HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Features * * * * * * * * * * * * * Applications * * * * Distributed power architectures Telecommunications equipment LAN/WAN Data processing * * RoHS lead solder exemption compliant Low profile - 12.7 mm height Input/output isolation: 1500 VDC Basic insulation High efficiency - up to 88% at full load Start-up into high capacitive load Low conducted and radiated EMI Output overcurrent protection Output overvoltage protection Back-drive protection Overtemperature protection Remote sense Remote on/off (primary referenced), positive or negative logic Output voltage trim adjust UL60950-3rd/ CSA C22.2 60950-00, TUV EN60950-1, IEC60950-1 Description The HHS40 is a series of high efficiency, high-density, single output dc-dc converters for onboard conversion of standard telecom and datacom input voltages into isolated low voltage outputs in a through-hole mounting package. The two-board construction provides a cool environment for control components and the integrated metal substrate PCB provides superior thermal management for power components resulting in enhanced product reliability. A heat sink can be conveniently and effectively attached to the IMS base plate for operations in elevated ambient conditions or where airflow is minimal. Model Selection Model Input Voltage VDC HHS40ZE HHS40ZD 1 Input Current, Max 2 ADC 36 -75 4.5 Output Voltage Vout, VDC 3.3 36 -75 3.6 2.5 Output Rated Current I rated, ADC 40 Output Ripple/Noise, mV p-p Typical Efficiency @ I rated, % 150 88 40 150 88 NOTES: 1 Consult factory for availability 2 @ Vin min. FEB 16, 2006 revised to JUN 15, 2006 Page 1 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect longterm reliability, and cause permanent damage to the converter. Table 1. Absolute Maximum Ratings Parameter Input voltage Conditions/Description Continuous Min Max 75 Units VDC 100 VDC Operating Temperature Transient (100 ms) Baseplate -40 115 C Storage Temperature Ambient -55 125 C ON/OFF Control Voltage Referenced to -Vin 10 VDC Environmental, Mechanical & Reliability Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Table 2. Environmental and Mechanical Specifications Parameter Operating Temperature Conditions/Description Baseplate Temperature Min -40 Nom Max 115 Units C Operating Humidity Relative humidity, non-condensing 95 % Storage Humidity Relative humidity, non-condensing 95 % Shock Halfsine wave (6ms), 3 axes 50 g Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 g Weight 1.9/54 Oz/g Water Washing Standard process Yes MTBF (calculated) Per Bellcore TR-NWT-000332 (Po=60W, Tc=40 C) 1,500 kHrs Dimensions (overall) 2.28(57.9) x 2.4(61) x 0.5(12.7) in (mm) FEB 16, 2006 revised to JUN 15, 2006 Page 2 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Isolation Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Table 3. Isolation Specifications Parameter Insulation Safety Rating Isolation Voltage Isolation Resistance Isolation Capacitance Conditions/Description Min Input to output, input to base plate Output to base plate 1500 707 10 Input to Output Nom Basic Max Units VDC VDC M pF 1000 Safety Regulatory Compliance Safety Agency Underwriters Laboratories TUV product Service CB report Standard Approved To: UL60950/CSA60950-00 Marking cULus TUV EN60950:2000 TUV PS Baurt mark IEC60950:1999 N/A. Input Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Table 4. Input Specifications 1 2 Parameter Input Voltage Turn-On Input Voltage 1 Turn-Off Input Voltage 1 Input over voltage protection Input Reflected Ripple Current 2 Conditions/Description Continuous Ramping Up Ramping Down Ramping up Full Load, 12 H source inductance Inrush Transient Vin = Vin.max Min 36 32.5 31.5 76 Nom 48 34 33 Max 75 35.5 34.5 84 50 Units VDC VDC VDC VDC mA p-p 1.0 A2s Refer to Figures 3 & 4 for actual characteristic waveforms. Refer to Figure 10 for test circuit. FEB 16, 2006 revised to JUN 15, 2006 Page 3 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Table 5. Output Specifications Parameter Output Voltage Setpoint Accuracy 2.5V 3.3V 1 Output Current Line Regulation Load Regulation Output Temperature Regulation Remote Sense Headroom 3 Ripple and Noise, DC to 20MHz 1, 5 Dynamic Regulation Peak Deviation Settling Time Peak Deviation Settling Time Turn-On Time (turn-on via application of Vin) Turn-On Time (turn-on via ON/OFF signal) Admissible Load Capacitance Output Current Limit Threshold 2 Short Circuit 2 Turn-On Overshoot Backdrive Protection Switching Frequency Overvoltage Protection, Clamp, Non Latching 3 Trim Range 1 