AVE360-48S12 DC/DC Converter TRN AVE360-48S12 DC/DC Converter Technical Reference Note Industry Standard Half Brick: 36~75V Input, 12V Single Output Features • Delivers up to 30A output current • Basic isolation • Ultra High efficiency • Improved thermal performance: • High power density Industry Standard Half Brick: 2.4” X 2.28’’ X 0.5’’ • Low output noise • 2:1 wide input voltage of 36-75V • CNT function Options • Remote sense • Trim function: +10%/-10% • Choice of positive logic or negative logic • Input under-voltage lockout for CNT function • Output over-current protection • Choice of short pins or long pins • Output over-voltage protection • Over-temperature protection Description The AVE360-48S12 is a new DC/DC converter for optimum efficiency and power density. AVE360-48S12 provides up to 30A output current in an industry standard Half Brick, which makes it an ideal choice for small space and high power applications. AVE360-48S12 uses an industry standard half brick 61.0mm × 57.9mm × 12.7mm (2.4”x2.28”x0.5”), provides CNT and trim functions. AVE360-48S12 can provide 12V@30A, single output and output is isolated from input. TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 1/19 BOM: 31020718 DATE: 2008-04-29 REV1.2 AVE360-48S12 DC/DC Converter TRN Module Numbering 360 48 P AVE - S 12 - 4 ± Pin length: -4---4.80 mm 0.5mm -6---3.80 mm ± 0.5mm -8---2.80 mm + 0.5 mm/-0.3 mm Default is 5.80 mm ± 0.5mm CNT logic, P---positive, open frame, by default: negative, open frame Output rated voltage: 12---12V Output number: S ---single output, D---dual output Input rated voltage Output rated power Series name TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 2/19 AVE360-48S12 DC/DC Converter TRN Electrical Specifications Unless otherwise indicated, specifications apply over all operating input voltage and temperature conditions. Standard test condition on a single unit is as following: Ta: 25°C +Vin: 48V ± 2% -Vin: return pin for +Vin CNT: connect to -Vin +Vout: connect to load -Vout: connect to load (return) +Sense: connect to +Vout -Sense: connect to -Vout Trim (Vadj): open Input Specifications Parameter Symbol Min Typ Max Unit Note - Operating Input Voltage VI 36 48 75 VDC Inrush transient - - - 2 A2s - 5Hz to 20MHz: 12µH source Input Reflected-ripple Current II - 50 80 mAp-p impedance, TA = 25ºC. CAUTION: This power module is not internally fused. An input line fuse must always be used. TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 3/19 AVE360-48S12 DC/DC Converter TRN Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings can cause permanent damage to the device. These are absolute stress ratings only. Functional operation of the device is not implied at these or any other conditions in excess of those given in the operational sections of the IPS. Exposure to absolute maximum ratings for extended periods can adversely affect device reliability. Parameter Symbol Min Typ Max Unit Note Continuous VI 0 - 80 Vdc - Input Voltage Transient VI, trans 0 - 100 Vdc 100ms Operating Ambient Temperature Ta -40 25 85 ºC See Thermal Consideration Operating Board Temperature Tc - 135 ºC Near temperature sensor Rt Storage Temperature TSTG -55 25 125 ºC - Operating Humidity - 5 - 95 % - 1mA for 5 sec, slew rate of Basic Input-Output Isolation - 1,500 - - Vdc 1,500V/10sec Output Power Po,max - - 360 W - TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 4/19 AVE360-48S12 DC/DC Converter TRN Output Specifications Parameter Symbol Min Typ Max Unit Conditions mVp-p Output Ripple& Noise - - - 300 Whole range (f<20MHz) (Ta: 25ºC, Vin: 48V, External Load Capacitance - 680 2200 10000 μF 30000μF can start-up) Output Voltage Setpoint Vo,set 11.8 12 12.2 Vdc Rating input@ Ionom Line - - - 0.3 %Vo (Vi,min to Vi,max) Load Output - - - 0.5 %Vo (Io = Io,min to Whole range Regulation Io,max) Temperature Regulation - - - 0.02 %Vo/ºC (Whole range) Rated Output Current Io 0 10 30 A - Output Current-limit Inception Io 31.5 - 45 A - (Hiccup) Ta: 25ºC, Air velocity: 300LFM, Vin: 48V, Load: Efficiency - 93 