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www.irf.com 1 afl120xxs series the afl series of dc/dc converters feature high power density with no derating over the full military temperature range. this series is offered as part of a complete family of converters providing single and dual output voltages and operating from nominal +28v, +50v, +120v or +270 v inputs with output power ranging from 80w to 120w. for applications requiring higher output power, multiple converters can be operated in parallel. the internal current sharing circuits assure equal current distribution among the paralleled converters. this series incorp orates international rectifier?s proprietary magnetic pulse feedback technology providing optimum dynamic line and load regulation response. this feedback system samples the output voltage at the pulse width modulator fixed clock frequency, nominally 550khz. multiple converters can be synchronized to a system clock in the 500khz to 700khz range or to the synchronization output of one converter. undervoltage lockout, primary and secondary referenced inhibit, soft-start and load fault protection are provided on all models. description 80v to 160v input range 5, 7.5, 8, 9, 12, 15 and 28v outputs available high power density - up to 84w/in 3 up to 120w output power parallel operation with stress and current sharing low profile (0.380") seam welded package ceramic feedthru copper core pins high efficiency - to 87% full military temperature range continuous short circuit and overload protection remote sensing terminals primary and secondary referenced inhibit functions line rejection > 50db - dc to 50khz external synchronization port fault tolerant design dual output versions available standard microcircuit drawings available features afl 120v input, single output hybrid-high reliability dc/dc converter these converters are hermetically packaged in two enclosure variations, utilizing copper core pins to minimize resistive dc losses. three lead styles are available, each fabricated with international rectifier?s rugged ceramic lead-to-package seal assuring long term hermeticity in the most harsh environments. manufactured in a facility fully qualified to mil-prf- 38534, these converters are fabricated utilizing dscc qualified processes. for available screening options, refer to device screening table in the data sheet. variations in electrical, mechanical and screening can be accommodated. contact ir santa clara for special requirements. pd-94447d
2 www.irf.com afl120xxs series specifications static characteristics -55c < t case < +125c, 80v < v in < 160v unless otherwise specified. for notes to specifications, refer to page 4 input voltage -0.5v to +180vdc soldering temperature 300c for 10 seconds operating case temperature -55c to +125c storage case temperature -65c to +135c absolute maximum ratings parameter group a subgroups test conditions min nom max unit input voltage note 6 80 120 160 v output voltage afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s 1 1 1 1 1 1 1 2, 3 2, 3 2, 3 2, 3 2, 3 2, 3 2, 3 v in = 120 volts, 100% load 4.95 7.42 7.92 8.91 11.88 14.85 27.72 4.90 7.35 7.84 8.82 11.76 14.70 27.44 5.00 7.50 8.00 9.00 12.00 15.00 28.00 5.05 7.58 8.08 9.09 12.12 15.15 28.28 5.10 7.65 8.16 9.18 12.24 15.30 28.56 v output current afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s v in = 80, 120, 160 volts - note 6 16.0 10.67 10.0 10.0 9.0 8.0 4.0 a output power afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s note 6 80 80 80 90 108 120 112 w maximum capacitive load note 1 10,000 f output voltage temperature coefficient v in = 120 volts, 100% load - notes 1, 6 -0.015 +0.015 %/c output voltage regulation afl12028s line all others line load 1, 2, 3 1, 2, 3 1, 2, 3 no load, 50% load, 100% load v in = 80, 120, 160 volts -70 -20 -1.0 +70 +20 +1.0 mv mv % output ripple voltage afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 v in = 80, 120, 160 volts, 100% load, bw = 10mhz 30 40 40 40 45 50 100 mv pp
www.irf.com 3 afl120xxs series static characteristics (continued) for notes to specifications, refer to page 4 parameter group a subgroups test conditions min nom max unit input current no load inhibit 1 inhibit 2 1 2, 3 1, 2, 3 1, 2, 3 v in = 120 volts i out = 0 pin 4 shorted to pin 2 pin 12 shorted to pin 8 20 25 5.0 50 ma input ripple current afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 v in = 120 volts, 100% load, bw = 10mhz 60 60 60 60 60 60 60 ma pp current limit point as a percentage of full rated load 1 2 3 v out = 90% v nom , v in = 120 volts note 5 115 105 125 125 115 140 % load fault power dissipation overload or short circuit 1, 2, 3 v in = 120 volts 32 w efficiency afl12005s afl12007r5s afl12008s afl12009s afl12012s afl12015s afl12028s 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 v in = 120 volts, 100% load 78 79 79 80 82 83 82 82 83 73 84 85 87 85 % enable inputs (inhibit function) converter off sink current converter on sink current 1, 2, 3 1, 2, 3 logical low on pin 4 or pin 12 note 1 logical high on pin 4 and pin 12 - note 9 note 1 -0.5 2.0 0.8 100 50 100 v a v a switching frequency 1, 2, 3 500 550 600 khz synchronization input frequency range pulse amplitude, hi pulse amplitude, lo pulse rise time pulse duty cycle 1, 2, 3 1, 2, 3 1, 2, 3 note 1 note 1 500 2.0 -0.5 20 700 10 0.8 100 80 khz v v ns % isolation 1 input to output or any pin to case (except pin 3). test @ 500vdc 100 m ? device weight slight variations with case style 85 g mtbf mil-hdbk-217f, aif @ t c = 70c 300 khrs