Conditions/Description Vin = Vin.nom, Full Load Irated Vin.min to Vin.max, Irated Vin = Vin.nom, 10% to 100%Irated Min Nom Max Units %Vout %Vout Amps %Vout %Vout 125 35 2.00 1.5 40 .5 1 0.03 10 150 60 8 200 13 300 20 100 7 25 200 15 5 10 ms 13,000 150 14 5 F %Irated ARMS %Vout -2.00 -1.5 0.5 .25 .5 (TBaseplate) = -40 C to +115 C) Over line and load Tamb= 0 C to 85 C 75-100-75% load step change, to 1% error band di/dt = 0.1A/s di/dt = 1A/s 4 Time from Vin = UVLO to regulation band Time from ON/OFF signal to regulation band Irated, Nom Vin Vou t 0.97Vout.nom Hiccup 110 9 1 Yes 300 No damage to converter %/C %Vout mV p-p mVRMS %Vout s %Vout s ms Over all input voltage and load conditions 120 140 kHz %Vout Irated, Vin = Vnom 90 110 %Vout At Iout<Iout.min, the output may contain low frequency component that exceeds ripple specifications. 2 Overcurrent protection is non-latching with auto recovery. 3 * Vout can be increased up to 10% via the sense leads or up to 10% via the trim function, however total output voltage trim from all sources should not exceed 10% of Vout 4 Adding output capacitance will have a significant effect in reducing the peak amplitude deviation when powering fast slew-rate loads. 5 Refer to Figure 11 for test circuit. FEB 16, 2006 revised to JUN 15, 2006 Page 4 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Feature Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. Table 6. Feature Specifications Parameter Shutdown (ON/OFF) Negative Logic (-N suffix) Converter ON Source Current Converter OFF Open Circuit Voltage Shutdown (ON/OFF) Positive Logic (Std. model) Converter ON Open Circuit Voltage Converter OFF Source Current Overtemperature Protection Conditions/Description ON/OFF signal is low or the pin is connected to -Vin - converter is ON Von/off in reference to -Vin ON/OFF pin is connected to -Vin Von/off in reference to -Vin ON/OFF pin is floating Min Nom Max Units 1.8 1 10 5 VDC mADC VDC VDC 10 5 1.8 1 130 VDC VDC VDC mADC -0.5 0.5 2.5 On/Off signal is low or the pin is floating -converter is OFF Von/off in reference to -Vin ON/OFF pin is floating Von/off in reference to -Vin ON/OFF pin is connected to -Vin -0.5 Baseplate temperature 120 2.5 0.5 125 C Characteristic Curves HHS40ZD EFFICIENCY VS. LOAD RESPONSE HHS40ZE EFFICIENCY VS. LOAD RESPONSE 100 100 95 95 90 90 85 EFFICIENCY % EFFICIENCY % 85 80 75 70 65 80 75 70 65 60 60 55 55 50 50 45 45 40 EFF.(36V) 40 10 20 30 40 EFF.(48V) 50 60 LOAD % 70 EFF.(75V) 80 90 EFF.(36V) 10 20 EFF.(48V) 30 40 EFF.(75V) 50 60 70 80 90 100 LOAD % 100 Figure 2. HHS40ZD Efficiency vs. Output Load Figure 1. HHS40ZE Efficiency vs. Output Load FEB 16, 2006 revised to JUN 15, 2006 Page 5 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter 5 4.5 Input Current (A) 4 3.5 3 2.5 2 1.5 1 0.5 0 0 10 20 30 40 50 Input Voltage (V) 60 70 Figure 3. HHS40ZE Input Characteristics 4 Input Current (A) 3.5 3 2.5 2 1.5 1 0.5 0 0 10 20 30 40 50 Input Voltage (V) 60 70 Figure 4. HHS40ZD Input Characteristics FEB 16, 2006 revised to JUN 15, 2006 Page 6 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter The user should avoid connecting a resistor between the ON/OFF pin and the +Vin (# 4) pin. Typical Application Figure 5 shows the recommended connections for the HHS40 Series converter. HHS40Zx HHS60ZX Fuse +Vi +Vo +Sense C1 On/Off Trim C2 C3 Note: If the ON/OFF pin is not used, it can be left floating (positive logic), or connected to the -Vin pin (negative logic). -Sense -Vi When the ON/OFF pin is used to achieve remote control, the user must take care to insure that the pin reference for the control is actually the -Vin pin. The control signal must not be referenced ahead of EMI filtering, or remotely from the unit. Optically coupling the information and locating the optical coupler directly at the module will solve any of these problems. -Vo Remote Sense Figure 5. Typical Application of the HHS40 Series These converter modules do not require any external components for proper operation. However, if the distribution of the input voltage to the converter contains significant inductance, the capacitor C1 may be required to enhance performance of the converter. A minimum of a 68 F electrolytic capacitor with the ESR<0.7 is recommended for the HHS40 Series. Refer to the "Inrush Current Control Application Note" on www.power-one.com for suggestions on how to limit the magnitude of the inrush current. For output decoupling we recommend to use a 10 F tantalum and a 0.1 F ceramic capacitors connected directly across the output pins of the converter. Note, that