BCM® Bus Converter BCM6123x60E15A3yzz ® S US C C NRTL US Fixed Ratio DC-DC Converter Features Product Ratings • Up to 130 A continuous output current • 2870 W/in3 power density VPRI = 54 V (36 – 60 V) PSEC= up to 1950 W VSEC = 13.5 V (9 – 15 V) (NO LOAD) K = 1/4 • 97.4% peak efficiency • 2,250 Vdc isolation • Parallel operation for multi-kW arrays • OV, OC, UV, short circuit and thermal protection • 6123 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 36 to 60 VDC primary bus to deliver an isolated, ratiometric output from 9 to 15 VDC. (61.00 mm x 25.14 mm x 7.26 mm) Typical Applications The BCM6123x60E15A3yzz 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 primary side of the BCM module. With a primary to secondary K factor of 1/4, that capacitance value can be reduced by a factor of 16x, resulting in savings of board area, material and total system cost. • High End Computing Systems • Automated Test Equipment • Industrial Systems • 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. BCM® Bus Converter Rev 1.1 vicorpower.com Page 1 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz Typical Application BCM TM EN enable/disable switch SW1 VAUX F1 VPRI +VPRI +VSEC –VPRI –VSEC CPRI GND POL PRIMARY SECONDARY ISOLATION BOUNDRY BCM6123x60E15A3yzz + Point of load BCM® Bus Converter Rev 1.1 vicorpower.com Page 2 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz Pin Configuration 1 TOP VIEW 2 +VSEC A A’ +VSEC -VSEC1 B B’ -VSEC2 -VSEC1 C C’ -VSEC2 +VSEC D D’ +VSEC +VSEC E E’ +VSEC -VSEC1 F F’ -VSEC2 -VSEC1 G G’ -VSEC2 +VSEC H H’ +VSEC +VPRI I I’ TM +VPRI J J’ EN +VPRI K K’ VAUX +VPRI L L’ -VPRI 6123 ChiP Package Pin Descriptions Pin Number Signal Name Type I1, J1, K1, L1 +VPRI PRIMARY POWER I’2 TM OUTPUT J’2 EN INPUT K’2 VAUX OUTPUT L’2 -VPRI A1, D1, E1, H1, A’2, D’2, E’2, H’2 B1, C1, F1, G1 B’2, C’2, F’2, G’2 +VSEC -VSEC* PRIMARY POWER RETURN SECONDARY POWER SECONDARY POWER RETURN Function Positive primary transformer power terminal Temperature Monitor; primary side referenced signals Enables and disables power supply; primary side referenced signals Auxilary Voltage Source; primary side referenced signals Negative primary transformer power terminal Positive secondary transformer power terminal Negative secondary transformer power terminal *For proper operation an external low impedance connection must be made between listed -VSEC1 and -VSEC2 terminals. BCM® Bus Converter Rev 1.1 vicorpower.com Page 3 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz Part Ordering Information Product Function Package Size Package Mounting Max Primary Input Voltage Range Identifier Max Secondary Voltage Secondary Output Current Temperature Grade Option BCM 6123 x 60 E 15 A3 y zz Bus Converter Module 61 = L 23 = W T = TH 36 – 60 V 15 V No Load 00 = Analog Ctrl S = SMT 60 V 130 A T = -40°C – 125°C 01 = PMBus Ctrl M = -55°C – 125°C 0R = Reversible Analog Ctrl 0P = Reversible PMBus Ctrl All products shipped in JEDEC standard high profile (0.400” thick) trays (JEDEC Publication 95, Design Guide 4.10). Standard Models Product Function Package Size Package Mounting Max Primary Input Voltage Range Identifier Max Secondary Voltage Secondary Output Current Temperature Grade Option BCM 6123 T 60 E 15 A3 T 00 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 +VPRI_DC to –VPRI_DC Min Max Unit -1 80 V 1 V/µs 20 V 4.6 V 5.5 V 4.6 V VPRI_DC or VSEC_DC slew rate (operational) +VSEC_DC to –VSEC_DC -1 TM to –VPRI_DC EN to –VPRI_DC -0.3 VAUX to –VPRI_DC BCM® Bus Converter Rev 1.1 vicorpower.com Page 4 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz 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 60 V 14 V General Powetrain PRIMARY to SECONDARY Specification (Forward Direction) Primary Input Voltage range, continuous VPRI µController PRI to SEC Input Quiescent Current 36 VPRI_DC VPRI_DC voltage where µC is initialized, (ie VAUX = Low, powertrain inactive) VµC_ACTIVE Disabled, EN Low, VPRI_DC = 54 V IPRI_Q 5 TINTERNAL ≤ 100ºC 10 VPRI_DC = 54 V, TINTERNAL = 25ºC PRI to SEC No Load Power Dissipation PRI to SEC Inrush Current Peak 7.5 VPRI_DC = 54 V PPRI_NL 14.7 35.2 25 VPRI_DC = 36 V to 60 V 38 40 TINTERNAL ≤ 100ºC DC Primary Input Current Transformation Ratio Secondary Output Power (continuous) Secondary Output Power (pulsed) Secondary Output Current (continuous) Secondary Output Current (pulsed) PRI to SEC Efficiency (ambient) IPRI_IN_DC PSEC_OUT_PULSE 1/4 ηAMB 1950 W Specified at VPRI_DC = 60 V; 10 ms pulse, 25% Duty cycle, PSEC_AVG = 50% rated PSEC_OUT_DC 2340 W 130 A 156 A 10 ms pulse, 25% Duty cycle, ISEC_OUT_AVG = 50% rated ISEC_OUT_DC VPRI_DC = 54 V, ISEC_OUT_DC = 130 A 96.2 VPRI_DC = 36 V to 60 V, ISEC_OUT_DC = 130 A 95.2 97 VPRI_DC = 54 V, ISEC_OUT_DC = 65 A 96.5 97.4 95.8 96.5 % PRI to SEC Efficiency (hot) ηHOT VPRI_DC = 54 V, ISEC_OUT_DC = 130 A PRI to SEC Efficiency (over load range) η20% 26 A < ISEC_OUT_DC < 130 A 90 RSEC_COLD VPRI_DC = 54 V, ISEC_OUT_DC = 130 A, TINTERNAL = -40°C 1.2 1.5 1.8 RSEC_AMB VPRI_DC = 54 V, ISEC_OUT_DC = 130 A 1.6 1.95 1.3 RSEC_HOT VPRI_DC = 54 V, ISEC_OUT_DC = 130 A, TINTERNAL = 100°C 2.2 2.5 2.8 FSW Frequency of the Output Voltage Ripple = 2x FSW 0.9 0.95 1.0 VSEC_OUT_PP CSEC_EXT = 0 µF, ISEC_OUT_DC = 130 A, VPRI_DC = 54 V, 20 MHz BW PRI to SEC Output Resistance Switching Frequency Secondary Output Voltage Ripple Secondary Output Leads Inductance (Parasitic) % % 120 TINTERNAL ≤ 100ºC Primary Input Leads Inductance (Parasitic) A V/V Specified at VPRI_DC = 60 V ISEC_OUT_DC ISEC_OUT_PULSE A 33 Primary to secondary, K = VSEC_DC / VPRI_DC, at no load PSEC_OUT_DC W 45 At ISEC_OUT_DC = 130 A, TINTERNAL ≤ 100ºC K 21.6 VPRI_DC = 36 V to 60 V, TINTERNAL = 25 ºC VPRI_DC = 60 V, CSEC_EXT = 1000 µF, RLOAD_SEC = 20% of full load current IPRI_INR_PK mA mΩ MHz mV 250 LPRI_IN_LEADS Frequency 2.5 MHz (double switching frequency), Simulated lead model 6.7 nH LSEC_OUT_LEADS Frequency 2.5 MHz (double switching frequency), Simulated lead model 0.64 nH BCM® Bus Converter Rev 1.1 vicorpower.com Page 5 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz 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 Conditions / Notes Min Typ Max Unit General Powetrain PRIMARY to SECONDARY Specification (Forward Direction) Cont. Effective Primary Capacitance (Internal) Effective Secondary Capacitance (Internal) Effective Secondary Output Capacitance (External) Effective Secondary Output Capacitance (External) CPRI_INT Effective Value at 54 VPRI_DC 11.2 µF CSEC_INT Effective Value at 15 VSEC_DC 140 µF CSEC_OUT_EXT Excessive capacitance may drive module into SC protection CSEC_OUT_AEXT CSEC_OUT_AEXT Max = N * 0.5 * CSEC_OUT_EXT MAX, where N = the number of units in