LDXX SERIES 3-5W,AC-DC CONVERTER LD---- are high efficiency green power modules with least packaging provided by Mornsun. The features of this series are: wide input voltage, DC and AC all in one, high efficiency, high reliability, low loss, safety isolation etc. They are widely used in industrial, office, civil and medical equipments. EMC and safety standards meet international standards IEC61000 EN60950/UL60601 and IEC60950, and Multi-certificate is in processing. MODEL SELECTION PRODUCT FEATURES 1. Universal Input :85 ~ 264VAC,50/60Hz 2. AC and DC all in one (input from the same terminal) 3. Low Ripple and Noise 4. Over output voltage protection , short circuit protection and Over temperature 5. High efficiency, High power density 6. Low loss, green power 7. Multiple models available 8. industrial, medical level specifications 9. 3 years warranty LD05-20B24 Out put Vol tage Out put S tyle Input Vol tage Is olati on Volt ag e Rated Powe r Pac kage St y le Product Seri es PRODUCT PROGRAM Approval Model Package LD03-10B03 UL/CE60950 2.3W Output (Vo1/Io1) Output (Iomax/T) Ripple and Noise (TYP) Efficiency (%)(TYP) 3.3V/700mA 900mA/60S LD03-10B05 5v/600mA 750mA/60S 72 LD03-10B09 9V/330mA 450mA/60S 74 12V/250mA 330mA/60S LD03-10B15 15V/200mA 250mA/60S LD03-10B24 24V/125mA 160mA/60S 78 3.3V/1250mA 1400mA/60S 66 LD05-20B05 5v/1000mA 1300mA/60S 72 LD05-20B09 9V/550mA 700mA/60S 12V/420mA 550mA/60S 15V/333mA 450mA/60S 76 24V/230mA 300mA/60S 78 37.0X23.0X15.0mm LD03-10B12 LD05-20B03 UL/CE60601 Power LD05-20B12 3W 4.2W 50.8X25.4X15.16mm 5W LD05-20B15 LD05-20B24 5.5W 63 30mV 76 76 30mV 74 76 Note: 1. Ripple and Noise were measured by the method of anear measure(The details see the anear measure); o 2. Unless otherwise specified, all specifications above are measured at rated input voltage and rated output load, TA=25 C, humidity < 75%; 3. All specifications stated in this datasheet are subject to the above listed models only. For specifications of non-standard models, please contact our technical Support team. 4. Product can not be continuously over current, or it will cause permanent damage to the device. INTPUT SPECIFICATIONS Input Voltage Range 85~264VAC, Input Frequency 47~440Hz 110~370VDC Input Current LD03 models LD05 models 110VAC 65mA, typ 110mA,typ 230VAC 30mA, typ 70mA, typ Inrush Current LD03 models LD05 models 110VAC 10A, typ 10A,typ 230VAC 20A, typ 20A, typ LD03 models LD05 models 0.5A/250V Slow blow 1A/250V Slow blow External input fuse(recommended) MORNSUN reserves the copyright Specifications subject to change without notice. LD03-05 A/2-2008 Page 1 of 4 OUTPUT SPECIFICATIONS Voltage set accuracy ±2%(±3% when 3.3V output ) (typ) Input variation ±0.5% (typ) ±1% (typ) Load variation (10% to 100%) 20MHz Bandwidth Ripple& noise(p-p) 30mV(typ) Short circuit protection Continuous, and auto resume Over temperature protection Over output voltage protection 150°C(max) chip lock up diode clamp and chip lock up LD03 models LD05 models COMMON SPECIFICATIONS Temperature ranges Operating Power derating Storage: Case temperature: Hold-up time (Vin=230VAC) -25°C ~ +70°C 2% / °C -40°C ~ +105°C +95°C max (above 55°C): 50ms(typ) Humidity 95%(max) Temperature coefficient 0.02%/°C Switching frequency 100kHz(typ) Efficiency LD03 models LD05 models 76% typ 3000VAC/1Min 4000VAC/1Min EMI/RFI conducted LD03 models LD05 models None EN55022, level A EN55011, level A IEC/EN 61000-4-2 level 4 IEC/EN 61000-4-3 8kV/15kV EMC compliance Electrostatic discharge ESD RF field susceptibility Electrical fast transients/bursts on mainsline LD03 models LD05 models Surge* LD03 models LD05 models IEC/EN 61000-4-4 IEC/EN 61000-4-4 IEC/EN 61000-4-5 IEC/EN 61000-4-5 2kV 4kV 1kV/2kV 2kV/4kV LD03 models LD05 models LD03 models LD05 models Safety Class IEC60950,EN60950,UL60950 