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AV 4 5 C Q u a r t e r - b r i c k S e r i e s Te c h n i c a l R e f e r e n c e N o t e s
1.5V, 1.8V, 3.3V, 5V Single Output 48V Input, 100W DC-DC Converter
(Rev01)
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-1Publishing Date: 20020621
AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Introduction
The AV45C quarter-brick series comes in a industry standard quarter-brick package of 1.45" x 2.28" x 0.5" and footprint, and incorporates the super high efficiency up to
Design Features
! ! ! ! ! ! ! ! High Efficiency High power density Low output noise Input under-voltage lockout CNT function Trim function Remote sense Output short circuit protection Output current limiting Output over-voltage protection Overtemperature protection High input-output isolation voltage
90%(@5Vout), and high power density up to 60.5W/in3. The input range is 36V-75V, and input is fully isolated from output and the isolation voltage is 1500Vdc.
The typical efficiencies are 90% for the 5V output, 89% for the 3.3V output, 85% for the 1.8V and 1.5V output.
! ! !
Designed using a synchronous rectification topology, AV45C series incorporates simple structure, good electrical performance and high reliability. Standard features include input LVP, output OVP, OCP, short circuit protection, and over-temperature protection.
!
Options
! ! Heat sink available for extended operation. Choice of CNT logic configuration.
The AV45C quarter-brick series is designed to meet CISPR22, FCC Class A, UL, TUV, and CSA certifications.
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Typical Application
Fuse* +Vin CNT C1* Trim -Vo -Vin -S
C3 C2 Load
+S +Vo
Vin
Fuse*: Use external fuse ( fast blow type ) for each unit.
5V output 3.3V output 1.8V output 1.5V output 10A (Pout=100W) 8A (Pout=66W) 5A (Pout=36W) 5A (Pout=30W)
C1*: Recommended input capacitor C1
-20 oC ~ +100 oC : 100F/100V high frequency aluminum electrolytic capacitor for 1.5Vout & 1.8Vout 220F/100V high frequency aluminum electrolytic capacitor for 3.3Vout & 5Vout -40 oC ~ +100 oC : 220F/100V high frequency aluminum electrolytic capacitor for 1.5Vout & 1.8Vout 470F/100V high frequency aluminum electrolytic capacitor for 3.3Vout & 5Vout
C2*: Recommended output capacitor C2
-20 oC ~ +100 oC : 1000F/10V (high frequency aluminum electrolytic capacitor) -40 oC ~ +100 oC : for this temperature, use two pieces of 1000F/10V capacitor in parallel or one 2200F high frequency aluminum electrolytic capacitor.
C3: Recommended 1F/10V ceramic type capacitor
Note: The AV45C modules can not be used in parallel mode directly!!
There is no minimum load requirement for the AV45C series modules.
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Block Diagram
+Vin +Vout
-Vin
-Vout
+Sense
Trim
CNT
-Sense
Ordering Information
Model Number Input Current Input Voltage CNT Logic Output Current Ripple (mV p-p) Noise (mV p-p) Efficiency typ Pin Length mm(inch)
AV45C-048L-050F20HA AV45C-048L-050F20HAN AV45C-048L-033F20HA AV45C-048L-033F20HAN AV45C-048L-018F20HA AV45C-048L-018F20HAN AV45C-048L-015F20HA AV45C-048L-015F20HAN
3.3A 3.3A 2.05A 2.05A 1.25A 1.25A 1.0A 1.0A
36-75V 36-75V 36-75V 36-75V 36-75V 36-75V 36-75V 36-75V
Positive Negative Positive Negative Positive Negative Positive Negative
20A 20A 20A 20A 20A 20A 20A 20A
70 70 70 70 70 70 70 70
150 150 150 150 150 150 150 150
90% 90% 89% 89% 86% 86% 85% 85%
4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189) 4.80(0.189)
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Absolute Maximum Rating Characteristic Input Voltage(continuous) Input Voltage(peak/surge) Operating case temperature storage temperature Min -0.3 -0.3 -40 -55 Typ Max 80 100 100 125 Units Vdc Vdc C C 100ms non-repetitive Notes
Input Characteristics Characteristic Input Voltage Range Input Reflected Current Turn-off Input Voltage Turn-on Input Voltage Turn On Time 31 Min 36 Typ 48 10 33 34 20 36 35 Max 75 15 Units Vdc mAp-p V V ms Notes
