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Eighth-brick
48V Input, 1.5VDC, 40A Output
Mars
Quarter-brick
The Mars CoolConverterTM 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. GAMW1V540 Features 48V Input 1.5VDC, 40A Output High Efficiency 85% at 1.5V, 40A 87% at 1.5V, 20A
3-Quarter-brick
Control Functions
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
(R)
Certified to ISO 9001:2000
Part No. 02-GAM-06 Rev. 1.0 - 042805
WWW.GALAXYPWR.COM
Telephone: 508-870-9775 Fax: 508-870-9796
GAMW1V540 - 1
Galaxy Power Inc.
155 Flanders Road
Westborough, MA 01581
e-mail: info@galaxypwr.com
General Specifications
VIN = 48VDC, TA@25 C, 300 LFM Airflow, VOUT=1.5VDC, 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 Min Typ Max Units
Operating Input Voltage Input Current (Model Dependent) Input Capacitance Input Hysteresis, Low Line
36
48 3 2
75 2.3
VDC A F VDC
Output Characteristics
Regulation Over Line, Load & Temperature Voltage Ripple Voltage Ripple, 20MHz BW Current Range Current Limit Inception Short Circuit Current, Peak1 Output Transient Response, 50% to 75% load change, 2.5A/sec2 Settling Time to 1% Turn-on Time to 98%Vnom Output Overshoot at Turn-on Trim Range Overvoltage Protection, Latching 70 130 2250 10 110 250 0 110 0 41.2 1.470 1.530 20 50 40 56 60 22 300 25 V mV RMS mV P-P A A A %VOUT S mS %VOUT %VOUT %VOUT VDC M C kHz
Isolation
Isolation Test Voltage, Input/Output (Basic) Isolation Resistance
Features
Overtemperature Protection, Thermal Sensor, Latching3 Switching Frequency, Fixed
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
Operating Temperature Storage Temperature Relative Humidity Vibration Material Flammability Weight MTBF Telcordia (Bellcore) -40 C to +100 C -55 C to +125 C 10% to 95% RH, Non-condensing 2 to 9Hz, 3mm disp., 9 to 200Hz, 1g UL V-0 35 grams TBD
Approvals and Standards
UL and c-UL Recognized Component, TUV**, UL60950, CSA 22.2 No. 950, IEC/EN 60950
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.
GAMW1V540 - 2
WWW.GALAXYPWR.COM
155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775
Part No. 02-GAM-06 Rev. 1.0 - 042805
Galaxy Power Inc.
Fax: 508-870-9796
e-mail: info@galaxypwr.com
Application Notes CoolConverterTM
Galaxy's proprietary CoolConverterTM 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
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. 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 100A. 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 100k to +5V.
Undervoltage Hysteresis
1.0
Output Voltage
Normalized
0 30
31
32
33
34
35
36
37
Input Voltage (V)
Overvoltage Hysteresis
1.0
Output Voltage
Normalized
0 76.5
77
77.5
78
78.5
79
79.5
80
80.5
Input Voltage (V)
Part No. 02-GAM-06 Rev. 1.0 - 042805
WWW.GALAXYPWR.COM
Telephone: 508-870-9775 Fax: 508-870-9796
GAMW1V540 - 3
Galaxy Power Inc.
155 Flanders Road
Westborough, MA 01581
e-mail: info@galaxypwr.com
Application Notes
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. 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. 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. External Output Trimming
+ Sense
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 =
{
1.5 (100+%) (100+2%) - 5.11k 1.225% %
1.5V Trim-up
}
1000
Trim Resistance (k)
100
10
1 0 1 2 3 4 5 6 7 8 9 10
Increase in Output Voltage (%)
Trim-down RTRIM-DOWN =
{
100 %
- 2 5.11k
}
Trim-down
1000
Trim Resistance (k)
100
10 0 1 2 3 4 5 6 7 8 9 10
Decrease in Output Voltage (%)
Trim
- Sense
GAMW1V540 - 4
WWW.GALAXYPWR.COM
155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775
Part No. 02-GAM-06 Rev. 1.0 - 042805
Galaxy Power Inc.
