Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC Converters 36-60 Vdc Input; 9.6V Output; 240 W Features RoHS Compliant Compliant to RoHS EU Directive 2002/95/EC (-Z versions) Compliant to ROHS EU Directive 2002/95/EC with lead solder exemption (non-Z versions) High efficiency – 96% at 9.6V, full load Excellent Thermal Performance: 240W at Vin=55Vdc, 55ºC at 1m/s (200LFM) 240W at Vin=60Vdc, 60ºC at 1.5m/s (300LFM) Industry standard Eighth brick: 57.9 mm x 23.6mm x 11.0 mm (2.28 in x 0.93 in x 0.44 in) Cost-efficient open frame design Applications Low output voltage ripple and noise Distributed Power Architecture Positive Remote On/Off logic Wireless Networks Output over-current protection, auto-restart Optical and Access Networks equipment Input over-voltage protection, auto-restart Enterprise Networks Input under-voltage lockout Over-temperature protection, auto-restart Operating temperature range (-40°C to 85°C) ISO** 9001 certified manufacturing facilities Basic Insulation (100% factory test to 1500Vdc) UL* 60950-1 Recognised, CSA† C22.2 No. 60950‡ 1-03 Certified, and EN 60950-1 (VDE 0805: 200112) Licensed Options Negative logic, Remote On/Off Pin length Description The EUK240-series DC-DC converters are single-output power modules designed to support intermediate bus applications using discrete/modular point of load (POL) converters. The output is unregulated and a fixed 5:1 ratio is maintained between the input and output voltages. By taking advantage of the absence of regulation, high efficiency topologies operated at fixed duty cycles can be employed leading to low cost open frame modules. The output is fully isolated from the input, allowing versatile polarity configurations and grounding connections. The high efficiency of this converter leads to lower power dissipation. Built-in filtering for both input and output minimizes the need for external filtering. The module package dimensions are 59.7 mm x 23.6 mm x 11.0 mm (2.28 in x 0.93 in x 0.44 in.). Standard features include remote On/Off, input over-voltage, output over-current and over-temperature protection. * UL is a registered trademark of Underwriters Laboratories, Inc. † CSA is a registered trademark of Canadian Standards Association. ‡ VDE is a trademark of Verband Deutscher Elektrotechniker e.V. ** ISO is a registered trademark of the International Organization of Standards Document No: DS06-113 ver. 1.03 PDF name: euk240_series_ds.pdf Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W 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 operations sections of the data sheet. Exposure to absolute maximum ratings for extended periods can adversely affect the device reliability. Parameter Device Symbol Min Max Unit Continuous All VIN -0.3 60 Vdc Non-Operating Condition All -0.3 75 Vdc Input Voltage Operating Ambient Temperature All TA -40 85 °C Storage Temperature All Tstg -55 125 °C I/O Isolation Voltage (100% factory tested) All Viso ⎯ 1500 Vdc Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. Parameter Device Symbol Min Typ Max Unit All VIN 36 48 60 Vdc All IIN,max 5 Adc Inrush Transient All 2 1 As Input Reflected Ripple Current, peak-to-peak (5Hz to 20MHz, 12μH source impedance; o Ta 25 C, Cin = 33 µF) All ⎯ 50 ⎯ mAp-p Input Ripple Rejection (120Hz) All ⎯ 14 ⎯ dB Operating Input Voltage Maximum Input Current (VIN=0 to 60Vdc, PO=PO, max ) It 2 CAUTION: This power module is not internally fused. An input line fuse must always be used. This power module can be used in a wide variety of applications, ranging from simple standalone operation to being part of complex power architecture. To preserve maximum flexibility, internal fusing is not included, however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a fastacting fuse with a maximum rating of 15 A (see Safety Considerations section). Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data sheet for further information. LINEAGE POWER 2 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Electrical Specifications (continued) Parameter Output Voltage Set-point Device Symbol All VO, set All VO Min Typ Max 9.6 Unit Vdc (VIN = VIN, min, IO = IO, max, TA =25°C) Output Voltage ⎯ 6.0 12.0 Vdc (Over all line, load, and Temp Conditions Until end of life) Output Regulation Line (VIN = VIN, min to VIN, max) All ⎯ 4.2 V Load (IO = IO, min to IO, max) All ⎯ ⎯ 500 mV Temperature (Tref =TA, min to TA, max) All ⎯ ⎯ 200 mV RMS (5Hz to 20MHz bandwidth) All ⎯ 33 65 mVrms Peak-to-Peak (5Hz to 20MHz bandwidth) All ⎯ 100 150 mVpk-pk 0 ⎯ 5000 μF 240 W 34 A dc Output Ripple and Noise on nominal output (VIN =VIN, nom and IO = IO, min to IO, max, Cout = 1μF ceramic // 10μF Tantalum capacitor) External Capacitance All Output Power CO,max Po Output Current All Io 0 ⎯ Output Current Limit Inception (Hiccup Mode) All IO, lim ⎯ 32 Efficiency All η ⎯ 96 All fsw 130 Peak Deviation All Vpk ⎯ Settling Time (Vo<10% peak deviation) All ts ⎯ Peak Deviation All Vpk Settling Time (Vo<10% peak deviation) All ts A dc ⎯ % 240 KHz 400 ⎯ mV 0.2 ⎯ ms ⎯ 400 ⎯ mV ⎯ 0.2 ⎯ ms VIN= 48V, TA=25°C, IO= IO, max Switching Frequency Dynamic Load Response (dIo/dt= 0.1A /μs; VIN = VIN, nom; TA=25°C) Load Change from Io= 50% to 75% of Io,max Load Change from Io= 50% to 25% of Io,max Isolation Specifications Parameter Min Typ Max Unit Isolation Capacitance ⎯ 1000 ⎯ pF Isolation Resistance 10 ⎯ ⎯ MΩ General Specifications Parameter Min Calculated MTBF (IO= 80% of IO, max, TA=40°C) Weight LINEAGE POWER ⎯ Typ Max Unit 2,511,340 ⎯ Hours 32.5 (1.15) ⎯ g (oz.) 3 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Feature Specifications Unless otherwise indicated, specifications apply over all operating input voltage, resistive load, and temperature conditions. See Feature Descriptions for additional information. Parameter Device Symbol Min Typ Max Unit All All All Ion/off Von/off Von/off ⎯ -0.3 2.0 ⎯ ⎯ ⎯ 1.0 0.8 4.7 mA Vdc Vdc All Ion/off ⎯ ⎯ 0.7 mA Von/off ⎯ ⎯ 13.5 Vdc All Tdelay ― 10 ― msec All Tdelay ― 8 ― msec All Trise ― 5 ― msec ― ― 400 mV Remote On/Off Signal Interface (VIN=VIN, min to VIN, max ; open collector or equivalent, Signal referenced to VIN- terminal) Negative Logic: device code suffix “1” Logic Low = module On, Logic High = module Off Positive Logic: No device code suffix required Logic Low = module Off, Logic High = module On Logic Low - Remote On/Off Current Logic Low - On/Off Voltage Logic High Voltage – (Typ = Open Collector) Logic High maximum allowable leakage current (Von/off = 2.0V) Maximum voltage allowed on On/Off pin Turn-On Delay and Rise Times o (IO=80 % IO, max , TA = 25 C) Case 1: On/Off input is set to Logic High and then input power is applied (delay from instant at which VIN = VIN, min until Vo =10% of Vo,nom) Case 2: Input power is applied for at least one second and then the On/Off input is set to logic high (delay from instant at which Von/Off = 0.9V until Vo=10% of Vo, set) Output voltage Rise time (time for Vo to rise from 10% Of Vo, nom to 90% of Vo, nom) Output voltage overshoot – Startup o IO= 80% of IO, max; TA = 25 C Input Under-voltage Lockout All All VUVLO Turn-on Threshold ― 34 35.5 V Turn-off Threshold 32.0 35 ― V ― 63 65 Input Over voltage Protection Over temperature protection LINEAGE POWER All All VI, prot ― 125 ― V 0 C 4 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Characteristic Curves The following figures provide typical characteristics for EUK240S9R0 at TA = 25O C ON/OFF VOLTAGE VO (V) (5V/div) 4 Io = 20.5A 3 Io = 0A 0 40 45 50 55 INPUT VOLTAGE, VIN (V) 60 Figure 1. Typical Input characteristics at room temperature . OUTPUT VOLTAGE 100 Vin = 36V