Vicor IB048E096T48N3-OO 5:1 intermediate bus converter module: up to 500 w output Datasheet

IBC Module
IB048E096T48N1-00
5:1 Intermediate Bus Converter Module: Up to 500 W Output
Features
• Input: 38 – 55 Vdc
• 98% peak efficiency
• Output: 9.6 Vdc at 48 Vin
• Low profile: 0.38” height above board
• Output current up to 48 A
• Industry standard 1/8 Brick pinout
• Output power: up to 500 W
Size:
2.30 x 0.9 x 0.38 in
58,4 x 22,9 x 9,5 mm
[A]
• 1,500 Vdc isolation
• Sine Amplitude Converter
• Low noise 1 MHz ZVS/ZCS
[A]
For lower power applications see 300 W model IB048E096T40N1-00
Product Overview
Applications
The Intermediate Bus Converter (IBC) Module is a very efficient, low profile, isolated, fixed
• Enterprise networks
ratio converter for power system applications in enterprise and optical access networks.
• Optical access networks
• Storage networks
Rated at up to 360 W from 38 Vin and up to 500 W from 54 to 55 Vin, the IBC
• Automated test equipment
conforms to an industry standard eighth brick footprint while supplying the power of
a quarter brick. Its leading efficiency enables full load operation at 55 °C with only
200 LFM airflow. Its small cross section facilitates unimpeded airflow — above and
below its thin body — to minimize the temperature rise of downstream components.
Absolute Maximum Ratings
Min
Max
Unit
36
60
Vdc
Non-operating
75
Vdc
Input voltage slew rate
5
V/μs
Notes
Input voltage (+In to –In)
Operating
<100 mS
EN to –IN
-0.5
20
Vdc
Output voltage (+Out to –Out)
-0.5
13.8
Vdc
48
A
Pout ≤ 500 W
Vdc
1 min.
Hottest Semiconductor
Output current
Dielectric withstand
(input to output)
1,500
Temperature
Operating junction
Storage
-40
125
°C
-55
125
°C
IBC MODULE
Rev 1.5
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IB048E096T48N1-00
SPECIFICATIONS
All specifications valid at 48 VIN , 100% rated load and 25 °C ambient, unless otherwise indicated.
Electrical Characteristics
Attribute
Symbol
Conditions / Notes
Min
Typ
Max
Unit
38
48
55
75
5
Vdc
Vdc
V/us
36
34
7
200
Vdc
Vdc
Vdc
µs
µs
64
64
4
Vdc
Vdc
µs
30
ms
50
µs
50
µs
250
ms
2.5
0.21
9.8
13.5
W
W
A
A
500
mArms
40
25
A
A
μF
nH
INPUT (Operating from DC input source)
Operating input voltage
Non-operating input surge withstand
Operating input dV/dt
<100 mS
0.003
Undervoltage protection
Turn-on
Turn-off
Turn-on/ Turn-off hysteresis
Time constant
Undervoltage blanking time
31
29
2
UV blanking time is enabled after start up
Overvoltage protection
Turn-off
Turn-on
Time constant
50
100
60
55
Turn ON delay
VIN reaching turn-on voltage
to enable function operational, see Figure 6
Enable to 90% VOUT; pre-applied VIN, see Figure 7,
0 load capacitance
From 10% to 90% Vout, 10% load,
0 load capacitance.
See page 10 for resart after EN pin disable
Start up inhibit
Turn-on delay
Output voltage rise time
Restart turn-on delay
No Load power dissipation
Enabled
Disabled
Input current
Inrush current overshoot
20
25
1.9
0.18
Low line, full load
Using test circuit in Figure 21
At max power;
Using test circuit in Figure 22
Input reflected ripple current
Peak short circuit input current
Repetitive short circuit peak current
Internal input capacitance
Internal input inductance
Recommended external
input capacitance
8.8
5
470
μF
11.0
V
0
0
360
450
W
W
0
500
48
W
A
15
%
mΩ
200 nH maximum source inductance
47
No load, over Vin range
7.6
OUTPUT
DC Output voltage band
Output power [a]
38-55 VIN
48-55 VIN
54-55 VIN
Output current
P ≤ 500 W
of Iout max, maximum output capacitance
Output start up load
Effective output resistance
Line regulation (K factor)
[a]
9.6
VOUT = K • VIN @ no load
0.198
4.7
0.200
0.2020
Does not exceed IPC-9592 derating guidelines. At 70 °C ambient, full power operation may exceed IPC-9592 guidelines, but does not exceed
component ratings, does not activate OTP and does not compromise reliability.
