PRELIMINARY 45 Intermediate Bus Converters Quarter-Brick, 48 Vin Family V•I Chip VIC-in-a-Brick TM 3 to 48 Vdc Bus Voltages; 100 A - 600 W Output Features • Up to 600 W • 95% efficiency @ 3 Vdc • 600 W @ 55ºC, 400 LFM • 125°C operating temperature • 400 W/in3 power density • 38-55 Vdc input range • 100 V input surge for 100 ms • SAC topology • Low noise ZCS/ZVS architecture • 3.5 MHz switching frequency • Fast dynamic response • Parallelable, with fault tolerance • 2,250 Vdc basic insulation V•I + + –K – © Absolute Maximum Ratings Product Overview These "VIC-in-a-Brick" Intermediate Bus Converter (IBC) modules use Vicor’s V•I Chip Bus Converter Modules (BCM) to achieve the highest performance for Intermediate Bus Architecture applications. Operating from a 38-55 Vdc input, ten different fixed ratio outputs are available from 3 to 48 Vdc. You can choose the intermediate bus voltage that is optimal for your system and load requirements. These quarter-bricks are available with a single BCM, rated up to 300 W or 70 A, or with dual BCMs, capable of 600 W or 100 A. Dual output pins are used for output currents over 50 A. Parameter Rating Unit Notes +In to –In voltage Continuous Surge -1.0 to +60.0 100 Vdc Vdc <100ms PC to –In voltage -0.3 to +7.0 Vdc Isolation voltage Input to output In/Out to heat sink 2,250 1,500 Vdc Vdc Operating temperature -40 to +125 °C 500 (260) 750 (390) °F (°C) °F (°C) Basic Insulation Pin soldering temperature Wave Hand Junction <5 sec <7 sec Thermal Resistance and Capacity Utilizing breakthrough Sine Amplitude Converter (SAC) technology, BCMs offer the highest efficiency, lowest noise, fastest transient response and highest power density. And full load power is available at 55ºC with only 200 LFM of air for single BCM versions and 400 LFM for dual BCM versions, without a heatsink. Parameter Typ Unit VIC to ambient; 0 LFM (Single BCM) 13.3 °C/W VIC to ambient; 0 LFM (Dual BCM) 11.7 °C/W VIC to ambient; 200 LFM (Single BCM) 6.1 °C/W VIC to ambient; 200 LFM (Dual BCM) 4.3 °C/W Thermal capacity (Single BCM) 14.3 Ws/°C Thermal capacity (Dual BCM) 22.8 Ws/°C Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 1 of 8 PRELIMINARY PART NUMBERING I 048 C 030 T 015 P 2 Format I = IBC Nominal Input Voltage C = 1/4 Brick Nominal Output Voltage (x10) Product Grade T= -40 to 125°C Output Power (x 0.1 Enable Polarity P=”+” M=”–” (see note 3) Package Style (See pg 7) PRODUCT MATRIX Output Voltage (see note 1) 3.0 4.0 6.0 8.0 9.6 12 16 24 32 48 * ** *** **** Full Load Output (Note 2) Watts Amps Bus Converter Model No. (see note 3) Number of BCMs 150 50 * I048C030T015P1 1 210 70 I048C030T021P2 1 300 100 ** I048C030T030P2 2 200 50 * I048C040T020P1 1 240 60 I048C040T024P2 1 400 100 ** I048C040T040P2 2 270 45 I048C060T027P1 1 540 90 I048C060T054P2 2 300 37 I048C080T030P1 1 400 50 *** I048C080T040P1 2 600 75 I048C080T060P2 2 240 25 I048C096T024P1 1 480 50 I048C096T048P1 2 200 17 I048C120T020P1**** 1 300 25 I048C120T030P1 1 400 34 I048C120T040P1**** 600 50 I048C120T060P1 300 18.8 I048C160T030P1 1 600 37.5 I048C160T060P1 2 300 12.5 I048C240T030P1 1 600 25 I048C240T060P1 2 300 9.4 I048C320T030P1 1 600 18.7 I048C320T060P1 2 K Factor (Transformation Ratio) 1/16 1/12 Full Load Efficiency (%) ROUT (mΩ) Max Load Capacitance 95.5 2.0 31,000 µF 94.7 2.0 31,000 µF 94.6 1.0 62,000 µF 96.0 2.3 17,000 µF 95.4 1.2 17,000 µF 96.0 1.2 34,000 µF (see note 4) 4.0 7,600 µF 2.0 15,200 µF 96.3 7.2 4,300 µF 96.9 3.6 8,600 µF 96.3 3.6 8,600 µF 10.0 3,000 µF 5.1 6,000 µF 95.7 20.5 1,000 µF 96.7 13.0 1,000 µF 2 95.7 10.3 2,000 µF 2 96.7 6.5 2,000 µF 20.0 900 µF 10.0 1,800 µF 42.0 470 µF 21.0 940 µF 300 6.3 I048C480T030P1 1 600 12.5 I048C480T060P1 2 1/8 1/6 1/5 1/4 1/3 1/2 2/3 96.2 96.3 96.8 97.2 97.0 67.0 200 µF 400 µF 1 97.0 150.0 100 µF 75.0 200 µF Full load capability is actually 70 A at 3 V and 60 A at 4 V. The maximum rating of the output pins is 50 A. Full load capability is actually 140 A at 3 V and 120 A at 4 V. The maximum rating of the output pins is 100 A. Full load capability is actually 75 A. The maximum rating of the output pins is 50 A. Input voltage range is 42 V min to 53 V max. Notes: 1: Output voltage at 48 Vdc input, no load and 25°C temperature. 