94 - % Ionom; forced air direction: from Vin+ to Vin- Ta: 25ºC, Air velocity: 300LFM, Vin: 48V, Load: Efficiency - 93 94 - % 70% Ionom; forced air direction: from Vin+ to Vin- TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 5/19 AVE360-48S12 DC/DC Converter TRN Output Specifications (Cont) Parameter Symbol Min Typ Max Unit Note Peak Deviation - - - 600 mV Dynamic 25% Ionom step from Settling Time Response (all) 50%Ionom, 0.1A/μS - - - 400 μsec (to Vo,nom) Io = Ionom; Turn-On Time - - - 100 msec Vo from 10% to 90% Io = Ionom; Output Voltage Overshoot - - - 5 %Vo TA = 25 C  Switching Frequency - - 280 - KHz - TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 6/19 AVE360-48S12 DC/DC Converter TRN Feature Specifications Parameter Symbol Min Typ Max Unit Note Logic Low - -0.7 - 1.2 Vdc - Enable pin voltage: Logic High - 3.5 - 5 Vdc - Logic Low - - - 1.0 mA Enable pin - current: Logic High - - - - μA Output Voltage Adjustment Range* - 90 - 110 %Vo - Output Over-voltage Protection (Static) Voclamp 14 - 16.5 V Hiccup Turn-on Point - 31 34 36 V Under-voltage - Lockout Turn-off Point - 30 33 35 V Isolation Capacitance - - - - PF - Isolation Resistance - 10 - - MΩ - Vin: 48V, Calculated MTBF - - 2,000,000 - Hours Load: Ionom Board@25oC Weight - - 72 - g(oz.) - Vibration level: 3.5mm (2 ~ 9Hz), 10m/s2 (9 ~ 200HZ), 15m/s2 (200 ~ 500HZ) Vibration (Sine wave) Directions and time: 3 axes (X, Y, Z), 30 minutes each Sweep velocity: 1oct / min Peak acceleration: 300m/s2 Shock (Half-sine wave) Duration time: 6ms Continuous shock 3 times at each of 6 directions (±X, ±Y, ±Z) TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 7/19 AVE360-48S12 DC/DC Converter TRN Characteristic Curves 96 95 94 93 36V 92 48V 91 75V 90 89 88 87 0 5 10 15 20 25 30 35 Output current (A) Fig. 1 AVE360-48S12 Typical Efficiency Fig. 2 AVE360-48S12-4 Typical Output Ripple Voltage o Ta: 25°C, Air velocity: 300LFM, Vin: 48V, Load: Ionom; Ta: 25 C, Air velocity: 300LFM, Vin: 48V, Vonom, Ionom, forced air direction: from Vin+ to Vin- 10μ tantalum (ESR≤100 mΩ)// 1μceramic capacitor Fig. 3 AVE360-48S12-4 Typical Transient Response to Fig. 4 AVE360-48S12-4 Typical Transient Response to Ta: 25℃, Air velocity: 300LFM, forced air direction: Ta: 25℃, Air velocity: 300LFM, forced air direction: from Vin+ to Vin-. Vin: 48V, Vonom, 25% Ionom step from Vin+ to Vin-. Vin: 48V, Vonom, 50% Ionom step from 50% Ionom, 0.1A/µs ”, the external capacitor from 75% Ionom, 0.1A/µs ”, the external capacitor should be “10µ tantalum (ESR≤100 mΩ) // 1µ ceramic should be “10µ tantalum (ESR≤100 mΩ) // 1µ ceramic capacitor capacitor TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 8/19 Efficiency (%) AVE360-48S12 DC/DC Converter TRN Performance Curves – Startup Characteristics Figure 5 Typical start-up from power on Figure 6 Typical start-up from CNT on TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 9/19 AVE360-48S12 DC/DC Converter TRN voltage of AVE360-48S12 in order to Feature Description compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. CNT Function When the converter is supporting loads far away, or is used with undersized cabling, Two CNT logic options are available. The CNT significant voltage drop can occur at the load. logic, CNT voltage and the module working The best defense against such drops is to state are as the following table. locate the load close to the converter and to L H OPEN ensure adequately sized cabling is used. When N ON OFF OFF this is not possible, the converter can P OFF ON ON compensate for a drop of up to 10%Vo, through use of the sense leads. N--- means “Negative Logic” When used, the + Sense and - Sense leads P--- means “Positive Logic” should be connected from the converter to the L--- means “Low Voltage”, -0.7V≤L≤1.2V point of load as shown in Figure 8, using H--- means “High Voltage”, 3.5V≤H≤5V twisted pair wire, or parallel pattern to reduce ON--- means “Module is on”, OFF--- means noise effect. The converter will then regulate its “Module is off” output voltage at the point where the leads