IEC60601,EN60601 EN60950,UL60950 EN60601-1 CLASS 2 Case material UL94V-0 Install PCB MTBF >200,000h @25°C I/O-isolation voltage Leakage current Safety standards Safety approvals level 3 level 4 level 3 level 4 Note: External input pressure sensitive resistor is required to LD03 models at inrush experiment, refer to typical application figure. TEMPERATURE VS LOAD INPUT VOLTAGE VS LOAD Loa d (% ) 100 80 Loa d (% ) 60 40 100 20 80 70 85 110 I nput v ol t age 2 40 264 ( Vac) 60 Loa d (%) 40 100 - 25 -10 55 0 70 80 Te m pe ratur e ( C) 60 40 20 70 MORNSUN reserves the copyright Specifications subject to change without notice. 110 I nput v ol tag e LD03-05 3 40 370 (Vdc) A/2-2008 Page 2 of 4 TYPICAL EFFICIENCY CURVE LD03-10B05 115VAC Efficiency(%) LD03-10B05 230VAC Efficiency(%) LD03-10B12 115VAC Efficiency(%) LD03-10B12 230VAC Efficiency(%) LD03-10B24 115VAC Efficiency(%) LD03-10B24 230VAC Efficiency(%) Efficiency(%) 80 75 70 65 60 55 50 45 10 20 30 40 50 60 70 80 90 100 Load(%) LD05-20BXX Efficiency Efficiency(%) LD03-10BXX Efficiency 85 LD05-20B05 115VAC Efficiency(%) LD05-20B05 230VAC Efficiency(%) LD05-20B12 115VAC Efficiency(%) LD05-20B12 230VAC Efficiency(%) LD05-20B24 115VAC Efficiency(%) LD05-20B24 230VAC Efficiency(%) 90 85 80 75 70 65 60 55 50 10 20 30 40 50 60 70 Load(%) 80 90 100 ANEAR MEASURE LD03-10BXX LD05-20BXX Connect Oscillograph probe Copper sheet Fuse Connect Oscillograph Probe Copper sheet FUSE L C3 C1 C2 Load Load N 3 25.4mm 25.4mm TYPICAL APPLICATIONS LD03-10B** *FUSE LD05-20B** *NTC L L C3 M OV C1 +V0 TVS *FUSE *NTC L + 22 + C2 L +V0 C1 C2 + RL RL 26 -V0 -V0 N N N N Figure 2 Figure1 * FUSE *NTC L L C7 C6 C3 NF MOV C8 + +V0 *FUSE C1 C2 TVS + 22 L L RL C7 C6 C1 C2 + NF RL C8 26 -V0 -V0 N N N +V0 N Figure4 LD05 EMC Application Figure Figure3 LD03 EMC Application Figure EXTERNAL CAPACITORS TYPICAL VALUE(Unit: µF) model C1 C2 C3 TVS model C1 C2 LD03-10B03 150 0.1 4.7/400V P4KE6.8A LD05-20B03 47 0.1 LD03-10B05 150 0.1 4.7/400V P4KE6.8A LD05-20B05 47 0.1 4.7/400V P4KE12A LD05-20B09 33 0.1 LD03-10B09 120 0.1 LD03-10B12 120 0.1 4.7/400V P4KE20A LD05-20B12 33 0.1 LD03-10B15 120 0.1 4.7/400V P4KE20A LD05-20B15 33 0.1 LD03-10B24 68 0.1 4.7/400V P4KE30A LD05-20B24 10 0.1 Note： 1. Output filtering capacitors C1, C3 is electrolytic capacitors, It is recommended to use high frequency and low impedance electrolytic capacitors. For capacitance and current of capacitor please refer to manufacture’s datasheet. Voltage derating of capacitor should be 80% or above. C2 is ceramic capacitor, it is used to filter high frequency noise. TVS is a recommended component to protect post-circuits (when converter fails). 2. MOV is required to LD03 models，model: 471KD05, it is used to protect the device under surge. 3. It is recommended to connect FUSE, the parameter for LD03 models is 0.5A/250V slow blow, for LD05 models is1A/250V slow blow. External input NTC is recommended to use 5D-14 or 10Ω/2W wire-round resistor. 4. If EMC performance is required, recommended to add “EMC filter” at the input end(see figure 3,4) C6:X capacitor, recommended parameter 0.1uF/275V; C7,C8:Y capacitor, recommended parameter 220pF/2000V; NF: common model choke, recommended inductance is about 10mH-30mH. 5. LD03 models: Terminals 22 and 26 are internal rectification and filtering terminals. To protect the models further, it is recommended to connect an electrolytic capacitor C3 (it is recommended to be 4.7uF/400V). If operation voltage of the module is between 160~264VAC, C3 can be removed. MORNSUN reserves the copyright Specifications subject to change without notice. LD03-05 A/2-2008 Page 3 of 4 OUTLINE DIMENSIONS & PIN CONNECTIONS LD03-10BXX First Angle Projection 1 3 13 Bottom view 26 22 16 14 RECOMMENDED FOOTPRINT Top view,grid:2.54mm(0.1inch), diameter:1.20mm(0.047inch) 1 7 .7 8 ( 0.70 ) 23 .0 0 ( 0.91) 37.00 (1.46) 22 26 3.26 (0.13) 16 14 5.08 (0.20) 15. 