AC100 SERIES Rev C December 2007 ISOLATED AC-DC Converter AC100 SERIES APPLICATION NOTE Rev C Page 1 AC100 SERIES Rev C December 2007 Content 1. INTRODUCTION 2. AC100 CONVERTER FEATURES 3. GENERAL DESCRIPTION ABSOLUTE MAXIMUM RATINGS 3 3 3 4 5. MAIN FEATURES AND FUNCTIONS 5.1 Operating Temperature Range 6 6 5.2 Output Voltage Adjustment 6 5.3 Over Current Protection 6 5.4 Over Voltage Protection 6 5.5 V-Sense 6 6. SAFETY 7. APPLICATIONS 7.1 Power De-Rating Curves 6 6 7 7.2 Efficiency vs. Load Curves 9 7.3 Test Set-Up 11 7.4 Output Ripple and Noise Measurement 11 7.5 Output Capacitance 11 7.6 EMI 11 8. MECHANICAL OUTLINE DIAGRAMS 8.1 AC100 Mechanical Outline Diagrams 12 12 9.INSTALLATION INSTRUCTION 12 10. PART NIMBER 14 Page 2 AC100 SERIES Rev C December 2007 • Universal Input Range • Regulated Outputs This application note describes the features and functions of Intronics • Continuous Short Circuit Protection power’s AC100 series of open frame, Isolated AC-DC Converters. • 3” X 5” size These are highly efficient, reliable and compact, high power density, • Open-Frame Type 1. Introduction single output AC/DC converters. Ultra-high efficiency operation is achieved through the use of synchronous rectification and drive control techniques. The modules are fully protected against short circuit and over-voltage conditions. Intronics power’s world class automated 3. General Description manufacturing methods, together with an extensive testing and qualification program; ensure that all AC100 series converters are A block diagram of the AC100 series converter is shown in Figure 1. extremely reliable. Extremely high efficiency power conversion is achieved through the use of synchronous rectification and drive techniques. Essentially, the 2. AC100 Converter Features powerful AC100 series topology is based on an isolated synchronous • 100W Isolated Output stability, fast transient response and a very tight line and load • High Efficiency Up to 85% regulation. The output voltage can be adjusted from +5% to –5%, using • Fixed Switching Frequency a variable resistor. • Power factor correction Up to 0.9 AC Input forward converter. The control loop is optimized for unconditional Input Filter Bridge Rectifier MOSFET Switch PFC Controller PFC Choke & MOSFET Switch PWM Controller Transformer MOSFET Rectifier Optocoupler Isolation Output Filter Vout Refernce &Error AMP Figure 1. Electrical Block Diagram Page 3 AC100 SERIES Rev C December 2007 4. Technical Specifications (All specifications are typical at nominal input, full load at 25℃ unless otherwise noted.) PARAMETER ABSOLUTE MAXIMUM RATINGS NOTES and CONDITIONS Device Min. Typical Max. Units Input Voltage Continuous 90 264 Vdc Operating Temperature 0 +40 ℃ -20 +85 ℃ Vdc 240 63 Vac Hz A Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Voltage Range Input Frequency Range Maximum Input Current Power factor correction 1 minute 4242 100 47 100% Load, Vin=90Vac 100% Load, Vin=Nominal Vin No-Load Input Power Vin=264Vac Leakage Current Inrush Current Vin=240Vac, cold 1.5 0.9 7.0 6.0 5.0 5.0 5.0 5.0 4.0 AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 start at 250C. W 3.5 80 mA A 5.05 9.09 12.12 15.15 18.18 24.24 48.48 Vdc OUTPUT CHARACTERISTIC Output Voltage Set Point Vin=Nominal Vin , Io=Io.max, Tc=25℃ AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 Operating Output Current Range Holdup Time Output Voltage Regulation AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 Vin=115Vac 4.95 8.91 11.88 14.85 17.82 23.76 47.52 5.0 9.0 12.0 15.0 18.0 24.0 48.0 20.0 11.2 8.4 6.7 5.6 4.2 2.1 20 A mS Load Regulation 10% load to Full load ±1.0 % Line Regulation Vin=high line to low line ±0.5 % Output Voltage Ripple and Noise 20MHz bandwidth Full load, 0.1uF ceramic and 220uF E.L capacitor AC100S050 AC100S090 AC100S120 100 90 120 mV Full load, 0.1uF ceramic and 10uF E.L capacitor AC100S150 AC100S180 AC100S240 AC100S480 150 180 240 480 mV Peak-to-Peak Page 4 AC100 SERIES Rev C December 2007 PARAMETER NOTES and CONDITIONS Output Current-Limit