are Open--- means “CNT pin is left open “ connected. Care should be taken not to Note: when CNT is left open, V may reach CNT reverse the sense leads. If reversed, the 6V. converter will trigger OVP protection and turn Figure 7 shows a few simple CNT circuits. off. When not used, the +Sense lead must be connected with +Vo, and -Sense with -Vo. CNT CNT Although the output voltage can be increased by both the remote sense and trim, the -Vin -Vin maximum increase for the output voltage is not Simple control Transistor control the sum of both. CNT CNT The maximum increase is the larger of either the remote sense or the trim. Note that at elevated output voltages the -Vin -Vin maximum power rating of the module remains Isolated control Relay control the same, and the output current capability will Figure 7 CNT circuits decrease correspondingly. Remote Sense +Vo +S AVE360-48S12 converter can remotely sense +Sense Twisted pair both lines of its output which moves the Load -Sense effective output voltage regulation point from -S -Vo the output terminals of the unit to the point of connection of the remote sense pins. This Figure 8 Sense connection feature automatically adjusts the real output TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 10/19 AVE360-48S12 DC/DC Converter TRN Note that the trim-up function is valid only when Trim the input is above 38V. The +Vo output voltage of AVE360-48S12 can Trim down be trimmed using the trim pin provided. Applying a resistor to the trim pin through a With an external resistor between the TRIM voltage divider from the output will cause the and -SENSE pins, the output voltage set point +Vo output to increase by up to 10% or decreases (see Figure 10). decrease by up to 20%. Trimming up by more than 10% of the nominal output may activate +Vin +Vo the OVP circuit or damage the converter. Trimming down more than 20% can cause the ON/OFF +Sense converter to regulate improperly. If the trim pin Load Trim is not needed, it should be left open. R adj_ down Vin - -Sense Trim up - Vo With an external resistor connected between the TRIM and +SENSE pins, the output voltage Figure 10 Trim down circuit set point increases (see Figure 9). The following equation determines the required external-resistor value to obtain a percentage +Vin +Vo output voltage change of %. ON/OFF +Sense Load Trim R adj_up S -ense - Vin -Vo Figure 9 Trim up circuit V tolerance less than ±2%, trim R tolerance is ±1% adj The following equation determines the required Although the output voltage can be increased external-resistor value to obtain a percentage by both the remote sense and the trim, the output voltage change of %. maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. Note that at elevated output voltages the maximum power rating of the module remains the same, and the output current capability will decrease correspondingly. V tolerance less than ±2%, trim R tolerance is ±1% adj TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 11/19 AVE360-48S12 DC/DC Converter TRN +Vo Minimum Load Requirements Load C1 There is no minimum load requirement for the -Vo AVE360-48S12 module. Parameter Device Symbol Typ Unit Figure 11 Output ripple filter Minimum 12V IMIN 0 A Extra care should be taken when long leads or Load traces are used to provide power to the load. Long lead lengths increase the chance for Output Over-current Protection noise to appear on the lines. Under these conditions C2 can be added across the load, AVE360-48S12 DC/DC converter feature with a 1μF ceramic capacitor C2 in parallel foldback current limiting as part of their generally as shown in Figure 12. Over-current Protection (OCP) circuits. When output current exceeds 105 to 140% of rated +Vo current, such as during a short circuit condition, C1 C2 Load the module will work on intermittent mode, also can tolerate short circuit conditions indefinitely. -Vo When the over-current condition is removed, the converter will automatically restart. Figure 12 Output ripple filter for a distant load Output Capacitance