2: Maximum power and current ratings should not be exceeded under normal operating conditions. 3: The ending "P" indicates positive enable logic (pull PC pin low to disable). Change to "M" to indicate negative logic (pull PC pin low to enable). 4: Exceeding this value can cause the unit not to turn on into load. Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 2 of 8 PRELIMINARY ELECTRICAL CHARACTERISTICS For comprehensive data on any of the configurations, please refer to the data sheet for the BCM with output voltage (K Factor) of the Intermediate Bus Converter of interest. Data sheets are available from our website at www.vicorpower.com. Electrical characteristics apply over the full operating range of input voltage, output load (resistive) and case temperature, unless otherwise specified. INPUT SPECIFICATIONS Parameter Min Typ Max Unit Notes Operating input voltage 38 48 55 Vdc 12 V 200 W & 400 W units are 42–53 Vdc 100 Vdc <100ms 38 Vdc Vdc Input surge withstand Undervoltage Turn-on Turn-off Overvoltage Turn-off Turn-on 32.6 36.1 33.8 55.0 59 Input reflected ripple current 3 Input dV/dt Vdc Vdc % Iin 10 mA p-p with recommended external input capacitor V/µs Turn-on time Power up PC enable 300 50 ms µs No load power dissipation 2.5 W per BCM 10 50 µF 200 nH maximum source inductance Min Typ Recommended external input capacitance OUTPUT SPECIFICATIONS Parameter Output voltage accuracy Max ±2 Peak repetitive output current 150 Unit Notes % 48 V input; no load; 25°C % <1 ms; see note 2 below See note 1 below Current limit 125 % Average short circuit current 200 mA Efficiency 96.0 % Output OVP setpoint 120 % 48 Vin; full load; 25°C Line regulation Fixed ratio; Vout = Vin•K (see product matrix) Load regulation ∆Vout = ∆Iout•Rout (see product matrix) Temperature regulation ±0.05 % / °C Ripple and noise, p-p 100 mV Switching frequency 3.5 Power sharing accuracy ±5 Transient response Voltage deviation Response time Recovery time 2 200 1 MHz ±10 % 48 Vin; full load; 20 MHz bandwidth Fixed 10 to 100% load No load - full load step change, see note 2 below % ns µs Note 1: Current limit parameter does not apply for all models. Please see product matrix on page 2 for exceptions. Note 2: For important information relative to applications where the unit is subjected to continuous dynamic loading, contact Vicor applications engineering at 800-927-9474. Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 3 of 8 PRELIMINARY SAFETY SPECIFICATIONS Parameter Min Typ Max Unit Isolation voltage Input to output In/Out to chassis 2,250 1,500 Vdc Vdc Isolation resistance 10 MΩ Notes Complies with basic insulation requirements Agency approvals (pending) cTÜVus CE Mark Input to output UL/CSA 60950, EN 60950 Low voltage directive THERMAL SPECIFICATIONS Parameter Min Operating junction temperature -40 Storage temperature -40 Temperature limiting 125 Thermal capacity 1 BCM 2 BCM Typ 130 Max Unit +125 °C +150 °C 135 °C 14.3 22.8 Pin soldering temperature Wave Hand Notes Junction temperature Ws/°C Ws/°C 500 (260) 750 (390) °F (°C) °F (°C) <5 sec <7 sec Max Unit Notes 3,600 4,200 Khrs Khrs 25°C, GB; per BCM per BCM 3.7 (104) oz (g) 2.3 x 1.45 x 0.47 58,4 x 36,8 x 11,9 in mm LxWxH LxWxH Unit Notes GENERAL SPECIFICATIONS Parameter Min MTBF MIL-HDBK-217F Telcordia TR-NT-000332 Weight Dimensions Typ CONTROL SPECIFICATIONS – PRIMARY CONTROL (PC PIN) Parameter Min Typ Max 5.2 Voltage (P version) 4.8 5.0 Disable voltage (P version) 2.4 2.5 Enable voltage (P version) Enable voltage (M version) 2.5 1.2 Disable voltage (M version) Current limit (P version) 2.4 Vdc Vdc 2.6 1.5 Vdc Vdc 1.5 3.5 Vdc 2.5 2.9 mA Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Source only Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 4 of 8 PRELIMINARY PIN/CONTROL FUNCTIONS +IN / –IN — DC Voltage Input Pins The "VIC-in-a-Brick" Intermediate Bus Converter (IBC) input voltage range should not be exceeded. The V•I Chip BCM’s internal under/over voltage lockout-function prevents operation outside of the normal input range. The BCM 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. Input impedance Vicor recommends a minimum of 10 µF bypass capacitance be used on-board across the +IN and –IN pins. The type of capacitor used should have a low Q with some inherent ESR such as an electrolytic capacitor. If ceramic capacitance is required for space or MTBF purposes, it should be damped with approximately 0.3 Ω series resistance. 