Eighth-brick Mars 48V Input, 2.0VDC, 40A Output Quarter-brick The Mars CoolConverter™ is the most cost-effective 100W quarter-brick on the market. Industry Standard Pinout and Footprint No Heat Sink Required Very Low Common-mode Noise for a Commercial DC/DC Converter Two-stage Input Filter Constant Switching Frequency Remote Sense Single Board Design Very Low Parts Count Optional Baseplate or Low Profile Heatsink for Improved Thermal Performance Header with M3 Metal Inserts for Mechanical Connection to PCB Two Year Warranty Half-brick The Mars Series of quarterbrick DC/DC converters offers high current performance with high efficiency at low cost. 3-Quarter-brick Control Functions GAMW2V040 Features: 48V Input 2.0VDC, 40A Output High Efficiency: 87% at 2.0V, 40A 89% at 2.0V, 20A Uses Patented Power Supply Control and Architecture Microprocessor Controlled Primary-side Enable, Choice of Logic SIP Protection Features Over Temperature Protection Over Voltage Protection Over Current Protection Over/Under Input Voltage Protection Typical Characteristics Output Setpoint Accuracy: ± 1% Load Regulation: ± 0.2% Line Regulation: ± 0.2% Regulation over Line, Load, and Temperature: ± 2% Low Output Ripple Output Trim ISO 9001 CERTIFIED ORGANISATION ® Certified to ISO 9001:2000 Part No. 02-GAM-04 Rev. 1.0 – 042805 Galaxy Power Inc. 155 Flanders Road WWW.GALAXYPWR.COM Westborough, MA 01581 Telephone: 508-870-9775 GAMW2V040 – 1 Fax: 508-870-9796 e-mail: [email protected] General Specifications VIN = 48VDC, TA@25° C, 300 LFM Airflow, VOUT=2.0VDC, IOUT = Full Load unless otherwise noted. Available output power depends on ambient temperature and good thermal management. (See application graphs for limits.) Input Characteristics Parameter Operating Input Voltage Min Typ Max Units 36 48 75 VDC 2.9 A Input Current Input Capacitance 3 µF Input Hysteresis, Low Line 2 VDC Output Characteristics Regulation Over Line, Load & Temperature 1.960 2.040 V Voltage Ripple 20 Voltage Ripple, 20MHz BW 60 mV RMS mV P–P 0 40 A 41.2 56 %Io MAX Short Circuit Current, Peak1 60 A Output Transient Response, 50% to 75% load change, 1A/µsec2 18 %VOUT 300 µS 25 mS Current Range Current Limit Inception Settling Time to ± 1% Turn-on Time to 98%Vnom Output Overshoot at Turn-on 0 Trim Range 70 Overvoltage Protection, Latching %VOUT 110 130 %VOUT %VOUT Isolation Isolation Test Voltage, Input/Output (Basic) Isolation Resistance 2250 VDC 10 MΩ Features Overtemperature Protection, Thermal Sensor, Latching3 110 Switching Frequency, Fixed 250 °C kHz Notes: 1. During short circuit, converter will shut down and attempt to restart once per second. The average current during this condition will be very low and the device can be safely left in this condition continuously. 2. Limited by output energy storage. For improved performance see Tuned (T) model information. 3. PCB less than 130° C General Specifications Approvals and Standards Operating Temperature –40° C to +100° C Storage Temperature –55° C to +125° C Relative Humidity 10% to 95% RH, Non-condensing Vibration 2 to 9Hz, 3mm disp., 9 to 200Hz, 1g Material Flammability UL V-0 Weight MTBF EMC Characteristics: Designed to meet emission and immunity requirements per EN55022, CISPR 22, Class B, and CISPR 24. ** An external fuse shall be used to comply with the requirements. 35 grams Telcordia (Bellcore) TBD WWW.GALAXYPWR.COM GAMW2V040 – 2 Galaxy Power Inc. UL and c-UL Recognized Component, TUV**, UL60950, CSA 22.2 No. 950, IEC/EN 60950 155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775 Part No. 02-GAM-04 Rev. 1.0 – 042805 Fax: 508-870-9796 e-mail: [email protected] Application Notes CoolConverter™ Galaxy’s proprietary CoolConverter™ provides: • Patented single-stage power conversion architecture, control, and magnetic design allow unprecedented power density and efficiency in an isolated power supply. • An advanced microcontroller reduces parts count while adding features, performance, and flexibility in the