00 (0 .59 ) Side view 4.1 0 ( 0.16 ) 1 0.80 (0.03) 3 13 FOOTPRINT DETAILS PIN FUNCTION 1 3 13 14 16 22 26 Note: Unit:mm( inch) Pin diameter:0.80 0.05mm Pin tolerances: 0.25mm General tolerances: 0.50mm Weight: 25g L N NC -Vo +Vo +Vin(DC) -Vin(DC) NC:No connection LD05-20BXX Bottom View 1 4 3 (0.50) 2 (0.40) (0.40) (0.40) First Angle Projection RECOMMENDED FOOTPRINT Top view,gr id:2.54mm(0.1inch), diameter:1.60mm(0.063inch) 1 3 (0.60) (0.24 0.01) 4 Side View 1.00 (0.16) 2 FOOTPRINT DETAILS Pin Note: Unit:mm(inch) Pin diameter:1.00 0.10mm General tolerances: 0.50mm Weight: 35g MORNSUN reserves the copyright 1 Function N 3 L +Vo 4 -Vo 2 Specifications subject to change without notice. LD03-05 A/2-2008 Page 4 of 4 AC-DC Converter Application Guidelines 1. Foreword The following guidelines should be carefully read prior to converter use. result in the risk of electric shock, damaging the converter, or fire. Improper use may 1．1 Risk of Injury A. To avoid the risk of burns, do not touch the heat sink or the converter ’s case. Do not touch the input terminals or open the case and touch internal components, which cold result in electric shock or burns. C. When the converter is in operation, keep hands and face at a distance to avoid potential injury during improper operation. B. 1．2 Installation Advice Please make sure the input terminals and signal terminals are properly connected in accordance with the stated datasheet requirements. B. To ensure safe operation and meet safety standard requirements, install a slow blow fuse at input of the converter. A. C. Installation and use of AC/DC converters should be handled by a qualified professional. D. AC/DC converters are used in the primary transmission stage of a design and thus, should be installed in compliance with certain safety standards. E. Please ensure that the input and output of the converter are incorporated into the design out of the reach of the end user. The end product manufacturer should also ensure that the converter is protected from being shorted by any service engineer or any metal filings. F. The application circuits and parameters shown are for reference only. All parameters and circuits are to be verified before completing the circuit design. G. These guidelines are subject to change without notice; please check our website for updates. 2. General AC-DC Converter Applications 2.1 Basic Application Circuit In Figure 1, F1 refers to the input fuse. Proper fuse selection should be a safety agency approved, slow blow fuse. Selection of the proper fuse rating is necessary to ensure power converter and system protection (potential failure if the rating is too high) and prevent false fuse blowing (which could happen if the rating is too low). Below is the formula to calculate the proper rating: I = 3 x Vo1 x Io1 / η / Vin(min.) Vo1 = output voltage Io1 = output current; η = the converter’s efficiency; Vin(min) = the minimum input voltage Futher circuit notations: ♦ NTC is a thermistor. ♦ CY and CX are safety capacitors. ♦ C1 is a high frequency ceramic capacitor or polyester capacitor, 0.1μF/50V. ♦ C2 is output filtering high frequency aluminum electrolytic capacitor. Select a 220μF rating if the output current is greater than 5A, or a 100μF rating if the output current is less than 5A. The insulation voltage should be derated to less than 80% of rated value. For dual or triple output converters, the circuit of input side remains the same and the outputs should be considered independently in component selection (see Figure 3). The application circuit shown in Figure 1 is typical application circuit, whereby all MORNSUN products will meet EMI Class B, and Class 3 lightening strike and surge testing (see component datasheets for more details). To comply with more stringent EMC testing, additional filtering should be incorporated. See Figure 2 for a suggested filtering circuit. For multi-output converters, the main output is typically a fully regulated output. If the end application requires critical regulation on the auxiliary output(s), a linear regulator or other regular should be added after the converter. (Note: Some MORNSUN converters have built in linear regulators; please contact our Technical Department for details). 