BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 GPBW52V04 – 1/2 Brick Bolero HV Series • • • • • • • • • • • Industry standard pinout and footprint Highest efficiency in the industry: 92% at 52V, 4A; 91% at 52V, 2A No heat sink required (baseplate standard) Very low common-mode noise for a commercial DC/DC converter Two-stage input filter Constant switching frequency, 330 kHz Remote sense Single board SMT construction Low profile, 0.43" Optional low profile heat sink or baseplate for improved thermal performance Header with M3 metal inserts for mechanical connection to PCB Typical Characteristics Control Functions • • • • • • • • • • Output setpoint accuracy: ± 2% Load regulation: ± 0.25% Line regulation: ± 0.25% Regulation over line, load and temperature: ± 2% Low output ripple 50% output trim-down Supports IEEE 802.3af power over LAN 2250V isolation Microprocessor controlled Primary-side enable, choice of logic Protection Features • • • • Over temperature protection Over voltage protection Over current protection Over/Under input voltage protection Ordering Information Standard Model Number GPBW52V04* * Options: M = 0.145" Pins (± .01") Input Voltage Output Voltage Max Current 48V 52V 4A R = Heat Sink-Ready G = Case Ground Pin Bolero HV Heat Sink Part Numbers Typical Thermal Performance Part Number Height Natural Convection Power Dissipation† Forced Convection Thermal Resistance‡ 001 0.25" 5W 5.8˚ C/W 002 0.50" 7W 3.2˚ C/W 003 1.00" 11W 2.0˚ C/W 004 0.13" TBD TBD † @ 60˚ C rise heat sink to ambient Example Part Number: (All options) ‡ @ 300'/min. GPBW52V04 M R G 0 0 X Part Number Options: Optional Pin Lengths E = 0.18" M = 0.145" (Std.) S = 0.12" Heat Sink-Ready Plate (Std.) Case Ground Pin (Std.) Heat Sink 001 = 0.25" 002 = 0.50" 003 = 1.00" 004 = 0.13" ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 1 POWER PRODUCTS BOLERO HV DC/DC CONVERTERS 48V Input – 52VDC – 4A Output GPBW52V04 Input Specifications Parameter Operating Input Voltage Min Typical Max Units 36 48 75 VDC 7 A Input Current Input Capacitance 5 µF Input Hysteresis, Low Line 2 VDC VIN = 48VDC, TA@25˚ C, 300 LFM Airflow, VOUT = 52VDC, IOUT = Full load unless otherwise noted. COUT = 180µF Al-Elec. Available output power depends on ambient temperature and good thermal management. (See application graphs for limits.) Output Specifications Parameter Min Typical Max Units 51.45 52.50 53.55 VDC Voltage Ripple, 180µF Load Capacitance 30 mV RMS Voltage Ripple, 180µF Load Capacitance 80 mV P–P 4 A Setpoint Current Range Current Limit Inception 0 100 120 %IOUT Short Circuit Current1 6 A Settling Time to ± 1%2 1 mS Turn-on Time to 98% Vnom 40 mS Output Overshoot at Turn-on None %VOUT 105 %VOUT Trim Range, Lucent 1/2 Brick Trim Over Voltage Protection, Latching 50 115 %VOUT 1. During short circuit, converter will shut down and attempt to restart once per second. The average current during this condition will be very low and the device can be safely left in this condition continuously. 2. 50% load change only resulted in 1% output voltage step. ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 2 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 Isolation Specifications Parameter Min Isolation Test Voltage, Input/Output (Basic) 2250 VDC 10 MΩ Isolation Resistance Typical Max Units Features Parameter Min Typical Over Temperature Protection, Thermal Sensor, Latching3 Input, Output Ripple Frequency, Fixed Max Units 115 ˚C 330 kHz 3. PCB less than 130˚ C. Approvals and Standards General Specifications Operating Temperature, Baseplate Storge Temperature Relative Humidity Vibration Material Flammability Weight -40˚ C to + 100˚ C -55˚ C + 125˚ C 10% to 95% RH, Non-condensing 2 to 9 Hz, 3mm disp., 9 to 200 Hz, 1g UL V-0 55 grams MTBF Bellcore TR-332 UL and c-UL Recognized Component, TUV, UL1950, CSA 22.2 No. 950, IEC/EN 60950** Pending. EMC Characteristics: Designed to meet emission and immunity requirements per EN55022, CISPR 22, Class B, and CISPR 24. ** An external fuse shall be used to comply with the requirements. 