4 www.irf.com afl120xxs series dynamic characteristics -55c < t case < +125c, v in =120v unless otherwise specified. notes to specifications: 1. parameters not 100% tested but are guaranteed to the limits specified in the table. 2. recovery time is measured from the initiation of the transient to where v out has returned to within 1.0% of v out at 50% load. 3. line transient transition time 100 s. 4. turn-on delay is measured with an input voltage rise time of between 100v and 500v per millisecond. 5. current limit point is that condition of excess load causing output voltage to drop to 90% of nominal. 6. parameter verified as part of another test. 7. all electrical tests are performed with the remote sense leads connected to the output leads at the load. 8. load transient transition time 10 s. 9. enable inputs internally pulled high. nominal open circuit voltage 4.0vdc. parameter group a subgroups test conditions min nom max unit load transient response afl12005s amplitude recovery amplitude recovery afl12007r5s amplitude recovery amplitude recovery afl12009s amplitude recovery amplitude recovery afl12012s amplitude recovery amplitude recovery afl12015s amplitude recovery amplitude recovery afl12028s amplitude recovery amplitude recovery 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 note 2, 8 load step 50% ? 100% load step 10% ? 50% load step 50% ? 100% load step 10% ? 50% load step 50% ? 100% load step 10% ? 50% load step 50% ? 100% load step 10% ? 50% load step 50% ? 100% load step 10% ? 50% load step 50% ? 100% load step 10% ? 50% -450 -450 -500 -500 -600 -600 -750 -750 -750 -750 -1200 -1200 450 200 450 300 500 200 500 300 600 200 600 300 750 200 750 300 750 200 750 300 1200 200 1200 300 mv s mv s mv s mv s mv s mv s mv s mv s mv s mv s mv s mv s line transient response amplitude recovery note 1, 2, 3 v in step = 80 ? 160 volts -500 500 500 mv s turn-on characteristics overshoot delay 4, 5, 6 4, 5, 6 v in = 30, 50, 80 volts. note 4 enable 1, 2 on. (pins 4, 12 high or open) 50 75 250 120 mv ms load fault recovery same as turn on characteristics. line rejection mil-std-461d, cs101, 30hz to 50khz note 1 60 70 db
www.irf.com 5 afl120xxs series block diagram figure i. afl single output figure ii. enable input equivalent circuit pin 4 or pin 12 1n4148 100k 290k 150k 2n3904 +5.6 v disable pin 2 or pin 8 circuit operation and application information remote sensing inhibiting converter output (enable) the afl series of converters employ a forward switched mode converter topology. (refer to figure i.) operation of the device is initiated when a dc voltage whose magnitude is within the specified input limits is applied between pins 1 and 2. if pin 4 is enabled (at a logical 1 or open) the primary bias supply will begin generating a regulated housekeeping voltage bringing the circuitry on the primary side of the converter to life. a power mosfet is used to chop the dc input voltage into a high frequency square wave, applying this chopped voltage to the power transformer at the nominal converter switching frequency. maintaining a dc voltage within the specified operating range at the input assures continuous generation of the primary bias voltage. the switched voltage impressed on the secondary output transformer winding is rectified and filtered to generate the converter dc output voltage. an error amplifier on the secondary side compares the output voltage to a precision reference and generates an error signal proportional to the difference. this error signal is magnetically coupled through the feedback transformer into the controller section of the converter varying the pulse width of the square wave signal driving the mosfet, narrowing the width if the output voltage is too high and widening it if it is too low, thereby regulating the output voltage. connection of the + and - sense leads at a remotely located load permits compensation for excessive resistance between the converter output and the load when their physical separation could cause undesirable voltage drop. this connection allows regulation to the placard voltage at the point of application. when the remote sensing feature is not used, the sense should be connected to their respective output terminals at the converter. figure iii. illustrates a typical remotely sensed application. as an alternative to application and removal of the dc voltage to the input, the user can control the converter output by providing ttl compatible, positive logic signals to either of two enable pins (pin 4 or 12). the distinction between these two signal ports is that enable 1 (pin 4) is referenced to the input return (pin 2) while enable 2 (pin 12) is referenced to the output return (pin 8). thus, the user has access to an inhibit function on either side of the isolation barrier. each port is internally pulled ?high? so that when not used, an open connection on both enable pins permits normal converter operation. when their use is desired, a logical ?low? on either port will shut the converter down. 1 + in p ut enable 1 4 s y nc out p u t 5 6 sync input case 3 2 input return input filter primary bias su pp l y control fb output filter current sense error amp & ref share am p lifier sense am p lifier 7 +output 10 +sense 11 share 12 enable 2 9 return sense 8 output return
