45 375Vin / 5Vout / 400Watts DC-DC Converter Module Model Number V375A5C400A* Features • • • • • • • • • • • DC input range: 250 - 425V Input surge withstand: 500V for 100ms DC output: 5V Programmable output: 10 to 110% Regulation: ±0.2% no load to full load Efficiency: 83.5% Maximum operating temperature: 90°C at full load Power density: 32W/cubic inch Height above board: 0.43 in. (10,9 mm) Parallelable, with N+M fault tolerance Low noise ZCS/ZVS architecture Shown actual size: 4.6 x 2.2 x 0.5 in 117 x 56 x 12,7 mm Typical Applications: distributed power; off-line systems using power PFC front-ends; electric vehicles Absolute Maximum Ratings Product Overview This DC-DC converter module uses 2nd Generation power processing, control and packaging technologies to provide the performance, flexibility and cost effectiveness expected of a mature power component. For example, a plated-cavity core transformer couples widely separated primary and secondary windings, resulting in low in-toout parasitic capacitance and noise. High frequency ZCS/ZVS switching, advanced power semiconductor packaging and thermal management provide high power density with low temperature gradients. Extensive use of silicon integration results in 1/3 the part count of a 1st Generation converter. Parameter Rating Unit +In to –In voltage -0.5 to +425.0 Vdc +In to –In voltage 500 Vdc PC to –In voltage -0.5 to +7.0 Vdc PR to –In voltage -0.5 to +7.0 Vdc +Out to –Out voltage -0.5 to +7.0 Vdc +Sense to –Out voltage -0.5 to +7.0 Vdc 1.0 Vdc -0.5 to +1.5 Vdc –Sense to –Out voltage SC to –Out voltage Isolation voltage (in to out) 3000 Vrms Isolation voltage (in to base) 1550 Vrms <100ms 500 Vrms Storage temperature (C–Grade) -40 to +125 °C * Part Numbering See part numbering chart on this page for other product grades. Operating temperature (C–Grade) -20 to +100 °C Baseplate V 375 A 5 C 400 A Pin soldering temperature 500 (260) °F (°C) <5 sec; wave solder Pin soldering temperature 750 (390) °F (°C) <7 sec; hand solder 5 (0.57) in-lbs (N-m) Input Voltage 24 = 24Vin 48 = 48Vin 300 = 300Vin 375 = 375Vin A = Maxi B = Mini C = Micro Output Voltage Output Power Pin Style Product Grade Temperatures (°C) Grade Storage Operating C = - 40 to +125 - 20 to +100 T = - 40 to +125 - 40 to +100 H = - 55 to +125 - 40 to +100 M = - 65 to +125 - 55 to +100 Isolation voltage (out to base) Notes Mounting torque 6 each, # 4-40 or M3 Baseplate Thermal Resistance and Capacity Parameter For pin styles see page 6. Slotted baseplate (style 1) requires no designator. For threaded baseplate add a “2” to the end of the part number. For thru-hole, add a “3”. See page 7 for dimensions. Min Typ Max Unit Baseplate to sink; flat, greased surface 0.08 °C/Watt Baseplate to sink; thermal pad (P/N 20263) 0.07 °C/Watt Baseplate to ambient 4.9 °C/Watt Baseplate to ambient; 1000 LFM 1.1 °C/Watt Thermal capacity 165 Watt-sec/°C Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 1 of 8 ELECTRICAL CHARACTERISTICS Electrical characteristics apply over the full operating range of input voltage, output load (resistive) and baseplate temperature, unless otherwise specified. All temperatures refer to the operating temperature at the center of the baseplate. MODULE OPERATING SPECIFICATIONS Parameter Min Typ Max Unit Operating input voltage 250 375 425 Vdc 500 Vdc <100ms Input surge withstand Notes Output voltage setpoint 4.95 5.00 5.05 Vdc Nominal input; full load; 25°C Output OVP setpoint 6.03 6.25 6.47 Vdc 25°C; recycle input voltage to restart ( 1 minute off ) 400 Watts Output power Efficiency 82.5 83.5 % At 100°C baseplate temperature Nominal input; 75% of full load; 25°C MODULE INPUT SPECIFICATIONS Parameter Min Undervoltage turn-on Typ Max Unit 242.5 247.5 Vdc Notes Undervoltage turn-off 204.7 212.2 Overvoltage turn-off/on 429.2 446.3 467.5 Vdc 6.3 7.3 Watts No load Typ Max Unit Notes