1.6 million hours ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 3 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 Application Notes CoolConverter™ Bel Power’s Proprietary CoolConverter™ • Patented single-stage power conversion architecture, control and magnetic design allow unprecedented power density and efficiency in an isolated power supply. • An advanced microcontroller reduces parts count while adding features, performance and flexibility in the design. Protection and Control Over Voltage Hysteresis 6 Output Voltage (V) Valid Input Voltage Range The converter measures the input voltage and will not allow operation outside of the input voltage specification. As shown by the graphs, hysteresis is added to both the high and low voltage to prevent the converter from turning on and off repeatedly when the voltage is held near either voltage extreme. At low line, this assures the maximum input current is not exceeded; at high line, this assures the semiconductor devices in the converter are not damaged by excessive voltage stress. ON/OFF Logic Option The ON/OFF control logic can be either Negative (standard) or Positive to enable the converter. For Negative logic, the ON/OFF pin is brought to below 1.0V with respect to the –INPUT pin to enable the converter. The pull-down must be able to sink 100µA. For Positive logic, the ON/OFF pin is brought to greater than 4.0V with respect to the –INPUT pin and be limited to less than 10V. To request the Positive logic version, add the suffix (P) to the standard part number. The ON/OFF pin has a built-in pull-up resistor of approximately 100kΩ to +5V. ©2006 Bel Fuse Inc. 4 3 2 1 0 76.5 77 77.5 78 78.5 79 79.5 80 Under Voltage Hysteresis 6 5 4 3 2 1 0 30 31 32 33 34 35 36 Input Voltage (V) Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 4 80.5 Input Voltage (V) Output Voltage (V) Output Over Voltage Protection The output voltage is constantly monitored by the microprocessor with a redundant secondary-side measurement circuit that both shuts down the duty cycle and triggers the microprocessor to shut down. If the output voltage exceeds the over voltage specification, the microprocessor will latch the converter off. To turn the converter on required either cycling the ON/OFF pin or power to the converter. This advanced feature prevents the converter from damaging the load if there is a converter failure or application error. If nonlatching is required, consult factory. 5 37 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 CoolConverter™ Protection and Control Thermal Shutdown The printed circuit board temperature is measured using a semiconductor sensor. If the maximum rated temperature is exceeded, the converter is latched off. To re-enable the converter requires cycling the ON/OFF pin or power to the converter. If non-latching shutdown is required, consult factory. Trim-up Rtrim-UP { = Vo (100+∆%) _ 1.225∆% } (100+2∆%) ∆% kΩ 52V Trim-up Control Options As the behavior of the circuit is determined by firmware in the microcontroller, specific requirements, such as: • non-latching thermal protection • custom valid input voltage range • controlled delay from initiating an ON/OFF signal for power sequencing can be accomplished with no change to hardware. The standard behavior was chosen based on system design experience, but