BCM® Bus Converter BCM384y120x1K5AC1 ® S US C C NRTL US Fixed Ratio DC-DC Converter Features Product Ratings • Up to 1500 W continuous output power • 2208 W/in3 power density VIN = 384 V (260 – 410 V) POUT = up to 1500 W VOUT = 12 V (8.1 – 12.8 V) (NO LOAD) K = 1/32 • 97.4% peak efficiency • 4242 Vdc isolation • Parallel operation for multi-kW arrays • OV, OC, UV, short circuit and thermal protection • 2361 through-hole ChiP package n 2.402” x 0.990” x 0.286” Product Description The VI Chip® Bus Converter (BCM) is a high efficiency Sine Amplitude Converter (SAC), operating from a 260 to 410 VDC primary bus to deliver an isolated ratiometric output from 8.1 to 12.8 VDC. (61.00 mm x 25.14 mm x 7.26 mm) • PMBusTM management interface* The BCM384y120x1K5AC1 offers low noise, fast transient response, and industry leading efficiency and power density. In addition, it provides an AC impedance beyond the bandwidth of most downstream regulators, allowing input capacitance normally located at the input of a POL regulator to be located at the input of the BCM module. With a K factor of 1/32, that capacitance value can be reduced by a factor of 1024x, resulting in savings of board area, material and total system cost. Typical Applications • 380 DC Power Distribution • High End Computing Systems • Automated Test Equipment • Industrial Systems The BCM384y120x1K5AC1, combined with the D44TL1A0 Digital Supervisor and I13TL1A0 Digital Isolator, provide a secondary referenced PMBus™ compatible telemetry and control interface. This interface provides access to the BCM’s internal controller configuration, fault monitoring, and other telemetry functions. • High Density Power Supplies • Communications Systems • Transportation Leveraging the thermal and density benefits of Vicor’s ChiP packaging technology, the BCM module offers flexible thermal management options with very low top and bottom side thermal impedances. Thermally-adept ChiP-based power components, enable customers to achieve low cost power system solutions with previously unattainable system size, weight and efficiency attributes, quickly and predictably. *When used with D44TL1A0 and I13TL1A0 chipset BCM® Bus Converter Rev 1.4 vicorpower.com Page 1 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Typical Application BCM SER-OUT SER-OUT EN SER-IN enable/disable switch SER-IN FUSE V IN C +IN +OUT –IN –OUT POL I_BCM_ELEC PRIMARY SOURCE_RTN SECONDARY ISOLATION BOUNDRY Digital Isolator NC Host μC PRI_OUT_A SEC_IN_A PRI_OUT_B SEC_IN_B TXD PRI_IN_C SEC_OUT_C RXD PRI_COM SEC_COM VDDB SER-IN t + SER-OUT Digital Supervisor SGND VDD – V EXT SGND PMBus PMBus SGND SGND SGND BCM384y120x1K5AC1 at point of load BCM® Bus Converter Rev 1.4 vicorpower.com Page 2 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Pin Configuration TOP VIEW 1 2 +OUT A A’ +OUT -OUT B B’ -OUT -OUT C C’ -OUT +OUT D D’ +OUT +OUT E E’ +OUT -OUT F F’ -OUT -OUT G G’ -OUT +OUT H H’ +OUT +IN I I’ SER-OUT +IN J J’ EN +IN K K’ SER-IN +IN L L’ -IN 2361 ChiP Package Pin Descriptions Pin Number Signal Name Type I1, J1, K1, L1 +IN INPUT POWER I’2 SER-OUT OUTPUT J’2 EN INPUT Enables and disables power supply; Primary side referenced signals K’2 SER-IN INPUT UART receive pin; Primary side referenced signals L’1 -IN INPUT POWER RETURN Negative input power terminal +OUT OUTPUT POWER Positive output power terminal -OUT OUTPUT POWER RETURN Negative output power terminal A1, D1, E1, H1, A’2, D’2, E’2, H’2 B1, C1, F1, G1, B’2, C’2, F’2, G’2 Function Positive input power terminal UART transmit pin; Primary side referenced signals BCM® Bus Converter Rev 1.4 vicorpower.com Page 3 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Part Ordering Information Device Input Voltage Range Package Type Output Voltage x 10 Temperature Grade Output Power Revision Package Size Version BCM 384 y 120 x 1K5 A C 1 BCM = BCM 384 = 260 to 410 V P = ChiP Through Hole 120 = 12 V T = -40 to 125°C M = -55 to 125°C 1K5 = 1,500 W A C = 2361 1 All products shipped in JEDEC standard high profile (0.400” thick) trays (JEDEC Publication 95, Design Guide 4.10). Standard Models Part Number VIN Package Type VOUT Temperature Power Package Size BCM384P120T1K5AC1 260 to 410 V ChiP Through Hole 12 V 8.1 to 12.8 V -40°C to 125°C 1,500 W 2361 BCM384P120M1K5AC1 260 to 410 V ChiP Through Hole 12 V 8.1 to 12.8 V -55°C to 125°C 1,500 W 2361 Absolute Maximum Ratings The absolute maximum ratings below are stress ratings only. Operation at or beyond these maximum ratings can cause permanent damage to the device. Parameter Comments +IN to –IN Min Max Unit -1 480 V 1000 V/ms 4242 V VIN slew rate (operational) Isolation voltage, input to output Dielectric test applied to 100% production units +OUT to –OUT -1 15 V SER-OUT to –IN -0.3 4.6 V EN to –IN -0.3 5.5 V SER-IN to –IN -0.3 4.6 V BCM® Bus Converter