Line regulation ±0.02 ±0.20 % Low line to high line; full load Load regulation ±0.06 ±0.20 % No load to full load; nominal input Temperature regulation ±0.002 ±0.005 % / °C Over operating temperature range 102 150 mV 81.6 95.0 112.0 Amps Output voltage 95% of nominal 56 97 112 Amps Output voltage <250mV ±2 ±5 % 10 to 100% of full load % Of nominal output voltage. For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required. Dissipation, standby Vdc MODULE OUTPUT SPECIFICATIONS Parameter Min Ripple and noise, p-p Current limit Short circuit current Power sharing accuracy Programming range 10 110 Nominal input, full load; 25°C; 20MHz bandwidth Note: For important information relative to applications where the converter modules are subject to continuous dynamic loading, contact Vicor applications engineering at 800-927-9474. MODULE MECHANICAL SPECIFICATIONS Baseplate Pin style Slotted (Style 1) Slotted baseplate (style 1) requires no designator. For threaded baseplate add a "2" to the end of the part number. For thru-hole add a "3". Short (Style 1) For long pin configuration add “L” to the end of the part number. See page 7 for pin dimensions. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 2 of 8 ELECTRICAL CHARACTERISTICS, continued MODULE CONTROL SPECIFICATIONS Parameter Min Typ Max Unit Notes PRIMARY SIDE (PC = Primary Control; PR = Parallel) PC bias voltage current limit 5.50 1.5 5.75 2.1 6.10 3.0 Vdc mA PC current = 1.0 mA PC voltage = 5.5V PC module disable 2.3 2.6 2.9 Vdc Must be able to sink ≥4 mA. See Fig. 1 4 7 ms 0.5 Vavg UV, OV, OT, module fault. See Figs. 2 and 4 6.1 Volts PR load >30 ohms, < 30 pF PC module enable delay PC module alarm PR emitter amplitude 5.7 5.9 PR emitter current 150 PR receiver impedance 375 500 625 ohms 25°C PR receiver threshold 2.4 2.5 2.6 Volts Minimum pulse width: 20ns 12 modules Without PR buffer amplifier mA PR drive capability SECONDARY SIDE (SC = Secondary Control) SC bandgap voltage 1.21 1.23 1.25 Vdc SC resistance 990 1000 1010 ohms SC capacitance SC module alarm Referenced to –Sense 0.033 µF 0 Vdc With open trim; referenced to –Sense. See Fig. 6 Max Unit Notes 0.5 Vdc 0.25V per leg (senses must be closed) MODULE GENERAL SPECIFICATIONS Parameter Min Typ Remote sense (total drop) Isolation voltage (in to out) 3000 Vrms Complies with reinforced insulation requirements Isolation voltage (in to base) 1550 Vrms Complies with basic insulation requirements Isolation voltage (out to base) 500 Vrms Complies with operational insulation requirements Isolation resistance (in to out) 10 Weight Temperature limiting Agency approvals 7.3 (210) 100 megohms 8 (227) 115 UL, CSA, TÜV, BABT, CE, VDE Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 ounces (grams) °C See Figs. 2 and 4 UL1950, CSA950, EN60950, VDE0805, BS7002, IEC 60950. With a fuse in series with the +Input V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 3 of 8 CONTROL FUNCTIONS - PC PIN Module Enable/Disable Module Alarm The module may be disabled by pulling PC below 2.3V with respect to the –Input. This may be done with an open collector transistor, relay, or optocoupler. Multiple converters may be disabled with a single transistor or relay either directly or via “OR’ing” diodes. See Figure 1. The module contains “watchdog” circuitry which monitors input voltage, operating temperature and internal operating parameters. In the event that any of these parameters are outside of their allowable operating range, the module will shut down and PC will go low. PC will periodically go high and the module will check to see if the fault (as an example, overtemperature) has cleared. If the fault has not been cleared, PC will go low again and the cycle will restart. The SC pin will go low in the event of a fault and return to its normal state after the fault has been cleared. See Figures 2 and 4. Primary