6 www.irf.com afl120xxs series figure iii. preferred connection for parallel operation optional synchronization connection power input (other converters) share bus 1 6 afl 7 12 - sense enable 2 + vout return + sense share vin rtn case enable 1 sync out sync in 1 6 afl 7 12 - sense enable 2 + vout return + sense share vin rtn case enable 1 sync out sync in 1 6 afl 7 12 - sense enable 2 + vout return + sense share vin rtn case enable 1 sync out sync in to load afl series operating in the parallel mode is that in addition to sharing the current, the stress induced by temperature will also be shared. thus if one member of a paralleled set is operating at a higher case temperature, the current it provides to the load will be reduced as compensation for the temperature induced stress on that device. synchronization of multiple converters parallel operation-current and stress sharing internally, these ports differ slightly in their function. in use, a low on enable 1 completely shuts down all circuits in the converter while a low on enable 2 shuts down the secondary side while altering the controller duty cycle to near zero. externally, the use of either port is transparent to the user save for minor differences in idle current. (see specification table). when operating multiple converters, system requirements often dictate operation of the converters at a common frequency. to accommodate this requirement, the afl series converters provide both a synchronization input and output. figure iii. illustrates the preferred connection scheme for operation of a set of afl converters with outputs operating in parallel. use of this connection permits equal sharing of a load current exceeding the capacity of an individual afl among the members of the set. an important feature of the than100ns, maximum low level of +0.8v and a minimum high level of +2.0v. the sync output of another converter which has been designated as the master oscillator provides a convenient frequency source for this mode of operation. when external synchronization is not required, the sync in pin should be left unconnected thereby permitting the converter to operate at its? own internally set frequency. the sync output signal is a continuous pulse train set at 550 50khz, with a duty cycle of 15 5.0%. this signal is referenced to the input return and has been tailored to be compatible with the afl sync input port. transition times are less than 100ns and the low level output impedance is less than 50 ? . this signal is active when the dc input voltage is within the specified operating range and the converter is not inhibited. this output has adequate drive reserve to synchronize at least five additional converters. a typical synchronization connection option is illustrated in figure iii. the sync input port permits synchronization of an afl converter to any compatible external frequency source operating between 500khz and 700khz. this input signal should be referenced to the input return and have a 10% to 90% duty cycle. compatibility requires transition times less
www.irf.com 7 afl120xxs series a conservative aid to estimating the total heat sink surface area (a heat sink ) required to set the maximum case temperature rise ( ? t) above ambient temperature is given by the following expression: a heat sink ? ? ? ? ? ? ? ? ? t p 80 30 085 143 . . . where ? t pp eff out = ==? ? ? ? ? ? ? case temperature rise above ambient device dissipation in watts 1 1 ? t = 85 - 25 = 60c () p =? ? ? ? ? ? ? ? =? = 120 1 83 1 120 0 205 24 6 . ..w and the required heat sink area is a = 60 80 24.6 in heat sink 0.85 ? ? ? ? ? ? ? ?= ? 143 2 30 71 . . from the specification table, the worst case full load efficiency for this device is 83%; therefore the power dissipation at full load is given by because of the incorporation of many innovative technological concepts, the afl series of converters is capable of providing very high output power from a package of very small volume. these magnitudes of power density can only be obtained by combining high circuit efficiency with effective methods of heat removal from the die junctions. this requirement has been effectively addressed inside the device; but when operating at maximum loads, a significant amount of heat will be generated and this heat must be conducted away from the case. to maintain the case temperature at or below the specified maximum of 125c, this heat must be transferred by conduction to an appropriate heat dissipater held in intimate contact with the converter base-plate. because effectiveness of this heat transfer is dependent on the intimacy of the baseplate/heatsink interface, it is strongly recommended that a high thermal conductivity heat transferance medium is inserted between the baseplate and heatsink. the material most frequently utilized at the factory during all testing and burn-in processes is sold under the trade name of sil-pad ? 