Output Votage-Limit Turn-On Transient Start-Up Time, From Input Output Voltage =90% Nominal Output Voltage Maximum Output Capacitance Device Min. 110 110 Typical Max. 130 150 130 150 Vin=90Vac Vin=Nominal Vin at Full load 5 20000 12000 8400 6700 5600 4200 2100 AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 Units % % s uF EFFICIENCY 100% Load ISOLATION CHARACTERISTICS Input to Output Input to Earth Output to Earth 82 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 85 85 85 85 85 85 1 minute 1 minute 1 minute Isolation Resistance FEATURE CHARACTERISTICS Switching Frequency Output Voltage Adjustment AC100S050 % 4242 2121 707 100 MΩ 67 Pout=max rated power Vdc Vdc Vdc -5 +5 KHz % GENERAL SPECIFICATIONS MTBF Weight Io=100%of Io.max;Ta=25℃ per MIL-HDBK-217F TBD M hours 0.385 Kg Page 5 AC100 SERIES Rev C December 2007 5. Main Features and Functions 5.1 Operating Temperature Range Intronics power’s AC100 series converters highly efficient converter design has resulted in its ability to operate ambient temperature environment (0℃ to 40℃). Due consideration must be given to the derating curves when ascertaining maximum power that can be drawn from the converter. The maximum power drawn is influenced by a 5.4 Over Voltage Protection All different voltage models have a full continuous over voltage protection. The power module will supply up to 150% of rated voltage. In the event of an over voltage converter will go into a hiccup mode protection. number of factors, such as: • Input voltage range. • Output load current. • These can be effective heat sinks for the converter. 5.2 Output Voltage Adjustment The output voltage on all models is in the range from +5% to –5% but can't exceed the watt value of the products . 5.3 Over Current Protection All different voltage models have a full continuous short-circuit 5.5 V-Sense V-sense measures the use as outputting the voltage. The maximum length of the sense lines is 1200mm. The min gauge wire that can be used 26AWG. If does not use and needn't need to join . 6. Safety CB Approval TUV Approval UL Approval protection. The unit will auto recover once the short circuit is removed. To provide protection in a fault condition, the unit is equipped with internal over-current protection. The unit operates normally once the fault condition is removed. The power module will supply up to 150% of rated current. In the event of an over current converter will go into a 7. Applications hiccup mode protection. Page 6 AC100 SERIES Rev C December 2007 7.1 Power De-Rating Curves g 100% 75% O u tp u t lo a d O u t p u t lo a d 100% 50% 25% 0% 0 10 20 30 40 50 60 75% 50% 25% 0% 70 0 Ambient temperature(oC) 20 30 40 50 70 60 o Ambient temperature( C) Figure 6a. Typical Power De-rating for AC100S050 Figure 6b.Typical Power De-rating for AC100S090 100% 75% 75% O u tp u t lo a d 100% O u tp u t lo a d 10 50% 25% 0% 50% 25% 0% 0 10 20 30 40 50 60 o Ambient temperature( C) Figure 6c.Typical Power De-rating for AC100S120 70 0 10 20 30 40 50 70 60 o Ambient temperature( C) Figure 6d.Typical Power De-rating for AC100S150 Page 7 AC100 SERIES Rev C December 2007 75% 75% O u tp u t lo a d 100% O u tp u t lo a d 100% 50% 25% 0% 50% 25% 0% 0 10 20 30 40 50 60 70 o 0 10 20 30 40 50 70 60 o Ambient temperature( C) Ambient temperature( C) Figure 6g.Typical Power De-rating for AC100S180 Figure 6h.Typical Power De-rating for AC100S240 g O u t p u t lo a d 100% 75% 50% 25% 0% 0 10 20 30 40 50 60 70 Ambient temperature(oC) Figure 6i.Typical Power De-rating for AC100S480 Page 8 AC100 SERIES Rev C December 2007 7.2 Efficiency vs. Load Curves AC100S090 AC100S050 95.0 90.0 90.0 85.0 Efficiency (% Efficiency (% 80.0 70.0 60.0 50.0 115VAC 75.0 70.0 65.0 60.0 230VAC 40.0 80.0 115VAC 55.0 30.0 1 2 3 4 5 6 7 8 230VAC 50.0 9 10 11 12 13 14 15 16 17 18 19 20 1 Output Current (A) 2 3 4 5 6 7 8 9 10 11 11.2 Output Current (A) Figure 7a. AC100S050 Figure 7b. AC100S090 AC100S150 AC100S120 95.0 95.0 90.0 90.0 Efficiency (%) Efficiency (% 85.0 80.0 75.0 70.0 65.0 60.0 115VAC 55.0 230VAC 