Rev 1.4 vicorpower.com Page 4 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Electrical Specifications Specifications apply over all line and load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. Attribute Symbol Conditions / Notes Min Typ Max Unit 260 410 V 260 410 V 130 V 1000 V/ms Powertrain Input voltage range, continuous Input voltage range, transient VIN_DC VIN_TRANS Full current or power supported, 50 ms max, 10% duty cycle max VIN µController Active Input Voltage Slew Rate Quiescent current VµC_ACTIVE dVIN/dt VIN voltage where µC is initialized, (ie VAUX = Low, powertrain inactive) VIN_UVLO- ≤ VIN ≤ VIN_OVLO+ 0.001 Disabled, EN Low, VIN = 384 V IQ 2 TINTERNAL ≤ 100ºC VIN = 384 V, TINTERNAL = 25ºC No load power dissipation Inrush current peak DC input current Transformation ratio Output power (continuous) Output power (pulsed) Output current (continuous) Output current (pulsed) VIN = 384 V PNL IINR_P IIN_DC K 5.9 Efficiency (hot) Efficiency (over load range) Output resistance Switching frequency VIN = 260 V to 410 V 27 VIN = 410 V, COUT = 1000 µF, RLOAD = 25% of full load current Input inductance (parasitic) Output inductance (parasitic) 10 15 At POUT = 1500 W, TINTERNAL ≤ 100ºC 4.1 1/32 10 ms pulse, 25% Duty cycle, PTOTAL = % rated POUT_DC IOUT_DC 10 ms pulse, 25% Duty cycle, ITOTAL = % rated IOUT_DC 96.2 hAMB V/V W 2000 W 125 A 167 A 97 95.2 VIN = 384 V, IOUT = 62.5 A 96.5 97.4 hHOT h20% VIN = 384 V, IOUT = 125 A, TINTERNAL = 100°C 95.8 97 ROUT_COLD VIN = 384 V, IOUT = 125 A, TINTERNAL = -40°C 1.10 1.50 1.80 ROUT_AMB VIN = 384 V, IOUT = 125 A 1.50 1.85 2.30 ROUT_HOT VIN = 384 V, IOUT = 125 A, TINTERNAL = 100°C 1.80 2.30 2.70 Frequency of the Output Voltage Ripple = 2x FSW 0.95 1.00 1.05 FSW VOUT_PP LIN_PAR LOUT_PAR Input Series inductance (internal) LIN_INT Effective Input capacitance (internal) CIN_INT A 1500 VIN = 260 V to 410 V, IOUT = 125 A 25 A < IOUT < 125 A, TINTERNAL ≤ 100ºC W A TINTERNAL ≤ 100ºC COUT = 0 F, IOUT = 125 A, VIN = 384 V, Output voltage ripple 25 19 K = VOUT / VIN, at no load IOUT_PULSE 17 VIN = 260 V to 410 V, TINTERNAL = 25ºC VIN = 384 V, IOUT = 125 A Efficiency (ambient) 11 POUT_DC POUT_PULSE mA 4 % % 90 % mΩ MHz 195 20 MHz BW mV TINTERNAL ≤ 100ºC Frequency 2.5 MHz (double switching frequency), Simulated lead model Frequency 2.5 MHz (double switching frequency), Simulated lead model Reduces the need for input decoupling inductance in BCM arrays Effective value at 384 VIN BCM® Bus Converter Rev 1.4 vicorpower.com Page 5 of 23 05/2015 800 927.9474 250 7 nH 0.64 nH 0.56 µH 0.37 µF BCM384y120x1K5AC1 Electrical Specifications (Cont.) Specifications apply over all line and load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. Attribute Symbol Effective Output capacitance (internal) COUT_INT Effective Output capacitance (external) COUT_EXT Array Maximum external output capacitance COUT_AEXT Auto Restart Time Input overvoltage lockout threshold tAUTO_RESTART Conditions / Notes Powertrain (Cont.) Effective value at 12 VOUT Excessive capacitance may drive module into SC protection Min Typ Max 208 µF 0 1000 µF 292.5 357.5 ms V COUT_AEXT Max = N * 0.5*COUT_EXT Max Powertrain Protection Startup into a persistent fault condition. Non-Latching fault detection given VIN > VIN_UVLO+, Module will ignore attempts to re-enable during time off VIN_OVLO+ 430 440 450 Input overvoltage recovery threshold VIN_OVLO- 410 430 440 Input overvoltage lockout hysteresis VIN_OVLO_HYST Overvoltage lockout response time tOVLO Soft-Start time tSOFT-START Output overcurrent trip threshold IOCP Overcurrent Response Time Constant tOCP Short circuit protection trip threshold ISCP Short circuit protection response time tSCP Overtemperature shutdown threshold tOTP Unit From powertrain active Fast Current limit protection disabled during Soft-Start 135 Effective internal RC filter V 100 µs 1 ms 170 210 3.0 A ms 187 A 1 Temperature sensor located inside controller IC V 10 µs ºC 125 Powertrain Supervisory Limits Input overvoltage lockout threshold VIN_OVLO+ 420 Input overvoltage recovery threshold VIN_OVLO- 405 Input overvoltage lockout hysteresis VIN_OVLO_HYST Overvoltage lockout response time Input undervoltage lockout threshold 434.5 450 424 440 10.5 tOVLO 100 µs 200 226 250 Input undervoltage recovery threshold VIN_UVLO+ 225 244 259 Input undervoltage lockout hysteresis VIN_UVLO_HYST Undervoltage lockout response time tUVLO Undervoltage startup delay tUVLO+_DELAY Output Overcurrent Trip Threshold IOCP Overcurrent Response Time Constant tOCP Overtemperature shutdown threshold tOTP Temperature sensor located inside controller IC Undertemperature shutdown threshold tUTP Temperature sensor located inside controller IC Startup into a persistent fault condition. Non-Latching fault detection given VIN > VIN_UVLO+ Undertemperature restart