parallel 1000 µF 560 ms Protection PRIMARY to SECONDARY (Forward Direction) Auto Restart Time Primary Overvoltage Lockout Threshold Primary Overvoltage Recovery Threshold Primary Overvoltage Lockout Hysteresis Primary Overvoltage Lockout Response Time Primary Undervoltage Lockout Threshold Primary Undervoltage Recovery Threshold Primary Undervoltage Lockout Hysteresis Primary Undervoltage Lockout Response Time Primary Undervoltage Startup Delay Primary Soft-Start Time Secondary Output Overcurrent Trip Threshold Secondary Output Overcurrent Response Time Constant Secondary Output Short Circuit Protection Trip Threshold Secondary Output Short Circuit Protection Response Time Overtemperature Shutdown Threshold Overtemperature Recovery Threshold Undertemperature Shutdown Threshold Undertemperature Restart Time tAUTO_RESTART Startup into a persistent fault condition. Non-Latching fault detection given VPRI_DC > VPRI_UVLO+ 490 VPRI_OVLO+ 64 66 68 V VPRI_OVLO- 60 64 66 V VPRI_OVLO_HYST 2 V tPRI_OVLO 100 µs VPRI_UVLO- 26 28 30 V VPRI_UVLO+ 28 30 32 V VPRI_UVLO_HYST 2 V tPRI_UVLO 100 µs From VPRI_DC = VPRI_UVLO+ to powertrain active, EN tPRI_UVLO+_DELAY floating, (i.e One time Startup delay form application of VPRI_DC to VSEC_DC) 20 ms From powertrain active. Fast Current limit protection disabled during Soft-Start 1 ms tPRI_SOFT-START 145 ISEC_OUT_OCP tSEC_OUT_OCP Effective internal RC filter tOTP– Temperature sensor located inside controller IC; Protection not available for M-Grade units. Startup into a persistent fault condition. Non-Latching fault detection given VPRI_DC > VPRI_UVLO+ BCM® Bus Converter Rev 1.1 vicorpower.com Page 6 of 23 09/2015 800 927.9474 µs 125 105 tUTP_RESTART A 1 Temperature sensor located inside controller IC A ms 195 tSEC_OUT_SCP tUTP 225 3 ISEC_OUT_SCP tOTP+ 180 °C 110 3 115 °C -45 °C s BCM6123x60E15A3yzz Primary/Secondary Output Power (W) 2400 2100 1800 1500 1200 900 600 300 0 35 45 55 65 75 85 95 105 115 125 Case Temperature (°C) Top only at temperature Leads at temperature Top and leads at temperature Top, leads and belly at temperature 2300 2200 2100 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100 1000 900 800 Secondary Output Current (A) Secondary Output Power (W) Figure 1 — Specified thermal operating area 36 38 41 43 46 48 50 53 55 58 200 150 100 50 0 60 36 38 41 Input Voltage (V) PSEC_OUT_DC 43 46 ISEC_OUT_DC PSEC_OUT_PULSE Figure 2 — Specified electrical operating area using rated RSEC_HOT Secondary Output Capacitance (% Rated CSEC_EXT_MAX) 48 50 53 Input Voltage (V) 110 100 90 80 70 60 50 40 30 20 10 0 0 20 40 60 80 Secondary Output Current (% ISEC_DC) Figure 3 — Specified Primary start-up into load current and external capacitance BCM® Bus Converter Rev 1.1 vicorpower.com Page 7 of 23 09/2015 800 927.9474 100 ISEC_OUT_PULSE 55 58 60 BCM6123x60E15A3yzz 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. Temperature Monitor • The TM pin is a standard analog I/O configured as an output from an internal µC. • The TM pin monitors the internal temperature of the controller IC within an accuracy of ±5°C. • µC 250 kHz PWM output internally pulled high to 3.3 V. SIGNAL TYPE STATE Startup ATTRIBUTE Powertrain active to TM time TM Duty Cycle SYMBOL CONDITIONS / NOTES TYP MAX 100 tTM 18.18 TMPWM TM Current MIN ITM UNIT µs 68.18 % 4 mA Recommended External