PALS AC-DC Series Data Sheet Power-over-Ethernet · PALS AC-DC Series Data Sheet JUL 06, 2006...

Power-over-EthernetPALS AC-DC Series Data Sheet

JUL 06, 2006 revised to SEP 19, 2006 of 5 www.power-one.com

Features• RoHS lead free solder and lead solder exempted

products are available• Single-phase AC input• Up to 9 W/in3 power density• 1U or 3U height configurations• Power Factor Correction (PFC) Meets EN61000-3-2• Current share with ORing diodes• Overtemperature, overload, and overvoltage

protection• Power supply status indicators• I2C protocol alarms, status, & control• Standby voltage - 12 VDC @ 500 mA with

ORing diode• Enable signal for each output

Model SelectionMODEL TOTAL OUTPUT OUTPUT MAXIMUM OUTPUT LINE LOAD RIPPLE & NOISE INITIAL SETTING

POWER (WATTS) VOLTAGE CURRENT REGULATION REGULATION 1 mVp-p 2 ACCURACY

PALS400-2482 400 48V 8A 0.1% 0.2% 120 0.2%12V 16A 0.1% 0.2% 120 0.2%

PALS600-2482 600 48V 9A 0.1% 0.2% 120 0.2%12V 16A 0.1% 0.2% 120 0.2%

NOTES:1 With Remote Sense connected.2 Maximum peak-to-peak noise expressed as a percentage of output voltage, 20 MHz bandwidth.

Input SpecificationsPARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS

Input Voltage - AC Single-phase continuous input range. 85 264 VACInput Frequency AC input. 47 63 HzHold-up Time After last AC line peak at full power. At 115 VAC. 20 msInput Current At full rated load. At 85 VAC. PALS400: 6.5 Arms

At 85 VAC. PALS600: 10Inrush Surge Current Internally limited by thermistor. Vin = 115VAC (one cycle). 25° C. 17 ApkPower Factor Per EN61000-3-2 0.98 W/VAOperating Frequencies Boost frequency 95 kHz

Forward converter frequency 125

The PALS Series consists of 400 and 600 watt ac-dc power supplies designed specifically for use in power-over-ethernet applications. The supplies have dual outputs of 48 and 12 volts which provide LAN port and internal systempower. A 500 mA standby output facilitates I2C interface operations. The units are fully-enclosed, have 1500 VAC(2250 VDC) output isolation, and comply to IEEE802.3AF.

The PALS Series provides excellent protection against input voltage transients. Supply outputs are fully floating,meaning that users can use them for either positive or negative polarity needs.

Output voltage terminals and interface access is through a hot-swap connector at the rear of the supply. The AC inputfans, handle, and LED indicator lights are located on the front panel of the supply. Airflow is from the front through therear. Alarm, monitoring, and control signals are floating from the rear output and can be referenced.

The PALS Series meets international safety requirements and is CE Marked to the Low Voltage Directive.

Courtesy of Steven Engineering, Inc.-230 Ryan Way, South San Francisco, CA 94080-6370-Main Office: (650) 588-9200-Outside Local Area: (800) 258-9200-www.stevenengineering.com



Output SpecificationsPARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS

Efficiency Full rated load. 82 85 %Minimum Loads Minimum loading required to maintain regulation. 0 AOutput Power (Does not include standby output power) PALS400: 400 Watts

PALS600: 600Overshoot / Undershoot Output voltage overshoot/undershoot at turn-on. 3 %Transient Response Maximum recovery time, to within 1% of initial set point due to a 400 µs

50% load change, 1A/µs, 2% max. deviation.Turn-On Delay Time required for initial output voltage stabilization. 1 SecTurn-on Rise Time Time required for output voltage to rise from 10% to 90%. 100 ms

Interface Signals and Internal ProtectionPARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS

Overvoltage Protection Latch style overvoltage protection. Vo1 55.2 60.0 VVo2 13.8 15.0

