Technical Reference Notes (TRN) REV A Description Initial Release AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Date 2/4/00 Approved TECHNICAL REFERENCE NOTES (TRN) AA05E SERIES DC-DC CONVERTER ASTEC POWER ANDOVER, MA _____________________________________________________________ ASTEC POWER - Andover 1 of 8 Technical Reference Notes (TRN) 1. AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W General Description and Scope This specification covers the requirements for AA05E-048L-XXXS switching DC-DC converter. This module operates off a 36 – 75V DC bus and provides both a single and dual isolated output. Six output options are available in the family as shown below. Table 1. Device Part Numbers Model Designation 033S 050S 120S 150S 120D 150D Part Number AA05E-048L-033S AA05E-048L-050S AA05E-048L-120S AA05E-048L-150S AA05E-048L-120D AA05E-048L-150D 2. Electrical Specifications 2.1 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 in not implied at these or any other conditions in excess of those given in the operational sections of the TRN. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Input Voltage: Continuous: Transient (100ms) Operating Case Temperature Storage Temperature Operating Humidity I/O Isolation Device Symbol Min Typ Max Unit All All All All All All VI VI, trans Tc Tstg - 0 0 -40 -55 - - 25 100 125 95 1500 Vdc Vdc ºC ºC % Vdc _____________________________________________________________ ASTEC POWER - Andover 2 of 8 Technical Reference Notes (TRN) 2.2 AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Input Specifications Table 2. Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 to VI,max: Io = Io,max) Input Reflected-ripple Current (5Hz to 20MHz: 12uH source Device All 033S 050S 120S 150S 120D 150D All Symbol VI II,max II,max II,max II,max II,max II,max II Min 36 - Typ 48 - Max 75 0.130 0.185 0.180 0.180 0.175 0.175 10 Unit Vdc A A A A A A mAp-p All - - - 0.75 W All - - - 3.0 uF impedance: TA = 25 ºC.) See Figure 1. No Load Input Power (VI = VI,nom ) Maximum Input Capacitance CAUTION: This power module is not internally fused. An input line fuse must always be used. 2.3 Output Specifications Table 3. Output Specifications Parameter Output Voltage Setpoint (VI = VI,min to VI,max: Io = Io,max; TA = 25 ºC ) Output Regulation: Line (VI = VI,min to VI,max) Device 033S 050S 120S 150S 120D 150D Symbol Vo,set Vo,set Vo,set Vo,set Vo,set Vo,set Min 3.267 4.95 11.88 14.85 ±11.88 ±14.85 Typ 3.3 5.0 12.0 15.0 ±12.0 ±15.0 Max 3.333 5.05 12.12 15.15 ±12.12 ±15.15 Unit Vdc Vdc Vdc Vdc Vdc Vdc All All - - 0.5 25 0.5 1.0 2.0 50 % % %Vo mVp-p All 033S 050S 120S 150S 120D 150D 033S 050S 120S 150S 120D 150D All Io Io Io Io Io Io Io Io Io Io Io Io - 0.1 0.1 0.04 0.03 ±0.02 ±0.02 - - 1000 1.0 1.0 0.41 0.33 ±0.20 ±0.16 1.70 1.70 0.70 0.56 ±0.35 ±0.27 190 uF A A A A A A A A A A A A Load(Io = Io,min to Io,max) Temperature (Tc = -40 ºC to +100 ºC) Output Ripple and Noise (Across 0.10 uF ceramic capacitors) See Figure 2. External Load Capacitance Output Current Output Current-limit Inception (Vo = 97% Vo,set) Output Short-circuit Current %Io,max (Vo = 250mV) _____________________________________________________________ ASTEC POWER - Andover 3 of 8 Technical Reference Notes (TRN) AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Table 3. Output Specifications (continued) Parameter Efficiency (VI = VI,nom ; Io = Io,max; TA = 25 ºC ) Device 033S 050S 120S 150S 120D 150D Symbol Io Io Io Io Io Io Min 71 74 75 75 77 77 Typ 73 76 77 77 79 79 Max - Unit % % % % % % All - - - 2 1000 %Vo usec All - - - 2 1000 %Vo usec All - - 150 200 msec All - - - 5 %Vo Symbol - Min - Typ 260 10 Max - Unit pF Mohm Device All Symbol - Min - Typ 1,000,000 Max - Unit hours All - - - 15(0.50) g (oz.) Dynamic Response: (∆Io/∆t = 1A/10us; VI = VI,nom ; TA = 25 ºC ) Load Change from Io = 50% to 75% of Io, max: Peak Deviation Settling Time Load Change from Io = 50% to 25% of Io, max: Peak Deviation Settling Time Turn-on Time (Io = Io,max; Vo within 1%) Output Voltage Overshoot (Io = Io,max; TA = 25 ºC) 2.4 Isolation Specifications Table 4. Isolation Specifications Parameter Isolation Capacitance Isolation Resistance 2.5 Device All All General Specifications Table 5. General Specifications Parameter Calculated MTBF (Io = Io,max; Tc = 25 ºC) Weight _____________________________________________________________ ASTEC POWER - Andover 4 of 8 Technical Reference Notes (TRN) 2.6 AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Test Configurations TO OSCILLOSCOPE Vi(+) Ltest 12 uH Cs 220 uF ESR < 0.1 OHM @ 20 ºC, 100 kHz BATTERY 33 uF ESR < 0.7 OHM @ 20 ºC, 100 kHz Vi(-) Note: Measure input reflected-ripple current with a simulated source inductance (Ltest) of 12 uH. Capacitor Cs offsets possible battery impedance. Measure current as shown above. Figure 1. Input Reflected-ripple Test Setup. COPPER STRIP Vo(+) 0.10uF SCOPE RESISTIVE LOAD Vo(-) Note: Use a 0.10 uF ceramic capacitors. Scope measurement should be made using a BNC socket. Position the load between 51 mm and 76 mm (2 in. and 3 in. ) from module. Figure 2. Peak-to-Peak Output Noise Measurement Test Setup. 