filtering DIGITAL OUTPUT Regular Operation TM Capacitance (External) CTM_EXT Recommended External filtering 0.01 µF TM Resistance (External) RTM_EXT Recommended External filtering 1 kΩ ATM 10 mV / °C VTM_AMB 1.27 V Specifications using recommended filter TM Gain TM Voltage Reference TM Voltage Ripple VTM_PP RTM_EXT = 1 K Ohm, CTM_EXT = 0.01 uF, VPRI_DC = 54 V, ISEC_DC = 130 A 28 mV TINTERNAL ≤ 100ºC 40 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. SIGNAL TYPE STATE Startup ANALOG INPUT Regular Operation ATTRIBUTE EN to Powertrain active time SYMBOL tEN_START EN Voltage Threshold VEN_TH EN Resistance (Internal) REN_INT EN Disable Threshold CONDITIONS / NOTES MIN VPRI_DC > VPRI_UVLO+, EN held low both conditions satisfied for T > tPRI_UVLO+_DELAY TYP MAX 250 µs 2.3 Internal pull up resistor V 1.5 kΩ 1 VEN_DISABLE_TH BCM® Bus Converter Rev 1.1 vicorpower.com Page 8 of 23 09/2015 800 927.9474 UNIT V BCM6123x60E15A3yzz Signal 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. Auxiliary Voltage Source • The VAUX pin is a standard analog I/O configured as an output from an internal µC. • VAUX is internally connected to µC output as internally pulled high to a 3.3 V regulator with 2% tolerance, a 1% resistor of 1.5 kΩ. • VAUX can be used as a "Ready to process full power" flag. This pin transitions VAUX voltage after a 2 ms delay from the start of powertrain activating, signaling the end of softstart. • VAUX can be used as "Fault flag". This pin is pulled low internally when a fault protection is detected. SIGNAL TYPE ANALOG OUTPUT STATE ATTRIBUTE SYMBOL Startup Powertrain active to VAUX time tVAUX VAUX Voltage VVAUX VAUX Available Current IVAUX Regular MIN TYP MAX 2 Powertrain active to VAUX High 2.8 UNIT ms 3.3 V 4 mA 50 VAUX Voltage Ripple VVAUX_PP Operation Fault CONDITIONS / NOTES VAUX Capacitance (External) CVAUX_EXT VAUX Resistance (External) RVAUX_EXT VAUX Fault Response Time tVAUX_FR 100 TINTERNAL ≤ 100ºC 0.01 VPRI_DC < VµC_ACTIVE From fault to VVAUX = 2.8 V, CVAUX = 0 pF BCM® Bus Converter Rev 1.1 vicorpower.com Page 9 of 23 09/2015 800 927.9474 1.5 mV µF kΩ 10 µs VAUX TM OUTPUT OUTPUT OUTPUT EN +VPRI +VSEC BIDIR INPUT VµC_ACTIVE BCM® Bus Converter Rev 1.1 vicorpower.com Page 10 of 23 09/2015 800 927.9474 STARTUP tVAUX tPRI_UVLO+_DELAY VPRI_UVLO+ VPRI_OVLO+ VNOM OVER VOLTAGE VPRI_UVLO- VPRI_OVLO- up ll u N ER T -O L P PU OV R N NA T T U T TER OU PU E U T IN ZE RY ON IN AG I P L RY L T IN U X IA DA N IT ON UR MA VO DC V A N I_ I T I R C PR VP N & µc SE E tAUTO-RESTART ENABLE CONTROL OVER CURRENT > tPRI_UVLO+_DELAY tSEC_OUT_SCP SHUTDOWN GE NT TA H L E W G EV VO LO HI S T F IT D ED RE U U F E P L L C UT IN N-O IR UL PUL P C P Y R T IN E E A R TU BL ABL OR DC M I I_ A H R S PR VP E N EN RT TA BCM6123x60E15A3yzz BCM Module Timing diagram BCM6123x60E15A3yzz High Level Functional State Diagram Conditions that cause state transitions are shown along arrows. Sub-sequence activities listed inside the state bubbles. Application of input voltage to VPRI_DC VμC_ACTIVE < VPRI_DC < VPRI_UVLO+ STANDBY SEQUENCE STARTUP SEQUENCE VPRI_DC > VPRI_UVLO+ TM Low TM Low EN High EN High VAUX Low VAUX Low Powertrain Stopped Powertrain Stopped ENABLE falling edge, or OTP detected tPRI_UVLO+_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 TM Low EN High VAUX Low Powertrain Stopped SUSTAINED