time 159 tUTP_RESTART Rev 1.4 vicorpower.com Page 6 of 23 05/2015 800 927.9474 V V 15 V 100 µs 20 ms 168 177 2 BCM® Bus Converter V V VIN_UVLO- From VIN = VIN_UVLO+ to powertrain active, EN floating, (i.e One time Startup delay from application of VIN to VOUT) V A ms 125 ºC -45 3 ºC s BCM384y120x1K5AC1 1800 Output Power (W) 1600 1400 1200 1000 800 600 400 200 0 35 45 55 65 75 85 95 105 115 125 Case Temperature (°C) Top only at temperature Top and leads at temperature Leads at temperature Top, leads, & belly at temperature 2100 185 1950 170 1800 Output Current (A) Output Power (W) Figure 1 — Specified thermal operating area 1650 1500 1350 1200 1050 155 140 125 110 95 80 900 65 750 260 275 290 305 320 335 350 365 380 395 260 410 275 290 Input Voltage (V) P (ave) 305 335 350 365 380 Input Voltage (V) I (ave) P (pk), t < 10 ms Figure 2 — Specified electrical operating area using rated ROUT_HOT Output Capacitance (% Rated COUT MAX) 320 110 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 Load Current (% IOUT_AVG) Figure 3 — Specified Primary start-up into load current and external capacitance BCM® Bus Converter Rev 1.4 vicorpower.com Page 7 of 23 05/2015 800 927.9474 100 110 I (pk), t < 10 ms 395 410 BCM384y120x1K5AC1 Reported Characteristics Specifications apply over all line, load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. Monitored Telemetry • The BCM communication version is not intended to be used without a Digital Supervisor. ACCURACY (RATED RANGE) FUNCTIONAL REPORTING RANGE UPDATE PMBusTM READ COMMAND Input voltage (88h) READ_VIN ± 5% ( LL - HL ) 130 V to 450 V 100 µs VACTUAL = VREPORTED x 10-1 Input current (89h) READ_IIN ± 5% ( 10 - 133% of FL) - 0.85 A to 5.9 A 100 µs IACTUAL = IREPORTED x 10-3 Output voltage[1] (8Bh) READ_VOUT ± 5% ( LL - HL ) 4.25 V to 14 V 100 µs VACTUAL = VREPORTED x 10-1 Output current (8Ch) READ_IOUT ± 5% ( 10 - 133% of FL ) - 27 A to 190 A 100 µs IACTUAL = IREPORTED x 10-2 Output resistance (D4h) READ_ROUT ± 5% ( 50 - 100% of FL) 1.0 mΩ to 3.0 mΩ 100 ms RACTUAL = RREPORTED x 10-5 (8Dh) READ_TEMPERATURE_1 ± 7°C ( Full Range) - 55ºC to 130ºC 100 ms TACTUAL = TREPORTED ATTRIBUTE Temperature[2] [1] [2] DIGITAL SUPERVISOR RATE REPORTED UNITS Default READ Output Voltage returned when unit is disabled = -300 V. Default READ Temperature returned when unit is disabled = -273°C. Variable Parameter • Factory setting of all below Thresholds and Warning limits are 100% of listed protection values. • Variables can be written only when module is disabled either EN pulled low or VIN < VIN_UVLO-. • Module must remain in a disabled mode for 3 ms after any changes to the below variables allowing ample time to commit changes to EEPROM. ATTRIBUTE DIGITAL SUPERVISOR PMBusTM COMMAND [3] Input / Output Overvoltage Protection Limit (55h) VIN_OV_FAULT_LIMIT Input / Output Overvoltage Warning Limit (57h) VIN_OV_WARN_LIMIT Input / Output Undervoltage Protection Limit (D7h) DISABLE_FAULTS CONDITIONS / NOTES ACCURACY (RATED RANGE) FUNCTIONAL REPORTING RANGE DEFAULT ± 5% ( LL - HL ) 130 V to 435 V 100% ± 5% ( LL - HL ) 130 V to 435 V 100% ± 5% ( LL - HL ) 130 V or 260 V 100% VIN_OVLO- is automatically 3% lower than this set point Can only be disabled to a preset default value VALUE Input Overcurrent Protection Limit (5Bh) IIN_OC_FAULT_LIMIT ± 5% ( 10 - 133% of FL) 0 to 5.25 A 100% Input Overcurrent Warning Limit (5Dh) IIN_OC_WARN_LIMIT ± 5% ( 10 - 133% of FL) 0 to 5.25 A 100% Overtemperature Protection Limit (4Fh) OT_FAULT_LIMIT ± 7°C ( Full Range) 0 to 125°C 100% Overtemperature Warning Limit (51h) OT_WARN_LIMIT ± 7°C ( Full Range) 0 to 125°C 100% ± 50 µs 0 to 100 ms 0 ms Turn on Delay [3] (60h) TON_DELAY Additional time delay to the Undervoltage Startup Delay Refer to Digital Supervisor datasheet for complete list of supported commands. BCM® Bus Converter Rev 1.4 vicorpower.com Page 8 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Signal Characteristics Specifications apply over all line, load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. UART SER-IN / SER-OUT Pins • Universal Asynchronous Receiver/Transmitter (UART) pins. • The BCM communication version is not intended to be used without a Digital Supervisor. • Isolated I2C communication and telemetry is available when using Vicor Digital Isolator and Vicor Digital Supervisor. Please see specific product data sheet for more details. • UART SER-IN pin is internally pulled high using a 1.5 kΩ to 3.3 V. SIGNAL TYPE STATE GENERAL I/O ATTRIBUTE SYMBOL Baud Rate CONDITIONS / NOTES BRUART MIN Rate TYP MAX 750 UNIT Kbit/s SER-IN Pin VSER-IN_IH 2.3 V SER-IN Input Voltage Range VSER-IN_IL DIGITAL 1 V SER-IN rise time tSER-IN_RISE 10% to 90% 400 ns SER-IN fall time tSER-IN_FALL 10% to 90% 25 ns SER-IN RPULLUP RSER-IN_PLP Pull up to 3.3 V 1.5 kΩ SER-IN External Capacitance