design. • Low common-mode noise as a result of lower capacitance in the transformer from balanced winding design. Protection and Control Undervoltage Hysteresis Normalized 1.0 Output Voltage Valid Input Voltage Range: The converter measures the input voltage and will not allow operation outside of the input voltage specification. As shown by the graphs, hysteresis is added to both the high and low voltage to prevent the converter from turning on and off repeatedly when the voltage is held near either voltage extreme. At low line this assures the maximum input current is not exceeded; at high line this assures the semiconductor devices in the converter are not damaged by excessive voltage stress. 0 30 31 32 33 35 34 36 37 Input Voltage (V) Overvoltage Hysteresis Normalized 1.0 Output Voltage ON/OFF Logic Option: The ON/OFF control logic can be either Negative (standard) or Positive to enable the converter. For Negative logic the ON/OFF pin is brought to below 1.0V with respect to the –INPUT pin to enable the converter. The pull down must be able to sink 100µA. For Positive logic the ON/OFF pin is brought to greater than 4.0V with respect to the –INPUT pin and be limited to less than 10V. To request the Positive logic version, add the suffix (P) to the standard part number. The ON/OFF pin has a built-in pull up resistor of approximately 100kΩ to +5V. 0 76.5 77 77.5 78 78.5 79 79.5 80 80.5 Input Voltage (V) Part No. 02-GAM-04 Rev. 1.0 – 042805 Galaxy Power Inc. 155 Flanders Road WWW.GALAXYPWR.COM Westborough, MA 01581 Telephone: 508-870-9775 GAMW2V040 – 3 Fax: 508-870-9796 e-mail: [email protected] Application Notes Thermal Shutdown: The printed circuit board temperature is measured using a semiconductor sensor. If the maximum rated temperature is exceeded, the converter is latched off. To re-enable the converter requires cycling the ON/ OFF pin or power to the converter. If non-latching is required, consult factory. Control Options: As the behavior of the circuit is determined by firmware in the microcontroller, specific customer requirements such as • non-latching thermal protection • custom valid input voltage range • controlled delay from initiating an ON/OFF signal for power sequencing can be accomplished with no change to hardware. The standard behavior was chosen based on system design experience but we understand that customers often have their own requirements. Please consult Galaxy Power for your special needs. Trim: To trim the output voltage higher, connect the required trim resistor from the Trim pin to the +Sense pin. To trim the output voltage lower, connect the required trim resistor from the Trim pin to the –Sense pin. Trim-up RTRIM-UP = { } 2 (100+∆%) (100+2∆%) 1.225∆% – ∆% 5.11kΩ 2.0V Trim-up 1000 Trim Resistance (kΩ) Output Over Voltage Protection: The output voltage is constantly monitored by the microprocessor with a redundant secondary-side measurement circuit that both shuts down the duty cycle and triggers the microprocessor to shut down. If the output voltage exceeds the over-voltage specification, the microprocessor will latch the converter off. To turn the converter on requires either cycling the ON/OFF pin or power to the converter. This advanced feature prevents the converter from damaging the load if there is a converter failure or application error. If non-latching is required, consult factory. 100 10 0 1 2 3 4 5 6 7 8 9 10 Increase in Output Voltage (%) Trim-down RTRIM-DOWN = 100 –2 ∆% { } 5.11kΩ Trim-down Remote Sense: The output voltage is regulated at the point where the sense pins connect to the power output pins. Total sense compensation should not exceed 0.4V or 10% of Vout, whichever is greater. Safety: An external input fuse must always be used to meet these safety requirements. Trim Resistance (kΩ) 1000 100 10 0 External Output Trimming 1 2 3 4 5 6 7 8 9 10 Decrease in Output Voltage (%) + Sense Trim – Sense WWW.GALAXYPWR.COM GAMW2V040 – 4 Galaxy Power Inc. 