BCM TM Bus Converter Features Size: 1.91 x 1.09 x 0.37 in 48,6 x 27,7 x 9,5 mm • 100°C baseplate operation • Typical efficiency 95% • 48 V to 6 V Bus Converter • <1 µs transient response • 240 Watt (360 Watt for 1 ms) • >3.5 million hours MTBF • High density – up to 312 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 060 Bus Converter Module Input Voltage Designator Package Size Output Voltage Designator (=VOUT x10) T 024 T= M= Bus Converter Module BC048A060T024FP 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 vicorpower.com F = Slotted flange T = Transverse heat sink[a] [a] contact P = Through hole factory Rev. 1.0 Page 1 of 11 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 12 Vdc Isolation voltage 2,250 Vdc Output current 46.5 A Continuous Peak output current 60.0 A For 1 ms Output power 240 W Continuous W For 1 ms °C °C T-Grade; baseplate M-Grade; baseplate T-Grade M-Grade Peak output power 360 -40 to +100 -55 to +100 -40 to +125 -65 to +125 Operating temperature Storage temperature For 100 ms Input to output °C °C 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 38 48 55 Vdc 1 V/µs Input dV/dt Input undervoltage turn-on 37.4 Input undervoltage turn-off 32.6 Input overvoltage turn-on 55.0 Unit Vdc Vdc Vdc Input overvoltage turn-off 59.3 Vdc Input quiescent current 2.7 mA Inrush current overshoot 1.3 A Input current 5.5 275 No load power dissipation 2.7 Internal input capacitance 1.9 µF Internal input inductance 5 nH Recommended external input capacitance 47 µF BC048A060T024FP mA p-p 3.50 PC low Using test circuit in Figure 15; See Figure 1 Adc Input reflected ripple current Bus Converter Module Notes Using test circuit in Figure 15; See Figure 4 W vicorpower.com 200 nH maximum source inductance; See Figure 15 Rev. 1.0 Page 2 of 11 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 Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 Page 3 of 11 SPECIFICATIONS (CONT.) Output Specifications (Conditions are at 48 Vin, full load, and 25°C ambient unless otherwise specified) Parameter Min 4.75 4.47 0 0 0 Output voltage Output power Rated DC current Typ Max 6.87 6.61 240 206 46.5 Unit Vdc Vdc W W Adc 360 W 10 % 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 10 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 94.8 94.0 95.6 94.6 1.1 35.6 4,000 6.9 145 13 275 47.4 1 2.5 2.1 0.1238 1/8 6.0 3.1 Note No load Full load 44 - 55 VIN 38 - 55 VIN POUT ≤ 240 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, 1.3 MHz per phase 0.1263 7.09 VOUT = K•VIN at no load mΩ 180 200 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 2 290 85 ms ms No output filter; See Figure 3 No output filter OUTPUT WAVEFORMS Efficiency vs. Output Power Power Dissipation 96 Power Dissipation (W) 14 Efficiency (%) 94 92 90 88 12 10 8 6 4 2 86 0 24 48 72 96 120 144 168 192 216 0 240 Bus Converter Module BC048A060T024FP 48 72 96 120 144 168 192 216 240 Output Power (W) Output Power (W) Figure 5 — Efficiency vs. output power 24 Figure 6 — Power dissipation as a function of output power vicorpower.com Rev. 1.0 Page 4 of 11 SPECIFICATIONS (CONT.) OUTPUT WAVEFORMS Figure 8 — Output voltage ripple at full load and 48 Vin with 10 µF ceramic external bypass capacitor and 20 nH of distribution inductance. Figure 7 — Output voltage ripple at full load and 48 Vin without any external bypass capacitor. Ripple vs. Output Power Output Ripple (mVpk-pk) 180 160 140 120 100 80 60 40 20 0 0 24 48 72 96 120 144 168 192 216 240 Output Power (W) Figure 9 — Output voltage ripple vs. output power at 48 Vin without any external bypass capacitor. Figure 10 — 0 -40 A load step with 100 µF input capacitor and no output capacitor. Figure 11 — 40- 0 A load step with 100 µF input capacitor and no output capacitor. Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 Page 5 of 11 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 Width 1.09/ 27,7 in / mm Baseplate model Height 0.37/ 9,5 in / mm Baseplate model Dimensions Baseplate model 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 5.2 Unit Notes Primary control (PC) DC voltage 4.8 5.0 Module disable voltage 2.4 2.5 Module enable voltage Current limit 2.4 Vdc Vdc 2.5 2.6 Vdc 2.5 2.9 mA Enable delay time 85 ms Disable delay time 10 µs Figure 12 — VOUT at full load vs. PC disable Bus Converter Module BC048A060T024FP Source only See Figure 12, time from PC low to output low Figure 13 — PC signal during fault vicorpower.com Rev. 1.0 Page 6 of 11 PIN / CONTROL FUNCTIONS +In / -In – DC Voltage Input Ports +Out / -Out – DC Voltage Output Ports The VI BRICK (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. 