3. AC-DC Converter Safety Related Design Notes 3.1 Marking Requirements Wherever, there are fuses, protective grounds, or switches, clear symbols should be indicated according safety standards. Touchable dangerous high voltage and energy sources should be marked with “Caution!” indications. 3.2 Input Cable Requirements: Input cables of L, N and E should be brown, blue and yellow/green cables, respectively. Ensure that the ground cable (yellow & green cable) of Type I devices (those that rely on basic insulation and protection ground to avoid electric shock) are securely connected to the ground, and the earth resistance is lower than 0.1Ω 3.3 Clearance and Creepage For Type I devices, ensure: ♦ L and N are in front of the fuse. ♦ The clearance distance between the input and the metal case is above 2mm and creepage is above 2.5mm. For Type II devices (those that rely on strengthened insulation or double insulation to avoid electric shock) ensure: ♦ L and N are in front of the fuse ♦ The clearance distance between the input and the metal case is above 2mm and creepage is above 2.5mm. ♦ The clearance between the input and the metal case or SELV is above 4mm, and creepage of that is above 5mm. 3.4 Input energy If the input capacitor is large, a discharge resistor may be added to ensure that, after disconnect, the voltage held between Input L, N, and the protective ground will be discharged to 37% of its maximum value or below. In Figure 2, R1 is the discharge resistor. 4. Heat Dissipation in AC/DC Converter Module Applications Trends toward higher density in AC/DC module designs make heat dissipation an important concern. The effect of heat on the electrolytic capacitor is of particular concern, as the life of such capacitors can be drastically reduced when operated in a constant high temperature environment, leading to a higher potential for failure. Proper handling of heat will increase the life of the converter and surrounding components, thus lowering risk of failures. Some suggestions for handling dissipated heat are summarized, below: (1) Ambient Air Cooling For miniature and high power density converters, free air cooling is recommended, mainly due to cost and space concerns. ♦ Heat dissipates to the ambient air through the converter case or exposed surfaces. Heat may also dissipate to ambient air if there is a gap between the converter and the PCB. ♦ Heat dissipates from the converter case and exposed surfaces to PCB by radiation. ♦ Heat conducts through terminals (pins) to PCB. In such applications, please pay particular attention to: A. Air Flow - Because the heat dissipation is mainly through convection and radiation, the converter needs an environment with good air flow. It may be helpful to design heat dissipation venting holes throughout the end product, near the converter ’s location. For best convection cooling, ensure that air flow is not blocked by large components B. Layout of Heat Generating Components - In most applications, the AC/DC converter is usually not the only heat generating component. It is recommended to keep a good distance between each heat generating component to minimize heat dissipating clusters. C. PCB Design - The PCB, which the power converter is