400 1 . this particular product is an insulator but electrically conductive versions are also available. use of these materials assures maximum surface contact with the heat dissipator thereby compensating for minor variations of either surface. while other available types of heat conductive materials and compounds may provide similar performance, these alternatives are often less convenient and are frequently messy to use. when operating in the shared mode, it is important that symmetry of connection be maintained as an assurance of optimum load sharing performance. thus, converter outputs should be connected to the load with equal lengths of wire of the same gauge and sense leads from each converter should be connected to a common physical point, preferably at the load along with the converter output and return leads. all converters in a paralleled set must have their share pins connected together. this arrangement is diagrammatically illustrated in figure iii. showing the outputs and sense pins connected at a star point which is located close as possible to the load. as a consequence of the topology utilized in the current sharing circuit, the share pin may be used for other functions. in applications requiring a single converter, the voltage appearing on the share pin may be used as a ?current monitor?. the share pin open circuit voltage is nominally +1.00v at no load and increases linearly with increasing output current to +2.20v at full load. the share pin voltage is referenced to the output return pin. thus, a total heat sink surface area (including fins, if any) of 71 in 2 in this example, would limit case rise to 60c above ambient. a flat aluminum plate, 0.25" thick and of approximate dimension 4" by 9" (36 in 2 per side) would suffice for this application in a still air environment. note that to meet the criteria in this example, both sides of the plate require unrestricted exposure to the ambient air. 1 sil-pad is a registered trade mark of bergquist, minneapolis, mn as an example, it is desired to maintain the case temperature of this device at +85c in an area where the ambient temperature is held at a constant +25c; then thermal considerations
8 www.irf.com afl120xxs series r = 100 - -.025 adj nom out nom ? ? ? ? ? ? ? v vv where v nom = device nominal output voltage, and v out = desired output voltage figure v. connection for v out adjustment input filter undervoltage lockout the afl120xxs series converters incorporate a lc input filter whose elements dominate the input load impedance characteristic at turn-on. the input circuit is as shown in figure iv. figure iv. input filter circuit pin 1 pin 2 16.8uh 0.78uf a minimum voltage is required at the input of the converter to initiate operation. this voltage is set to 74v 4.0v. to preclude the possibility of noise or other variations at the input falsely initiating and halting converter operation, a hysteresis of approximately 7.0v is incorporated in this circuit. thus if the input voltage droops to 67v 4.0v, the converter will shut down and remain inoperative until the input voltage returns to 74v. output voltage adjust in addition to permitting close voltage regulation of remotely located loads, it is possible to utilize the converter sense pins to incrementally increase the output voltage over a limited range. the adjustments made possible by this method are intended as a means to ?trim? the output to a voltage setting for some particular application, but are not intended to create an adjustable output converter. these output voltage setting variations are obtained by connecting an appropriate resistor value between the +sense and -sense pins while connecting the -sense pin to the output return pin as shown in figure v. below. the range of adjustment and corresponding range of resistance values can be determined by use of the following equation. finding a resistor value for a particular output voltage, is simply a matter of substituting the desired output voltage and the nominal device voltage into the equation and solving for the corresponding resistor value. enable 2 share + sense - sense return + v out to load r adj afl120xxs note: r adj must be set 500 ? attempts to adjust the output voltage to a value greater than 120% of nominal should be avoided because of the potential of exceeding internal component stress ratings and subsequent operation to failure. under no circumstance should the external setting resistor be made less than 500 ? . by remaining within this specified range of values, completely safe operation fully within normal component derating limits is assured. examination of the equation relating output voltage and resistor value reveals a special benefit of the circuit topology utilized for remote sensing of output voltage in the afl120xxs series of converters. it is apparent that as the resistance increases, the output voltage approaches the nominal set value of the device. in fact the calculated limiting value of output voltage as the adjusting resistor becomes very large is 25mv above nominal device voltage. the consequence is that if the +sense connection is unintentionally broken, an afl120xxs has a fail-safe output voltage of vout + 25mv, where the 25mv is independent of the nominal output voltage. it can be further demonstrated that in the event of both the + and - sense connections being broken, the output will be limited to vout + 440mv. this 440mv is also essentially constant independent of the nominal output voltage.