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 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. 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. Bus Converter Module BC048A060T024FP Figure 14 — VI BRICK BCM pin configuration (viewed from pin side) vicorpower.com Rev. 1.0 Page 7 of 11 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. 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. Input Fuse Recommendations 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, click on the link below: http://www.vicorpower.com/technical_library/technical_documentation/quality_and _certification/safety_approvals/ Application Notes Input Impedance Recommendations 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. For BCM and VI BRICK application notes on soldering, board layout, and system design please click on the link below: http://www.vicorpower.com/technical_library/application_information/ Applications Assistance Please contact Vicor Applications Engineering for assistance, 1-800-927-9474, or email at [email protected]. Input reflected ripple measurement point 7 A [a] Fuse F1 + +IN + +OUT Enable/Disable Switch -OUT C1 47 µF R2 2 kΩ electrolytic SW1 TM RSV PC BCM D1 -IN R3 10 mΩ Load +OUT C3 10 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 Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 Page 8 of 11 BEHAVIORAL MODELS VI BRICK Bus Converter Level 1 DC Behavioral Model for 48 V to 6 V, 240 W ROUT IOUT + + 6.0 mΩ 1/8 • Iout VIN + + – IQ 56 mA 1/8 • Vin V•I VOUT – K – – © 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 6 V, 240 W 3.2 nH ROUT IOUT L IN = 5 nH + 6.0 mΩ RCIN 1.3 mΩ CIN VIN Lout = 1.11 nH V•I 1/8 • Iout 1.9 µF IQ 56 mA + + – RCOUT 10 mΩ + 1 mΩ 1/8 • Vin COUT 35.6 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. Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 Page 9 of 11 MECHANICAL DRAWINGS Baseplate - Slotted Flange Heat Sink (Transverse) Figure 18 — Module outline Recommended PCB Pattern (Component side shown) Figure 19 — PCB mounting specifications Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 Page 10 of 11 Warranty Vicor products are guaranteed for two years from date of shipment against defects in material or workmanship when in normal use and service. This warranty does not extend to products subjected to misuse, accident, or improper application or maintenance. Vicor shall not be liable for collateral or consequential damage. This warranty is extended to the original purchaser only. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY, VICOR MAKES NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Vicor will repair or replace defective products in accordance with its own best judgement. 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. Information published by Vicor has been carefully checked and is believed to be accurate; however, no responsibility is assumed for inaccuracies. Vicor reserves the right to make changes to any products without further notice to improve reliability, function, or design. Vicor does not assume any liability arising out of the application or use of any product or circuit; neither does it convey any license under its patent rights nor the rights of others. Vicor general policy does not recommend the use of its components in life support applications wherein a failure or malfunction may directly threaten life or injury. Per Vicor Terms and Conditions of Sale, the user of Vicor components in life support applications assumes all risks of such use and indemnifies Vicor against all damages. 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 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. 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. 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] Bus Converter Module BC048A060T024FP vicorpower.com Rev. 1.0 3/08