CNT Function Characteristic Logic High Logic Low Control Current Min 3.5 -0.7 Typ Max 15 1.8 2 Units Vdc Vdc mA Notes
General Specifications Characteristic MTBF Isolation Pin solder temperature Hand Soldering Time Weight 60 1500 260 5 Min Typ 2000 Max Units k Hrs Vdc C s grams wave solder < 10 s iron temperature 425C Notes Bellcore TR332, Tcase=30C
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
AV45C-048L-050F20HA(N) Output Characteristics
Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 1 100 50-25% load 1 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 5.7 22 27 90 110 6.8 0.5 0.02 70 150 115 28 30 %Vo s %Vo s A A % %Vo V V %Vo/C mV mV C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s 4.90 20 5.00 0.02 0.03 5.10 0.2 0.5 Min Typ Max 100 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
AV45C-048L-033F20HA(N) Output Characteristics
Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 2 100 50-25% load 2 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 3.9 22 27 89 110 5.0 0.5 0.02 70 150 115 28 30 %Vo s %Vo s A A % %Vo V V %Vo/C mV mV C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s 3.24 20 3.3 0.02 0.03 3.36 0.2 0.5 Min Typ Max 66 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s P o w e r C o n v e r t e r s 3 6 V D C t o 7 5 V D C I n p u t , 5 V a n d 1 . 8 V O u t p u t , 1 0 0 Wa t t O u t p u t
AV45C-048L-018F20HA(N) Output Characteristics
Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 3 100 50-25% load 3 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 2.2 22 27 86 110 2.8 10 0.02 70 150 115 28 30 %Vo s %Vo s A A % %Vo V %Vo %Vo/C mV mV C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s 1.77 20 1.80 0.02 0.1 1.83 0.2 0.5 Min Typ Max 36 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
AV45C-048L-015F20HA(N) Output Characteristics
Characteristic Power Output Current Output Setpoint Voltage Line Regulation Load Regulation Dynamic Response 50-75% load 3 100 50-25% load 3 100 Current Limit Threshold Short Circuit Current Efficiency Trim Range Over Voltage Protection Setpoint Sense Compensation Temperature Regulation Ripple (p-p) Noise (p-p) Over Temperature Protection Switching Frequency 100 250 0.003 40 100 80 1.9 22 27 85 110 2.5 10 0.02 70 150 115 28 30 %Vo s %Vo s A A % %Vo V %Vo %Vo/C mV mV C kHz ( 0 to 20MHz Bandwidth ) ( 0 to 20MHz Bandwidth ) Vin=48V, Io=20A Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s Ta=25C, DI/Dt=1A/10s 1.47 20 1.50 0.02 0.1 1.53 0.2 0.5 Min Typ Max 30 Units W A Vdc %Vo %Vo Vin=48V, Io=20A Vin=36~75V, Io=20A Io=0~20A, Vin=48V Notes
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Characteristic Curves
Typical Efficiency AV45C-048L-050F20HAN
95
(at 25 C )
Typical Efficiency AV45C-048L-033F20HAN
90
90 85
EFFICIENCY(%)
EFFICIENCY (%)
80
75Vin
80
48Vin
75 70
70
36Vin
60
65 60
75Vin 48Vin 36Vin
50
2 4 6 8 10 12 14 16 18 20
0
4
8
12
16
20
OUTPUT CURRENT, Io(A)
OUTPUT CURRENT(A)
Typical Efficiency AV45C-048L-018F20HAN
Typical Efficiency AV45C-048L-015F20HAN
90 85 80
90 85
Efficiency(%)
80 75 70 65 60 55 50 75Vin 48Vin 36Vin
EFFICIENCY (%)
75 70 65 60 55 50
75Vin 48Vin 32Vin
2
4
6
8
10
12
14
16
18
20
0
4
8
12
16
20
OUTPUT CURRENT, Io(A)
OUTPUT CURRENT(A)
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Characteristic Curves
Typical Output Overcurrent Characteristics AV45C-048L-050F20HAN
(at 25 C )
Typical Output Overcurrent Characteristics AV45C-048L-018F20HAN
5.5 5
1.9
1.8
Output Voltage (volts)
4 3.5 3 2.5 2 1.5 0 5 10 15 20 25 30
Output Voltage (volts)
4.5
1.7 Vin=36V 1.6 Vin=48V Vin=72V 1.5
Vin=36V Vin=48V Vin=72V
1.4 0 5 10 15 20 25
Output Curent (amps)
Output Curent (amps)
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
T ransient response
(48V rated input voltage, full load, at 25 C)
Typical Transient Response to Step Load Change from 50%-75%-50%Iomax,AV45C-048L-050F20HAN