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 Output Current (A) 6 6.5 7 7.5 8 80.0 75.0 70.0 65.0 115VAC 60.0 230VAC 55.0 50.0 0.5 85.0 8.5 50.0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 Output Current (A) Figure 7c. AC100S120 Figure 7d. AC100S150 Page 9 7 AC100 SERIES Rev C December 2007 AC100S240 AC100S180 95.0 95.0 90.0 90.0 85.0 Efficiency (% 80.0 75.0 70.0 65.0 60.0 115VAC 230VAC 55.0 80.0 75.0 70.0 65.0 60.0 115VAC 55.0 230VAC 50.0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 Output Current (A) 5.6 50.0 0.5 1 1.5 2 2.5 3 3.5 4 4.2 Output Current (A) Figure 7g. AC100S180 Figure 7h. AC100S240 AC100S480 95.0 90.0 85.0 Efficiency (% Efficiency (% 85.0 80.0 75.0 70.0 65.0 60.0 115VAC 55.0 230VAC 50.0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.1 Output Current (A) Figure 7i. AC100S480 Page 10 AC100 SERIES Rev C December 2007 7.3 Test Set-Up 7.4 Output Ripple and Noise Measurement The basic test set-up to measure parameters such as efficiency and The test set-up for noise and ripple measurements is shown in Figure load regulation is shown in Figure 8. When testing the Intronics power’s 10. Measured method : AC100 series under any transient conditions please ensure that the Add a terminal wire is 50mmMIN that the output end needs to connect transient response of the source is sufficient to power the equipment the sub length of line of one end . under test. We can calculate the 1. Add a 0.1 uF ceramic capacitor and a 220 uF electrolytic capacitor • Efficiency • Load regulation and line regulation. to output at 20 MHz Band Width for AC100S050 , AC100S090 and AC100S120. The value of efficiency is defined as: 2. Add a 0.1 uF ceramic capacitor and a 10 uF electrolytic capacitor to output at 20 MHz Band Width for AC100S150 , AC100S180 , η= Where: Vo × Io × 100% Pin AC100S240 and AC100S480. Terminal wire Vo is output voltage, AC Io is output current, L Loa +Vo + Pin is input power, Suppl Oscillosco 0.1uF N -Vo The value of load regulation is defined as: Load .reg = VFL − VNL ×100% VNL 10uF/100V or220uF/35V AC100 Figure 10. Output Voltage Ripple and Noise Measurement Set-Up Where: VFL is the output voltage at full load VNL is the output voltage at 10% load 7.5 Output Capacitance Intronics power’ AC100 series converters provide unconditional stability The value of line regulation is defined as: Line.reg = with or without external capacitors. Intronics power’ converters are VHL − VLL ×100% VLL designed to work with load capacitance up-to 1000uF per amp. Where: VHL is the output voltage of maximum input voltage at full load. VLL is the output voltage of minimum input voltage at full load. L A +Vo 7.6 EMI Conductive EMI meets CISPR/FCC Class B AC V Pin Supply N Load -Vo Figure 8. AC100 Series Test Setup Page 11 AC100 SERIES Rev C December 2007 8. Mechanical Outline Diagrams 8.1 AC100 Mechanical Outline Diagrams Dimensions are in millimeters Tolerance: x.x ±0.5mm, unless otherwise noted Annotations：All models height does not exceed 34mmMAX . for AC100S050 Figure 11. AC100 Mechanical Outline Diagram 9. Installation Instruction Please use the mounting hold as: AC100S series : 4 holds of ψ 3.17 And insert the spacer (Maxψ 6) of height over 8mm to lift the unit .The vibration spec. is the value take when the unit is raised by 8mm spacers. Page 12 AC100 SERIES Rev C December 2007 Please reserve 4mm space from the surfaces and the sides of PCB, especially from the solder surface, 8mm space is necessary. If the space is not enough, the specification of insulation and withstand will not be satisfied. FG should be connected to the earth terminal of the apparatus. If not, the conducted noise and output noise will increase. Page 13 AC100 SERIES Rev C December 2007 10. Part Number AC – XXX S XXX AC SERIES 100： Supply Max. Power S： Single Output 050：Output Voltage 5.0 VDC 090：Output Voltage 9.0 VDC 120：Output Voltage 12 VDC 150：Output Voltage 15 VDC 180：Output Voltage 18 VDC 240：Output Voltage 24 VDC 480：Output Voltage 48 VDC INTRONICS POWER INCORPORATED. Page 14