EFFICIENCY, η (%) 95 90 Vin = 48V 85 Vin = 60V 80 75 70 0 5 10 15 20 25 30 TIME, t (5 ms/div) Figure 4. Typical Start-Up Characteristics from Remote ON/OFF. 35 OUTPUT CURRENT, IO (A) Figure 2. Typical Converter Efficiency versus Output Current at room temperature. VO (V) (200 mV/div) 35 IO (A) (5A/div) 30 VOn/off (V) (2V/div) Io = 10.25A 1 OUTPUT VOLTAGE 2 OUTPUT CURRENT INPUT CURRENT, IIN (A) 5 Figure 5. Transient Response to a Dynamic Load Change from 50% to 75% 50% of full load. Vin = 60V 8 OUTPUT VOLTAGE, VO (V) VO (V) (50mV/div) OUTPUT RIPPLE VOLTAGE Vin = 36V Vin = 48V TIME, t (20 μs/div) 7 6 Io = 0A 5 4 Io = 10.25A 3 2 Io = 20.5A 1 0 33 TIME, t (2 μs/div) Figure 3. Output ripple voltage at full load and minimum, nominal and maximum input voltage. LINEAGE POWER 33.5 34 34.5 35 INPUT VOLTAGE, Vin (V) Figure 6. Typical Output Voltage start up vs. Input Voltage Characteristic at Room Temperature. 5 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Characteristic Curves (continued) The following figures provide typical characteristics for EUK240S9R0 at TA = 25O C 240.0 11 OUTPUT POWER. PO (W) OUTPUT VOLTAGE, VO (V) 12 Vin = 60V 10 9 Vin = 48V 8 Vin = 36V 7 6 0 5 10 15 20 25 30 220.0 3 m/s (600LFM) 200.0 180.0 2 m/s (400LFM) 160.0 1 m/s (200LFM) 140.0 120.0 100.0 35 20 OUTPUT CURRENT, IO (A) 11 220.0 OUTPUT POWER. PO (W) OUTPUT VOLTAGE, VO (V) 240.0 10 Io = 20.5A Io = 10.25A 8 7 6 30 35 40 45 50 55 60 200.0 60 70 80 90 3 m/s (600LFM) 180.0 2 m/s (400LFM) 160.0 1 m/s (200LFM) 140.0 120.0 100.0 65 20 INPUT VOLTAGE, Vin (V) 30 40 50 60 70 80 90 LOCAL AMBIENT TEMPERATURE, TA (°C) Figure 8. Typical Output Voltage vs. Input Voltage Characteristic at Room Temperature. Figure 11. Thermal derating of the module in the Transverse Orientation; Airflow Direction from Vin(-) to Vin(+); Vin = 55V. 240.0 240.0 OUTPUT POWER. PO (W) OUTPUT POWER. PO (W) 50 Figure 10. Thermal derating of the module in the Transverse Orientation; Airflow Direction from Vin(-) to Vin(+); Vin = 48V. 12 9 40 LOCAL AMBIENT TEMPERATURE, TA (°C) Figure 7. Typical Output Voltage vs. Output Current Characteristic at Room Temperature. Io = 0A 30 220.0 200.0 3 m/s (600LFM) 180.0 2 m/s (400LFM) 160.0 1 m/s (200LFM) 140.0 120.0 220.0 200.0 2 m/s (400 LFM) & 3 m/s (600 LFM) 180.0 160.0 1.5 m/s (300 LFM) 140.0 1 m/s (200 LFM) 120.0 100.0 100.0 20 30 40 50 60 70 80 LOCAL AMBIENT TEMPERATURE, TA (°C) Figure 9. Thermal derating of the module in the Transverse Orientation; Airflow Direction from Vin(-) to Vin(+); Vin = 38V. LINEAGE POWER 90 20 30 40 50 60 70 80 90 LOCAL AMBIENT TEMPERATURE, TA (°C) Figure 12. Thermal derating of the module in the Transverse Orientation; Airflow Direction from Vin(-) to Vin(+); Vin = 60V. 6 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Test Configurations Safety Considerations For safety agency approval the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standards, i.e., UL 60950-1, CSA C22.2 No. 60950-103, and EN60950-1 (VDE 0850) (IEC60950, 3rd edition) Licensed. The power modules meet the 73/23/EEC and 93/68/EEC Directives and will be marked with the Conformite Europeane (CE) mark. For the converter output to be considered meeting the requirements of safety extra-low voltage (SELV), the input must meet SELV requirements. Figure 13. Input Reflected Ripple Current Test Setup. The input to these units is to be provided with a fastacting fuse with a maximum rating of 15 A in the ungrounded lead. Figure 14. Output Ripple and Noise Test Setup. Figure 15. Output Voltage and Efficiency Test Setup. VO. IO Efficiency η = LINEAGE POWER VIN. IIN x 100 % 7 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Feature Description Input Under-voltage Lockout Remote On/Off At input voltages below the input under voltage lockout limit, the module operation is disabled. The