® 1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015 AC60 Single Rev A January 2007 AC-DC Switching Power Module AC60 series APPLICATION NOTE Rev A Page 1 ® AC60 Single 1400 PROVIDENCE HIGHWAY • BUILDING 2 Rev A January 2007 NORWOOD, MASSACHUSETTS 02062-5015 Content 1. INTRODUCTION 2. AC60 SERIES CONVERTER FEATURES 3. TECHNICAL SPECIFICATIONS 4. MAIN FEATURES AND FUNCTIONS 3 3 4 5 4.1 Operating Temperature Range 5 4.3 Output Protection 5 5. SAFETY 6. APPLICATIONS 5 5 6.1 Power De-Rating Curve 5 6.2 Test Set-Up 6 6.3 Output Ripple and Noise Measurement 6 6.4 Installation Instruction 6 7. AC60 SERIES MECHANICAL OUTLINE DIAGRAMS 8. PART NUMBER 7 8 Page 2 ® AC60 Single 1400 PROVIDENCE HIGHWAY • BUILDING 2 Rev A January 2007 NORWOOD, MASSACHUSETTS 02062-5015 1. Introduction 2. AC60 series Converter Features This application note describes the features and functions of Intronics AC60 series of open frame, switching AC-DC power module. These are highly efficient, reliable and compact, high power density, single output AC/DC power module. The module is fully protected against short circuit and over-voltage conditions. Intronics world class automated manufacturing methods, together with an extensive testing and qualification program; ensure that the AC60S480 power module is extremely reliable. • 60W Isolated Output • High Efficiency Up to 88% • Fixed Switching Frequency • Universal Input Range • Regulated Output • Continuous Short Circuit Protection • 2” X 4” size, low profile • Open-Frame Type Page 3 ® AC60 Single 1400 PROVIDENCE HIGHWAY • BUILDING 2 Rev A January 2007 NORWOOD, MASSACHUSETTS 02062-5015 3. Technical Specifications (All specifications are typical at nominal input, full load at 25℃ unless otherwise noted.) PARAMETER ABSOLUTE MAXIMUM RATINGS Input Voltage Continuous Operating Temperature Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Voltage Range Input Frequency Range Maximum Input Current Leakage Current Inrush Current OUTPUT CHARACTERISTIC Output Voltage Set Point NOTES and CONDITIONS Device 1 minute Typical Units 90 0 -20 4242 264 +50 +85 Vac ℃ ℃ Vdc 100 47 240 63 Vac Hz A mA A 1.4 3.5 50 Vin=264Vac, cold start at 250C. AC60S033 AC60S050 AC60S090 AC60S120 AC60S150 AC60S240 AC60S280 AC60S360 AC60S480 AC60S033 AC60S050 AC60S090 AC60S120 AC60S150 AC60S240 AC60S280 AC60S360 AC60S480 Vin=Nominal Vin , Io=Io.max, Tc=25℃ Holdup Time Vin=115Vac Output Voltage Regulation Load Regulation Line Regulation 10% load to Full load Vin=high line to low line Output Voltage Ripple and Noise 20MHz bandwidth ISOLATION CHARACTERISTICS Input to Output Input to Earth Output to Earth Isolation Resistance Max. 100% Load, Vin=90Vac Operating Output Current Range Peak-to-Peak Min. Full load, 0.1uF ceramic and capacitor 3.26 4.95 8.91 11.88 14.85 23.76 27.72 35.64 47.52 3.3 5.0 9.0 12.0 15.0 24.0 28.0 36.0 48.0 8 8 6.67 5 4 2.5 2 1.67 1.25 8 3.33 5.05 9.09 12.12 15.15 24.24 28.28 36.36 48.48 Vdc A mS ±1.0 ±0.5 10uF E.L % % AC60S033 AC60S050 AC60S090 AC60S120 50 50 90 120 AC60S150 AC60S240 AC60S280 AC60S360 AC60S480 150 240 280 360 480 mV 4242 2121 707 Vdc Vdc Vdc MΩ 1 minute 1 minute 1 minute 100 FEATURE CHARACTERISTICS Switching Frequency 60 KHz GENERAL SPECIFICATIONS MTBF Weight Io=100%of Io.max;Ta=25 MIL-HDBK-217F ℃ per TBD 0.175 M hours Kg Page 4 ® 1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015 AC60 Single R ev A January 2007 4. Main Features and Functions 6. Applications 4.1 Operating Temperature Range 6.1 Power De-Rating Curve Intronics AC60 series power modules, which highly efficient design, has resulted in its ability to operate ambient temperature environment (0℃ to 50℃). Due to consideration must be given to the de-rating curves when ascertaining maximum power that can be drawn from the power module. The maximum power drawn is influenced by a number of factors, such as: • Input voltage range. • Output load current. • These can be effective heat sinks for the power module. 4.3 Output Protection The power modules provide a full continuous short-circuit 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 will operate normally once the fault condition is removed. The power module will go to hiccup mode if the output current or voltage is set from 110% to 150% of rated current or voltage. 5. Safety CB TUV Approval Approval UL Approval CE Approval Page 5 ® AC60 Single 1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015 Rev A January 2007 6.2 Test Set-Up 6.3 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 2. load regulation is shown in Figure 1. When testing the Intronics AC60 Measured method : series under any transient conditions, please ensure that the Add a 0.1 uF ceramic capacitor and a 10 uF electrolytic capacitor to output at 20 MHz Band Width. transient response of the source is sufficient to power the equipment under test. We can calculate the • Efficiency • Load regulation and line regulation. Terminal wire 800mmMin The value of efficiency is defined as: AC Vo × η= Io × 100% Pin Where: Supply +Vo + N Load Oscilloscope 0.1uF -Vo 10uF/100V Vo is output voltage, AC60S Series Io is output current, Figure 2. Output Voltage Ripple and Noise Measurement Set-Up Pin is input power, The value of load regulation is defined as: 6.4 Installation Instruction V FL -V Load reg = NL × 100% V L Please use the mounting hold as: AC60 series : 4 holds of ψ3.17 And insert the spacer (Maxψ6) of height over 8mm to lift the unit .The vibration spec. is the value take when the unit is raised by 8mm spacers. NL Where VFL is the output voltage at full load VNL is the output voltage at 10% load The value of line regulation is defined as: − Line reg = V HL V V LL LL × 100% 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. AC L +Vo N -Vo V Pin Supply A Load + Figure 1. AC60 Series Test Setup Page 6 ® 1400 PROVIDENCE HIGHWAY • BUILDING 2 NORWOOD, MASSACHUSETTS 02062-5015 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. AC60 Single Rev A January 2007 7.AC60 Series Mechanical Outline Diagrams Dimensions are in millimeters Tolerance: x.x ±0.5mm, unless otherwise noted Annotations：All models height does not exceed 34mmMAX . FG should be connected to the earth terminal of the apparatus. If not, the conducted noise and output noise will increase. Figure 6. AC60 series Mechanical Outline Diagram Page 7 ® AC60 Single 1400 PROVIDENCE HIGHWAY • BUILDING 2 Rev A January 2007 NORWOOD, MASSACHUSETTS 02062-5015 8. Part Number AC XX S XXX AC SERIES 60： Supply Max. Power S：Single Output • • • • • • • • • 033：Output Voltage3.3 VDC 050：Output Voltage 5.0 VDC 090：Output Voltage 9.0 VDC 120：Output Voltage 12 VDC 150：Output Voltage 15 VDC 240：Output Voltage 24 VDC 280：Output Voltage 28 VDC 360：Output Voltage 36 VDC 480：Output Voltage 48 VDC Page 8