customers may have their own requirements. Please contact Bel Power for any special needs. Trim Resistance (kΩ) 10000 1000 100 0 2 1 3 4 5 6 7 8 9 10 9 10 Increase in Output Voltage (%) Remote Sense The output voltage is regulated at the point where the sense pins connect to the power output pins. Total sense compensation should not exceed 0.4V or 2% of Vout, whichever is greater. Trim-down Safety An external input fuse must always be used to meet these safety requirements. Rtrim-DOWN = { External Output Trimming 100 _ 2 ∆% } kΩ Trim-down 6 7 7 8 8 Trim To trim the output voltage higher, connect the required trim resistor from the Trim pin to the +Sense pin. To trim the output voltage lower, connect the required trim resistor from the Trim pin to the –Sense pin. See diagram above. 1000 Trim Resistance (kΩ) 6 100 10 0 0 1 2 3 4 5 6 7 8 Decrease in Output Voltage (%) ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 5 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 Efficiency Data Efficiency Power Dissipation 94 Efficiency (%) 92 36V Vin 48V Vin 75V Vin 90 88 86 40V Vin 48V Vin 60V Vin 84 82 80 1 0 2 4 3 Load Current (A) Start Up [ VoltageRipple Ripple ] T 150 T Vout (mV) 100 1 50 0 Vout -50 2 -100 -150 Ch1 20.0V BW Ch2 5.00 V BW M 10.0ms A Ch2 1.80V 1. VOUT 20V/div 10mS/div 2. VOUT 5V/div 10mS/div 0 5 10 15 Time (µS) 20 25 1. VOUT 50mV/div 2µS/div 10µF ext cap 2MHz BW Line/Load Regulation 53.700 Output Voltage (V) 53.600 53.500 53.400 53.300 53.200 53.100 36V Vin 48V Vin 75V Vin 53.000 52.900 52.800 0 2 4 Output Current (A) ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 6 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 Transient Response Transient Response 50% to 75% Load Transients 75% to 50% Load Transients at VIN = 48V@TA = 25˚C at VIN = 48V@TA = 25˚C ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 Bel Power Inc. 155 Flanders Road, Westborough, MA 01581 • Tel 508-870-9775 • Fax 508-870-9796 • www.belpower.com page 7 BOLERO HV DC/DC CONVERTERS POWER PRODUCTS 48V Input – 52VDC – 4A Output GPBW52V04 Mechanical 0.5 ± 0.01 GPBW52V04 MOUNTING INSERT CONNECTED TO CASE PIN 2 SIDE VIEW 2.000 PIN 4, 1.700 1.700 PIN 5 PIN 3, 1.300 1.300 PIN 6 2.40 1.000 PIN 7 PIN 2, .700 .700 PIN 8 PIN 1, .300 .300 PIN 9 Pin Configuration – Bottom View 0 0 REF. MOUNTING INSERT M3 X 0.5, 4 PLACES .19 .20 Function Pin Dia. (In.) 1 – Input 0.040 2 Case Ground Pin 0.040 3 On/Off 0.040 4 + Input 0.040 5 + Output 0.080 6 + Sense 0.040 3. Workmanship: Meets or exceeds IPC-A-610B Class II 7 Trim 0.040 4. Min. screw length for heat sink attachment = 4.5mm + heat sink flange + locking hardware 8 – Sense 0.040 9 – Output 0.080 BOTTOM VIEW 1.900 0 Pin 2.28 Notes: 1. Mechanical tolerances x.xxx in. = ± 0.005 in. x.xx in = ± 0.01 in. 2. Pin material: Brass with tin/lead plating over nickel RoHS Compliance Complies with the European Directive 2002/95/EC, calling for the elimination of lead and other hazardous substances from electronic products. These parts are not however compatible with the higher temperatures associated with lead free solder processes and must be soldered using a reflow profile with a peak temperature of no more than 240˚C. ©2006 Bel Fuse Inc. Specifications subject to change without notice. 11.06 CORPORATE FAR EAST EUROPE Bel Fuse Inc. 206 Van Vorst Street Jersey City, NJ 07302 Tel 201-432-0463 Fax 201-432-9542 www.belfuse.com Bel Fuse Ltd. 8F / 8 Luk Hop Street San Po Kong Kowloon, Hong Kong Tel 852-2328-5515 Fax 852-2352-3706 www.belfuse.com Bel Fuse Europe Ltd. Preston Technology Management Centre Marsh Lane, Suite G7, Preston Lancashire, PR1 8UD, U.K. Tel 44-1772-556601 Fax 44-1772-888366 www.belfuse.com page 8