Fax: 508-870-9796
e-mail: info@galaxypwr.com
GAMW1V54o Operation
Efficiency
90 14
Power Dissipation
Power Dissipation (W)
12 10 8 6 4 2 0 0 5 10 15 20 25
88
Efficiency (%)
86 84 82 80 78 76 0 5 10 15 20 25 30 35 40
36V Vin 48V Vin 75V Vin
36V Vin 48V Vin 75V Vin
30 35 40
Output Current (A)
Output Current (A)
Start Up
Voltage Ripple
CH2
CH3
CH1
1) Vout 1V/div 4mS/div 2) Iout 10A/div 3) Enable 5V/div
1) Vout 20mV/div 2S/div 10F ext cap 20MHz BW
Transient Response
1.53
Line/Load Regulation
Setpoint Accuracy 0.1267% Line Regulation 0.0300% Load Regulation 0.0200% Line & Load Regulation 0.0366%
CH1
Output Voltage (V)
1.51
1.49
CH2
36V Vin 48V Vin 75V Vin
0 5 10 15 20 25 30 35 40
1.47
1) Vout 200mV/div 200S/div 2) Iout 10A/div
Output Current (A)
Part No. 02-GAM-06 Rev. 1.0 - 042805
WWW.GALAXYPWR.COM
Telephone: 508-870-9775 Fax: 508-870-9796
GAMW1V540 - 5
Galaxy Power Inc.
155 Flanders Road
Westborough, MA 01581
e-mail: info@galaxypwr.com
GAMW1V540 Operation
Back Bias
1.6 1.4
Over-current Protection
Note: Over-current protection is blip-mode (aka hiccup).
Output Voltage (V)
1.2 1.0 0.8 0.6 0.4 0.2 0 47 48 49 50 51 52
36V Vin 48V Vin 75V Vin
1) Vout 500mV/div 2mS/div
Output Current (A)
Thermal Derating
Crosswise Airflow 45 40 45 40
Thermal Derating
Lengthwise Airflow
Output Current (A)
35 30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 300 LFM 200 LFM 100 LFM
Output Current (A)
35 30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 300 LFM 200 LFM 100 LFM
Ambient Temperature (C)
Ambient Temperature (C)
Over Voltage Protection
1) Vout 500mV/div 200S/div
GAMW1V540 - 6
WWW.GALAXYPWR.COM
155 Flanders Road Westborough, MA 01581 Telephone: 508-870-9775
Part No. 02-GAM-06 Rev. 1.0 - 042805
Galaxy Power Inc.
Fax: 508-870-9796
e-mail: info@galaxypwr.com
PACKAGE DETAIL
.45 2.28 2.000 .070 MOUNTING THREADS M3 X 0.5, 4 PLACES .21 1.860
.120
.815 PIN 4 PIN 3 1.45 1.030 PIN 1 .215 PIN 2 .815 .515 .665 PIN 5 .515 PIN 6 .365 PIN 7 .215 PIN 8 0
Pin Configuration
Pin Function
(Bottom View) Pin Dia. (in.)
1 2 3 4 5 6 7 8
+ Input On/Off - Input - Output - Sense Trim + Sense + Output
0.040 0.040 0.040 0.060 0.040 0.040 0.040 0.060
.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.
ORDERING INFORMATION
Standard Model Number Input Voltage Output Voltage Max Current
Example Part No.:
(All options shown)
GAMW1V540*
48V
1.5V
40A
* 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**
GAMW1V540 P S T
Part Number Options: Positive Logic Version Optional Pin Lengths E = 0.18" M = 0.145" S = 0.12" Tuned Model
**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 5600F with an impedance magnitude of less than 0.005 at 15kHz. It offers a minimum 3X improvement in the peak response compared to a standard unit.
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-06 Rev. 1.0 - 042805
WWW.GALAXYPWR.COM
Telephone: 508-870-9775 Fax: 508-870-9796
GAMW1V540 - 7
Galaxy Power Inc.
155 Flanders Road
Westborough, MA 01581
e-mail: info@galaxypwr.com

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