IBC MODULE
Rev 1.5
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IB048E096T48N1-00
SPECIFICATIONS (CONT.)
All specifications valid at 48 VIN , 100% rated load and 25 °C ambient, unless otherwise indicated.
Electrical Characteristics (Continued)
Attribute
Symbol
Conditions / Notes
Min
Typ
Max
Unit
10
%
4500
12.8
%
%
nH
μF
μF
Vdc
150
mVp-p
150
%
5
1.5
ms
µs
MHz
100
mV
1.25
µs
V
12
Vdc
OUTPUT (Continued)
Full power operation; See Parallel Operation
on page 11; up to 3 units
Current share accuracy
Efficiency
50% load
Full load
Internal output inductance
Internal output capacitance
Load capacitance
Output OVP set point
Output voltage ripple
Output Overload protection threshold
See Figure 1,2 and 3
See Figure 1,2 and 3
97.5
96.9
Nominal load
Module will shutdown
20 MHz bandwidth, using test circuit in
Figure 23
Of Iout max., will not shutdown when started
into max Cout and 15% load
Auto restart with duty cycle <10%
0
12.0
98.0
97.1
1.6
55
60
105
Over current protection time constant
Short circuit current response time
Switching frequency
Transient Response
1.0
25% load step; See Figures 11 - 14
using test set up in Figure 24
See Figures 11 - 14 using test set up in Figure 24
5 V step in 1 µs within Vin operating range
Unit will start up
into pre-bias voltage on output
Voltage overshoot
Response time
VIN step
Pre-bias voltage
1
0
General Characteristics
Conditions: 25°C case, 75% rated load and specified input voltage range unless otherwise specified.
Attribute
Symbol
MTBF
Service life
Conditions / Notes
Calculated per Telcordia SR-332, 40 °C
Calculated at 30 °C
TJ ; Converter will reset when over
temperature condition is removed
Input to output
Input to output
Over temperature shut down
Dielectric withstand
Insulation resistance
Mechanical
Weight
Length
Width
Height above customer board
Clearance to customer board
From lowest component on IBC
UL/cUL 60950-1, EN 60950-1, IEC 60950-1
Low voltage directive (CE Mark)
Derate operating temp 1 °C
per 1,000 feet above sea level
Non condensing
Compatible with RoHS directive 2002/95/EC
Agency approvals
Altitude, operating
Relative humidity, Operating
RoHS compliance
IBC MODULE
Rev 1.5
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Min
Typ
Max
1.0
7
125
Unit
Mhrs
Years
130
135
1,500
°C
Vdc
MΩ
30
0.71 / 20.3
2.30 /58.4
0.9/22.9
0.38 /9.5
0.12/3.0
oz/g
in/mm
in/mm
in/mm
in/mm
cTUVus
CE
-500
10,000
Feet
10
90
%
IB048E096T48N1-00
SPECIFICATIONS (CONT.)