module will begin to operate at an input voltage above the under voltage lockout turn-on threshold. Two remote on/off options are available. Positive logic remote on/off turns the module on during a logic-high voltage on the ON/OFF pin, and off during logic low. Negative logic remote on/off turns the module off during a logic high and on during a logic low. Negative logic, device code suffix "1," is the factory-preferred configuration. To turn the power module on and off, the user must supply a switch to control the voltage between the on/off terminal and the VI (-) terminal (Von/off). The switch can be an open collector or equivalent (see Figure 16). A logic low is Von/off = -0.3 V to 0.8 V. The maximum Ion/off during a logic low is 10 mA. The switch should maintain a logic-low voltage while sinking 10 mA. During logic high, the maximum Von/off generated by the power module is 4.7 V. The maximum allowable leakage current of the switch at Von/off = 2.0V is 0.7 mA. If not using the remote on/off feature, perform one of the following to turn the unit on: For negative logic, short ON/OFF pin to VI(-). For positive logic: leave ON/OFF pin open. Ion/off + ON/OFF Von/off – These modules feature an over-temperature protection circuit to safeguard against thermal damage. The protection circuit shuts down the module when the maximum device reference temperature is exceeded. When the module cools down and the reference device temperature falls below the recovery threshold, the module will resume operation. Over-voltage Protection The input/output over-voltage protection circuit is designed to shut down the module when the input voltage exceeds the over-voltage threshold. The module will resume operation when the input voltage enters the normal input operating range Short Circuit Protection The power modules shall sustain no damage when subjected to a short circuit of any duration on its output. The output of the module shall recover automatically in a hiccup (auto-restart) manner identical to that described in the over-current protection section. Pre-Bias Immunity VO(+) LOAD VI(+) Over-temperature Protection VO(–) VI(–) Figure 16. Circuit configuration for using Remote On/Off Implementation. The startup/shutdown characteristics of the module accommodates external voltage source clamping on the output via external diodes without exhibiting nonmonotonic startup (See figure 17). The monotonic startup of the module will not be affected by the customer application of the pre-biasing of the output. During shutdown an internal feature implemented in the module ensures there will be no reverse current. During Hiccup operation, the reverse current protection will be enabled. Over-current Protection To provide protection in an output overload condition, the module is equipped with internal current-limiting circuitry and can endure current limiting for unlimited duration. If the output current exceeds the current limit inception value, the module enters into the hiccup (auto-restart) mode operation, where it shuts down and automatically attempts to restart. As long as the fault condition exists, the module will remain in this hiccup mode, and can sustain this mode of operation until the over-current fault condition is corrected. LINEAGE POWER Vout Module L O A D Vs Figure 17. Pre-bias immunity configuration. 8 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Thermal Considerations Power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation. Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in reliability. The thermal data is based on physical measurements taken in a wind tunnel. The test set-up is shown in Figure 18. The module delivers full power over an input voltage range of 36V to 55V, at an ambient o temperature of 55 C, at the airflow rate of 200LFM environment, at sea level, at 50 % relative humidity, with specified orientation. For higher local ambient temperature operation, the modules output power should be derated, as shown in Figures 9 - 12. Figure 19. Temperature Measurement Locations Please refer to the Application Note “Thermal Characterization Process For Open-Frame BoardMounted Power Modules” for a detailed discussion of thermal aspects including maximum device temperatures. 25.4 (1.0) Wind Tunnel PWBs Power Module 76.2 (3.0) x 6.55 (0.258) Probe Location for measuring airflow and ambient temperature Air flow Figure 18. Thermal Test Set up. LINEAGE POWER 9 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Post Solder Cleaning and Drying Considerations Post solder cleaning is usually the final circuit-board assembly process prior to electrical board testing. The result of inadequate cleaning and drying can affect both the reliability of a power module and the testability of the finished circuit-board assembly. For guidance on appropriate soldering, cleaning and drying procedures, refer to Lineage Power Board Mounted Power Modules: Soldering and Cleaning Application Note (AP01-056EPS). Through-Hole Lead-Free Soldering Information The RoHS-compliant through-hole products use the SAC (Sn/Ag/Cu) Pb-free solder and RoHS-compliant components. They are designed to be processed through single or dual wave soldering machines. The pins have an RoHS-compliant finish that is compatible with both Pb and Pb-free wave soldering processes. A maximum preheat rate of 3°C/s is suggested. The wave preheat process should be such that the temperature of the power module board is kept below 210°C. For Pb solder, the recommended pot temperature is 260°C, while the Pb-free solder pot is 270°C max. Not all RoHS-compliant through-hole products can be processed with paste-through-hole Pb or Pb-free reflow process. If additional information is needed, please consult with your Lineage Power representative for more details. LINEAGE POWER 10 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Mechanical Outline Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] TOP VIEW SIDE VIEW † Optional pin lengths shown in Table 2, Device Options. BOTTOM VIEW LINEAGE POWER 11 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Recommended Pad Layout Dimensions are in millimeters and [inches]. Tolerances: x.x mm ± 0.5 mm [x.xx in. ± 0.02 in.] (Unless otherwise indicated) x.xx mm ± 0.25 mm [x.xxx in ± 0.010 in.] LINEAGE POWER 12 Data Sheet March 26, 2008 EUK240 Series Power Modules; DC-DC converters 36 – 60Vdc input; 9.6Vdc Output; 240W Ordering Information Please contact your Lineage Power Sales Representative for pricing, availability and optional features. Table 1. Device Codes Input Voltage Output Voltage Output Power Efficiency Connector Type Comcodes EUK240S9R041Z 36-60 Vdc 9.6V 240W 96% Through hole CC109114294 EUK240S9R0641Z 36-60 Vdc 9.6V 240W 96% Through hole CC109143525 Product codes -Z indicates RoHS Compliant modules Table 2. Device Options Option Negative remote on/off logic Suffix 1 Auto-restart (must be ordered) 4 Pin Length: 3.68 mm ± 0.25mm , (0.145 in. ± 0.010 in.) 6 Pin Length: 2.79 mm ± 0.25mm , (0.110 in. ± 0.010 in.) 8 Asia-Pacific Headquarters Tel: +65 6416 4283 World Wide Headquarters Lineage Power Corporation 3000 Skyline Drive, Mesquite, TX 75149, USA +1-800-526-7819 (Outside U.S.A.: +1-972-284-2626) www.lineagepower.com e-mail: [email protected] Europe, Middle-East and Africa Headquarters Tel: +49 89 6089 286 India Headquarters Tel: +91 80 28411633 Lineage Power reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such product(s) or information. © 2008 Lineage Power Corporation, (Mesquite, Texas) All International Rights Reserved. Document No: DS06-113 ver. 1.03 PDF name: euk240_series_ds.pdf