the capacitors do not substitute the filtering required by the load. Shutdown Feature Description The ON/OFF (# 3) pin of the HHS40 Series converters are referenced to the -Vin (# 1) pin (see Figure 5). Both negative and positive logic models are available. The HHS40 Series converters have the capability to remotely sense both lines of the output. This feature moves the effective output voltage regulation point from the output of the unit to the point of connection of the remote sense pins. This feature automatically adjusts the real output voltage of the converter in order to compensate for voltage drops in distribution and maintain a regulated voltage at the point of load. This is shown in Figures 6 & 7. If the remote sense feature is not to be used, the sense pins should be connected locally. The +Sense (#8) pin should be connected to the +Vout (#9) pin directly at the output of the converter and the -Sense (#6) pin should be connected to the -Vout (#5) pin directly at the output of the converter. If sense pins are not connected to load, or the respective output pins, the converter will not be damaged, but may not meet the output voltage regulation specifications. With negative logic (which is denoted by the suffix "-N" in the part number), when the ON/OFF pin is pulled low, the unit is turned on. With the positive logic, when the ON/OFF pin is pulled low, the output is turned off and the unit goes into a very low input power mode. An open collector switch is recommended to control the voltage between the ON/OFF pin and the -Vin pin of the converter. The ON/OFF pin is pulled up internally, so no external voltage source is required. FEB 16, 2006 revised to JUN 15, 2006 Page 7 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter OUTPUT VOLTAGE TRIM Negative-Trim Models (No P/N suffix) Industry Standard (Positive) Trim (-T suffix) The trim feature allows the user to adjust the output voltage from its nominal value. All HHS40 negative-trim models trim up with a resistor connected from the TRIM (#7) pin to the (-) Sense (#6) pin and trim down with a resistor from the TRIM pin to the (+) Sense (#8) pin as shown in Figure 7. The HHS40 positive-trim (-T) models trim up with a resistor from the Trim (#7) pin to the +Sense (#8) pin and trims down with a resistor from the Trim pin to the - Sense (#6) pin as shown in the Figure 6. Figure 7. HLS Series Negative Trim Schematic The following equation determines the required external resistor value to obtain an output voltage change of %. Figure 6. HHS40 Series Positive Trim (-T) Schematic The equations below determine the trim resistor value required to achieve a V change in the output voltage. Vo(100 + %) 100 Radj - up = - - 2 k % 1.225% a b 100 Radj - up = - c k a + b % 100 Radj - down = - 2 k % where V% is the output voltage change expressed in percent of the nominal output voltage, Vout. FEB 16, 2006 revised to JUN 15, 2006 a 2 100 Radj - down = - a - c k a + b % Page 8 of 11 Trim parameters for a, b & c are defined in the following table. Model Name a b c HHS40ZD /-N HHS40ZE /-N 1.04 1.69 1.00 1.00 3.92 3.92 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Notes: 1. When the output voltage is trimmed up, the output power from the converter must not exceed its maximum rating. The power is determined by measuring the output voltage on the output pins, and multiplying it by the output current. 2. In order to avoid creating apparent load regulation degradation, it is important that the trim resistors are connected directly to the remote sense pins, and not to the load or to traces going to the load. 3. The output voltage increase can be accomplished by either the trim or by the remote sense or by the combination of both. In any case the absolute maximum output voltage increase shall not exceed the limits defined in section 6 above. 4. Either Rup or Rdown should be used to adjust the output voltage according to the equations above. If both Rup and Rdown are used simultaneously, they will form a resistive divider and the equations above will not apply only if the output is grounded per the requirements of the standard. * If the voltage source feeding the module is a Hazardous Voltage Secondary Circuit, the voltage source feeding the module must be provided with at least Basic insulation between the source to the converter and any hazardous voltages. The entire system, including the HHS40 converter, must pass a dielectric withstand test for Reinforced insulation. Design of this type of systems requires expert engineering and understanding of the