Decoupling High output current transient rate of change The converter does not always create noise on (high di/dt) loads may require high values of the power distribution system. High-speed output capacitance to supply the instantaneous analog or digital loads with dynamic power energy requirement to the load. To minimize demands can cause noise to cross the power the output voltage transient drop during this inductor back onto the input lines. Noise can be transient, low Equivalent Series Resistance reduced by decoupling the load. In most cases, (ESR) capacitors may be required, since a high connecting a 10μF ceramic capacitor in parallel ESR will produce a correspondingly higher with a 0.1μF ceramic capacitor across the load voltage drop during the current transient. will decouple it. The capacitors should be When the load is sensitive to ripple and noise, connected as close to the load as possible. an output filter can be added to minimize the effects. A simple output filter to reduce output Ground Loops ripple and noise can be made by connecting a capacitor C1 across the output as shown in Ground loops occur when different circuits are Figure 11. C1 ranges from 680μF to 10000μF , given multiple paths to common or earth the recommended value for C1 is 2200μF. ground, as shown in Figure 13. Multiple ground points can slightly different potential and cause TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 12/19 AVE360-48S12 DC/DC Converter TRN current flow through the circuit from one point mode when the maximum device reference to another. This can result in additional noise in temperature is exceeded. When the all the circuits. To eliminate the problem, over-temperature condition is removed, the circuits should be designed with a single converter will automatically restart. ground connection as shown in Figure 14. R R Line Line Design Consideration +Vo Load Load Typical Application R R Line Line -Vo + Fuse +Sense R Ground +Vin Line R Line Loop +Vo C3 CNT + + C2 + + Vin Trim Load + C1 Figure 13 Ground loops -Vo -Vin -Sense R R Line Line +Vo Figure 15 Typical application +Vin Load Load F1: Fuse*: Use external fuse (fast blow type) -Vin R R for each unit. Line Line -Vo For 12V output: 30A (Pout=360W) R Line C1: Recommended input capacitor C1 ≥ 100μF/100V electrolytic or ceramic type Figure 14 Single point ground capacitor. Output Over-Voltage Protection C2: Recommended -40°C ~ 100°C uses: 2,200μF/25V (electrolytic capacitor) The output over-voltage protection consists of C3: Recommended 10μF/25V circuitry that monitors the voltage on the output terminals. If the voltage on the output terminals Fusing exceeds the over voltage protection threshold, then the module will work on hiccup mode. The AVE360-48S12 power module has no When the over-voltage condition is removed, internal fuse. An external fuse must always be the converter will automatically restart. employed! To meet international safety The protection mechanism is such that the unit requirements, a 250 Volt rated fuse should be can continue in this condition until the fault is used. If one of the input lines is connected to cleared. chassis ground, then the fuse must be placed in the other input line. Over-Temperature Protection Standard safety agency regulations require input fusing. Recommended fuse ratings for the These modules feature an over-temperature AVE360-48S12 are shown as following list. protection circuit to safeguard against thermal For 12V output : 30A (Pout=360W) damage. The module will work in intermittent TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 13/19 AVE360-48S12 DC/DC Converter TRN Note: the fuse is fast blow type. 