Auxiliary Supply At 5.7V, PC can source up to 1.5mA. In the example shown in Figure 3, PC powers a module enabled LED. +In +In SW1 PC Input Undervoltage Input Overvoltage Overtemperature Module Faults Auto Restart PC 2-20ms typ. f (VIN) Disable SW2 SW3 1K SC –S 5.7Vdc (0-3mA) –In –In +S 50Ω SW1, 2, & 3 shown in "Fault" position PR PR +Out 1.23 Vdc 6K –Out Disable = PC <2.3V Figure 1—Module enable/disable. Figure 2—PC/SC module alarm logic. +In Fault PC "Module Enabled" PC 40µs typ. 5.7V 4kΩ PR SC –In Figure 3—LED on-state indicator. Optocoupler 1.23V 2-20ms typ. Figure 4—PC/SC module alarm timing. +In +Out PC +S SC 4kΩ PR –S –In –Out Figure 5—Isolated on-state indicator. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Alarm 1.00V Figure 6—Secondary side on-state indicator. V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 4 of 8 CONTROL FUNCTIONS - SC PIN Output Voltage Programming The output voltage of the converter can be adjusted or programmed via fixed resistors, potentiometers or voltage DACs. See Figures 7 and 8. +Out +Out +S Error Amp SC 1kΩ 0.033µF –S +S RD Trim Down Load Error Amp SC 1kΩ Load –S 0.033µF –Out RU Trim Up –Out 1.23V 1.23V RD (ohms) = 1,000 Vout Vnom - Vout RU (ohms) = 1,000 (Vout-1.23) Vnom 1.23 (Vout-Vnom) –1,000 Figure 7—Output voltage trim down circuit. Figure 8—Output voltage trim up circuit. Trim Down Trim Up 1. This converter is not a constant power device – it has a constant current limit. Hence, available output power is reduced by the same percentage that output voltage is trimmed down. Do not exceed maximum rated output current. 1. The converter is rated for a maximum delivered power. To ensure that maximum rated power is not exceeded, reduce maximum output current by the same percentage increase in output voltage. 2. The trim down resistor must be connected to the –Sense pin. 2. The trim up resistor must be connected to the +Sense pin. 3. Do not trim the converter above maximum trim range (typically +10%) or the output over voltage protection circuitry may be activated. Trim resistor values calculated automatically: On-line calculators for trim resistor values are available on the vicor website at: vicorpower.com/tools.html. Resistor values can be calculated for fixed trim up, fixed trim down and for variable trim up or down cases for both 1st and 2nd Generation DC-DC converters. In addition to trimming information, the web site and the Applications Manual also include design tips, applications circuits, EMC suggestions, thermal design guidelines and PDF data sheets for all available Vicor products. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 5 of 8 CONTROL FUNCTIONS - PR PIN Parallel Operation The PR pin supports paralleling for increased power with N+1 (N+M) redundancy and phased array capability. Modules of the same input voltage, output voltage, and power level will current share if all PR pins are suitably interfaced. Compatible interface architectures include the following: DC coupled single-wire interface. All PR pins are directly connected to one another. This interface supports current sharing but is not fault tolerant. Minus In pins must be tied to the same electric potential. See Figure 9. AC coupled single-wire interface. All PR pins are connected to a single communication bus through 0.001µF (500V) capacitors. This interface supports current sharing and is fault tolerant except for the communication bus. See Figure 10. +In +In PC PC 0.001µF Module 1 Module 1 PR PR –In –In +In +In PC PR Module 2 (up to 12) PC 0.001µF PR –In –In Ground plane Ground plane Figure 10—AC coupled single-wire interface. Figure 9—DC coupled single-wire interface. +Out +S SC –S Module 1 • The +Out and –Out power buses should be designed to minimize and balance parasitic impedance from each module output to the load. +S –S –Out +S +Out +S SC –S Module 2 +S Load +Out • The +Sense pins should be tied to the same point on the +Out power bus; the –Sense pins should be tied to the same point on the –Out power bus. +S SC –S –Out –S • At the discretion of the power system designer, a subset of all modules within an array may be configured as slaves by shorting SC to –S. –S –Out +Out +S SC –S Module N+1 –Out Module 2 (up to 12) • OR’ing diodes may be inserted in series with the +Out pins of each module to provide module output fault tolerance. Figure 11—N+1 module array output connections. +Sense from other modules in the array Figure 12—OR’ing diodes connections. PIN STYLES * Designator Description Notes (None) Short solder Requires in-board, mounting L Long solder On-board mounting for 0.065" boards S Short ModuMate SurfMate or in-board socket mounting N Long ModuMate On-board socket mounting * Pin style designator follows the “A” after the output power and precedes the baseplate designator. Ex. V375A24C600AN — Long ModuMate Pins Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 6 of 8 MECHANICAL DRAWINGS MODULE OUTLINE 0.50 ±0.02 12,7 ±0,5 No. 1 Converter Pins Function Label +In + PC 3 Parallel PR 4 –In – 5 –Out – 6 –Sense –S 7 Secondary Control SC 8 +Sense +S 9 +Out + 2.20 55,9 0.23 (REF) 5,8 1.74 44,2 1 0.300±0.015 7,62±0,38 0.01 2 PINS: TIN/LEAD HOT SOLDER DIP 9 3 6 or 4-40 UNC-2B (6X) FULL R (6X) 3.60 91,4 0.13 (6X) 3,3 5 0.180 DIA,(2X) 4,57 0.080 DIA,(7X) 2,03 0.700 17,78 1.000 25,40 1.400 35,56 Threaded (Style 2) 1.80 45,7 4.60 116,8 4.200 106,68 7 0.10 2,5 0.10 X 45° 2,5 CHAMFER ALUMINUM BASEPLATE 8 2.00 50,8 0.38 (2X) 9,6 4 0.400 10,16 Slotted (Style 1) 0.50 12,7 4-40 UNC-2B 0.12* 0.20** Thru (4X)*** 3,1 5,08 (Style 2 and 3 only) (ALL MARKINGS THIS SURFACE) 2 Primary Control 0.300±0.015 7,62±0,38 0.43 10,9 R 0.06 (3X) 1,5 Use a 4-40 Screw (6x) Torque to: 5 in-lbs 0.57 N-m 2.20 55,9 (REF) 0.54 (9X) Pin Style 1&S 13,7 (Short Pin) 0.62 (9X) Pin Style 2&N 15,7 (Long Pin) or Thru Hole (Style 3) * Style 1 baseplate only ** Style 2 & 3 baseplates *** Reserved for Vicor accessories Not for mounting #30 Drill Thru (6X) (0.1285) ALL MARKINGS THIS SURFACE PCB MOUNTING SPECIFICATIONS PCB THICKNESS R 0.062 ±0.010 1,57 ±0,25 PLATED THRU HOLE DIA 1.790 45,47 0.06 (4X) 1,5 INBOARD SOLDER MOUNT ONBOARD SOLDER MOUNT PIN STYLE 1&S PIN STYLE 2&N (7X) 0.094 ±0.003 2,39 ±0,08 0.094 ±0.003 2,39 ±0,08 (2X) 0.194 ±0.003 4,93 ±0,08 0.194 ±0.003 4,93 ±0,08 0.178 4,52 1 2 3 ALUMINUM BASEPLATE 4 PINS STYLES STYLE 1 & 2: TIN/LEAD HOT SOLDER DIPPED STYLE S & N: GOLD PLATED COPPER 4.200* 106,68 3.844 97,64 9 8 7 6 5 Unless otherwise specified, dimensions are in inches mm 0.400* 10,16 0.195 4,95 0.700* 17,78 1.000* 25,40 1.400* 35,56 0.43 10,9 0.53 13,5 0.XX Tol. 0.XXX Angles ±0.01 ±0,25 * DENOTES ±0.003 TOL = ±0,08 Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Decimals ±1° ±0.005 ±0,127 V375A5C400A DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.3 Page 7 of 8 Vicor’s comprehensive line of power solutions includes modular, high density DC-DC converters and accessory components, configurable power supplies, and custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. No license is granted by implication or otherwise under any patent or patent rights of Vicor. Vicor components are not designed to be used in applications, such as life support systems, wherein a failure or malfunction could result in injury or death. All sales are subject to Vicor’s Terms and Conditions of Sale, which are available upon request. Specifications are subject to change without notice. 45 Component Solutions for Your Power System Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 Email Vicor Express: [email protected] Technical Support: [email protected] Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 V375A5C400A DC-DC Converter Rev. 5.3 Set your site on VICOR at www.vicorpower.com 08/03