Control & Interface Specifications
Attribute
Symbol
Enable (negative logic)*
Module enable threshold
Module enable current
Module disable threshold
Module disable current
Disable hysteresis
Enable pin open circuit voltage
EN to –IN resistance
Enable (positive logic)*
Module enable threshold
Module disable threshold
EN source current (operating)
EN voltage (operating)
Conditions / Notes
Min
Typ
Max
130
200
2.4
10
Unit
Referenced to –IN
0.8
VEN = 0.8 V
VEN = 2.4 V
500
2.5
35
Open circuit, 10 V applied between EN and -IN
Referenced to –IN
2.0
2.5
4.7
5
VEN = 5 V
Vdc
µA
Vdc
µA
mV
Vdc
kΩ
3.0
3.0
1.45
2
5.3
Vdc
Vdc
mA
Vdc
*See part numbering on page 11
IPC-9592A, Based on Class II Category 2 the following detail is applicable. – Pre-conditioning required
Environmental Qualification
Test Description
5.2.3 HALT (Highly Accelerated Life testing)
Test Detail
Low Temp
High Temp
Rapid Thermal Cycling
6 DOF Random Vibration Test
Input Voltage Test
Output Load Test
Combined Stresses Test
Quantity Tested
3
3
3
3
3
3
3
5.2.4 THB (Temp. Humidity Bias)
(72 hr presoak required) 1000 hrs – Continuous Bias
5.2.5 HTOB (High Temp. Operating Bias)
Power cycle - On 42 minutes
Off 1 minute, On 1 minute, Off 1 minute, On 1 minute, Off 1 minute,
On 1 minute, Off 1 minute, On 1 minute, Off 10 minutes. Alternating
between maximum and minimum operating Voltage every hour.
5.2.6 TC (Temp. Cycling)
700 cycles , 30 minute dwell at each extreme – 20C minimum ramp rate.
30
5.2.7 Power Cycling
Reference IPC-9592A
3
5.2.8 – 5.2.13 Shock and Vibration
Random Vibration – Operating IEC 60068-2-64 (normal operation vibration)
Random Vibration Non-operating (transportation) IEC 60068-2-64
Shock Operating - normal operation shock IEC 60068-2-27
Free fall - IEC 60068-2-32
Drop Test 1 full shipping container (box)
3
3
3
3
12
5.2.14 Other Environmental Tests
5.2.14.1 Corrosion Resistance – Not required
5.2.14.2 Dust Resistance – Unpotted class II GR-1274-CORE
5.2.14.3 SMT Attachment Reliability IPC-9701 - J-STD-002
5.2.14.4 Through Hole solderability – J-STD-002
N/A
3
3
5
ESD Classification Testing
Sample size assumes CDM testing
Total Quantity
30
30
12
161
IBC MODULE
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IB048E096T48N1-00
SPECIFICATIONS (CONT.)
WAVEFORMS
Efficiency TAMB 25 °C
Efficiency TAMB 55 °C
99
98
98
97
97
Efficiency (%)
Efficiency (%)
99
96
95
94
93
96
95
94
93
92
92
10
0
VIN :
19
Iout (A)
38 V
29
38
48 V
48
0
55 V
10
VIN :
19
38 V
Iout (A)
29
48 V
38
48
55 V
Figure 2 — Efficiency vs. output current, 55°C ambient
Figure 1 — Efficiency vs. output current, 25°C ambient
Efficiency TAMB 70 °C
99
Efficiency (%)
98
97
96
95
94
93
92
0
10
VIN :
19
38 V
Iout (A)
29
48 V
38
48
55 V
Figure 3 — Efficiency vs. output current, 70°C ambient
Figure 4 — Inrush current at high line 15% load
Figure 5 — Input reflected ripple current at nominal line, full load
Figure 6 — Turn on delay time;
VIN turn on delay at nominal line, 15% load; start up inhibit time
IBC MODULE
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IB048E096T48N1-00
SPECIFICATIONS (CONT.)
WAVEFORMS (CONT.)
Figure 7 — Turn on delay time;
Enable turn on delay at nominal line, 15% load
Figure 8 — Output voltage rise time at nominal line, 10% load
Figure 9 — Overshoot at turn on at nominal line, 15% load
Figure 10 — Undershoot at turn off at nominal line, 15% load
Figure 11 — Load transient response; nominal line
Load step 75– 100%
Figure 12 — Load transient response; Full load to 75%; nominal line
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IB048E096T48N1-00
SPECIFICATIONS (CONT.)
WAVEFORMS (CONT.)