Typical Transient Response to Step Load Change from 75%-50%Iomax, AV45C-048L-050F20HAN
Typical Transient Response to Step Load Change from 50%-75%Iomax, AV45C-048L-050F20HAN
Typical Transient Response to Step Load Change from 50%-75%-50%Iomax, AV45C-048L-018F20HAN
Typical Transient Response to Step Load Change from 75%-50%Iomax, AV45C-048L-018F20HAN
Typical Transient Response to Step Load Change from 50%-75%Iomax, AV45C-048L-018F20HAN
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Characteristic Curves
Typical Start-Up from Power On AV45C-048L-050F20HAN
(48V rated input voltage, full load, at 25 C)
Typical Start-Up from Power On AV45C-048L-018F20HAN
Typical Shut-down from Power Off AV45C-048L-050F20HAN
Typical Shut-down from Power Off AV45C-048L-018F20HAN
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Characteristic Curves
Typical Start-Up Transient with CNT AV45C-048L-050F20HAN
(48V rated input voltage, full load, at 25 C)
Typical Start-Up Transient with CNT AV45C-048L-018F20HAN
Typical Shut-down Transient with CNT AV45C-048L-050F20HAN
Typical Shut-down Transient with CNT AV45C-048L-018F20HAN
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Characteristic Curves
Typical Output Ripple Voltage AV45C-048L-050F20HAN
(48V rated input voltage, full load, at 25 C)
Typical Output Ripple Voltage AV45C-048L-018F20HAN
Overvoltage Protection AV45C-048L-050F20HAN
Overvoltage Protection AV45C-048L-018F20HAN
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Pin Location
The +Vin and -Vin input connection pins are located as shown in Figure 1. AV45C series converters have a 2:1 input voltage range and can accept 36-75 Vdc input. Care should be taken to avoid applying reverse polarity to the input which can damage the converter.
Note: the fuse is normal blow type. Input Reverse Voltage Protection Under installation and cabling conditions where reverse polarity across the input may occur, reverse polarity protection is recommended. Protection can easily be provided as shown in Figure 2. In both cases the diode rating is determined by the power of the converter.
+Vin
+Vin -Vin
-Vin CNT +Vin
-Vo -Sense TRIM +Sense +Vo
-Vin
Fig.2 Reverse Polarity Protection Circuits Placing the diode across the inputs rather than in-line with the input offers an advantage in that the diode only conducts in a reverse polarity condition, which increases circuit efficiency and thermal performance. Input Undervoltage Protection The AV45C quarter-brick series is protected against undervoltage on the input. If the input voltage drops below the acceptable range, the converter will shut down. It will automatically restart when the undervoltage condition is removed. Input Filter Input filters are included in the converters to help achieve standard system emissions certifications. Some users however, may find that additional input filtering is necessary. The AV45C quarter-brick series has an internal switching frequency of 250 kHz so a high frequency capacitor mounted close to the input terminals produces the best results. To reduce reflected noise, a capacitor can be added across the input as shown in Figure 3, forming
Fig.1 Pins Location ( Pin-side View )
Input Characteristic
Fusing The AV45C power module has no internal fuse. An external fuse must always be employed! To meet international safety requirements, a 250 Volt rated fuse should be used. If one of the input lines is connected to chassis ground, then the fuse must be placed in the other input line. Standard safety agency regulations require input fusing. Recommended fuse ratings for the AV45C quarter-brick are shown in Table 1. Table 1 Series
AV45C 5Vout AV45C 3.3Vout AV45C 1.8Vout AV45C 1.5Vout Fuse Rating(48Vin) 10A (Pout=100W)
8A 5A 5A
(Pout=66W) (Pout=36W) (Pout=30W)
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
a filter. The recommended value of the capacitor C1 can refer to the Typical Application on page 3.
