1 ALQ07 DC-DC Converter Technical Reference Notes Industry Standard Size – 36-75V Input, 3.3V/1.8V, 3.3V/1.5V and 3.3V/1.2V dual Output Features Industry Standard Size: 2.28”X 1.45’’ X 0.43’’package • • • • • • • • • • 2.28”X1.45’’ X0.43”package Basic isolation High power density 2:1 wide input of 36-75V CNT function Trim function Input under-voltage lockout Output over-current protection Output over-voltage protection Wide operating case temperature range Options Choice of positive logic or negative logic for CNT function Choice of short pins or long pins Description The ALQ07 series is a new open frame DC-DC converter. It is one of the most effective options available in component power. The ALQ07 series uses an industry standard package size: 36.8mm×57.9mm×10.9mm (2.28”x1.45”x0.43”) and standard pin-out configuration, provides CNT and trim functions. ALQ07 series comes in 48V input versions, each of which uses a 2:1 input range of 36~75V. The series can provide 3.3V@6A+1.8V@4A, 3.3V@6A+1.5V@4A and 3.3V@6A+1.2V@4A dual output, and output is isolated from input. And the converters are capable of providing up to 30 watts of output power. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 2 Contents Options ......................................................................................................................................1 Description.................................................................................................................................1 Module Numbering ...........................................................................................................................4 Electrical Specifications ....................................................................................................................5 Input Specifications ...................................................................................................................5 Absolute Maximum Ratings .......................................................................................................6 Output Specifications.................................................................................................................7 Output Specifications (Cont.).....................................................................................................8 Feature Specifications ...............................................................................................................9 Characteristic Curves .....................................................................................................................10 Performance Curves – Efficiency ............................................................................................10 Performance Curves – Output Performance Curves ...............................................................11 Performance Curves – Transient Response............................................................................12 Performance Curves – Transient Response (Cont.)................................................................13 Performance Curves – Transient Response (Cont.)................................................................14 Performance Curves – Startup Characteristics........................................................................15 Performance Curves – Startup from CNT Control ...................................................................16 Feature Description ........................................................................................................................17 CNT Function ..........................................................................................................................17 Trim .........................................................................................................................................18 Minimum Load Requirements..................................................................................................19 Output Over-current Protection................................................................................................19 Output Over-voltage Protection ...............................................................................................19 Over Temperature Protection ..................................................................................................19 Output Filters ...........................................................................................................................19 Decoupling ..............................................................................................................................20 Ground Loops..........................................................................................................................20 Design