (A) 29 48 V 38 48 55 V Figure 3 — Efficiency vs. output current, 70 °C ambient Figure 4 — Inrush current at high line 15% load Figure 5 — Input reflected ripple current at nominal line, full load Figure 6 — Turn on delay time; VIN turn on delay at nominal line, 15% load; start up inhibit time IBC MODULE Rev 1.1 vicorpower.com Page 5 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS (CONT.) WAVEFORMS (CONT.) Figure 7 — Turn on delay time; Enable turn on delay at nominal line, 15% load Figure 8 — Output voltage rise time at nominal line, 10% load Figure 9 — Overshoot at turn on at nominal line, 15% load Figure 10 — Undershoot at turn off at nominal line, 15% load Figure 11 — Load transient response; nominal line Load step 75– 100% Figure 12 — Load transient response; Full load to 75%; nominal line IBC MODULE Rev 1.1 vicorpower.com Page 6 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS (CONT.) WAVEFORMS (CONT.) Figure 13 — Load transient response; nominal line Load step 0 – 25% Figure 14 — Load transient response; 25–0%; nominal line Figure 15 — Input transient response; Vin step low line to high line at full load Figure 16 — Output ripple; Nominal line, full load Figure 17 — Three module parallel array test. Vout change when one module is disabled. Nominal Vin, Iout = 96 A Figure 18 — Three module parallel array test. Vout change with two modules operating and a third module enabled. Nominal Vin, Iout = 96 A IBC MODULE Rev 1.1 vicorpower.com Page 7 of 13 10/2012 800 735.6200 IB054E096T48N1-00 SPECIFICATIONS (CONT.) SPECIFICATIONS Output Current Derating 50 45 45 40 40 Output Current (A) 35 30 25 20 15 10 35 30 25 20 15 10 5 5 0 25 35 45 55 65 75 85 0 95 25 35 45 Ambient Air Temperature (°C) 200 LFM 400 LFM EN 47 µF 85 95 200 LFM 400 LFM 600 LFM Current Probe +IN 10 µH +OUT IBC Load _ 75 Figure 20 — Maximum output power derating vs ambient air temperature. Longitudinal airflow, Board and junction temperatures <125 °C tested with IBC evaluation board IB054E096T48N1-CB Current Probe + 65 Ambient Air Temperature (°C) 600 LFM Figure 19 — Maximum output power derating vs ambient air temperature. Transverse airflow, Board and junction temperatures <125 °C tested with IBC evaluation board IB054E096T48N1-CB Vsource 55 –IN +IN + C* Vsource _ –OUT +OUT EN 470 µF Load Output Current (A) Output Current Derating 50 IBC –IN –OUT *Maximum load capacitance Figure 21 — Inrush current overshoot +OUT 10 µF 0.1 µF IBC –IN E – Load +IN + –OUT Vsource _ CIN EN +OUT IBC –IN Cya Cyc Cyb Cyd COUT RL –OUT CIN = 500 µF COUT = 0.4 x [ POUT MAX (w) ] µF RL = 20 MHz BW VOUT 0.25 x IOUT MAX Cy a-d = 4700 pF Figure 23 — Test circuit; output voltage ripple Figure 24 — Load transient response IBC MODULE Rev 1.1 vicorpower.com Page 8 of 13 10/2012 800 735.6200 Ω Load +IN Figure 22 — Input reflected ripple current IB054E096T48N1-00 SPECIFICATIONS (CONT.) THERMAL DATA Figure 25 — Thermal plot, 200 LFM, 25 °C, 48 Vin, 450 W output power Figure 26 — Thermal plot, 200 LFM, 25 °C, 48 Vin, 450 W output power Figure 27 — Thermal plot, 400 LFM, 25 °C, 48 Vin, 450 W output power Figure 28 — Thermal plot, 400 LFM, 25 °C, 48 Vin, 450 W output power Figure 29 — Thermal plot, 600 LFM, 25 °C, 48 Vin, 450 W output power Figure 30 — Thermal plot, 600 LFM, 25 °C, 48 Vin, 450 W output power IBC MODULE Rev 1.1 vicorpower.com Page 9 of 13 10/2012 800 735.6200 IB054E096T48N1-00 PIN / CONTROL FUNCTIONS +In / -In – DC Voltage Input Pins The IBC input voltage range should not be exceeded. An internal undervoltage /overvoltage lockout function prevents operation outside of the normal operating input range. The IBC turns on within an input voltage window bounded by the “Input under-voltage turn-on” and “Input over-voltage turn-off” levels, as specified. The IBC may be protected against accidental application of a reverse input voltage by the addition of a rectifier in series with the positive input, or a reverse rectifier in shunt with the positive input located on the load side of the input fuse. 1 5 2 Top View 3 The connection of the IBC to its power source should be implemented with minimal distribution inductance. If the interconnect inductance exceeds 100 nH, the input should be bypassed with a RC damper to retain low source impedance and stable operation. With an interconnect inductance of 200 nH, the RC damper may be 47 μF in series with 0.3 Ω. A single electrolytic or equivalent low-Q capacitor may be used in place of the series RC bypass. 