4:1 Intermediate Bus Converter Module: Up to 500 W Output IB054E120T40N1-00 Features • Input: 36 – 60 Vdc • 98% peak efficiency • Output: 12.0 Vdc at 48 Vin • Low profile: 0.38” height above board • Output current up to 40 A • Industry standard 1/8 Brick pinout • Output power: up to 500 W • 2,250 Vdc isolation [A] • Sine Amplitude Converter • Low noise 1 MHz ZVS/ZCS Size: 2.30 x 0.9 x 0.38 in 58,4 x 22,9 x 9,5 mm [A] For lower power applications see 300 W model IB054E120T32N1-00 Product Overview Applications The Intermediate Bus Converter (IBC) Module is a very efficient, low profile, isolated, fixed • Enterprise networks ratio converter for power system applications in enterprise and optical access networks. • Optical access networks Rated at up to 360 W from 36 Vin and up to 500 W from 50 to 60 Vin, the IBC • Storage networks conforms to an industry standard eighth brick footprint while supplying the power of • Automated test equipment a quarter brick. Its leading efficiency enables full load operation at 55°C with only 200 LFM airflow. Its small cross section facilitates unimpeded airflow — above and below its thin body — to minimize the temperature rise of downstream components. Absolute Maximum Ratings Min Max Unit 36 60 Vdc 75 Vdc 5 V/µs Notes Input voltage (+In to –In) Operating Input voltage slew rate <100 mS EN to –IN -0.5 20 Vdc Output voltage (+Out to –Out) -0.5 17.2 Vdc 18.75 V for 100 mS 40 A Pout ≤ 500 W Vdc 1 min. Hottest Semiconductor Output current Dielectric withstand (input to output) 2,250 Temperature Operating junction Storage VI BRICK IBC Module -40 125 °C -55 125 °C IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 1 of 13 SPECIFICATIONS All specifications valid at 48 VIN , 100% rated load and 25°C ambient, unless otherwise indicated. Electrical Characteristics Attribute Symbol Conditions / Notes Min Typ Max Unit 36 48 60 75 5 Vdc Vdc V/us 36 34 7 200 Vdc Vdc Vdc µs µs 79.5 78 4 Vdc Vdc µs 30 ms 50 µs 50 µs 250 ms 3.5 0.24 10.1 25 W W A A 400 mArms 30 25 A A µF nH 470 µF 15.0 V 0 0 360 480 W W 0 500 40 W A 15 % mΩ INPUT (Operating from DC input source) Operating input voltage Operating input surge withstand Operating input dV/dt <100 mS 0.003 Undervoltage protection Turn-on Turn-off Turn-on/ Turn-off hysteresis Time constant Undervoltage blanking time 31 29 2 UV blanking time is enabled after start up Overvoltage protection Turn-off Turn-on Time constant 50 100 76 75 Turn ON delay VIN reaching turn-on voltage to enable function operational , see Figure 6 Enable to 10% VOUT; pre-applied VIN ,see Figure 7, 0 load capacitance From 10% to 90% Vout, 10% load, 0 load capacitance See page 10 for restart after EN pin disable Start up inhibit Turn-on delay Output voltage rise time Restart turn-on delay No Load power dissipation Enabled Disabled Input current Inrush current overshoot 20 25 2.8 0.17 Using test circuit in Figure 21, 15% load, highline At max power; Using test circuit in Figure 22 Input reflected ripple current Peak short circuit input current Repetitive short circuit peak current Internal input capacitance Internal input inductance Recommended external input capacitance 8.8 5 200 nH maximum source inductance 47 DC Output voltage band Output power [a] 36-60 VIN 48-60 VIN 50-60 VIN Output current No load, over Vin range 9.0 Output start up load Effective output resistance Line regulation (K factor) of Iout max, maximum output capacitance OUTPUT VOUT = K • VIN @ no load Full power operation; See Parallel Operation on page 11; up to 3 units Current share accuracy [a] 0.247 12.0 4.8 0.250 0.253 10 % Does not exceed IPC-9592 derating guidelines. At 70°C ambient, full power operation may exceed IPC -9592 guidelines, but does not exceed component ratings, does not activate OTP and does not compromise reliability. VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 2 of 13 SPECIFICATIONS (CONT.) All specifications valid at 48 VIN , 100% rated load and 25°C ambient, unless otherwise indicated. Electrical Characteristics (Continued) Attribute Symbol OUTPUT (Continued) Efficiency 50% load Full load Internal output inductance Internal output capacitance Load capacitance Output OVP set point Conditions / Notes See figures 1,2 and 3. See figures 