Table 2
L N ON OFF H OFF ON Open OFF ON
+Vin C1 -Vin
P
Fig.3 Ripple Rejection Input Filter
Also when a filter inductor is connected in series with the power converter input or when the input wiring is long (since the wiring can act as an inductor), an input capacitor C1 should be added. Failure to use an input capacitor under these conditions can produce large input voltage spikes and an unstable output. For conditions where EMI is a concern, Figure 4 shows an input filter designed to reduce EMI effects.
C1 2200P C2 2200P
N--- means "Negative Logic" P--- means "Positive Logic" L--- means "Low Voltage", -0.7V [ L [ 1.8V H--- means "High Voltage", 3.5V [ H [ 15V ON--- means "module is on" OFF--- means "module is off" Open--- means " CNT pin is left open " Note: The VCNT [ 15V The following figure 5 to 8 are a few simple CNT circuits.
CNT
-Vin
Fig.5 Simple CNT Control
CNT
-Vin
+Vin
C3 2200P C6 100 C10 2200P C11 2200P C12 2200P L1 2.5mH C4 2200P C7 100
+Vo
C5 2200P C9 4700P C8 1000
Fig.6 Transistor CNT Control
CNT
-Vin
C13 2200P
-Vo
C14 2200P
-Vin
Fig.7 Isolated CNT Control
CNT
Fig.4 EMI Reduction Input Filter
-Vin
CNT Function Two CNT logic options are available. The CNT logic, CNT voltage and the module working state is as the following Table 2.
Fig.8 Relay CNT Control
Safety Consideration
For safety-agency approval of the system in which the power module is used, the power
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e., UL1950, CSA C22.2 No. 950-95, and EN60950. The input-to-output 1500VDC isolation is an operational insulation. The DC/DC power module should be installed in end-use equipment, in compliance with the requirements of the ultimate application, and is intended to be supplied by an isolated secondary circuit. When the supply to the DC/DC power module meets all the requirements for SELV(<60Vdc), the output is considered to remain within SELV limits (level 3). If connected to a 60Vdc power system, double or reinforced insulation must be provided in the power supply that isolates the input from any hazardous voltages, including the ac mains. One input pin and one output pin are to be grounded or both the input and output pins are to be kept floating. Single fault testing in the power supply must be performed in combination with the DC/DC power module to demonstrate that the output meets the requirement for SELV. The input pins of the module are not operator accessible. Note: Do not ground either of the input pins of the module, without grounding one of the output pins. This may allow a non-SELV voltage to appear between the output pin and ground.
the output terminals of the unit to the point of connection of the remote sense pins. This feature automatically adjusts the real output voltage of the AV45C series in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. When the converter is supporting loads far away, or is used with undersized cabling, significant voltage drop can occur at the load. The best defense against such drops is to locate the load close to the converter and to ensure adequately sized cabling is used. When this is not possible, the converter can compensate for a drop of up to 10%Vo, through use of the sense leads. When used, the + and - Sense leads should be connected from the converter to the point of load as shown in Figure 9 using twisted pair wire. The converter will then regulate its output voltage at the point where the leads are connected. Care should be taken not to reverse the sense leads. If reversed, the converter will trigger OVP protection and turn off. When not used, the +Sense lead must be connected with +Vo, and -Sense with -Vo. Also note that the output voltage and the remote sense voltage offset must be less than the minimum overvoltage trip point.
Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly.
Output Characteristics
Minimum Load Requirement There is no minimum load requirement for the AV45C quarter-brick series modules. Remote Sensing The AV45C quarter-brick series can remotely sense both lines of its output which moves the effective output voltage regulation point from
+Vout +Sense -Sense -Vout +S Twisted Pair Load -S
Fig.9 Sense Connections
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Adjustment Resistor Value (k)
Output Trimming Trimming Users can increase or decrease the output voltage set point of a module by connecting an external resistor between the TRIM pin and either the SENSE (+ ) or SENSE ( - ) pins. The trim resistor should be positioned close to the module. If not using the trim feature, leave the TRIM pin open. Trimming up by more than 10% of the nominal output may damage the converter or trig the OVP protection. Trimming down more than 20% can cause the converter to regulate improperly. Trim down and trim up circuits and the corresponding configuration are shown in Figure 10 to Figure 14. Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly.