OPERATION TM PWM EN High VAUX High Powertrain Active Short Circuit detected BCM® Bus Converter Rev 1.1 vicorpower.com Page 11 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz Application Characteristics 24 22 20 18 16 14 12 10 8 6 39 41 44 47 49 52 55 57 60 98.0 97.5 97.0 96.5 96.0 -40 -20 0 Primary Input Voltage (V) - 40°C 25°C 90°C VPRI: 80 98 70 96 60 94 50 PD 40 90 30 88 20 86 10 84 0 0 13 26 39 52 65 78 91 104 117 PRI to SEC, Power Dissipation PRI to SEC, Efficiency (%) 100 92 54 V 60 50 92 40 30 90 PD 88 10 86 0 84 13 26 60 50 PD 40 90 30 88 20 86 10 84 0 50 63 75 88 100 36 V 54 V 52 65 78 91 104 117 130 113 125 36 V 54 V 60 V 3 2 1 0 -40 -20 Secondary Output Current (A) VPRI : 39 Figure 7 — Efficiency and power dissipation at TCASE = 25°C PRI to SEC, Power Dissipation PRI to SEC, Efficiency (%) 70 38 20 Load Current (A) 96 25 60 V 94 VPRI : 98 13 54 V 70 60 V 80 0 36 V 96 0 100 92 100 98 130 Figure 6 — Efficiency and power dissipation at TCASE = -40°C 94 80 80 PRI to SEC, Output Resistance (mΩ) 36 V 60 100 Secondary Output Current (A) VPRI : 40 Figure 5 — Full load efficiency vs. temperature; VPRI_DC Figure 4 — No load power dissipation vs. VPRI_DC PRI to SEC, Efficiency (%) TTOP SURFACE CASE: 20 Case Temperature (ºC) PRI to SEC, Power Dissipation 36 PRI to SEC, Full Load Efficiency (%) PRI to SEC, Power Dissipation (W) Product is mounted and temperature controlled via top side cold plate, unless otherwise noted. All data presented in this section are collected data form primary sourced units processing power in forward direction.See associated figures for general trend data. 0 20 40 60 Case Temperature (°C) 60 V ISEC: Figure 8 — Efficiency and power dissipation at TCASE = 80°C 130 A Figure 9 — RSEC vs. temperature; Nominal VPRI_DC ISEC_DC = 125 A at TCASE = 80°C BCM® Bus Converter Rev 1.1 vicorpower.com Page 12 of 23 09/2015 800 927.9474 80 100 BCM6123x60E15A3yzz Voltage Ripple (mVPK-PK) 200 175 150 125 100 75 50 25 0 0 13 26 39 52 65 78 91 104 117 130 Load Current (A) VPRI: 54 V Figure 10 — VSEC_OUT_PP vs. ISEC_DC ; No external CSEC_OUT_EXT. Board mounted module, scope setting : 20 MHz analog BW Figure 11 — Full load ripple, 2700 µF CPRI_IN_EXT; No external CSEC_OUT_EXT. Board mounted module, scope setting : 20 MHz analog BW Figure 12 — 0 A– 130 A transient response: CPRI_IN_EXT = 2700 µF, no external CSEC_OUT_EXT Figure 13 — 130 A – 0 A transient response: CPRI_IN_EXT = 2700 µF, no external CSEC_OUT_EXT Figure 14 — Start up from application of VPRI_DC= 54 V, 20% IOUT, 100% CSEC_OUT_EXT Figure 15 — Start up from application of EN with pre-applied VPRI_DC = 54 V, 20% ISEC_DC, 100% CSEC_OUT_EXT BCM® Bus Converter Rev 1.1 vicorpower.com Page 13 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz 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] mm/[in] Volume Vol Weight W Lead finish Without Heatsink 7.26 / [0.286] 7.31 / [0.288] 11.13 / [0.679] cm3/[in3] 41 / [1.45] g/[oz] Nickel 0.51 2.03 Palladium 0.02 0.15 0.003 0.051 -40 125 Gold µm Thermal Operating Temperature TINTERNAL BCM6123x60E15A3yzz (T-Grade) Thermal Resistance Top Side ΦINT-TOP Estimated thermal resistance to maximum temperature internal component from isothermal top 1.26 °C/W Estimated thermal resistance to maximum temperature internal component from isothermal leads 1.21 °C/W 1.03 °C/W 34 Ws/°C Thermal