3.0 Thermal Considerations The power module operates in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Heat-dissipating components inside the unit are thermally coupled to the case. Heat is removed by conduction, convection, and radiation to the surrounding environment. Increasing airflow over the module enhances the heat transfer via convection. Figure 3 shows the maximum power that can be dissipated by the module without exceeding the maximum case temperature versus local ambient temperature (Ta) for natural convection through 3.0 m/s (600 ft/min). Systems in which these power modules are used typically generate natural convection airflow rates of 0.25 m/s (50 ft/min) due to other heat dissipating components in the system. Therefore, the natural convection condition represents airflow rates of approximately 0.25 m/s (50 ft/min). Use of Figure 3 is shown in the following example: _____________________________________________________________ ASTEC POWER - Andover 5 of 8 Technical Reference Notes (TRN) AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Thermal Considerations (continued) Example What is the minimum airflow necessary for a 050S operating at 48V, an output current of 1.0 A, and a maximum ambient temperature of 90 ºC? Solution: Given: Vi = 12V, Io = 1.0 A, Ta = 90 ºC. Determine Pd from Figure 5: Pd = 1.6 W. Determine Airflow from Figure 3: v = 2.0 m/s (400 ft/min). Nat. Conv. AA05E SERIES Power Derating Curve 1.0 m/s (200 ft/min) 2.0 m/s (400 ft/min) 3.0 m/s (600 ft/min) 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 Ambient Temperature (ºC) Figure 3. Forced Convection Power Derating. Vin= 36.0 AA05E-048L-033S Power Dissipation vs Output Current Tc = Tc,max Vin= 36.0 AA05E-048L-050S Power Dissipation vs Output Current Tc = Tc,max Vin= 48.0 Vin= 75.0 1.60 1.80 1.40 1.60 Vin= 48.0 Vin= 75.0 1.40 1.20 1.20 1.00 1.00 0.80 0.80 0.60 0.60 0.40 0.40 0.20 0.00 0.10 0.20 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 Output Current (Amps) Output Current (Amps) Figure 4. 033S Power Dissipation Figure 5. 050S Power Dissipation 1.00 _____________________________________________________________ ASTEC POWER - Andover 6 of 8 Technical Reference Notes (TRN) AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Thermal Considerations (continued) Vin= 36.0 AA05E-048L-120S Power Dissipation vs Output Current Tc = Tc,max Vin= 75.0 1.80 1.60 1.60 1.40 1.40 Vin= 36.0 AA05E-048L-150S Power Dissipation vs Output Current Tc = Tc,max Vin= 48.0 Vin= 48.0 Vin= 75.0 1.20 1.20 1.00 1.00 0.80 0.80 0.60 0.60 0.40 0.40 0.20 0.20 0.00 0.042 0.084 0.126 0.168 0.210 0.252 0.294 0.336 0.378 0.420 0.00 0.033 0.066 0.099 0.132 0.165 0.198 0.231 0.264 0.297 0.330 Output Current (Amps) Output Current (Amps) Figure 6. 120S Power Dissipation Figure 7. 150S Power Dissipation Vin= 36 AA05E-048L-120D Power Dissipation vs Output Current Tc = Tc,max Vin= 75 1.80 1.80 1.60 1.60 1.40 1.40 1.20 1.20 1.00 1.00 0.80 0.80 0.60 0.60 0.40 0.40 0.20 Vin= 36 AA05E-048L-150D Power Dissipation vs Output Current Tc = Tc,max Vin= 48 Vin= 48 Vin= 75 0.20 0.00 0.020 0.040 0.060 0.080 0.100 0.120 0.140 0.160 0.180 0.200 0.00 0.016 0.032 0.048 0.064 0.080 0.096 0.112 0.128 0.144 0.160 Output Current (Amps) Output Current (Amps) Figure 8. 120D Power Dissipation Figure 9. 150D Power Dissipation 4.0 Input Fusing Considerations An input fuse is recommended to protect the module, as well as external circuitry, in case of an input reverse voltage fault condition or other fault conditions where excess amounts of input current could be present. Generally the fuse should be rated at 1.5 times the maximum operating input current. _____________________________________________________________ ASTEC POWER - Andover 7 of 8 Technical Reference Notes (TRN) 5.0 AA05E Series 36 Vdc to 75 Vdc Inputs, 5 W Outline Diagram 0.40 [10.2] 0.18 [4.6] 0.10 [2.54] 0.02 [0.50] 0.60 [15.24] 1.27 [32.2] 23 0.10 [2.54] 9 10 11 0.60 0.80 [15.24] [20.3] 0.010 [0.25] 23 24 1615 14 Figure 10 . AA05E Unit Outline – Pin View Pin Assignment Single Output Dual Output Pins 2 & 3: -Vin Pins 22 & 23: +Vin Pin 14: +Vout Pin 16: Com Remaining pins NC Pins 2 & 3: -Vin Pins 22 & 23: +Vin Pin 14: +Vout Pins 9 & 16: Com Pin 11: -Vout Remaining pins NC _____________________________________________________________ ASTEC POWER - Andover 8 of 8