VI(+) VO(+) SENSE(+) CNT TRIM VI(-) SENSE(-) VO(-) Radj-up RLOAD
Adjustment Resistor Value (k)
1600 1400 1200 1000 800 600 400 200 0 0 2 4 6 8 10 12
% Change In Output Voltage (y)
Fig.12 Resistor Selection for 5Vout Trimming Up
250 225 200 175 150 125 100 75 50 25 0 0 2 4 6 8 10 12
% Change In Output Voltage (y)
5.1Vo(100+y) 510 - 10.2 Radj-up = y 1.225y
where y is the adjusting percentage of the voltage. 0 < y < 10 Radj-up is in k.
Fig.13 Resistor Selection for 1.8Vout Trimming Up
Adjustment Resistor Value (k)
Fig.10 Circuit Configuration and Equation to Trim Up Output Voltage
VI(+) VO(+) SENSE(+) CNT TRIM Radj-down VI(-) SENSE(-) VO(-) RLOAD
500 450 400 350 300 250 200 150 100 50 0 0 5 10 15 20 25
Radj-down =
510 y - 10.2
0 < y < 20 where y is the adjusting percentage of the voltage. Radj-up is in k.
% Change In Output Voltage (y)
Fig.11 Circuit Configuration and Equation to Trim Down Output Voltage
Fig.14 Resistor Selection for Trimming Down Output
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Output Over-Current Protection AV45C quarter-brick series DC/DC converters feature foldback current limiting as part of their Overcurrent Protection (OCP) circuits. When output current exceeds 110 to 140% of rated current, such as during a short circuit condition, the output will shutdown immediately, and can tolerate short circuit conditions indefinitely. When the overcurrent condition is removed, the converter will automatically restart. Output Filters When the load is sensitive to ripple and noise, an output filter can be added to minimize the effects. A simple output filter to reduce output ripple and noise can be made by connecting a capacitor across the output as shown in Figure 15. The recommended value for the output capacitor C1 is 2200F/10V (refer to page 3).
+Vout C1 Load -Vout
Decoupling Noise on the power distribution system is not always created by the converter. High speed analog or digital loads with dynamic power demands can cause noise to cross the power inductor back onto the input lines. Noise can be reduced by decoupling the load. In most cases, connecting a 10 F tantalum capacitor in parallel with a 0.1F ceramic capacitor across the load will decouple it. The capacitors should be connected as close to the load as possible. Ground Loops Ground loops occur when different circuits are given multiple paths to common or earth ground, as shown in Figure 17. Multiple ground points can slightly different potential and cause current flow through the circuit from one point to another. This can result in additional noise in all the circuits. To eliminate the problem, circuits should be designed with a single ground connection as shown in Figure 18.
RLine RLine
+Vout
Fig.15 Output Ripple Filter
Load Load
RLine RLine RLine
Ground Loop
Extra care should be taken when long leads or traces are used to provide power to the load. Long lead lengths increase the chance for noise to appear on the lines. Under these conditions C2 can be added across the load as shown in Figure 16. The recommended component for C2 is 2200F/10V capacitor and connecting a 0.1F ceramic capacitor C1 in parallel generally.
+Vout C1 -Vout C2 Load
-Vout
RLine
Fig.17 Ground Loops
RLine
RLine
+Vout Load -Vout
RLine RLine RLine
Load
Fig.16 Output Ripple Filter For a Distant Load
Fig.18 Single Point Ground
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
Output Over-Voltage Protection Over-Voltage The over-voltage protection has a separate feedback loop which activates when the output voltage is between 5.7~6.8V (for 5Vout) and 2.2~2.8V (for 1.8Vout). When an over-voltage condition occurs, an internal " turn off " signal shut off the module. The module will restart after power on again. Parallel Power Distribution Figure 19 shows a typical parallel power distribution design. Such designs, sometimes called daisy chains, can be used for very low output currents, but are not normally recommended. The voltage across loads far from the source can vary greatly depending on the IR drops along the leads and changes in the loads closer to the source. Dynamic load conditions increase the potential problems.
I1 + I2 + I3 I2 + I3 I3
Mixed Distribution In the real world a combination of parallel and radial power distribution is often used. Dynamic and high current loads are connected using a radial design, while static and low current loads can be connected in parallel. This combined approach minimizes the drawbacks of a parallel
design when a purely radial design is not feasible.