155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775 Part No. 02-GAM-04 Rev. 1.0 – 042805 Fax: 508-870-9796 e-mail: [email protected] GAMW2V04o Operation Power Dissipation Efficiency 14 Power Dissipation (W) 92 Efficiency (%) 90 88 86 84 82 36V Vin 48V Vin 75V Vin 80 78 12 10 8 6 36V Vin 48V Vin 75V Vin 4 2 0 76 0 5 10 20 15 25 30 35 5 0 40 10 15 20 25 30 Output Current (A) Output Current (A) Start Up Voltage Ripple 35 40 CH2 CH1 CH3 1) Vout 20mV/div 2µS/div 10µF ext cap 20MHz BW 1) Vout 1V/div 4mS/div 2) Iout 10A/div 3) Enable 5V/div Line/Load Regulation Transient Response Output Voltage (V) 2.04 CH1 CH2 Setpoint Accuracy 0.4450% Line Regulation 0.0847% Load Regulation 0.0498% Line & Load Regulation 0.1121% 2.03 2.02 2.01 2.00 1.99 36V Vin 48V Vin 75V Vin 1.99 1.98 1.97 0 Part No. 02-GAM-04 Rev. 1.0 – 042805 155 Flanders Road 10 15 20 25 30 35 40 Output Current (A) 1) Vout 200mV/div 200µS/div 2) Iout 10A/div Galaxy Power Inc. 5 WWW.GALAXYPWR.COM Westborough, MA 01581 Telephone: 508-870-9775 GAMW2V040 – 5 Fax: 508-870-9796 e-mail: [email protected] GAMW2V040 Operation Back Bias Over-current Protection Note: Over-current protection is blip-mode (aka hiccup). Output Voltage (V) 2.5 2.0 1.5 1.0 36V Vin 48V Vin 75V Vin 0.5 0 40 41 42 1) Vout 500mV/div 2mS/div Thermal Derating 40 35 35 Output Current (A) Output Current (A) 40 30 25 20 300 LFM 200 LFM 100 LFM 5 0 0 10 20 30 45 46 Lengthwise Airflow 45 10 44 Thermal Derating Crosswise Airflow 45 15 43 Output Current (A) 40 50 60 70 80 90 30 25 20 15 300 LFM 200 LFM 100 LFM 10 5 0 0 Ambient Temperature (°C) 10 20 30 40 50 60 70 80 90 Ambient Temperature (°C) Over Voltage Protection 1) Vout 0.5V/div 0.25mS/div WWW.GALAXYPWR.COM GAMW2V040 – 6 Galaxy Power Inc. 155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775 Part No. 02-GAM-04 Rev. 1.0 – 042805 Fax: 508-870-9796 e-mail: [email protected] PACKAGE DETAIL .45 .120 2.28 2.000 .070 MOUNTING THREADS M3 X 0.5, 4 PLACES .21 1.860 .815 PIN 4 1.45 PIN 3 .815 PIN 2 .515 PIN 1 .215 .665 PIN 5 Pin Configuration Pin .515 PIN 6 .365 PIN 7 1.030 .215 PIN 8 0 .21 BOTTOM VIEW Notes: 1. Mechanical tolerances: x.xxx in. = ± 0.005 in. x.xx in. = ± 0.01 in. 2. Pin material: brass with tin/lead plating over nickel 3. Workmanship: Meets or exceeds IPC-A-610B Class II 4. "A" = 0.040" dia. pins 5. "B" = 0.060" dia. pins 6. Min. screw length for heatsink attachment = 4.5mm + heatsink flange + locking hardware. (Bottom View) Function Pin Dia. (in.) 1 + Input 0.040 2 On/Off 0.040 3 – Input 0.040 4 – Output 0.060 5 – Sense 0.040 6 Trim 0.040 7 + Sense 0.040 8 + Output 0.060 ORDERING INFORMATION Standard Model Number GAMW2V040* Input Voltage Output Voltage Max Current 48V 2.0V 40A Example Part No.: (All options shown) GAMW2V040 P S T * Options: P = Positive Logic Version; High = On E = 0.18" Pins (± .01") M = 0.145" Pins (± .01") S = 0.12" Pins (± .01") T = Tuned model** Part Number **T (Tuned Model) Option Designed for higher di/dt and ∆I applications, the transient response has been modified to take advantage of the capacitance on the customer's PCB. This unit requires a minimum load capacitance of 5600µF with an impedance magnitude of less than 0.005Ω at 15kHz. It offers a minimum 3X improvement in the peak response compared to a standard unit. Options: Positive Logic Version Optional Pin Lengths E = 0.18" M = 0.145" S = 0.12" Tuned Model Galaxy Power Inc. warrants to the original purchaser that the products conform to this data sheet and are free from material and workmanship defects for a period of two (2) years from the date of manufacture, if this product is used within specified conditions. Galaxy Power Inc. 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 products or information. For additional details on this limited warranty consult the factory. Part No. 02-GAM-04 Rev. 1.0 – 042805 Galaxy Power Inc. 155 Flanders Road WWW.GALAXYPWR.COM Westborough, MA 01581 Telephone: 508-870-9775 GAMW2V040 – 7 Fax: 508-870-9796 e-mail: [email protected]