assembled on, is not only a base to mount the converter, but also acts as a heat sink for it, therefore heat dissipation should be considered in PCB layout. We recommend extended the area of the main copper loop and decrease the component density on the PCB to improve the ambient environment. (2) Heat Sinks When free air convection is not sufficient enough, we recommend the use of a heat sink for further cooling. As the converters are filled with heat conductive silicon or epoxy, the heat distribution in converter is even and it radiates from the converter to the air. The efficiency of this convection is dependent on the size of the surface area of the converter. The use of heat sinks is a practical method to add surface area and improve the convection. There are many kinds of heat sinks available in the market. MORNSUN recommends considering the following factors in selecting a heat sink: ♦ The heat sink should be made of a good heat conducting material, such as aluminum and copper. ♦ The larger the surface area, the better the radiation. Therefore, heat sinks usually have a ridged surface or special coatings to make a larger surface area. ♦ Use the longest and thickest possible heat sink for best convection. Heat sinks are best attached to the converter’s surface, where the difference in temperature between the surface and the ambient is largest. The use of heat conductive material between the heat sink and the converter ’s surface to make a better contact and to improve heat conductance is suggested. To avoid case distortion, please do not affix the heat sink too firmly to the converter case. (3) Forced Air Cooling In some systems, where a heat sink does not effectively reduce the ambient temperature, a fan is used to improve the heat radiation. Fans can lower the surface temperature of the converter, but large fans also occupy extra space in the system. It is important to select a suitable fan size, where the speed of the fan will determines how effective it is. The faster the speed, the better the effect on reducing radiated heat. As high speed will also cause increased noise, there is a need to balance the choice between the how effective the fan is against how much audible noise it generates. A long, rectangular shaped AC/DC converter should use a horizontal fan, and channeled heat sinks should use vertical fans, in order to encourage air flow through the channels. 5. Input Under Voltage Impact 5.1 Block Diagram of AC/DC Converter 5.2 Impact to Converter Reliability The input voltage range of MORNSUN’s AC/DC converters is 85~264VAC or 120~370VDC. When the converter is operated within the rated input voltage range, the output current can be used up to the maximum rated specification. The total output power is Io x Vo. If the converter is operated with an input voltage that is under the rated voltage, offering the same output power of I o x Vo , causes the current (Is) at the transistor (S) to be increased. Long term operation under this condition will damage the transistor (S). 5.3 Input Voltage vs Load Capability (LD03-00B24) Output voltage(V) 30 25 85VAC 20 80VAC 75VAC 15 70VAC 10 65VAC 5 60VAC Load(%) 0 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 130% 140% Load 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120% 130% 140% 85VAC 23.85 23.82 23.79 23.77 23.74 23.71 23.68 23.65 23.61 23.58 23.57 23.19 19.2 14.7 11 80VAC 23.83 23.82 23.82 23.83 23.82 23.82 23.81 23.81 23.81 23.8 21 18.5 15 13 10.5 75VAC 23.83 23.83 23.83 23.83 23.82 23.82 23.82 23.81 23.77 20.29 16.65 14.02 10.98 9.39 7.04 70VAC 23.83 23.83 23.83 23.83 23.82 23.82 23.81 23.79 19.96 16.44 13.32 11.14 8.79 65VAC 23.83 23.83 23.83 23.83 23.82 23.82 23.82 23.8 19.6 15.67 12.46 9.57 7.65 60VAC 23.83 23.83 23.83 23.83 23.82 23.51 17.86 14.13 10.52 8.28 0