Consideration .....................................................................................................................21 Typical Application...................................................................................................................21 Fusing......................................................................................................................................21 Input Reverse Voltage Protection ............................................................................................22 EMC ........................................................................................................................................22 Safety Consideration ...............................................................................................................24 Thermal Consideration ...................................................................................................................25 MTBF..............................................................................................................................................25 Mechanical Considerations.............................................................................................................26 Installation ...............................................................................................................................26 ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 3 Soldering .................................................................................................................................26 Mechanical Chart (pin side view) ....................................................................................................27 Ordering Information.......................................................................................................................28 ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 4 Module Numbering A L Q 07 1 2 3 FM 48 N- 7 4 5 6 7 8 Explanation: 1－Series name 2－Low profile 3－Quarter brick 4－Output current: 7A 5－Dual output: F: 3.3V, M: 1.5V, Y: 1.8V 6－Input voltage range: 36V to 72V 7—CNT logic, N---Negative enable, default is positive enable 8—Pin length: 6---3.80mm 8---2.80mm 7---5.8mm By default: 5mm ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 5 Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage and temperature conditions. Standard test condition on a single unit is as following: Ta(ambient): 25 oC +Vin: 48V±2% -Vin: return pin for +Vin CNT: connect to COM for negative logic produce open for positive logic produce +Vo1, +Vo2: connect to load COM: connect to load (return) Trim(Vadj): open Input Specifications Parameter Operating Input Voltage Maximum Input Current (VI = 0 to VI,max, Io = Io,max) Device Symbol Min Typ. Max Unit All VI 36 48 75 Vdc All II,max - - 1 A All II - - 10 mAp-p All - - - 3.3 W Input Reflected-ripple Current (5Hz to 20MHz: 12μH source impedance: Ta = 25 ºC.) No Load Input Power (VI = VI,nom ) CAUTION: This power module is not internally fused. An input line fuse must always be used. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 6 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 is not implied at these or any other conditions in excess of those given in the operational sections of the IPS. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Device Symbol Min Typ. Max Unit Continuous: All VI 0 - 80 Vdc Transient (100ms) All VI, trans 0 - 100 Vdc Operating Ambient Temperature All Ta -40 - 60 ºC Storage Temperature All TSTG -55 - 125 ºC Operating Humidity All - - - 95 % All - - - 1,500 Vdc All Po,max - - 30 W Input Voltage Basic Input-Output Isolation (Conditions: 50µA for 5 sec, slew rate of 1500V/10sec) Output Power ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 7 Output Specifications Parameter Device Symbol Min Typ Output Ripple and Noise (When measure ripple, noise and dynamic response, external 10uF tantalum capacitor and 0.1uF ceramic capacitor required for each output.) All Max Unit Ripple Noise Vo1 - - 50 50 mVp-p Vo2 - - 50 50 mVp-p Vo1 0 - 4000 µF Vo2 0 - 4000 µF Vo1set 3.25 3.3 3.35 Vdc Vo2set 1.77 1.8 1.83 Vdc Vo1set 3.25 3.3 3.35 Vdc Vo2set 1.48 1.5 1.52 Vdc Vo1set 3.25 3.3 3.35 Vdc Vo2set 1.18 1.2 1.22 Vdc 0.5 %Vo,nom Peak-to-Peak (5 Hz to 20 MHz) External Load Capacitance Output Voltage Setpoint (Rating input, 3.3V@4A+1.8V@6A, 3.3V@4A+1.5V@6A,3.3V@4A+1 .2V@6A, Ta = 25 ºC ) Cross regulation (Any one output Vs. others) Output Regulation: Line (Vi=Vi,min to Vi,max) Load (Io = Io,min to Io,max, other Io =50%Io,nom) (Ta=-40 ºC~60ºC) Rated Output Current (Io1+Io2≤10A) Output Current Protection (When unit is shut down) All ALQ07FY ALQ07FM ALQ07FK All All Vo1 - 5 8 mV (Line Regulation) Vo2 - 3 5 mV All Vo1 10 15 mV (Load