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 over/under voltage detection circuitry of the BCM(s) could be activated. PC — Primary Control Pin The Primary Control pin is a multifunction node that provides the following functions: Enable/Disable Standard "P" configuration — If the PC pin is left floating, the BCM output is enabled. Once this port is pulled lower than 2.4 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. Optional "M" configuration — This is the reverse function as above: when the PC pin is left floating , the BCM output is disabled. Primary Auxiliary Supply — The PC pin can source up to 2.4 mA at 5.0 Vdc. (P version only) Alarm — The BCM contains watchdog circuitry that monitors output overload, input over voltage or under voltage, and internal junction temperatures. In response to an abnormal condition in any of the monitored parameters, the PC pin will toggle. (P version only) +OUT / – OUT — DC Voltage Output Pins The 0.062" diameter + and – output pins are rated for a maximum current of 50 A. Two sets of pins are provided for all units with a current rating over 50 A. These pins must be connected in parallel with minimal interconnect resistance. Within the specified operating range, the average output voltage is defined by the Level 1 DC behavioral model of the on board BCM(s) as defined in the appropriate BCM data sheet. Output impedance The very low output impedance of the IBC, as shown in the Product Matrix table, reduces or eliminates the need for limited life aluminum electrolytic or tantalum capacitors at the input of the non-isolated point-of-load converters. Load capacitance Total load capacitance at the output of the IBC should not exceed the specified maximum as shown in the Product Matrix table. Owing to the wide bandwidth and low output impedance of the BCM, low frequency bypass capacitance and significant energy storage may be more densely and efficiently provided by adding capacitance at the input of the IBC. Bi-directional operation The BCM power train and control architecture allow bidirectional power transfer, including reverse power processing from the BCM output to its input. Reverse power transfer is enabled if the BCM input is within its operating range and the BCM is otherwise enabled. The BCM’s ability to process power in reverse significantly improves the IBC transient response to an output load dump. THERMAL MANAGEMENT Figures 2 to 5 provide the IBC’s maximum ambient operating temperature vs. BCM power dissipation for a variety of airflows. In order to determine the maximum ambient environment for a given application, the following procedure should be used: Fig. 6 on the appropriate BCM data sheet corresponding to the output voltage of the IBC. This number should then be multiplied by 2 to reflect the total dissipation. 3. Determine the airflow orientation from Fig.1. 1. Determine the maximum load powered by the IBC. 2. Determine the power dissipated at this load by the on-board BCM(s). a) If using a 1 BCM configuration, this dissipation is found in Fig. 6 on the appropriate BCM data sheet corresponding to the output voltage of the IBC. b) If using a 2 BCM configuration, divide the maximum load by 2. The power dissipated by each BCM is found in 4. Using the chart corresponding to the appropriate airflow angle, find the curve corresponding to the airflow velocity and read the maximum ambient operating temperature of the IBC (y-axis) based on the total BCM power dissipation (x-axis). For additional information on V•I Chip thermal design, please read the "Thermal Management" section of the BCM data sheet. Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 5 of 8 PRELIMINARY THERMAL MANAGEMENT (Cont.) 0 degree airflow ™ BCM BCM ™ 90 degree airflow Note: Other configurations and orientations are available, including versions with integral heatsinks. Please consult the factory for additional information. 