www.irf.com 9 afl120xxs series general application information table 1. nominal resistance of cu wire the afl120xxs series of converters are capable of providing large transient currents to user loads on demand. because the nominal input voltage range in this series is relatively low, the resulting input current demands will be correspondingly large. it is important therefore, that the line impedance be kept very low to prevent steady state and transient input currents from degrading the supply voltage between the voltage source and the converter input. in applications requiring high static currents and large transients, it is recommended that the input leads be made of adequate size to minimize resistive losses, and that a good quality capacitor of approximately 100 f be connected directly across the input terminals to assure an adequately low impedance at the input terminals. table i relates nominal resistance values and selected wire sizes. wire size, awg resistance per ft 24 ga 25.7 m ? 22 ga 16.2 m ? 20 ga 10.1 m ? 18 ga 6.4 m ? 16 ga 4.0 m ? 14 ga 2.5 m ? 12 ga 1.6 m ? incorporation of a 100f capacitor at the input terminals is recommended as compensation for the dynamic effects of the parasitic resistance of the input cable reacting with the complex impedance of the converter input, and to provide an energy reservoir for transient input current requirements. figure vi. problems of parasitic resistance in input leads (see text) vin rtn case enable 1 sync out sync in r p r p i rtn i in e source system ground e rtn 100 fd
10 www.irf.com afl120xxs series mechanical outlines case x case w pin variation of case y 1.260 1.500 2.500 2.760 3.000 ? 0.128 0.250 1.000 ref 0.200 typ non-cum 0.050 0.220 pin ? 0.040 0.238 max 0.380 max 2.975 max 1 6 7 12 0.050 0.220 0.250 1.000 pin ? 0.040 0.525 0.380 max 2.800 0.42 case y case z pin variation of case y 1.500 1.750 2.500 0.25 typ 1.150 0.050 0.220 1 6 7 12 1.750 0.375 2.00 0.250 1.000 ref 0.200 typ non-cum pin ? 0.040 0.300 ? 0.140 0.238 max 0.380 max 2.975 max 0.050 0.220 0.250 1.000 ref pin ? 0.040 0.525 0.380 max 2.800 0.36 ber yllia w arning : these converters are hermetically sealed; however they contain beo substrates and should not be ground or subjected to any o ther operations including exposure to acids, which may produce beryllium dust or fumes containing beryllium tolerances, unless otherwise specified: .xx = 0.010 .xxx = 0.005
www.irf.com 11 afl120xxs series pin designation standard microcircuit drawing equivalence table standard microcircuit ir standard drawing number part number 5962-99608 afl12005s 5962-02549 afl12008s 5962-02550 afl12009s 5962-02551 afl12012s 5962-02552 afl12015s 5962-02553 afl12028s pin # designation 1 + input 2 input return 3 case ground 4 enable 1 5 sync output 6 sync input 7 + output 8 output return 9 return sense 10 + sense 11 share 12 enable 2
12 www.irf.com afl120xxs series part numbering world headquarters: 233 kansas st., el segundo, california 90245, tel: (310) 322 3331 ir santa clara: 2270 martin av., santa clara, california 95050, tel: (408) 727-0500 visit us at www.irf.com for sales contact information . data and specifications subject to change without notice. 04/2007 notes: best commercial practice sample tests at low and high temperatures -55c to +105c for ahe, ato, atw device screening requirement mil-std-883 method no suffix es hb ch temperature range -20c to +85c -55c to +125c -55c to +125c -55c to +125c element evaluation mil-prf-38534 n/a n/a n/a class h non-destructive bond pull internal visual 2017 yes yes yes temperature cycle 1010 n/a cond b cond c cond c constant acceleration 2001, y1 axis n/a 500 gs 3000 gs 3000 gs pind 2020 n/a n/a n/a n/a burn-in 1015 n/a 48 hrs@hi temp 160 hrs@125c 160 hrs@125c final electrical mil-prf-38534 25c 25c -55c, +25c, -55c, +25c, ( group a ) & specification +125c +125c pda mil-prf-38534 n/a n/a n/a 10% seal, fine and gross 1014 cond a cond a, c cond a, c cond a, c radiographic 2012 n/a n/a n/a n/a external visual 2009 yes yes yes n/a n/a 2023 n/a n/a afl 120 05 s x /ch model input voltage 28 = 28v 50 = 50v 120 = 120v 270 = 270v output voltage 05 = 5v, 06 = 6v 07 = 7v, 07r5 = 7.5v 08 = 8v, 09 = 9v 12 = 12v,15 = 15v 28 = 28v output s = single case style w, x, y, z screening level (please refer to screening table) no suffix, es, hb, ch

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