EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BCM® Bus Converter BC048A240T030FP Advanced Sine Amplitude Converter™ (SAC™) Technology Features • 100°C baseplate operation • Typical efficiency 96% • 48 V to 24 V Bus Converter • <1 µs transient response • 300 Watt (450 Watt for 1 ms) • >3.5 million hours MTBF • High density – up to 390 Size: 1.91 x 1.09 x 0.37 in 48,6 x 27,7 x 9,5 mm W/in3 • Isolated output • Small footprint – 1.64 and 2.08 in2 • No output filtering required • Height above board – 0.37 in (9.5 mm) • Lead free wave solder compatible • Low weight – 1.10 oz (31.3 g) • Agency approvals • ZVS / ZCS isolated sine amplitude converter Applications • Isolated intermediate bus for non-isolated POL Product Overview • Telecommunication systems VI Brick® BCM modules use advanced Sine Amplitude ConverterTM (SACTM) technology, • Networking thermally enhanced packaging technologies, and advanced CIM processes to provide high • Servers power density and efficiency, superior transient response, and improved thermal • ATE management. These modules can be used to provide an isolated intermediate bus to power non-isolated POL converters and due to the fast response time and low noise of the BCM, capacitance can be reduced or eliminated near the load. Part Numbering BC 048 A 240 Bus Converter Module Input Voltage Designator Package Size Output Voltage Designator (=VOUT x10) T 0 30 T= M= P Baseplate Pin Style Output Power Designator (=POUT /10) Product Grade Temperatures (°C) Grade F Operating Storage –40 to +100 –40 to +125 –55 to +100 –65 to +125 BCM® Bus Converter Rev 1.0 vicorpower.com Page 1 of 11 01/2014 800 927.9474 F = Slotted flange T = Transverse heat sink[a] [a] contact factory P = Through hole EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP SPECIFICATIONS 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. Absolute Maximum Ratings Parameter Values Unit Notes +In to -In -1.0 to 60 Vdc +In to -In 100 Vdc PC to -In -0.3 to 7.0 Vdc +Out to -Out -0.5 to 50 Vdc Isolation voltage 2,250 Vdc Output current 14.8 A Peak output current 18.8 A For 1 ms Output power 300 W Continuous Peak output power 450 -40 to +100 -55 to +100 -40 to +125 -65 to +125 Operating temperature Storage temperature For 100 ms Input to output Continuous W For 1 ms °C °C T-Grade; baseplate M-Grade; baseplate °C °C T-Grade M-Grade Note: Stresses in excess of the maximum ratings can cause permanent damage to the device. Operation of the device is not implied at these or any other conditions in excess of those given in the specification. Exposure to absolute maximum ratings can adversely affect device reliability. Input Specifications (Conditions are at 48 Vin, full load, and 25°C ambient unless otherwise specified) Parameter Input voltage range Min Typ Max Unit 38 48 53 Vdc 1 V/µs 37.4 Vdc Input dV/dt Input undervoltage turn-on Input undervoltage turn-off 32.8 Vdc Input overvoltage turn-on 53.0 Vdc Input overvoltage turn-off 57.5 Input quiescent current 2.6 Inrush current overshoot 3.5 Input current Vdc mA A 6.8 PC low Using test circuit in Figure 15; See Figure 1 Adc Input reflected ripple current 120 No load power dissipation 4.0 mA p-p Internal input capacitance 1.9 µF Internal input inductance 5 nH Recommended external input capacitance 47 µF 5.9 Notes Using test circuit in Figure 15; See Figure 4 W BCM® Bus Converter Rev 1.0 vicorpower.com Page 2 of 11 01/2014 800 927.9474 200 nH maximum source inductance; See Figure 15 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP SPECIFICATIONS (CONT.) INPUT WAVEFORMS Figure 1 — Inrush transient current at full load and 48 Vin with PC enabled Figure 2 — Output voltage turn-on waveform with PC enabled at full load and 48 Vin Figure 3 — Output voltage turn-on waveform with input turn-on at full load and 48 Vin Figure 4 — Input reflected ripple current at full load and 48 Vin BCM® Bus Converter Rev 1.0 vicorpower.com Page 3 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP SPECIFICATIONS (CONT.) Output Specifications (Conditions are at 48 Vin, full load, and 25°C ambient unless otherwise specified) Parameter Min 19.0 18.2 0 0 0 Output voltage Output power Rated DC current Typ Peak repetitive power Current share accuracy Efficiency Half load Full load Internal output inductance Internal output capacitance Load capacitance Output overvoltage setpoint Output ripple voltage No external bypass 3.3 µF bypass capacitor Short circuit protection set point Average short circuit current Effective switching frequency Line regulation K Load regulation ROUT Transient response Voltage overshoot Response time Recovery time Output overshoot Input turn-on PC enable Output turn-on delay From application of power From release of PC pin 5 95.0 94.7 Max 26.5 25.8 300 269 14.8 Unit Vdc Vdc W W Adc 450 W 10 % 95.7 95.8 1.1 7.7 300 26.5 150 13 348 15.1 0.62 3.4 3.0 0.4950 1/2 3.8 Note No load Full load 42 - 53 VIN 38 - 53 VIN POUT ≤ 300 W Max pulse width 1ms, max duty cycle 10%, baseline power 50% See Parallel