Resistance Leads Thermal Resistance Bottom Side ΦINT-LEADS Estimated thermal resistance to ΦINT-BOTTOM maximum temperature internal component from isothermal bottom Thermal Capacity °C Assembly Storage temperature ESD Withstand BCM6123x60E15A3yzz (T-Grade) -55 ESDHBM Human Body Model, "ESDA / JEDEC JDS-001-2012" Class I-C (1kV to < 2 kV) ESDCDM Charge Device Model, "JESD 22-C101-E" Class II (200 V to < 500 V) BCM® Bus Converter Rev 1.1 vicorpower.com Page 14 of 23 09/2015 800 927.9474 125 °C BCM6123x60E15A3yzz 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. Soldering[1] Peak Temperature Top Case 135 °C Safety Isolation voltage / Dielectric test VHIPOT PRIMARY to SECONDARY 2,250 PRIMARY to CASE 2,250 SECONDARY to CASE 707 Isolation Capacitance CPRI_SEC Unpowered Unit 620 Insulation Resistance RPRI_SEC At 500 Vdc 10 MTBF VDC 780 MIL-HDBK-217Plus Parts Count - 25°C Ground Benign, Stationary, Indoors / Computer 4.45 MHrs Telcordia Issue 2 - Method I Case III; 25°C Ground Benign, Controlled 7.01 MHrs cURus "UL 60950-1" CE Marked for Low Voltage Directive and RoHS Recast Directive, as applicable [1] pF MΩ cTÜVus "EN 60950-1" Agency Approvals / Standards 940 Product is not intended for reflow solder attach. BCM® Bus Converter Rev 1.1 vicorpower.com Page 15 of 23 09/2015 800 927.9474 VAUX -VPRI EN 1.5 kΩ TM BCM® Bus Converter Rev 1.1 vicorpower.com Page 16 of 23 09/2015 800 927.9474 -Vcc Startup / Re-start Delay Over-Temp Under-Temp Cntrl SEPIC EN Over Voltage UnderVoltage Cntrl EN TM PWM Current Flow detection + Forward IIN sense 1.5 kΩ 3.3v Linear Regulator Digital Controller +VPRI +Vcc Current Monitor Differential Current Sensing Fast Current Limit Slow Current Limit Modulator Temperature Sensor Soft-Start On/Off SEPIC Q02 Q01 Primary Stage Primary and Secondary Gate Drive Transformer Cr Lr Q03 Q04 Q07 Q05 Secondary Stage Half-Bridge Synchronous Rectification Q08 Q6 COUT2 COUT1 -VSEC2 +VSEC -VSEC1 +VSEC BCM6123x60E15A3yzz BCM Module Block Diagram Analog Controller BCM6123x60E15A3yzz Sine Amplitude Converter™ Point of Load Conversion RSEC 1.96 mΩ 0.53 nH ISEC IOUT LPRI_IN_LEADS = 6.7 nH + VVPRI IN CPRI_INT_ESR 0.75 mΩ CPRI_INT C IN 11.2 µF RCIN ROUT IPRI_Q IQ 270 mA + + – RCCSEC_INT_ESR OUT 10 mΩ V•I 1/4 • ISEC LSEC_OUT_LEADS = 0.64 nH + 60.4 µΩ 1/4 • VPRI COUT CSEC_INT 140 µF – VSEC VOUT K – – Figure 16 — BCM module AC model The Sine Amplitude Converter (SAC™) uses a high frequency resonant tank to move energy from Primary to secondary and vice versa. (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 primary and secondary stages of the module is sufficient for full functionality and is key to achieving high power density. The BCM6123x60E15A3yzz SAC can be simplified into the preceeding model. The use of DC voltage transformation provides additional interesting attributes. Assuming that RSEC = 0 Ω and IPRI_Q = 0 A, Eq. (3) now becomes Eq. (1) and is essentially load independent, resistor R is now placed in series with VIN. RRIN Vin V PRI + – SAC™ SAC 1/4 KK==1/32 VSEC Vout At no load: VSEC = VPRI • K (1) K represents the “turns ratio” of the SAC. Rearranging Eq (1): K= Figure 17 — K = 1/4 Sine Amplitude Converter with series input resistor The relationship between VPRI and VSEC becomes: VSEC (2) VPRI VSEC = (VPRI – IPRI • RIN) • K Substituting the simplified version of Eq. (4) (IPRI_Q