Figure 13 — Load transient response; nominal line
Load step 0 – 25%
Figure 14 — Load transient response; 25–0%; nominal line
Figure 15 — Input transient response;
Vin step low line to high line at full load
Figure 16 — Output ripple; Nominal line, full load
Figure 17 — Three module parallel array test. Vout change when one
module is disabled. Nominal Vin, Iout = 96 A
Figure 18 — Three module parallel array test. Vout change with two
modules operating and a third module enabled. Nominal Vin,
Iout = 96 A
IBC MODULE
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SPECIFICATIONS (CONT.)
SPECIFICATIONS
Output Current Derating
50
45
45
40
40
Output Current (A)
35
30
25
20
15
10
35
30
25
20
15
10
5
5
0
25
35
45
55
65
75
85
0
95
25
35
45
Ambient Air Temperature (°C)
200 LFM
400 LFM
EN
47 µF
85
95
200 LFM
400 LFM
600 LFM
Current Probe
+IN
10 µH
+OUT
IBC
Load
_
75
Figure 20 — Maximum output power derating vs ambient air temperature.
Longitudinal airflow, Board and junction temperatures <125 °C
tested with IBC evaluation board IB048E096T48N1-CB
Current Probe
+
65
Ambient Air Temperature (°C)
600 LFM
Figure 19 — Maximum output power derating vs ambient air temperature.
Transverse airflow, Board and junction temperatures <125 °C
tested with IBC evaluation board IB048E096T48N1-CB
Vsource
55
–IN
–OUT
+IN
+
C*
Vsource
_
+OUT
EN
470 µF
Load
Output Current (A)
Output Current Derating
50
IBC
–IN
–OUT
*Maximum load capacitance
Figure 21 — Inrush current overshoot
+OUT
10 µF
0.1 µF
IBC
–IN
E – Load
+IN
+
–OUT
Vsource
_
CIN
EN
+OUT
IBC
–IN
Cya
Cyc
Cyb
Cyd
COUT
RL
–OUT
CIN = 500 µF
COUT = 0.4 x [ POUT MAX (w) ] µF
RL =
20 MHz BW
VOUT
0.25 x IOUT MAX
Cy a-d = 4700 pF
Figure 23 — Test circuit; output voltage ripple
Figure 24 — Load transient response
IBC MODULE
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800 735.6200
Ω
Load
+IN
Figure 22 — Input reflected ripple current
IB048E096T48N1-00
SPECIFICATIONS (CONT.)
THERMAL DATA
Figure 25 — Thermal plot, 200 LFM, 25 °C, 48 Vin, 450 W output power
Figure 26 — Thermal plot, 200 LFM, 25 °C, 48 Vin, 450 W output power
Figure 27 — Thermal plot, 400 LFM, 25 °C, 48 Vin, 450 W output power
Figure 28 — Thermal plot, 400 LFM, 25 °C, 48 Vin, 450 W output power
Figure 29 — Thermal plot, 600 LFM, 25 °C, 48 Vin, 450 W output power
Figure 30 — Thermal plot, 600 LFM, 25 °C, 48 Vin, 450 W output power
IBC MODULE
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IB048E096T48N1-00
PIN / CONTROL FUNCTIONS
+In / -In – DC Voltage Input Pins
The IBC input voltage range should not be exceeded. An internal
undervoltage /overvoltage lockout function prevents operation outside of
the normal operating input range. The IBC 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.
1
5
2 Top View
3
The connection of the IBC 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 47 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.
4
Pin
1
2
3
4
5
EN - Enable/Disable
Negative Logic Option
If the EN port is left floating, the IBC output is disabled. Once this port ispulled lower than 0.8 Vdc with respect to –In, the output is enabled. The
EN port can be driven by a relay, opto-coupler, or open collector transistor.
Refer to Figures 6 and 7 for the typical enable / disable characteristics. This
port should not be toggled at a rate higher than 1 Hz. The EN port should
also not be driven by or pulled up to an external voltage source.
Figure 31 — IBC Pin Designations
Positive Logic Option
If the EN port is left floating, the IBC output is enabled. Once this port is
pulled lower than 1.4 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.