Operation on Page 8 % % nH µF µF Vdc See Figure 5 See Figure 5 Effective value mVp-p mVp-p Adc A MHz See Figures 7 and 9 See Figure 8 Module will shut down Fixed, 1.7 MHz per phase 0.5050 43.6 60.0 VOUT = K•VIN at no load mΩ 600 200 1 mV ns µs 100% load step; See Figures 10 and 11 See Figures 10 and 11 See Figures 10 and 11 0 0 mV mV No output filter; See Figure 3 No output filter; See Figure 2 260 65 ms ms No output filter; See Figure 3 No output filter OUTPUT WAVEFORMS Power Dissipation (W) 98 Efficiency (%) 96 94 92 90 12 10 8 6 4 2 88 0 30 60 90 120 150 180 210 240 Power Dissipation 14 Efficiency vs. Output Power 270 300 0 Output Power (W) Figure 5 — Efficiency vs. output power 30 60 90 120 150 180 Output Power (W) 210 240 Figure 6 — Power dissipation as a function of output power BCM® Bus Converter Rev 1.0 vicorpower.com Page 4 of 11 01/2014 800 927.9474 270 300 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP SPECIFICATIONS (CONT.) OUTPUT WAVEFORMS Figure 7 — Output voltage ripple at full load and 48 Vin without any external bypass capacitor. Ripple vs. Output Power 175 Output Ripple (mVpk-pk) Figure 8 — Output voltage ripple at full load and 48 Vin with 3.3 µF ceramic external bypass capacitor and 20 nH of distribution inductance. 150 125 100 75 50 25 0 30 60 90 120 150 180 Output Power (W) 210 240 270 300 Figure 9 — Output voltage ripple vs. output power at 48 Vin without any external bypass capacitor. Figure 10 — 0 -12.5 A load step with 100 µF input capacitor and no output capacitor. Figure 11 — 12.5- 0 A load step with 100 µF input capacitor and no output capacitor. BCM® Bus Converter Rev 1.0 vicorpower.com Page 5 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP SPECIFICATIONS (CONT.) General Specifications Parameter Min Typ Max Unit Notes Mhrs 25°C, GB MTBF MIL-HDBK-217F 3.5 Isolation specifications Voltage 2,250 Capacitance 3,000 Resistance 10 Agency approvals Vdc Input to output pF Input to output MΩ Input to output cTÜVus UL /CSA 60950-1, EN 60950-1 CE Mark Low voltage directive RoHS Mechanical See Mechanical Drawings, Figure 18, 19 Weight 1.10/31,3 oz /g Length 1.91/ 48,6 in / mm Baseplate model Width 1.09/ 27,7 in / mm Baseplate model Height 0.37/ 9,5 in / mm Baseplate model Dimensions Thermal Over temperature shutdown 125 130 135 °C Thermal capacity 23.8 Ws /°C Baseplate to ambient 7.7 °C / W Baseplate to ambient; 1000 LFM 2.9 °C / W Baseplate to sink; flat greased surface 0.40 °C / W Baseplate to sink; thermal pad 0.36 °C / W Junction temperature Auxiliary Pins Parameter Min Typ Max Unit DC voltage 4.8 5.0 5.2 Vdc Module disable voltage 2.4 2.5 2.6 Vdc 2.5 2.9 mA Notes Primary control (PC) Module enable voltage Current limit 2.4 2.5 Vdc Enable delay time 65 ms Disable delay time 20 µs Figure 12 — VOUT at full load vs. PC disable Source only See Figure 12, time from PC low to output low Figure 13 — PC signal during fault BCM® Bus Converter Rev 1.0 vicorpower.com Page 6 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP PIN / CONTROL FUNCTIONS +In / -In – DC Voltage Input Ports +Out / -Out – DC Voltage Output Ports Brick® The VI (BCM) input voltage range should not be exceeded. An internal under / over voltage lockout function prevents operation outside of the normal operating input range. The BCM turns on within an input voltage window bounded by the “Input undervoltage turn-on” and “Input overvoltage turn-off” levels, as specified. The BCM 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. The connection of the BCM 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. Two sets of contacts are provided for the +Out port. They must be connected in parallel with low interconnect resistance. Similarly, two sets of contacts are provided for the –Out port. They must be connected in parallel with low interconnect resistance. Within the specified operating range, the average output voltage is defined by the Level 1 DC behavioral model of Figure 16. The current source capability of the BCM is rated in the specifications section of this document. The low output impedance of the BCM reduces or eliminates the need for limited life aluminum electrolytic or tantalum capacitors at the input of POL converters. Total load capacitance at the output of the BCM should not exceed the specified maximum. Owing to the wide bandwidth and low output impedance of the BCM, low frequency bypass capacitance and significant energy storage may be more densely and efficiently provided by adding capacitance at the input of the BCM. PC – Primary Control The Primary Control port is a multifunction node that provides the following functions: Enable / Disable – If the PC port is left floating, the BCM output is enabled. Once this port is pulled lower than 2.4 Vdc with respect to –In, the output is disabled. This action can be realized by employing a relay, opto-coupler, or open collector transistor. Refer to Figures 1-3, 12 and 13 for the typical enable / disable characteristics. This port should not be toggled at a rate