CSER-IN_EXT INPUT Regular Operation pF SER-OUT Pin VSER-OUT_OH 0 mA ≥ IOH ≥ -4 mA VSER-OUT_OL 0 mA ≤ IOL ≤ 4 mA SER-OUT rise time tSER-OUT_RISE 10% to 90% 55 ns SER-OUT fall time tSER-OUT_FALL 10% to 90% 45 ns SER-OUT Output Voltage Range DIGITAL OUTPUT 400 SER-OUT source current ISER-OUT SER-OUT output impedance ZSER-OUT 2.8 V 0.5 VSER-OUT = 2.8 V 6 120 V mA Ω Enable / Disable Control • The EN pin is a standard analog I/O configured as an input to an internal µC. • It is internally pulled high to 3.3 V. • When held low the BCM internal bias will be disabled and the powertrain will be inactive. • In an array of BCMs, EN pins should be interconnected to synchronize startup and permit startup into full load conditions. • Enable / disable command will have no effect if the EN pin is disabled. SIGNAL TYPE STATE ATTRIBUTE SYMBOL CONDITIONS / NOTES Startup EN to Powertrain active time tEN_START VIN > VIN_UVLO+, EN held low both conditions satisfied for t > tUVLO+_DELAY EN Voltage Threshold VENABLE EN Resistance (Internal) REN_INT ANALOG INPUT Regular Operation EN Disable Threshold MIN TYP MAX 250 µs 2.3 Internal pull up resistor VEN_DISABLE_TH BCM® Bus Converter Rev 1.4 vicorpower.com Page 9 of 23 05/2015 800 927.9474 UNIT V 1.5 kΩ 1 V OUTPUT BIDIR INPUT VOUT EN +IN VμC STARTUP VIN_UVLO- VIN_OVLO- OVER VOLTAGE VIN_OVLO+ VNOM tUVLO+_DELAY VIN_UVLO+ p l -u O N Pul E RN AL AG TU R N N T L O E TE NVO AG IN E R IZ TUR LT IN L E O IA V EROV IT U T UT & S I N TP UT P P U c I N EN µ O IN BCM® Bus Converter Rev 1.4 vicorpower.com Page 10 of 23 05/2015 800 927.9474 tAUTO-RESTART ENABLE CONTROL OVER CURRENT tWAIT ≥ tENABLE_OFF tSCP SHUTDOWN F OF NT NH E R W G EV TU LO HI E IT T D ED G R U E A A L L LL RC LT ST U CI PU RE T VO E LE P R L T T O AB AB PU PU SH IN IN E N EN BCM384y120x1K5AC1 BCM Module Timing diagram BCM384y120x1K5AC1 High Level Functional State Diagram Conditions that cause state transitions are shown along arrows. Sub-sequence activities listed inside the state bubbles. Application of VIN VμC < VIN < VIN_UVLO+ STARTUP SEQUENCE VIN > VIN_UVLO+ STANDBY SEQUENCE EN High EN High Powertrain Stopped Powertrain Stopped ENABLE falling edge, or OTP detected tUVLO+_DELAY expired ONE TIME DELAY INITIAL STARTUP Input OVLO or UVLO, Output OCP, or UTP detected Fault Autorecovery ENABLE falling edge, or OTP detected FAULT SEQUENCE Input OVLO or UVLO, Output OCP, or UTP detected EN High Powertrain Stopped SUSTAINED OPERATION EN High Powertrain Active Short Circuit detected BCM® Bus Converter Rev 1.4 vicorpower.com Page 11 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Application Characteristics Product is mounted and temperature controlled via top side cold plate, unless otherwise noted. See associated figures for general trend data. 20 98 Full Load Efficiency (%) 16 14 12 10 8 6 97 96 95 4 260 277 293 310 327 343 360 377 393 -40 410 -20 - 40°C 25°C VIN: 90°C 88 80 72 64 56 PD 48 40 32 24 16 8 0 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0 112.5 125.0 η 0.0 Power Dissipation (W) Efficiency (%) 98 97 96 95 94 93 92 91 90 89 88 87 98 97 96 95 94 93 92 91 90 89 88 87 384 V VIN : 384 V 384 V 260 V 410 V 88 80 72 64 56 48 40 32 24 16 8 0 384 V 410 V 3 2 1 0 -40 -20 Load Current (A) 260 V 260 V Figure 7 — Efficiency and power dissipation at TCASE = 25°C Power Dissipation (W) Efficiency (%) 88 80 72 64 56 PD 48 40 32 24 16 8 0 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0 112.5 125.0 VIN : 100 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0 112.5 125.0 410 V η 0.0 80 Load Current (A) Figure 6 — Efficiency and power dissipation at TCASE = -40°C 98 97 96 95 94 93 92 91 90 89 88 87 60 PD 0.0 ROUT (mΩ) 260 V 40 η Load Current (A) VIN : 20 Figure 5 — Full load efficiency vs. temperature; VIN Figure 4 — No load power dissipation vs. VIN Efficiency (%) TTOP SURFACE CASE: 0 Case Temperature (ºC) Input Voltage (V) 0 20 40 60 Case Temperature (°C) 410 V Figure 8 — Efficiency and power dissipation at TCASE = 90°C IOUT: 125 A Figure 9 — ROUT vs. temperature; Nominal VIN BCM® Bus Converter Rev 1.4 vicorpower.com Page 12 of 23 05/2015 800 927.9474 80 100 Power Dissipation (W) Power Dissipation (W) 18 BCM384y120x1K5AC1 Voltage Ripple (mVPK-PK) 350 300 250 200 150 100 50 0 0.0 12.5 25.0 37.5 50.0 62.5 75.0 87.5 100.0 112.5 125.0 Load Current (A) VIN: 384 V Figure 10 — VRIPPLE vs. IOUT ; No external COUT. Board mounted module, scope setting : 20 MHz analog BW Figure 11 — Full load ripple, 10 µF CIN; No external COUT. Board mounted module, scope setting : 20 MHz analog BW Figure 12 — 0 A– 125 A transient response: CIN = 10 µF, no external COUT Figure 13 — 125 A – 0 A transient response: CIN = 10 µF, no external COUT Figure 14 — Start up from application of VIN = 384 V, 50% IOUT, 100% COUT Figure 15 — Start up from application of EN with pre-applied VIN = 