+Vout
RL1 RL3 RL2 RL4
Load 1
RG1 RG2
Load 2
Load 3
RG3
Load 4
RG4
-Vout
RL = Lead Resistance RG = Ground Lead Resistance
Fig.21 Mixed Power Distribution Redundant Operation A common requirement in high reliability systems is to provide redundant power supplies. The easiest way to do this is to place two converters in parallel, providing fault tolerance but not load sharing. Oring diodes should be used to ensure that failure of one converter will not cause failure of the other converter. Figure 22 shows such an arrangement. Upon application of power, one of the converters will provide a slightly higher output voltage and will support the full load demand. The second converter will see a zero load condition and will "idle". If the first converter should fail, the second converter will support the most load. When designing redundant converter circuits, Shottky diodes should be used to minimize the forward voltage drop. The voltage drop across the Shottky diodes must also be considered when determining load voltage requirements.
+Vout -Vout
Load
RL1
RL2
RL3
+Vout Load 1 -Vout
RG1 RG2 RG3 RL = Lead Resistance RG = Ground Lead Resistance
Load 2
Load 3
Fig.19 Parallel Power Distribution Radial Power Distribution Radial power distribution is the preferred method of providing power to the load. Figure 20 shows how individual loads are connected directly to the power source. This arrangement requires additional power leads, but it avoids the voltage variation problems associated with the parallel power distribution technique.
+Vout
RL3 RL2
RL1
Load 1
RG1 RG2
Load 2
Load 3
RG3
+Vout -Vout
-Vout
RL = Lead Resistance RG = Ground Lead Resistance
Fig.20 Radial Power Distribution
Fig.22 Redundant Operation
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
AV45C Quarter-brick Series Mechanical Considerations
Installation Although AV45C quarter-brick series converters can be mounted in any orientation, free airflowing must be taken. Normally power components are always put at the end of the airflow path or have the separate airflow paths. This can keep other system equipment cooler and increase component life spans. Soldering AV45C quarter-brick series is compatible with standard wave soldering techniques. When wave soldering, the converter pins should be preheated for 20-30 seconds at 110 C, and wave soldered at 260C for less than 10 seconds. When hand soldering, the iron temperature should be maintained at 425C and applied to the converter pins for less than 5 seconds. Longer exposure can cause internal damage to the converter. Cleaning can be performed with cleaning solvent IPA or with water.
AV45C Hole Pattern
Component-side footprint. Dimensions are in millimeters and (inches). Fig. 23 is mechanical chart. Fig. 24 is hole pattern.
MTBF
The MTBF, calculated in accordance with Bellcore TR-NWT-000332 is 2,000,000 hours. Obtaining this MTBF in practice is entirely possible. Mounting the modules in the well ventilated conditions or with heatsink on are expected to raise the MTBF. ASTEC can offer custom thermal solutions.
Please contact the factory for details.
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AV 4 5 C Q u a r t e r - B r i c k S e r i e s 1 0 0 W P o w e r C o n v e r t e r s 36Vdc to 75Vdc Input, Single Output
2.28 (57.9) 0.21 (5.33) 1.86 (47.27)
M3 x 0.5 Mounting Inserts Typical 4 Places
0.189 (4.8) Pin EXT.