overall safety requirements and should be performed by qualified personnel. Safety Considerations Thermal Considerations The HHS40 Series converters feature 1500 Volt DC isolation from input to output. The input-to-output resistance is greater than 10M. These converters are provided with Basic insulation between input and output circuits according to all IEC60950 based standards. Nevertheless, if the system using the converter needs to receive safety agency approval, certain rules must be followed in the design of the system. In particular, all of the creepage and clearance requirements of the enduse safety requirements must be observed. These documents include UL60950 - CSA60950-00 and EN60950, although other or additional requirements may be needed for specific applications. The HHS40 Series converters are designed for natural or forced convection cooling. The maximum allowable output current of the converters is determined by meeting the derating criteria for all components used in the converters. For example, the maximum semiconductor junction temperature is not allowed to exceed 120 C to ensure reliable long-term operation of the converters. The HHS40 Series converters have no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 5. Refer to the "Input Fuse Selection for DC/DC converters" application note on www.power-one.com for proper selection of the input fuse. Both input traces and the chassis ground trace (if applicable) must be capable of conducting a current of 1.5 times the value of the fuse without opening. The fuse must not be placed in the grounded input line, if any. The graphs in Figures 8 & 9 show the maximum output current of the HHS40 Series converters at different ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4). For example, from Figure 8, the HHS40ZE operating at 55 C can deliver up to 27 A reliably with 200 LFM forced air, while up to 36 A reliably with 400 LFM forced air. In order for the output of the HHS40 Series converter to be considered as SELV (Safety Extra Low Voltage) or TNV-1, according to all IEC60950 based standards, one of the following requirements must be met in the system design: * If the voltage source feeding the module is SELV or TNV-2, the output of the converter may be grounded or ungrounded. * If the voltage source feeding the module is ELV, the output of the converter may be considered SELV FEB 16, 2006 revised to JUN 15, 2006 Page 9 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Power Derating Characteristics Test Setup THERMAL DERATING CURVE HHS40ZE Vin = 54V, Orientation : Vin- to Vin + 45 TO OSCILLOSCOPE Data Rev: 01 40 30 Load Current (A) Vi(+) Ltest 12 uH 35 Cs 220 uF ESR < 0.1 OHM @ 20 C, 100 kHz BATTER Y 25 22 uF ESR < 0.7 OHM @ 20 C, 100 kHz Vi(-) 20 15 Figure 10. Input Reflected Ripple Current Test Set-up 10 5 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM 0 25 40 55 70 85 Note: Measure input reflected-ripple current with a simulated inductance (Ltest) of 12 H. Capacitor Cs offsets possible battery impedance. Measure current as shown above. Ambient Temperature (Deg C) Figure 8. HHS40ZE (3.3V) Derating Curve THERMAL DERATING CURVE HHS40ZD Vin = 54V, Orientation : Vin- to Vin + 45 Data Rev: 01 COPPER STRIPS (2 to 3 inches) DUT 40 +Vo1 35 0.1uf ceramic Load Current (A) 30 10uF Tantalum SCOPE LOAD1 -Vo1 25 20 15 Figure 11. Output Ripple Measurement Test Setup 10 Note: Use a 0.1 f ceramic and 10 f tantalum capacitor. Scope measurement should be made using a BNC socket. 5 NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM 0 25 40 55 70 85 Ambient Temperature (Deg C) Figure 9. HHS40ZD (2.5V) Derating Curves FEB 16, 2006 revised to JUN 15, 2006 Page 10 of 11 www.power-one.com HHS40 DC-DC Series Data Sheet 40A Half-Brick Converter Mechanical Drawing Table 7. Pinout/Functions Pin 1 2 3 4 5 6 7 8 9 Function -Vin Case On/Off +Vin -Vo -Sense Trim +Sense +Vo Mechanical Tolerances Inches X.XX X.XXX 0.020 0.010 PIN DIA Millimeters X.X 0.5 X.XX 0.25 0.002 0.05 Ordering: Table 8. Ordering Information Options Trim Remote ON/OFF Pin Length Notes: 1 P/N Suffixes Positive (Industry std) - Add "T" suffix Negative - no suffix required Positive - no suffix required Negative - Add "N" suffix 0.18"- Standard - no suffix required 0.11"- Add "8" suffix 1 0.15"- Add "9" suffix 1 Consult factory for available options. NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respective divisional president of Power-One, Inc. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. FEB 16, 2006 revised to JUN 15, 2006 Page 11 of 11 www.power-one.com