is assumed = 0 A) into Eq. (5) yields: In the presence of load, VOUT is represented by: VSEC = VPRI • K – ISEC • RSEC (3) VSEC = VPRI • K – ISEC • RIN • K2 and IOUT is represented by: ISEC = (5) IPRI – IPRI_Q 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 1.1 vicorpower.com Page 17 of 23 09/2015 800 927.9474 (6) BCM6123x60E15A3yzz This is similar in form to Eq. (3), where RSEC is used to represent the characteristic impedance of the SAC™. However, in this case a real R on the primary side of the SAC is effectively scaled by K2 with respect to the secondary. Assuming that R = 1 Ω, the effective R as seen from the secondary side is 62.5 mΩ, with K = 1/4 . A similar exercise should be performed with the additon of a capacitor or shunt impedance at the primary input to the SAC. A switch in series with VPRI 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 PRI 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 = 1/4 K = 1/32 VVout SEC The two main terms of power loss in the BCM module are: n No load power dissipation (PPRI_NL): defined as the power used to power up the module with an enabled powertrain at no load. n Resistive loss (RSEC): refers to the power loss across the BCM® module modeled as pure resistive impedance. Figure 18 — Sine Amplitude Converter with input capacitor PDISSIPATED= PPRI_NL + PRSEC A change in VPRI with the switch closed would result in a change in capacitor current according to the following equation: IC(t) = C dVPRI dt (7) Assume that with the capacitor charged to VPRI, the switch is opened and the capacitor is discharged through the idealized SAC. In this case, IC= ISEC • K (8) (10) Therefore, PSEC_OUT = PPRI_IN – PDISSIPATED = PRI_IN – PPRI_NL – PRSEC The above relations can be combined to calculate the overall module efficiency: h = PSEC_OUT PIN = PPRI_IN – PPRI_NL – PRSEC PIN substituting Eq. (1) and (8) into Eq. (7) reveals: ISEC C • = K2 dISEC 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 secondary output when expressed in terms of the input. With a K= 1/4 as shown in Figure 18, C = 1 μF would appear as C = 16 μF when viewed from the secondary. (11) = VPRI • IPRI – PPRI_NL – (ISEC)2 • RSEC VIN • IIN = 1– ( ) PPRI_NL + (ISEC)2 • RSEC VPRI • IPRI BCM® Bus Converter Rev 1.1 vicorpower.com Page 18 of 23 09/2015 800 927.9474 (12) BCM6123x60E15A3yzz 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 primary and secondary 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 6123 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 primary/secondary 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 RSEC 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). CSEC_EXT = CPRI_EXT MAX INTERNAL TEMP 1.26°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.03°C / W TCASE_BOTTOM(°C) Power Dissipation (W) 1.21°C / W + – TLEADS(°C) + – + – Figure 19 — Top case, Bottom case 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 1.26°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.03°C / W 1.21°C / W Power Dissipation (W) TCASE_BOTTOM(°C) TLEADS(°C) + – (13) K2 This enables a reduction in the size and number of capacitors used in a typical system. TCASE_TOP(°C) Figure 20 — Top case and leads thermal model BCM® Bus Converter Rev 1.1 vicorpower.com Page 19 of 23 09/2015 800 927.9474 TCASE_TOP(°C) + – BCM6123x60E15A3yzz 