130 120 110 100 90 1000LFM 850LFM 80 70 600LFM 500LFM 400LFM 60 50 300LFM 40 200LFM 30 20 100LFM 10 0 1 2 3 4 5 6 7 8 9 10 11 Maximum Operating Ambient Temperature (C) Maximum Operating Ambient Temperature (C) Figure 1— 0 and 90 degree airflow orientations for 1 or 2 BCM configurations 130 120 110 100 1000LFM 850LFM 90 80 60 600LFM 500LFM 400LFM 300LFM 50 200LFM 70 40 100LFM 30 20 10 0 12 1 Power Dissipation (W) 130 Max. Operating Ambient (C) 120 110 100 90 80 70 1000LFM 850LFM 60 50 40 600LFM 30 500LFM 20 400LFM 10 100LFM 0 200LFM 300LFM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 8 Power Dissipation (W) 9 10 11 12 120 110 100 90 1000LFM 850LFM 80 70 60 600LFM 500LFM 50 400LFM 40 300LFM 30 200LFM 20 10 100LFM 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Power Dissipation (W) Figure 5— Maximum operating ambient temp. curves for 2 BCM with 90 degree airflow Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power 4 130 Power Dissipation (W) Figure 4— Maximum operating ambient temp. curves for 2 BCM with 0 degree airflow 3 Figure 3— Maximum operating ambient temp. curves for 1 BCM with 90 degree airflow Maximum Ambient Operating Temperature Figure 2— Maximum operating ambient temp. curves for 1 BCM with 0 degree airflow 2 Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 6 of 8 PRELIMINARY MECHANICAL DRAWINGS 12.52 0.493 58.4 2.30 +IN +OUT 27.94 1.100 ON/OFF 36.8 1.45 TWO OUTSIDE PINS ONLY PRESENT FOR OUTPUT CURRENTS OVER 50 A (PACKAGE 2) SEATING PLANE 15.24 0.600 – OUT –IN 7.62 0.300 6.35 0.250 4.4 0.18 TOP VIEW (COMPONENT SIDE) 4.1 0.16 50.80 2.000 BOTTOM VIEW SECOND BCM FOR DUAL BCM MODELS 16.3 0.64 mm NOTES 1. DIMENSIONS ARE inch 2. UNLESS OTHERWISE SPECIFIED, TOLERANCES ARE: .X/(.XX) = +/-0.25/(.01), .XX/(.XXX) = +/-0.13/(.005) ø 1.02 (3) PL. 0.040 ø 1.52 (4) PL. 0.060 PACKAGING CONFIGURATIONS PACKAGE STYLE DESCRIPTION 1 Single output pins 2 Dual output pins INPUT FUSING V•I Chips are not internally fused in order to provide flexibility in power system configuration. However, input line fusing of V•I Chips must always be incorporated within the power system. The input line fuse should be placed in series with +IN. INPUT FUSE VALUE Bus Converter Model No. Little Fuse Nano 451/453 Series I048C030T015P1 6.3 A I048C030T021P2 8A I048C030T030P2 12 A I048C040T020P1 8A I048C040T024P2 10 A I048C040T040P2 15 A I048C060T027P1 12 A San–O SV 12/14 5/20 Series I048C060T054P2 25 A I048C080T030P1 12 A I048C080T040P1 15 A I048C080T060P2 I048C096T024P1 25 A 10 A I048C096T048P1 20A I048C120T020P1 8A I048C120T030P1 12 A I048C120T040P1 15 A I048C120T060P1 I048C160T030P1 25 A 12 A I048C160T060P1 25 A I048C240T030P1 12 A I048C240T060P1 25 A I048C480T030P1 12 A I048C480T060P1 Vicor Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Little Fuse 3AB Series 25 A Quarter-Brick Intermediate Bus Converters Rev. 1.3 Page 7 of 8 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 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. Intellectual Property Notice Vicor and its subsidiaries own Intellectual Property (issued U.S. and Foreign Patents and pending patent applications) relating to the product described in this data sheet including; • The electrical and thermal utility of the V•I Chip package • The design of the V•I Chip package • The Power Conversion Topology utilized in the V•I Chip package • The Control Architecture utilized in the V•I Chip package • The Factorized Power Architecture. Purchase of this product conveys a license to use it. However, no responsibility is assumed by Vicor for any infringement of patents or other rights of third parties which may result from its use. Except for its use, no license is granted by implication or otherwise under any patent or patent rights of Vicor or any of its subsidiaries. Anybody wishing to use Vicor proprietary technologies must first obtain a license. Potential users without a license are encouraged to first contact Vicor’s Intellectual Property Department. 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 Corporation Tel: 800-735-6200 vicorpower.com Factorized Power Quarter-Brick Intermediate Bus Converters P/N 27663 Rev. 1.3 7/04/10M