1,2 and 3. Module will shutdown 20 MHz bandwidth, using test circuit in Figure 23 Of Iout max., will not shutdown when started into max Cout; and 15% load Auto restart with duty cycle <10% Output voltage ripple Output Overload protection threshold Over current protection time constant Short circuit current response time Switching frequency Transient Response Voltage overshoot Response time VIN step Min Typ 97.4 97.0 97.8 97.4 1.6 55 0 16.2 Max 3000 60 105 Pre-bias voltage mVp-p 150 % 1.2 1.5 ms µs MHz 100 1.25 mV µS V 15 Vdc 1 0 % % nH µF µF Vdc 150 1.0 25% load step; 1A /µS; See Figures 13 & 14 See Figures 13 & 14 5 V step in 1 µS within Vin operating range Unit will start up into pre-bias voltage on output Unit General Characteristics Conditions: 25°C case, 75% rated load and specified input voltage range unless otherwise specified. Attribute Symbol MTBF Service life Calculated per Telcordia SR-332, 40°C Calculated at 30°C TJ ; Converter will reset when over temperature condition is removed Input to output Input to output Over temperature shut down Dielectric withstand Insulation resistance Mechanical Weight Length Width Height above customer board Clearance to customer board Min Typ Max 1.0 7 125 From lowest component on IBC UL/cUL60950-1, EN60950-1, IEC60950-1 Low voltage directive (CE Mark) Derate operating temp 1°C per 1,000 feet above sea level Non condensing Compatible with RoHS directive 2002/95/EC Altitude, operating Relative humidity, Operating RoHS compliance IB054E120T40N1-00 vicorpower.com Unit Mhrs Years 130 135 2,250 °C Vdc MΩ 30 0.71 / 20.3 2.30 /58.4 0.9/22.9 0.38 /9.5 Agency approvals VI BRICK IBC Module Conditions / Notes oz/g in/mm in/mm in/mm in/mm 0.12/0.30 cTUVus CE -500 10,000 Feet 10 90 % Rev. 1.1 Page 3 of 13 SPECIFICATIONS (CONT.) Control & Interface Specifications Attribute Symbol Enable (negative logic) Module enable threshold Module enable current Module disable threshold Module disable current Disable hysteresis Enable pin open circuit voltage Conditions / Notes Min Typ Max 130 200 2.4 130 Unit Referenced to –IN 0.8 VEN = 0.8 V VEN = 2.4 V 500 2.5 EN to –IN resistance Enable (positive logic) Module enable threshold Module disable threshold EN source current (operating) EN voltage (operating) Open circuit, 10 V applied between EN and -IN Referenced to –IN Vdc µA Vdc µA mV Vdc 3.0 35 2.0 2.5 4.7 5 VEN = 5 V kΩ 3.0 1.45 2 5.3 Vdc Vdc mA Vdc IPC-9592A, Based on Class II Category 2 the following detail is applicable. – Pre-conditioning required Environmental Qualification Test Description Test Detail Quantity Tested 5.2.3 HALT (Highly Accelerated Life testing) Low Temp High Temp Rapid Thermal Cycling 6 DOF Random Vibration Test Input Voltage Test Output Load Test Combined Stresses Test 3 3 3 3 3 3 3 5.2.4 THB (Temp. Humidity Bias) (72 hr presoak required) 1000 hrs – Continuous Bias 30 5.2.5 HTOB (High Temp. Operating Bias) Power cycle - On 42 minutes Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 10 minutes. Alternating between maximum and minimum operating Voltage every hour. 5.2.6 TC (Temp. Cycling) 700 cycles , 30 minute dwell at each extreme – 20C minimum ramp rate. 30 5.2.7 Power Cycling Reference IPC-9592A 3 5.2.8 – 5.2.13 Shock and Vibration Random Vibration – Operating IEC 60068-2-64 (normal operation vibration) Random Vibration Non-operating (transportation) IEC 60068-2-64 Shock Operating - normal operation shock IEC 60068-2-27 Free fall - IEC 60068-2-32 Drop Test 1 full shipping container (box) 3 3 3 3 12 5.2.14 Other Environmental Tests 5.2.14.1 Corrosion Resistance – Not required 5.2.14.2 Dust Resistance – Unpotted class II GR-1274-CORE 5.2.14.3 SMT Attachment Reliability IPC-9701 - J-STD-002 5.2.14.4 Through Hole solderability – J-STD-002 N/A 3 3 5 ESD Classification Testing Sample size assumes CDM testing 12 Total Quantity VI BRICK IBC Module 30 161 IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 4 of 13 SPECIFICATIONS (CONT.) WAVEFORMS Efficiency TAMB 55°C 99% 98% 98% 97% 97% Efficiency (%) Efficiency (%) Efficiency TAMB 25°C 99% 96% 95% 94% 93% 96% 95% 94% 93% 92% 92% 8 0 16 24 32 40 0 8 16 Iout (A) VIN : 38 V 24 32 40 Iout (A) 48 V 55 V VIN : 38 V 48 V 55 V Figure 2 — Efficiency vs. output current, 55°C ambient