4 Pin 1 2 3 4 5 EN - Enable/Disable Negative Logic Option If the EN port is left floating, the IBC output is disabled. Once this port ispulled lower than 0.8 Vdc with respect to –In, the output is enabled. The EN port can be driven by a relay, opto-coupler, or open collector transistor. Refer to Figures 6 and 7 for the typical enable / disable characteristics. This port should not be toggled at a rate higher than 1 Hz. The EN port should also not be driven by or pulled up to an external voltage source. Figure 31 — IBC Pin Designations Positive Logic Option If the EN port is left floating, the IBC output is enabled. Once this port is pulled lower than 1.4 Vdc with respect to –In, the output is disabled. This action can be realized by employing a relay, opto-coupler, or open collector transistor. This port should not be toggled at a rate higher than 1 Hz. The EN port should also not be driven by or pulled up to an external voltage source. The EN port can source up to 2 mA at 5 Vdc. The EN port should never be used to sink current. If the IBC is disabled using the EN pin, the module will attempt to restart approximately every 250ms. Once the module has been disabled for at least 250ms, the turn on delay after the EN pin is enabled will be as shown in Figure 7. +Out / -Out – DC Voltage Output Pins Total load capacitance at the output of the IBC should not exceed the specified maximum. Owing to the wide bandwidth and low output impedance of the IBC, low frequency bypass capacitance and significant energy storage may be more densely and efficiently provided by adding capacitance at the input of the IBC. IBC MODULE Rev 1.1 vicorpower.com Page 10 of 13 10/2012 800 735.6200 Function Vin+ Enable VinVoutVout+ IB054E096T48N1-00 APPLICATIONS NOTE Parallel Operation Input Impedance Recommendations The IBC will inherently current share when operated in an array. Arrays may be used for higher power or redundancy in an application. Current sharing accuracy is maximized when the source and load impedance presented to each IBC within an array are equal. The recommended method to achieve matched impedances is to dedicate common copper planes within the PCB to deliver and return the current to the array, rather than rely upon traces of varying lengths. In typical applications the current being delivered to the load is larger than that sourced from the input, allowing narrower traces to be utilized on the input side if necessary. The use of dedicated power planes is, however, preferable. To take full advantage of the IBC capabilities, the impedance presented to its input terminals must be low from DC to approximately 5 MHz. The source should exhibit low inductance and should have a critically damped response. If the interconnect inductance is excessive, the IBC input pins should be bypassed with an RC damper (e.g., 47 μF in series with 0.3 Ω) to retain low source impedance and proper operation. Given the wide bandwidth of the IBC, the source response is generally the limiting factor in the overall system response. Anomalies in the response of the source will appear at the output of the IBC multiplied by its K factor. The DC resistance of the source should be kept as low as possible to minimize voltage deviations. This is especially important if the IBC is operated near low or high line as the overvoltage /undervoltage detection circuitry could be activated. One or more IBCs in an array may be disabled without adversely affecting operation or reliability as long as the load does not exceed the rated power of the enabled IBCs. The IBC power train and control architecture allow bi-directional power transfer, including reverse power processing from the IBC output to its input. The IBC’s ability to process power in reverse improves the IBC transient response to an output load dump. Input Fuse Recommendations The IBC is not internally fused in order to provide flexibility in configuring power systems. However, input line fusing of VI Bricks must always be incorporated within the power system. A fast acting fuse should be placed in series with the +In port. See safety agency approvals. Thermal Considerations The temperature distribution of the VI Brick can vary significantly with its input /output operating conditions, thermal management and environmental conditions. Although the PCB is UL rated to 130 °C, it is recommended that PCB temperatures be maintained at or below 125 °C. For maximum long term reliability, lower PCB temperatures are recommended for continuous operation, however, short periods of operation at 125 °C will not negatively impact performance or reliability. Application Notes For IBC and VI Brick application notes on soldering, thermal management, board layout, and system design visit vicorpower.com. WARNING: Thermal and voltage hazards. The IBC can operate with surface temperatures and operating voltages that may be hazardous to personnel. Ensure that adequate protection is in place to avoid inadvertent contact. PART NUMBERING Product Family Input Voltage Package Nominal Output Voltage Temperature Grade Output Current Enable Logic Pin Length IB 054 = 36-60 Vdc E 096 T 48 N = Negative P = Positive 1 = 0.145 2 = 0.210 3 = 0.180 IBC MODULE Rev 1.1 vicorpower.com Page 11 of 13 10/2012 800 735.6200 Options -00 = Open frame IB054E096T48N1-00 MECHANICAL DRAWINGS Pin Length (X) Designator Length 1 0.145 [3.68] 2 0.21 [5.33] 3 0.18 [4.57] (X) Figure 32 — IBC outline drawing Top View Figure 33 — IBC PCB recommended hole pattern IBC MODULE Rev 1.1 vicorpower.com Page 12 of 13 10/2012 800 735.6200 IB054E096T48N1-00 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] IBC MODULE Rev 1.1 vicorpower.com Page 13 of 13 10/2012 800 735.6200