Regulation) Vo2 5 10 mV Io1 0 - 6 A Io2 0 - 7 A All Io1+ Io2 11 - 15 A ALQ07FY - 80 82 % ALQ07FM - 80 82 % ALQ07FK - 80 82 % All - All Efficiency (Rating input,3.3V@6A, 1.8V/1.5V/1.2V@0A ; Ta = 25°C) Switching Frequency ALQ07 DC-DC Converter Technical Reference Notes 360 kHz DATE: Aug., 9, 2003 8 Output Specifications (Cont.) Parameter Dynamic Response*: (∆Io/∆t = 1A/µs; VI = VI,nom ; Ta = 25°C) Device Symbol Min Typ Max Unit Load Change from Io = 50% to 75% of Io,max ,when the other output current is 50% Io.nom All - - - 5 %Vo Peak Deviation Settling Time (to Vo,nom) All - - - 200 µsec Load Change from Io = 50% to 25% of Io,max ,when the other output current is 50% Io.nom. All - - - 5 %Vo Peak Deviation Settling Time (to Vo,nom ) All - - - 200 µsec All - 5 10 msec Vo1 0 3 %Vo Vo2 0 5 %Vo Turn-On Time Output Voltage Overshoot (3.3V@6A,1.8V@4A, 3.3V@6A,1.5V@4A, 3.3V@6A,1.2V@4A All Ta = 25°C) Note: The output capacitance 220uF+220uF tantalum (Each capacitor ESR＜100m Ω)may be used to meet the specified dynamic response. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 9 Feature Specifications Parameter Device Symbol Min Typ Max Unit Logic Low All -0.7 - 1.8 V Logic High All 3.5 - 12 V Enable pin current (Logic Low) All - - 2.0 mA Output Voltage Adjustment Range All Vo2 80 - 110 %Vonom Over Temperature Protect All T 101 115 ℃ Vo1 3.90 - 5.00 V Vo2(1.8V) 2.20 - 2.60 V Vo2(1.5V) 1.80 - 2.26 V Vo2(1.2V) 1.45 - 1.80 V Enable pin voltage Output Over-voltage (latch) All Turn-on Point All - 31 34 36 V Turn-off Point All - 30 33 35 V Isolation Capacitance All - - 1500 - pF Isolation Resistance All - 10 - - MΩ All - - 1,800,000 - Hours All - - - 30 g Under-voltage Lockout Calculated MTBF (Io = Io,max ; Ta = 25°C) Weight ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 10 Characteristic Curves 85 85 80 80 75 75 Efficiency (%) Efficiency (%) Performance Curves – Efficiency 70 65 60 Vin=36V 55 Vin=48V 50 3 4 5 6 Total output current (A) 7 8 9 Typical Efficiency ALQ07FY* 60 Vin=36V 55 Vin=48V Vin=75V 45 45 2 65 50 Vin=75V 1 70 1 2 3 4 5 6 Total output current (A) 7 8 9 Typical Efficiency ALQ07FM* 80 75 Efficiency (%) 70 65 60 55 Vin=36V 50 Vin=48V 45 Vin=75V 40 1 2 3 4 5 6 Total output current (A) 7 8 9 Typical Efficiency ALQ07FK* Note: Both Io1 and Io2 increase by 10% until Io1+Io2=10A ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 11 Performance Curves – Output Performance Curves Typical Output Over-current ALQ07FY* Typical Output Over-current ALQ07FM* Typical Output Over-current ALQ07FK* Note: When Io1+Io2≥10A, the module will shut down ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 12 Performance Curves – Transient Response ALQ07FY 25%-50%-25%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FY 25%-50%-25%Io2,nom (Io2) load change, Io1 =50%Io1,nom(ch1:Vo1,ch2:Vo2) ALQ07 DC-DC Converter Technical Reference Notes ALQ07FY 50%-75%-50%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FY 50%-75%-50%Io2,nom (Io2) load change, Io1 =50%Io1,nom(ch1:Vo1,ch2:Vo2) DATE: Aug., 9, 2003 13 Performance Curves – Transient Response (Cont.) ALQ07FM 25%-50%-25%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FM 25%-50%-25%Io2,nom (Io2) load change, Io1 =50%Io1,nom(ch1:Vo1,ch2:Vo2) ALQ07 DC-DC Converter Technical Reference Notes ALQ07FM 50%-75%-50%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FM 50%-75%-50%Io2,nom (Io2) load change, Io1=50%Io1,nom(ch1:Vo1,ch2:Vo2) DATE: Aug., 9, 2003 14 Performance Curves – Transient Response (Cont.) ALQ07FK 25%-50%-25%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FK 50%-75%-50%Io1,nom (Io1) load change, Io2 =50%Io2,nom(ch1:Vo1,ch2:Vo2) ALQ07FK 25%-50%-25%Io2,nom (Io2) ALQ07FK 50%-75%-50%Io2,nom (Io2) load change, Io1 =50%Io1,nom(ch1:Vo1,ch2:Vo2) load change, Io1 =50%Io1,nom(ch1:Vo1,ch2:Vo2) ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 15 Performance Curves – Startup Characteristics ALQ07FY Start-up from Power On ALQ07FM Start-up from Power On ALQ07FK Start-up from Power On ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 16 Performance Curves – Startup from CNT Control ALQ07FY Start-up from CNT On ALQ07FM Start-up from CNT On ALQ07FK Start-up from CNT On ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 17 Feature Description CNT Function Two CNT logic options are available. The CNT logic, CNT voltage and the module working state are as the following Table 1. L H OPEN N ON OFF OFF P OFF ON ON Table 1 N--- means “Negative Logic”, P--- means “Positive Logic” L--- means “Low Logic Voltage”, -0.7V≤L≤1.8V H--- means “High Logic Voltage”, 3.5V≤H≤12V ON--- means “Module is on”, OFF--- means “Module is off” Open--- means “CNT pin is left open “ Note: Normally, VCNT ≤12V, but when CNT is left open, VCNT may reach to 15V. The following Figure shows a few simple CNT circuits. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 18 Trim The +Vo2 output voltage of the ALQ07 series can be trimmed using the trim pin provided. Applying a resistor Rtrim between the trim pin and either the COM or +Vo2 pin will cause the +Vo2 output to increase by up to 10% or decrease by down to 20%. Trimming up by more than 10% of the nominal output may activate the OVP circuit or damage the converter. Trimming down more than 20% can cause the converter to regulate improperly. If the trim pin is not needed, it should be left open. Trim up Trim down ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 19 Minimum Load Requirements Parameter Device Minimum Load All Symbol Typ Unit Io1MIN 0 A Io2MIN 0 A Output Over-current Protection For ALQ07 series DC/DC converters, when any output occurs over-current, all outputs shut down after 100-300ms. The module can be restarted by resetting the input power or CNT control. Output Over-voltage Protection The over-voltage protection has a separate feedback loop, which is activated when the output voltage exceeds 120% to 150% of the nominal output voltage. The module can be restarted by resetting the input power or CNT control. Over Temperature Protection ALQ07 DC/DC converters will shut down when the temperature of the board reaches 101℃ to 115℃, and the module will automatically restart if the temperature of the board is under 100℃. Output Filters When the load is sensitive to ripple and noise, an output filter can be added to minimize the effects. A simple output filter to reduce output ripple and noise can be made by connecting a capacitor Cout across the output as shown in Figure ‘Output Ripple Filter’. The recommended value for the output tantalum capacitor Cout is 220uF. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 20 Extra care should be taken when long leads or traces are used to provide power to the load. Long lead lengths increase the chance for noise to appear on the lines. Under these conditions C1 can be added across the load, with a 0.1uF ceramic capacitor C1 in parallel generally as shown in Figure ‘Output Ripple Filter for a Distant Load’. Decoupling Noise on the power distribution system is not always created by the converter. High speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a 10uF tantalum or ceramic capacitor in parallel with a 0.1uF ceramic capacitor across the load will decouple it. The capacitors should be connected as close to the load as possible. Ground Loops Ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in Figure ‘Ground Loops’. Multiple ground points can be slightly different potential and cause current flow through the circuit from one point to another. This can result in additional noise in all the circuits. To eliminate the problem, circuits should be designed with a single ground connection as shown in Figure ‘Single Point Ground’. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 21 Design Consideration Typical Application Cin: Recommended input capacitor 47uF, aluminum electrolytic type Cout: Recommended output capacitor 220uF, Tantalum type, each capacitor ESR<100mΩ C1,C2: Recommended 0.1uF ceramic capacitor Note: Io1+Io2≤10A Fusing The ALQ07 power modules have no internal fuse. An external fuse must always be employed! To meet international safety requirements, a 250 Volt rated fuse should be used. If one of the input lines is connected to chassis ground, then the fuse must be placed in the other input line. Standard safety agency regulations require input fusing. Recommended fuse rating for the ALQ07 Series is 2A. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 22 Input Reverse Voltage Protection Under installation and cabling conditions where reverse polarity across the input may occur, reverse polarity protection is recommended. Protection can easily be provided as shown in Figure ‘Reverse Polarity Protection Circuit’. In both cases the diode used is rated for 3A/100V. Placing the diode across the inputs rather than in-line with the input offers an advantage in that the diode only conducts in a reverse polarity condition, this increases circuit efficiency and thermal performance. Reverse Polarity Protection Circuit EMC Input filters are included in the converters to help achieve standard system emissions certifications. Some users however, may find that additional input filtering is necessary. The ALQ07 series has an internal switching frequency of 360kHz so a high frequency capacitor mounted close to the input terminals produces the best results. To reduce reflected noise, a capacitor can be added across the input as shown in Figure ‘Ripple Rejection Input Filter’, forming a filter. A 47uF/100V electrolytic capacitor is recommended for Cin. Ripple Rejection Input Filter For conditions where EMI is a concern, a different input filter can be used. The following figure ‘EMI Reduction Filter’ shows a filter designed to reduce EMI effects. ALQ07 series can meet EN55022 CLASS A with the following figure. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 23 The recommended values can refer to the following table: Component Value/Rating Type Description Price C1 None None None － C2 2.2uF/250Vac Metal film capacitor － － 4700pF/250Vac Safety Y capacitor － － C5、C6 0.022uF/275Vac Safety Y capacitor － － C7 1000pF/100V Ceramic － － C12、C13 0.1uF/50V Ceramic － － Cin 47uF/100V Aluminum Electrolytic C3、C4、C8、 C9、C10、C11 Aluminum Electrolytic －100V－47uF±20％ － －10*12.5－105℃ Cout 220uF/10V L1 2.7mH L2、L3 -- Tantalum Each capacitor ESR<100mΩ Common Ferrite coreφ16 8/8， mode ferrite Ferrite Bead Ferrite, 1206 package, 3A/50Ω ALQ07 DC-DC Converter Technical Reference Notes － － － DATE: Aug., 9, 2003 24 Safety Consideration For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL1950, CSA C22.2 No. 950-95, and EN60950. The ALQ07 series input-to-output isolation is an basic insulation. The DC/DC power module should be installed in end-use equipment, in compliance with the requirements of the ultimate application, and is intended to be supplied by an isolated secondary circuit. When the supply to the DC/DC power module meets all the requirements for SELV(<60Vdc), the output is considered to remain within SELV limits (level 3). If connected to a 60Vdc power system, double or reinforced insulation must be provided in the power supply that isolates the input from any hazardous voltages, including the ac mains. One input pin and one output pin are to be grounded or both the input and output pins are to be kept floating. Single fault testing in the power supply must be performed in combination with the DC/DC power module to demonstrate that the output meets the requirement for SELV. The input pins of the module are not operator accessible. Note: Do not ground either of the input pins of the module, without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 25 Thermal Consideration When 48V input, 60℃ ambient temperature, and 150LFM airflow, ALQ07 series are rated for full power, and in this condition the case temperature can reach 90℃. For operation above ambient temperature of 60℃, output power must be derated as shown in Figure ‘Temperature Derating’, meantime, airflow at least 150LFM over the converter must be provided to make the module working properly. the case temperature should be used to determine maximum temperature limits. The minimum operating temperature for the ALQ07 is -40℃. Temperature Derating Curves MTBF The MTBF, calculated in accordance with Bellcore TR-NWT-000332 is 1,800,000 hours. Obtaining this MTBF in practice is entirely possible. If the ambient air temperature is expected to exceed +25℃, then we also advise an oriented for the best possible cooling in the air stream. ASTEC can supply replacements for converters from other manufacturers, or offer custom solutions. Please contact the factory for details. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 26 Mechanical Considerations Installation Although ALQ07 series converters can be mounted in any orientation, free air-flowing must be taken. Normally power components are always put at the end of the airflow path or have the separate airflow paths. This can keep other system equipment cooler and increase component life spans. Soldering ALQ07 series converters are compatible with standard wave soldering techniques. When wave soldering, the converter pins should be preheated for 20-30 seconds at 110℃, and wave soldered at 260℃ for less than 10 seconds. When hand soldering, the iron temperature should be maintained at 425℃ and applied to the converter pins for less than 5 seconds. Longer exposure can cause internal damage to the converter. Cleaning can be performed with cleaning solvent IPA or with water. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 27 Mechanical Chart (pin side view) Note: Pin length is optional Default: 5.8mm±0.5mm ( 0.228in.±0.02in.) Product name with suffix “-4”: 4.8mm±0.5mm ( 0.189in.±0.02in.) Product name with suffix “-6”: 3.8mm±0.25mm ( 0.15in.±0.01in.) Product name with suffix “-8”: 2.8mm±0.25mm ( 0.11in.±0.01in.) ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003 28 Ordering Information Model Number Input Voltage (V) ALQ07FY 36-75 ALQ07FM ALQ07FK Output Voltage (V) Output Current * (A) Ripple (mV ms) max. Noise (mV pp) max. Vo1 3.3 6 50 50 Vo2 1.8 4 50 50 Vo1 3.3 6 50 50 Vo2 1.5 4 50 50 Vo1 3.3 6 50 50 Vo2 1.2 4 50 50 Efficiency % typ. 81 36-75 81 36-75 81 Note: Io1: 0A~6A, Io2: 0A~7A, Io1+Io2≤10A. ALQ07 DC-DC Converter Technical Reference Notes DATE: Aug., 9, 2003