Figure 1 — Efficiency vs. output current, 25°C ambient Efficiency TAMB 70°C 99% Efficiency (%) 98% 97% 96% 95% 94% 93% 92% 8 0 16 24 32 40 Iout (A) VIN : 38 V 48 V 55 V Figure 3 — Efficiency vs. output current, 70°C ambient Figure 4 — Inrush current at high line 15% load; 10 A/div Figure 5 — Input reflected ripple current at nominal line, full load Figure 6 — Turn on delay time; VIN turn on delay at nominal line, 15% load VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 5 of 13 SPECIFICATIONS (CONT.) WAVEFORMS (CONT.) Figure 7 — Turn on delay time; Enable turn on delay at nominal line, 15% load Figure 8 — Output voltage rise time at nominal line, 10% load Figure 9 — Overshoot at turn on at nominal line, 15% load Figure 10 — Undershoot at turn off at nominal line, 10% load Figure 11 — Load transient response; nominal line Load step 75– 100%; 20 A/div Figure 12 — Load transient response; Full load to 75%; nominal line VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 6 of 13 SPECIFICATIONS (CONT.) WAVEFORMS (CONT.) Figure 13 — Load transient response; nominal line Load step 0 – 25%; 10 A/div Figure 14 — Load transient response; 25–0%; nominal line Figure 15 — Input transient response; Vin step low line to high line at full load Figure 16 — Output ripple; Nominal line, full load Figure 17 — Three module parallel array test. Vout change when one module is disabled. Nominal Vin, Iout = 80 A Figure 18 — Three module parallel array test. Vout change with two modules operating and a third module enabled Nominal Vin, Iout = 80 A VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 7 of 13 SPECIFICATIONS (CONT.) WAVEFORMS (CONT.) Output Current Derating 45 40 40 35 35 Output Current (A) Output Current (A) Output Current Derating 45 30 25 20 15 10 30 25 20 15 10 5 5 0 0 25 35 55 45 65 75 85 25 95 35 45 Ambient Temperature (°C) 200 LFM 400 LFM 65 55 75 85 95 Ambient Temperature (°C) 200 LFM 600 LFM Figure 19 — Maximum output power derating vs ambient air temperature. Transverse airflow, Board and junction temperatures within IPC-9592 derating guidelines 400 LFM 600 LFM Figure 20 — Maximum output power derating vs ambient air temperature. Longitudinal airflow, Board and junction temperatures within IPC-9592 derating guidelines Current Probe _ 47 µF Current Probe +OUT IBC –IN 10 µH C* + –OUT Vsource _ 470 µF +IN EN –IN +OUT Load Vsource EN Load +IN + IBC –OUT *Maximum load capacitance Figure 21 — Inrush current overshoot 10 µF +IN Figure 22 — Input reflected ripple current 0.1 µF +OUT PCD –IN E – Load –OUT Cya Cyc Cyb Cyd 20 MHz BW Cy a-d = 4700 pF Figure 23 — Test circuit; output voltage ripple VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 8 of 13 SPECIFICATIONS (CONT.) THERMAL DATA Figure 24 — Thermal plot, 200 LFM, 25°C, 48 Vin, 450 W output power Figure 25 — Thermal plot, 200 LFM, 25°C, 48 Vin, 450 W output power Figure 26 — Thermal plot, 400 LFM, 25°C, 48 Vin, 450 W output power Figure 27 — Thermal plot, 400 LFM, 25°C, 48 Vin, 450 W output power Figure 28 — Thermal plot, 600 LFM, 25°C, 48 Vin, 450 W output power Figure 29 — Thermal plot, 600 LFM, 25°C, 48 Vin, 450 W output power VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 9 of 13 PIN / CONTROL FUNCTIONS +In / -In – DC Voltage Input Pins The IBC input voltage range should not be exceeded. An internal undervoltage/overvoltage lockout function prevents operation outside of the normal operating input range. The IBC turns on within an input voltage window bounded by the “Input under-voltage turn-on” and “Input over-voltage turn-off” levels, as specified. The IBC 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. 5 1 2 Top View 3 The connection of the IBC 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. 