higher than 1 Hz. The PC port should also not be driven by or pulled up to an external voltage source. Primary Auxiliary Supply – The PC port can source up to 2.4 mA at 5.0 Vdc. The PC port should never be used to sink current. Alarm – The BCM contains circuitry that monitors output overload, input overvoltage or undervoltage, and internal junction temperatures. In response to an abnormal condition in any of the monitored parameters, the PC port will toggle. Refer to Figure 13 for PC alarm characteristics. TM and RSV – Reserved for factory use. Figure 14 — VI Brick BCM pin configuration (viewed from pin side) BCM® Bus Converter Rev 1.0 vicorpower.com Page 7 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP APPLICATION NOTES AND TEST CIRCUIT Parallel Operation The BCM 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 BCM 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 traces to be utilized on the input side if necessary. The use of dedicated power planes is, however, preferable. The BCM power train and control architecture allow bi-directional power transfer, including reverse power processing from the BCM output to its input. Reverse power transfer is enabled if the BCM input is within its operating range and the BCM is otherwise enabled. The BCM’s ability to process power in reverse improves the BCM transient response to an output load dump. VI Bricks are 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. For agency approvals and fusing conditions, please go to: vicorpower.com Application Notes www.vicorpower.com/application-notes To take full advantage of the BCM capabilities, the impedance presented to its input terminals must be low from DC to approximately 5 MHz. The source should exhibit low inductance (less than 100 nH) and should have a critically damped response. If the interconnect inductance exceeds 100 nH, the BCM 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 stable operations. Given the wide bandwidth of the BCM, the source response is generally the limiting factor in the overall system response. + Input Fuse Recommendations For BCM and VI Brick® application notes on soldering, board layout, and system design please click on the link below: Input Impedance Recommendations 10 A [a] Fuse Anomalies in the response of the source will appear at the output of the BCM 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 BCM is operated near low or high line as the over/under voltage detection circuitry could be activated. Applications Assistance Please contact Vicor Applications Engineering for assistance, 1-800-927-9474, or email at [email protected]. Input reflected ripple measurement point F1 +IN + +OUT Enable/Disable Switch C1 47 µF R2 electrolytic SW1 D1 2 kΩ TM RSV PC -OUT BCM -IN +OUT R3 10 mΩ Load C3 3.3 µF -OUT – Notes: 1. Source inductance should be no more than 200 nH. If source inductance is greater than 200 nH, additional bypass capacitance may be required. 2. C3 should be placed close to the load. 3. R3 may be ESR of C3 or a separate damping resistor. 4. D1 power good indicator will dim when a module fault is detected. [a] See Input Fuse Recommendations section Figure 15 — VI Brick BCM test circuit BCM® Bus Converter Rev 1.0 vicorpower.com Page 8 of 11 01/2014 800 927.9474 – EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP BEHAVIORAL MODELS VI Brick Bus Converter Level 1 DC Behavioral Model for 48 V to 24 V, 300 W ROUT IOUT + + 43.6 mΩ 1/2 • Iout VIN + – IQ 83 mA V•I K 1/2 • Vin + VOUT – – – © Figure 16 — This model characterizes the DC operation of the VI Brick® bus converter, including the converter transfer function and its losses. The model enables estimates or simulations of output voltage as a function of input voltage and output load, as well as total converter power dissipation or heat generation. VI Brick Bus Converter Level 2 Transient Behavioral Model for 48 V to 24 V, 300 W 3.44 nH IOUT + Lout = 1.11 nH 43.6 mΩ RCIN 1.3 mΩ VIN ROUT CIN 1/2 • Iout 1.9 µF IQ 83 mA RCOUT 11.13 mΩ V•I + + – – + 1 mΩ 1/2 • Vin COUT 7.7 µF VOUT K – – © Figure 17 — This model characterizes the AC operation of the VI Brick bus converter including response to output load or input voltage transients or steady state modulations. The model enables estimates or simulations of input and output voltages under transient conditions, including response to a stepped load with or without external filtering elements. BCM® Bus Converter Rev 1.0 vicorpower.com Page 9 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP MECHANICAL DRAWINGS Baseplate - Slotted Flange Heat Sink (Transverse) Figure 18 — Module outline Recommended PCB Pattern (Component side shown) Figure 19 — PCB mounting specifications BCM® Bus Converter Rev 1.0 vicorpower.com Page 10 of 11 01/2014 800 927.9474 EOL - Not Recommended for New Designs; Alternate Solution is BCM48Bx240y300A00 BC048A240T030FP 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] BCM® Bus Converter Rev 1.0 vicorpower.com Page 11 of 11 01/2014 800 927.9474