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 Input Reverse Voltage Protection in combination with the DC/DC power module Under installation and cabling conditions where to demonstrate that the output meets the reverse polarity across the input may occur, requirement for SELV. The input pins of the reverse polarity protection is recommended. module are not operator accessible. Protection can easily be provided as shown in Note: Do not ground either of the input pins of Figure 16. In both cases the diode used is the module, without grounding one of the rated for 15A/100V. Placing the diode across output pins. This may allow a non-SELV the inputs rather than in-line with the input voltage to appear between the output pin and offers an advantage in that the diode only ground. The circuit cannot withstand transient conducts in a reverse polarity condition, which over-voltage. increases circuit efficiency and thermal performance. Thermal Consideration + Vin + Vin - Vin - Vin Technologies Figure 16 Reverse polarity protection circuit AVE360-48S12 modules have ultra high efficiency at full load. With less heat dissipation Safety Consideration and temperature-resistant components such as For safety-agency approval of the system in ceramic capacitors, these modules exhibit which the power module is used, the power good behavior during pro-longed exposure to module must be installed in compliance with high temperatures. Maintaining the operating the spacing and separation requirements of the board temperature within the specified range end-use safety agency standard, i.e., UL60950, helps keep internal component temperatures CSA C22.2, and EN60950. AVE360-48S12 within their specifications which in turn help input-to-output isolation is a basic insulation. keep MTBF from falling below the specified The DC/DC power module should be installed rating. Proper cooling of the power modules is in end-use equipment, in compliance with the also necessary for reliable and consistent requirements of the ultimate application, and is operation. intended to be supplied by an isolated secondary circuit. When the supply to the Basic Thermal Management DC/DC power module meets all the requirements for SELV (<60Vdc), the output is Measuring the board temperature of the considered to remain within SELV limits (level module is shown in Figure 17. 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 TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 14/19 AVE360-48S12 DC/DC Converter TRN Because each power module output voltage MEASURE CASE TEMPERATURE HERE has a different power dissipation curve, a plot of power dissipation versus output current over three different line voltages are given in Figure Vin (+) Vo (+) 19. CNT +SENSE TRIM Module Derating -SENSE Vo (-) Vin (-) Experiment Setup From the experiment setup shown in Figure 18, DIMENSIONS: milimeters (inches) the derating curves shown in Figure 19 can be Figure 17 Temperature measurement location drawn. Note that the Printed Wiring Board The module should work under 85°C ambient (PWB) and the module must be mounted for the reliability of operation and the board vertically. The Passage has a rectangular temperature must not exceed 112°C while cross-section. The clearance between the operating in the final system configuration. The facing PWB and the top of the module is kept measurement can be made with a surface 13 mm (0.5 in.) constantly. probe after the module has reached thermal 13(0.5) equilibrium. No heatsink is mounted, make the measurement as close as possible to the indicated position. It makes the assumption PWB Facing PWB that the final system configuration exists and can be used for a test environment. Note that the board temperature of module must always be checked in the final system configuration to Converter verify proper operational due to the variation in Air velocity and ambient temperature testing point test conditions. Thermal management acts to transfer the heat dissipated by the module to the surrounding environment. The amount of 50.8(2.0) power dissipated by the module as heat (PD) is got by the equation: PD = PI-PO Where PI is input power; PO is output power; Air flow PD is dissipated power. Dimensions: millimeters (inches) Also, module efficiency () is defined as the following equation:  = PO / PI Figure 18 Experiment setup If eliminating the input power term, from two above equations can yield the equation