4 Pin 1 2 3 4 5 EN - Enable/Disable Function Vin+ Enable VinVoutVout+ Negative Logic Option If the EN port is left floating, the IBC output is disabled. Once this port ispulled lower than 0.8 Vdc with respect to –In, the output is enabled. The EN port can be driven by a relay, opto-coupler, or open collector transistor. Refer to Figures 6 and 7 for the typical enable / disable characteristics. This port should not be toggled at a rate higher than 1 Hz. The EN port should also not be driven by or pulled up to an external voltage source. Figure 30 — IBC Pin Designations Positive Logic Option If the EN port is left floating, the IBC output is enabled. Once this port is pulled lower than 1.4 Vdc with respect to –In, the output is disabled. This action can be realized by employing a relay, opto-coupler, or open collector transistor. This port should not be toggled at a rate higher than 1 Hz. The EN port should also not be driven by or pulled up to an external voltage source. The EN port can source up to 2 mA at 5 Vdc. The EN port should never be used to sink current. If the IBC is disabled using the EN pin, the module will attempt to restart approximately every 250ms. Once the module has been disabled for at least 250ms, the turn on delay after the EN pin is enabled will be as shown in Figure 7. +Out / -Out – DC Voltage Output Pins Total load capacitance at the output of the IBC should not exceed the specified maximum. Owing to the wide bandwidth and low output impedance of the IBC, low frequency bypass capacitance and significant energy storage may be more densely and efficiently provided by adding capacitance at the input of the IBC. VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 10 of 13 APPLICATIONS NOTE Parallel Operation Input Impedance Recommendations The IBC 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 IBC 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 narrower traces to be utilized on the input side if necessary. The use of dedicated power planes is, however, preferable. To take full advantage of the IBC capabilities, the impedance presented to its input terminals must be low from DC to approximately 5 MHz. The source should exhibit low inductance and should have a critically damped response. If the interconnect inductance is excessive, the IBC 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 proper operation. Given the wide bandwidth of the IBC, the source response is generally the limiting factor in the overall system response. Anomalies in the response of the source will appear at the output of the IBC 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 IBC is operated near low or high line as the overvoltage/undervoltage detection circuitry could be activated. One or more IBCs in an array may be disabled without adversely affecting operation or reliability as long as the load does not exceed the rated power of the enabled IBCs. The IBC power train and control architecture allow bi-directional power transfer, including reverse power processing from the IBC output to its input. The IBC’s ability to process power in reverse improves the IBC transient response to an output load dump. Input Fuse Recommendations The IBC is 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. See safety agency approvals. Thermal Considerations The temperature distribution of the VI Brick can vary significantly with its input /output operating conditions, thermal management and environmental conditions. Although the PCB is UL rated to 130°C, it is recommended that PCB temperatures be maintained at or below 125°C. For maximum long term reliability, lower PCB temperatures are recommended for continuous operation, however, short periods of operation at 125°C will not negatively impact performance or reliability. Application Notes For IBC and VI Brick application notes on soldering, thermal management, board layout, and system design visit vicorpower.com. WARNING: Thermal and voltage hazards. The IBC can operate with surface temperatures and operating voltages that may be hazardous to personnel. Ensure that adequate protection is in place to avoid inadvertent contact. PART NUMBERING Product Family Input Voltage Package IB 054 E VI BRICK IBC Module Nominal Output Voltage IB054E120T40N1-00 120 Temperature Grade T vicorpower.com Output Current 40 Enable Logic Pin Length N = Negative 1 = 0.145 P = Positive 2 = 0.210 Rev. 1.1 Options -00 = Open frame Page 11 of 13 MECHANICAL DRAWINGS Figure 31 — IBC outline drawing Figure 32 — IBC PCB recommended hole pattern VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 Page 12 of 13 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] VI BRICK IBC Module IB054E120T40N1-00 vicorpower.com Rev. 1.1 1/2012