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 1.26°C / W Thermal Resistance Bottom Thermal Resistance Leads 1.03°C / W 1.21°C / W Power Dissipation (W) TCASE_BOTTOM(°C) TLEADS(°C) TCASE_TOP(°C) + – ZIN_EQn BCM®n ZOUT_EQn R0_n Figure 21 — Top case 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) Current Sharing n Maximum voltage rating 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. n Ambient temperature (usually greater than the maximum possible input voltage) 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 Nominal melting I2t n Recommend fuse: ≤ 40 A Littelfuse 456 Series 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 VPRI • K. The module will continue operation in this fashion for as long as no faults occur. Transient operation in reverse is expected in cases where there is significant energy storage on the output and transient voltages appear on the input. 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 prevent circulating currents. For further details see AN:016 Using BCM Bus Converters in High Power Arrays. BCM® Bus Converter Rev 1.1 vicorpower.com Page 20 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz BCM Module Through Hole Package Mechanical Drawing and Recommended Land Pattern 12.57 .495 0 11.81 .465 2.03 .080 (9) PL. 0 2.03 .080 (9) PL. 11.43 .450 11.81 .465 25.14±.38 .990±.015 27.21 1.071 (2) PL. 21.94 .864 (2) PL. 17.09 .673 (2) PL. 30.50 1.201 12.52 .493 (2) PL. 7.94 .312 (2) PL. 0 1.49 .058 (2) PL. 0 61.00±.13 2.402±.005 1.02 .040 (3) PL. 1.02 .040 (3) PL. 0 0 3.37 .132 (2) PL. 6.76 .266 (2) PL. 18.05 .710 (2) PL. 20.84 .820 (2) PL. 27.55 1.085 (2) PL. 0 0 23.64 .931 (2) PL. TOP VIEW (COMPONENT SIDE) BOTTOM VIEW .05 [.002] NOTES: 1- RoHS COMPLIANT PER CST-0001 LATEST REVISION. 2- UNLESS SPECIFIED OTHERWISE, DIMENSIONS ARE MM / [INCH], TOLERANCE ± 0.127 / [0.005] .41 .016 (24) PL. 21.94±.08 .864±.003 (2) PL. 12.52±.08 .493±.003 (2) PL. 6.76±.08 .266±.003 (2) PL. 2.54±.08 .100±.003 PLATED THRU .38 [.015] ANNULAR RING (18) PL. 20.84±.08 .820±.003 (2) PL. 27.55±.08 1.085±.003 (2) PL. 0 +VSEC +VSEC -VSEC -VSEC -VSEC -VSEC +VSEC +VSEC +VSEC +VSEC -VSEC -VSEC -VSEC -VSEC +VSEC +VSEC +VPRI TM +VPRI +VPRI EN VAUX +VPRI -VPRI 27.21±.08 1.071±.003 (2) PL. 17.09±.08 .673±.003 (2) PL. 7.94±.08 .312±.003 (2) PL. 0 1.49±.08 .058±.003 (2) PL. 1.52±.08 .060±.003 PLATED THRU .25 [.010] ANNULAR RING (6) PL. 18.05±.08 .710±.003 (2) PL. 23.64±.08 .931±.003 (2) PL. 0 3.37±.08 .132±.003 (2) PL. 0 11.81±.08 .465±.003 4.17 .164 (24) PL. 11.81±.08 .465±.003 SEATING PLANE 7.26±.05 .286±.002 RECOMMENDED HOLE PATTERN (COMPONENT SIDE) BCM® Bus Converter Rev 1.1 vicorpower.com Page 21 of 23 09/2015 800 927.9474 BCM6123x60E15A3yzz Revision History Revision Date 1.0 08/26/15 1.1 09/28/15 Description Initial Release Page Number(s) n/a Changed PRI to SEC Input Quiescent Current Added certifications BCM® Bus Converter Rev 1.1 vicorpower.com Page 22 of 23 09/2015 800 927.9474 5 1 & 15 BCM6123x60E15A3yzz 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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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 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: 6,911,848; 6,930,893; 6,934,166; 7,145,786; 7,782,639; 8,427,269 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 1.1 vicorpower.com Page 23 of 23 09/2015 800 927.9474