below: Forced Convection PD = PO (1-) /  Figure 19 shows the change of the module The module power dissipation then can be output current with the change of ambient calculated through the equation. temperature. In the test, the airflow was TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 15/19 AVE360-48S12 DC/DC Converter TRN created with externally adjustable fans. A heatsink should be fitted in the case the input voltage is 36V or 75V. 35 30 25 Dimensions: milimeters (inches) 20 36V 48V 15 75V Figure 20 Non-standard heatsink 10 5 0 0 5 10 15 20 25 30 35 Output current (A) Figure 19 Forced convection power derating Airflow direction from Vin(+) to Vin(-): Vin=36,48,75V; Dimensions: milimeters (inches) Heatsink Configuration Figure 21 Longitudinal fins heatsink Several standard heatsinks available for the AVE360-48S12 are shown in Figure 20 to 22. The heatsinks mounted to the top surface of the module with screws torqued to 0.56 N-m (5 in.-Ib). A thermally conductive dry pad or thermal grease is placed between the case and the heatsink to minimize contact resistance (typically 0.1°C/W to 0.3°C /W) and temperature differential. Dimensions: milimeters (inches) Nomenclature for heatsink configurations is as Figure 22 Transverse fins heatsink follows: WDxyyy40 Heatsink Mounting x = fin orientation: longitudinal (L) or transverse A crucial part of the thermal design strategy is (T) the thermal interface between the baseplate of yyy = heatsink height (in 100ths of inch) the module and the heatsink. Inadequate measures taken will quickly negate any other For example, WDT5040 is a heatsink that is attempts to control the baseplate temperature. transverse mounted for a 61mm × 57.9mm For example, using a conventional dry insulator (2.4in × 2.28in) module with a heatsink height can result in a case-heatsink thermal of 0.5 in. o impedance of >0.5 C/W, while use one of the recommended interface methods (using silicon grease or thermal pads) can result in a TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 16/19 Power dissipation (W) AVE360-48S12 DC/DC Converter TRN case-heatsink thermal impedance around have separate airflow paths. This can keep o 0.1 C/W. other system equipment cooler and increase component life spans. Soldering AVE360-48S12 converter is compatible with standard wave soldering techniques. When wave soldering, the converter pins should be o preheated for 20-30 seconds at 110 C, and o wave soldered at 260 C for less than 10 seconds. Figure 23 Heatsink mounting When hand soldering, the iron temperature o should be maintained at 425 C and applied to Installation the converter pins for less than 5 seconds. Longer exposure can cause internal damage to Although AVE360-48S12 converters can be the converter. Cleaning can be performed with mounted in any orientation, free air-flowing cleaning solvent IPA or with water. must be taken. Normally power components are always put at the end of the airflow path or TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 17/19 AVE360-48S12 DC/DC Converter TRN Mechanical Chart L Device Code Suffix 4.8mm+/-0.5mm -4 -6 3.8mm+/-0.5mm -8 2.8mm+0.5/-0.3mm NONE 5.8mm+/-0.5mm TOLERANCES: X.Xmm= +/-0.5mm X.XXmm=+/-0.25mm Pins Definition Pin Number Function Pin Number Function P1 +Vin P5 +SENSE P2 CNT P6 TRIM P3 -Vin P7 -SENSE P4 +Vout P8 -Vout TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 18/19 AVE360-48S12 DC/DC Converter TRN Ordering Information Ripple Input Output Output Efficiency &Noise Model Number Voltage Voltage Current (%) (mV pp, (V) (V) (A) Typ. Max.) AVE360-48S12-4 36~75 12 30 300 94 AVE360-48S12P-4 36~75 12 30 300 94 有毒有害物质或元素标识表 有毒有害物质或元素 部件 铅 汞 镉 六价铬 多溴联苯 多溴联苯醚 名称 6＋ Pb Hg Cd C PBB PBDE 制成板 × ○ ○ ○ ○ ○ ○：表示该有毒有害物质在该部件所有均质材料中的含量在 SJ/T-11363-2006规定的限量要求以下。 ×：表示该有毒有害物质至少在该部件的某一均质材料中的含量超出 SJ/T-11363-2006规定的限量要求 艾默生网络能源有限公司一直致力于设计和制造环保的产品，我们会通过持续的研究来减少和消除产品中的有毒有害 物质。以下部件或应用中含有有毒有害物质是限于目前的技术水平无法实现可靠的替代或者没有成熟的解决方案： 1．器件的高温焊料中含有铅。 2 ．电子器件的玻璃中含有铅。 3 ．插针的铜合金中含有铅 适用范围：AVE360-48S12 TEL: (86) 755-86010808 www.emersonnetworkpower.com.cn 19/19