384 V, 50% IOUT, 100% COUT BCM® Bus Converter Rev 1.4 vicorpower.com Page 13 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 General Characteristics Specifications apply over all line, load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. Attribute Symbol Conditions / Notes Min Typ Max Unit Mechanical Length L 60.87 / [2.396] 61.00 / [2.402] 61.13 / [2.407] mm / [in] Width W 24.76 / [0.975] 25.14 / [0.990] 25.52 / [1.005] mm / [in] Height H 7.21 / [0.284] 7.26 / [0.286] 7.31 / [0.288] mm / [in] Volume Vol 11.13 / [0.679] cm3/ [in3] Weight W 41 / [1.45] g / [oz] Without heatsink Lead finish Nickel 0.51 2.03 Palladium 0.02 0.15 Gold 0.003 0.051 BCM384P120T1K5AC1 (T-Grade) -40 125 °C BCM384P120M1K5AC1 (M-Grade) Estimated thermal resistance to maximum temperature internal component from isothermal top -55 125 °C µm Thermal Operating temperature Thermal resistance top side Thermal resistance leads Thermal resistance bottom side TINTERNAL fINT-TOP fINT-LEADS fINT-BOTTOM 1.14 °C/W Estimated thermal resistance to maximum temperature internal component from isothermal leads 1.35 °C/W Estimated thermal resistance to maximum temperature internal component from isothermal bottom 1.07 °C/W 34 Ws /°C Thermal capacity Assembly Storage Temperature TST ESDHBM ESD Withstand ESDCDM BCM384P120T1K5AC1 (T-Grade) -55 125 °C BCM384P120M1K5AC1 (M-Grade) -65 125 °C Human Body Model, "ESDA / JEDEC JDS-001-2012" Class I-C (1kV to < 2 kV) Charge Device Model, "JESD 22-C101-E" Class II (200V to < 500V) BCM® Bus Converter Rev 1.4 vicorpower.com Page 14 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 General Characteristics (Cont.) Specifications apply over all line, load conditions, unless otherwise noted; Boldface specifications apply over the temperature range of -40°C ≤ TINTERNAL ≤ 125°C (T-Grade); All other specifications are at TINTERNAL = 25ºC unless otherwise noted. Attribute Symbol Conditions / Notes Min Typ Max Unit 135 °C Soldering [1] Peak temperature Top case Safety Isolation voltage VHIPOT 4,242 IN to CASE 2,121 OUT to CASE 2,121 Isolation capacitance CIN_OUT Unpowered unit 620 Isolation resistance RIN_OUT At 500 Vdc 10 MTBF Agency approvals / standards [1] IN to OUT MIL-HDBK-217Plus Parts Count 25°C Ground Benign, Stationary, Indoors / Computer VDC 780 BCM® Bus Converter Rev 1.4 vicorpower.com Page 15 of 23 05/2015 800 927.9474 pF MΩ 2.31 Telcordia Issue 2 - Method I Case III; 3.41 25°C Ground Benign, Controlled cTUVus "EN 60950-1" cURus "UL 60950-1" CE Marked for Low Voltage Directive and RoHS Recast Directive, as applicable Product is not intended for reflow solder attach. 940 MHrs MHrs SER-IN 1.5 kΩ -VIN EN BCM® Bus Converter Rev 1.4 vicorpower.com Page 16 of 23 05/2015 800 927.9474 -Vcc Startup / Re-start Delay Over-Temp Under-Temp Cntrl SEPIC EN Over Voltage UnderVoltage SER-IN EN SER-OUT Current Flow detection + Forward IIN sense 1.5 kΩ SER-OUT 3.3v Linear Regulator Digital Controller SEPIC Modulator Differential Current Sensing Fast Current Limit Slow Current Limit Soft-Start Temperature Sensor +Vcc Startup Circuit ( +VIN /4 ) - X On/Off +VIN /4 Analog Controller +VIN Primary and Secondary Gate Drive Transformer C10 C09 C08 Cr C07 IIN Lr +VIN /4 C06 C05 C04 C03 C02 C01 Primary Stage L01 Q08 Q07 Q06 Q05 Q04 Q03 Q02 Q01 Q09 Secondary Stage Full-Bridge Synchronous Rectification Q10 COUT -VOUT +VOUT BCM384y120x1K5AC1 BCM Module Block Diagram BCM384y120x1K5AC1 System Diagram -OUT BCM SER-OUT -IN BCM SEC-IN-B TX D 1 ’ SEC-OUT-C RXD1 PRI-OUT-B PRI-IN-C PRI-COM RXD4 VDDB RXD3 VDD RXD2 SEC-COM RXD1 TXD4 VDD TXD3 Digital Supervisor D44TL1A0 SDA 5V EXT NC SEC-IN-A PRI-OUT-A SDA NC SER-IN SCL BCM EN NC Digital Isolator I13TL1A0 SGND SCL 3 kΩ VDD CP NC NC NC SSTOP 3 kΩ D Q SGND VCC D Flip-flop FDG6318P R2 10 kΩ NC SADDR NC NC TXD2 TXD1 74LVC1G74DC 10 kΩ EN Control 3.3V, at least 20mA when using 4xDISO Ref to Digital Isolator datasheet for more details SD RD Q SDA SCL Host μc PMBus R1 SGND The BCM384y120x1K5AC1 bus converter provides accurate telemetry monitoring and reporting, threshold and warning limits adjustment, in addition to corresponding status flags. The BCM internal µC is referenced to primary ground. The Digital Isolator allows UART communication interface with the host Digital Supervisor at typical speed of 750 KHz across the isolation barrier. One of the advantages of the Digital Isolator is its low power consumption. Each transmission channel is able to draw its internal bias circuitry directly from the input signal being transmitted to the output with minimal to no signal distortion. The Digital Supervisor provides the host system µC with access to an array of up to 4 BCMs. This array is constantly polled for status by the Digital Supervisor. Direct communication to individual BCM is enabled by a page command. For example, the page (0x00) prior to a telemetry inquiry points to the Digital Supervisor data and pages (0x01 – 0x04) prior to a telemetry inquiry points to the array of BCMs connected data. The Digital Supervisor constantly polls the BCM data through the UART interface. The Digital Supervisor enables the PMBusTM compatible host interface with an operating bus speed of up to 400 kHz. The Digital Supervisor follows the PMBus command structure and specification. Please refer to the Digital Supervisor data sheet for more details. BCM® Bus Converter Rev 1.4 vicorpower.com Page 17 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 Sine Amplitude Converter™ Point of Load Conversion ROUT 0.124 nH + RCIN 21.5 mΩ CIN VIN V IN – 1.85 mΩ IOUT IOUT LIN_LEADS = 7 nH RCIN CIN + + IIQQ 31 mA – LOUT_LEADS = 0.64 nH + RRC COUT OUT 122 mΩ V•I 1/32 • IOUT 0.37 µF ROUT 53 µΩ 1/32 • VIN COUT COUT 208 µF VOUT VOUT – K LIN_INT = 0.56 µH – Figure 16 — BCM module AC model The Sine Amplitude Converter (SAC™) uses a high frequency resonant tank to move energy from input to output. (The resonant tank is formed by Cr and leakage inductance Lr in the power transformer windings as shown in the BCM module Block Diagram). The resonant LC tank, operated at high frequency, is amplitude modulated as a function of input voltage and output current. A small amount of capacitance embedded in the input and output stages of the module is sufficient for full functionality and is key to achieving high power density. The BCM384y120x1K5AC1 SAC can be simplified into the preceeding model. The use of DC voltage transformation provides additional interesting attributes. Assuming that ROUT = 0 Ω and IQ = 0 A, Eq. (3) now becomes Eq. (1) and is essentially load independent, resistor R is now placed in series with VIN. RRIN VIN Vin + – SAC™ SAC 1/32 KK == 1/32 V OUT Vout At no load: VOUT = VIN • K (1) K represents the “turns ratio” of the SAC. Rearranging Eq (1): K= Figure 17 — K = 1/32 Sine Amplitude Converter with series input resistor The relationship between VIN and VOUT becomes: VOUT VIN (2) VOUT = (VIN – IIN • RIN) • K Substituting the simplified version of Eq. (4) (IQ is assumed = 0 A) into Eq. (5) yields: In the presence of load, VOUT is represented by: VOUT = VIN • K – IOUT • ROUT (3) VOUT = VIN • K – IOUT • RIN • K2 and IOUT is represented by: IOUT = (5) IIN – IQ K (4) ROUT represents the impedance of the SAC, and is a function of the RDSON of the input and output MOSFETs and the winding resistance of the power transformer. IQ represents the quiescent current of the SAC control, gate drive circuitry, and core losses. BCM® Bus Converter Rev 1.4 vicorpower.com Page 18 of 23 05/2015 800 927.9474 (6) BCM384y120x1K5AC1 This is similar in form to Eq. (3), where ROUT is used to represent the characteristic impedance of the SAC™. However, in this case a real R on the input side of the SAC is effectively scaled by K2 with respect to the output. Assuming that R = 1 Ω, the effective R as seen from the secondary side is 0.98 mΩ, with K = 1/32 . A similar exercise should be performed with the addition of a capacitor or shunt impedance at the input to the SAC. A switch in series with VIN is added to the circuit. This is depicted in Figure 18. A solution for keeping the impedance of the SAC low involves switching at a high frequency. This enables small magnetic components because magnetizing currents remain low. Small magnetics mean small path lengths for turns. Use of low loss core material at high frequencies also reduces core losses. SS VVin IN + – Low impedance is a key requirement for powering a high-current, lowvoltage load efficiently. A switching regulation stage should have minimal impedance while simultaneously providing appropriate filtering for any switched current. The use of a SAC between the regulation stage and the point of load provides a dual benefit of scaling down series impedance leading back to the source and scaling up shunt capacitance or energy storage as a function of its K factor squared. However, the benefits are not useful if the series impedance of the SAC is too high. The impedance of the SAC must be low, i.e. well beyond the crossover frequency of the system. C C SAC™ SAC K = 1/32 K = 1/32 VVout OUT The two main terms of power loss in the BCM module are: n No load power dissipation (PNL): defined as the power used to power up the module with an enabled powertrain at no load. n Resistive loss (ROUT): refers to the power loss across the BCM® module modeled as pure resistive impedance. Figure 18 — Sine Amplitude Converter with input capacitor PDISSIPATED = PNL + PROUT A change in VIN with the switch closed would result in a change in capacitor current according to the following equation: IC(t) = C dVIN dt Therefore, (7) Assume that with the capacitor charged to VIN, the switch is opened