The EN port should also not be driven by or pulled up to an external voltage source. The EN port can source up to 2 mA at 5 Vdc. The EN port
should never be used to sink current.
If the IBC is disabled using the EN pin, the module will attempt to restart
approximately every 250ms. Once the module has been disabled for at least
250ms, the turn on delay after the EN pin is enabled will be as shown in
Figure 7.
+Out / -Out – DC Voltage Output Pins
Total load capacitance at the output of the IBC should not exceed the
specified maximum. Owing to the wide bandwidth and low output
impedance of the IBC, low frequency bypass capacitance and significant
energy storage may be more densely and efficiently provided by adding
capacitance at the input of the IBC.
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Function
Vin+
Enable
VinVoutVout+
IB048E096T48N1-00
APPLICATIONS NOTE
Parallel Operation
Input Impedance Recommendations
The IBC will inherently current share when operated in an array. Arrays may
be used for higher power or redundancy in an application. Current sharing
accuracy is maximized when the source and load impedance presented to
each IBC within an array are equal. The recommended method to achieve
matched impedances is to dedicate common copper planes within the PCB
to deliver and return the current to the array, rather than rely upon traces
of varying lengths. In typical applications the current being delivered to the
load is larger than that sourced from the input, allowing narrower traces to
be utilized on the input side if necessary. The use of dedicated power
planes is, however, preferable.
To take full advantage of the IBC capabilities, the impedance presented to
its input terminals must be low from DC to approximately 5 MHz.
The source should exhibit low inductance and should have a critically
damped response. If the interconnect inductance is excessive, the IBC input
pins should be bypassed with an RC damper (e.g., 47 μF in series with
0.3 Ω) to retain low source impedance and proper operation. Given the
wide bandwidth of the IBC, 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
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
overvoltage /undervoltage detection circuitry could be activated.
One or more IBCs in an array may be disabled without adversely affecting
operation or reliability as long as the load does not exceed the rated power
of the enabled IBCs.
The IBC power train and control architecture allow bi-directional power
transfer, including reverse power processing from the IBC output to its
input. The IBC’s ability to process power in reverse improves the IBC transient response to an output load dump.
Input Fuse Recommendations
The IBC is not internally fused in order to provide flexibility in configuring
power systems. However, input line fusing of VI Bricks must always be
incorporated within the power system. A fast acting fuse should be placed
in series with the +In port. See safety agency approvals.
Thermal Considerations
The temperature distribution of the VI Brick can vary significantly
with its input /output operating conditions, thermal management and
environmental conditions. Although the PCB is UL rated to 130 °C, it is
recommended that PCB temperatures be maintained at or below 125 °C.
For maximum long term reliability, lower PCB temperatures are
recommended for continuous operation, however, short periods of
operation at 125 °C will not negatively impact performance or reliability.
Application Notes
For IBC and VI Brick application notes on soldering, thermal management,
board layout, and system design visit vicorpower.com.
WARNING: Thermal and voltage hazards. The IBC can operate with surface
temperatures and operating voltages that may be hazardous to personnel.
Ensure that adequate protection is in place to avoid inadvertent contact.
PART NUMBERING
Product
Family
Input
Voltage
Package
Nominal
Output Voltage
Temperature
Grade
Output
Current
Enable
Logic
Pin
Length
IB
048 = 38-55 Vdc
E
096
T
48
N = Negative
P = Positive
1 = 0.145
2 = 0.210
3 = 0.180
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Options
-00 = Open frame
IB048E096T48N1-00
MECHANICAL DRAWINGS
Pin Length (X)
Designator
Length
1
0.145 [3.68]
2
0.21 [5.33]
3
0.18 [4.57]
(X)
Figure 32 — IBC outline drawing
Top View
Figure 33 — IBC PCB recommended hole pattern
IBC MODULE
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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.
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All sales are subject to Vicor’s Standard Terms and Conditions of Sale, which are available on Vicor’s webpage or upon request.
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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
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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
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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;
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Andover, MA, USA 01810
Tel: 800-735-6200
Fax: 978-475-6715
email
Customer Service: [email protected]
Technical Support: [email protected]
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