0.50 (12.7)
0.43 (10.92)
0.21 (5.33) 0.150 (3.81) 0.300 (7.62) 0.450 (11.43) 0.600 1.030 (15.24) (26.16)
1
0.600 1.450 (15.24) (36.83) 0.300 7.62
4
5
2 6 7 3 8
0.040 (1.020) Dia Plated Brass Pins Typical 6 Places 0.060 (1.57) Dia Plated Brass Pins Typical 2 Places
2.00 (50.8) 0.140 (3.56)
Dimensions: inches (mm)
Tolerances: Inches .xx !0.020 .xxx !0.010 Pins >4mm <4mm
Millimeters .x !0.5 .xx !0.25 !0.02inch ( !0.5mm) !0.01inch ( !0.25mm)
Pin 1 2 3
Function -Vin CNT +Vin
Pin 4 5 6 7 8
Function -Vo -Sense Trim +Sense +Vo
Fig.23 Mechanical Chart ( Pin-side view )
5.3 (0.21) 7.62 (0.300) 26.16 (1.030) 15.24 (0.600)
Vin (+) CNT Vin (-)
47.2 (1.86)
VO(+) + SENSE TRIM - SENSE VO(-)
7.62 (0.300) 3.81 (0.150)
15.24 (0.600)
11.43 (0.450) MOUNTING INSERTS M3 x 0.5 THROUGH, 4 PLACES
Dimensions: mm(inches)
5.3 (0.21)
10.9 (0.43) 3.6 (0.14) 50.80 (2.000)
Fig.24 Hole Pattern ( Base-plate side view )
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PART NUMBER DESCRIPTION
ss pp c 0 iv L xxx f yy h n p mx-Options
iv = Input Voltage 05 = Range centered on 5V 12 = Range centered on 12V 24 = 18 to 36(2:1), 9 to 36V(4:1) 36 = 20 to 60V 46 = 18V to 75V (4:1) 48 = Typ 36 to 75V
c = Pinout compatability
A= Astec Footprint or "non Lucent" footprint
p = Pin Length Omit this digit for Standard 5mm 6 = 3.8mm, 7= 5.8mm 8 = 2.8mm Enable Logic Polarity Omit for Positive Enable Logic N = Negative Enable Except: AK60C-20H, BK60C-30H Omit for Negative Logice P = Positive Logic H = High Efficiency (Synch rect.) Omit H if Conventional Diode (low Eff) yy = Output Current ie. 08 = 8 Amps f = # of Outputs F = Single Output D = Dual Output xxx = Output Voltage Format is XX.X (ie 1.8V = 018)
C= Ind Std, Exact Lucent drop in
pp = Package Type 40 = 1" x 2" SMD 42 = 1.5" x 2" SMD 45 = 1.45" X 2.3" (1/4 Brk) 60 = 2.4" X 2.3" (1/2 Brk) 80 = Full size 4.6" x 2.4" 72= 2.35" X 3.3 (3/4 Brk) ss = Series AA = 1/2brick Dual (Old designator)
AK = Ind Std sizes (1/4, 1/2, full) <150W AM/BM = Full size, astec pin out AL = Half size, astec pin-out BK = Ind Std size =>150W or feature rich
mx = Options M1,M2 = .25" Height Heatsink M3,M4 = .5" height Heatsink M5.M6 = 1.0" Height Heatsink
AV = Avansys Product
Note: For some products, they may not conform with the PART NUMBER DESCRIPTION above absolutely.
REVISION Q
ATTACHMENT I
Page 1 of 2
NEW PART NUMBER DESCRIPTION
A c s ii V1 V2 V3
Output Voltage A = 5.0V F = 3.3V G = 2.5V D = 2.0V / 2.1V Y = 1.8V M = 1.5V K = 1.2V J = 0.9V
ii = Output Current Max ie 60 = 60 Amps
Vin
-
e t p Mx
E = 7.5V B = 12V, C = 15V L = 8V, H = 24V, R = 28V
Omit V2 and V3 if Single Output Omit V3 if Dual Output ie for Dual Output 5 and 3.3V V1 =A, V2 = F, V3 =Omit
V1 =A, V2 = F, V3 =Omit
S = Size F = Full Brick H = Half Brick Q = Quarter Brick S = 1 X 2 18 Pin SMT E = 1 X 2 Thru Hole C = (.53X1.3X.33) SMT (Austin Lite drop in) V = Conventional Package (2X2.56") or ( A = SIP W = Convent pkg (Wide 2.5X3) R = 1 X 1 Thru Hole A = SIP T = 1.6 X 2 c = Construction E = Enhanced Thermals (Baseplate or adapter plate) I = Integrated (Full Featured) Hong Kong models L = Low Profile (Open Frame, No case - Isolated) P = Open Frame (SIP or SMT) non-isolated
Vin = Input Voltage range 300 = 250V to 450V 48 = 36V to 75V 24 = 18V to 36V 03 = 1.8V to 5.0V 08 = 5.0V to 13.0V PFC: Power Factor Corrected E = Enable Logic for > 15W Omit this digit for Positive enable N = Negative Logic E = Enable Logic for < 15W Omit this digit for no enable option 1 = Negative Logic 4 = Positive Logic Trim for 1W to 15W 9 = Trim Added
P = Pin Length Omit this digit for Standard 5mm 6 = 3.8mm 8 = 2.8mm 7 = 5.8 mm Mx - Factory Options customer Specific
Note: For some products, they may not conform with the NEW PART NUMBER DESCRIPTION above absolutely.
REVISION Q
ATTACHMENT I
Page 2 of 2

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