and the capacitor is discharged through the idealized SAC. In this case, IC= IOUT • K (10) (8) POUT = PIN – PDISSIPATED = PIN – PNL – PROUT The above relations can be combined to calculate the overall module efficiency: h = POUT = PIN – PNL – PROUT PIN PIN substituting Eq. (1) and (8) into Eq. (7) reveals: IOUT C • dVOUT = K2 dt (9) The equation in terms of the output has yielded a K2 scaling factor for C, specified in the denominator of the equation. A K factor less than unity results in an effectively larger capacitance on the output when expressed in terms of the input. With a K = 1/32 as shown in Figure 18, C=1 μF would appear as C = 1024 μF when viewed from the output. (11) = VIN • IIN – PNL – (IOUT)2 • ROUT VIN • IIN = 1– ( ) PNL + (IOUT)2 • ROUT VIN • IIN BCM® Bus Converter Rev 1.4 vicorpower.com Page 19 of 23 05/2015 800 927.9474 (12) BCM384y120x1K5AC1 Input and Output Filter Design Thermal Considerations A major advantage of SAC™ systems versus conventional PWM converters is that the transformer based SAC does not require external filtering to function properly. The resonant LC tank, operated at extreme high frequency, is amplitude modulated as a function of input voltage and output current and efficiently transfers charge through the isolation transformer. A small amount of capacitance embedded in the input and output stages of the module is sufficient for full functionality and is key to achieving power density. The ChiP package provides a high degree of flexibility in that it presents three pathways to remove heat from internal power dissipating components. Heat may be removed from the top surface, the bottom surface and the leads. The extent to which these three surfaces are cooled is a key component for determining the maximum power that is available from a ChiP, as can be seen from Figure 1. This paradigm shift requires system design to carefully evaluate external filters in order to: n Guarantee low source impedance: To take full advantage of the BCM module’s dynamic response, the impedance presented to its input terminals must be low from DC to approximately 5 MHz. The connection of the bus converter module 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 as high as 1 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. Since the ChiP has a maximum internal temperature rating, it is necessary to estimate this internal temperature based on a real thermal solution. Given that there are three pathways to remove heat from the ChiP, it is helpful to simplify the thermal solution into a roughly equivalent circuit where power dissipation is modeled as a current source, isothermal surface temperatures are represented as voltage sources and the thermal resistances are represented as resistors. Figure 19 shows the “thermal circuit” for a VI Chip® BCM module 2361 in an application where the top, bottom, and leads are cooled. In this case, the BCM power dissipation is PDTOTAL and the three surface temperatures are represented as TCASE_TOP, TCASE_BOTTOM, and TLEADS. This thermal system can now be very easily analyzed using a SPICE simulator with simple resistors, voltage sources, and a current source. The results of the simulation would provide an estimate of heat flow through the various pathways as well as internal temperature. Thermal Resistance Top n Further reduce input and/or output voltage ripple without sacrificing dynamic response: Given the wide bandwidth of the module, 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 module multiplied by its K factor. n Protect the module from overvoltage transients imposed by the system that would exceed maximum ratings and induce stresses: The module input/output voltage ranges shall not be exceeded. An internal overvoltage lockout function prevents operation outside of the normal operating input range. Even when disabled, the powertrain is exposed to the applied voltage and power MOSFETs must withstand it. Total load capacitance at the output of the BCM module shall not exceed the specified maximum. Owing to the wide bandwidth and low output impedance of the module, low-frequency bypass capacitance and significant energy storage may be more densely and efficiently provided by adding capacitance at the input of the module. At frequencies <500 kHz the module appears as an impedance of ROUT between the source and load. Within this frequency range, capacitance at the input appears as effective capacitance on the output per the relationship defined in Eq. (13). COUT = CIN MAX INTERNAL TEMP 1.14°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.07°C / W TCASE_BOTTOM(°C) Power Dissipation (W) 1.35°C / W + – TLEADS(°C) + – TCASE_TOP(°C) Figure 19 — Double side cooling and leads thermal model Alternatively, equations can be written around this circuit and analyzed algebraically: TINT – PD1 • 1.24 = TCASE_TOP TINT – PD2 • 1.24 = TCASE_BOTTOM TINT – PD3 • 7 = TLEADS PDTOTAL = PD1+ PD2+ PD3 Where TINT represents the internal temperature and PD1, PD2, and PD3 represent the heat flow through the top side, bottom side, and leads respectively. Thermal Resistance Top MAX INTERNAL TEMP 1.14°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.07°C / W 1.35°C / W Power Dissipation (W) TCASE_BOTTOM(°C) TLEADS(°C) + – TCASE_TOP(°C) (13) K2 This enables a reduction in the size and number of capacitors used in a typical system. + – Figure 20 — One side cooling and leads thermal model BCM® Bus Converter Rev 1.4 vicorpower.com Page 20 of 23 05/2015 800 927.9474 + – BCM384y120x1K5AC1 Figure 20 shows a scenario where there is no bottom side cooling. In this case, the heat flow path to the bottom is left open and the equations now simplify to: ZIN_EQ1 Vin BCM®1 TINT – PD1 • 1.24 = TCASE_TOP ZOUT_EQ1 Vout R0_1 TINT – PD3 • 7 = TLEADS PDTOTAL = PD1 + PD3 ZIN_EQ2 BCM®2 ZOUT_EQ2 R0_2 + DC Thermal Resistance Top Load MAX INTERNAL TEMP 1.14°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.07°C / W 1.35°C / W Power Dissipation (W) TCASE_BOTTOM(°C) TLEADS(°C) TCASE_TOP(°C) + – ZIN_EQn BCM®n ZOUT_EQn R0_n Figure 21 — One side cooling thermal model Figure 22 — BCM module array Figure 21 shows a scenario where there is no bottom side and leads cooling. In this case, the heat flow path to the bottom is left open and the equations now simplify to: TINT – PD1 • 1.24 = TCASE_TOP PDTOTAL = PD1 Please note that Vicor has a suite of online tools, including a simulator and thermal estimator which greatly simplify the task of determining whether or not a BCM thermal configuration is valid for a given condition. These tools can be found at: http://www.vicorpower.com/powerbench. Fuse Selection In order to provide flexibility in configuring power systems VI Chip® modules are not internally fused. Input line fusing of VI Chip products is recommended at system level to provide thermal protection in case of catastrophic failure. The fuse shall be selected by closely matching system requirements with the following characteristics: n Current rating (usually greater than maximum current of BCM module) n Maximum voltage rating Current Sharing (usually greater than the maximum possible input voltage) The performance of the SAC™ topology is based on efficient transfer of energy through a transformer without the need of closed loop control. For this reason, the transfer characteristic can be approximated by an ideal transformer with a positive temperature coefficient series resistance. This type of characteristic is close to the impedance characteristic of a DC power distribution system both in dynamic (AC) behavior and for steady state (DC) operation. When multiple BCM modules of a given part number are connected in an array they will inherently share the load current according to the equivalent impedance divider that the system implements from the power source to the point of load. Some general recommendations to achieve matched array impedances include: n Dedicate common copper planes within the PCB to deliver and return the current to the modules. n Provide as symmetric a PCB layout as possible among modules n An input filter is required for an array of BCMs in order to n Ambient temperature n Nominal melting I2t n Recommend fuse: ≤ 5 A Bussmann PC-Tron Reverse Operation BCM modules are capable of reverse power operation. Once the unit is started, energy will be transferred from secondary back to the primary whenever the secondary voltage exceeds VIN • K. The module will continue operation in this fashion for as long as no faults occur. The BCM384y120x1K5AC1 has not been qualified for continuous operation in a reverse power condition. Furthermore fault protections which help protect the module in forward operation will not fully protect the module in reverse operation. Transient operation in reverse is expected in cases where there is significant energy storage on the output and transient voltages appear on the input. Transient reverse power operation of less than 10 ms, 10% duty cycle is permitted and has been qualified to cover these cases. prevent circulating currents. For further details see AN:016 Using BCM Bus Converters in High Power Arrays. BCM® Bus Converter Rev 1.4 vicorpower.com Page 21 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 BCM Module Through Hole Package Mechanical Drawing and Recommended Land Pattern SER-OUT EN SER-IN BCM® Bus Converter Rev 1.4 vicorpower.com Page 22 of 23 05/2015 800 927.9474 BCM384y120x1K5AC1 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; 7,145,186; 7,166,898; 7,187,263; 7,202,646; 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] BCM® Bus Converter Rev 1.4 vicorpower.com Page 23 of 23 05/2015 800 927.9474