Overcurrent Protection Straight line current limit, as a percentage of maximum rated load. 110 120 %Short Circuit Protection Enabled during overcurrent conditions. 25 %

Overtemperature/ Time to shutdown due to excessive internal temperature or fan failure. TBD msFan Failure Warning Latching shutdown. (Note 1)Output Good TTL open collector signal. Percent of output voltage when V1 output is 3 5 %

within nominal range. Signal high indicates out of tolerance output.(Note 1)

Input Power Fail Warning TTL open collector signal. Time before VOUT drops to 95% due to loss of input power. 5 ms(Note 1)

Power Supply Present Signal Resistance of connection to logic ground to allow user to determine if 100 Ohmspower supply is present. (Note 1)

Current Share Active current share on Vo1 & Vo2 for load current >10% of full load share within: 5 %Remote Sense Total voltage compensation for cable losses with respect to the main output. 1.0 VEnable TTL compatible logic signal. Logic “low” required to enable each output. 2 mA

(Note 1)Auxiliary Power Rated current of isolated 12 VDC power source. 500 mA

I2C Bus Management InterfaceSTATIC

Includes static information such as: part number and revision level, output rating, serial number, date code, and manufacturing location.STATUS (Logic 1 or 0)

Power Supply OKAC Input OKDC Output OKPower Supply SeatedOvertemperature.

CONTROL SIGNALInhibit

Safety, Regulatory, and EMI SpecificationsPARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS

Agency Approvals UL60950-1/CSA 22.2 No. 60950-1, EN60950-1 (TUV), and IEC60950-1.Electromagnetic Interference FCC CFR title 47 Part 15 Sub-Part B - Conducted. B

EN55022 / CISPR 22 Conducted. B Class

ESD Susceptibility Per EN61000-4-2, level 4. 8 kVRadiated Susceptibility Per EN61000-4-3, level 3. 10 V/MEFT/Burst Per EN61000-4-4, level 4. ±4 kVSurge Per EN61000-4-5, level 3. Line-to-Line 1 kV

Line-to-Ground 2Leakage Current Per EN60950. at 265 VAC, 60 Hz 2.6 mA

NOTE: 1) Also available on I2C data line.




Environmental SpecificationsPARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS

Altitude Operating. 10k ASL Ft.Non-Operating. 40k ASL Ft.

Operating Temperature At 100% load: 0 50 °CAt 50% load: 70 °C

Storage Temperature -40 85 °CTemperature Coefficient 0 °C to 70 °C (after 15-minute warm-up). .02 %/°CRelative Humidity Non-Condensing. 95 %RHShock Operating: half-sine 10ms, 3 axis +20 GPK

Non-operating: half-sine 10ms, 3 axis +40Vibration Operating: swept sine 5-2000-5 Hz, 5-32 Hz, 0.02îDA, 32-2000 Hz 1 GPK

Non-operating: random 10-2000 Hz 6.15 Grms

DC OK

AC OK

O.T.P

40.1

(1.5

8")

40.4

(1.5

9")

30.1

20.0

5

POWERLED AC Inl

116.6

33.0 22.0 19.5

10.0

17.5

19.0

20.0

109.22 (4.3")

Fastener Screw:

Features required for mounting...

SOUTHCO 52-19-11-4

THREAD SIZE #4-40

OR EQU TYPE

PALS Front Panel View

PALS Rear Connector Panel ViewOutput Connector

AMP 2-1450130-9(2P+24S+2P)

FCI 51730-016(2P+24S+2P)

or EQU TYPE

48.26

Mates with:

FCI 51740-10202402AA

or equivalent.

26.67

50.8

13.7

6

Ordering Information:OPTIONS SUFFIXES TO ADD TO PART NUMBER

RoHS lead solder exemption No RoHS character required.RoHS compliant for all 6 substances Add “G” as the last character of the part number.




PALS Right Side View#4-40-3PL

Mounting Holes

Marked "B"102.0

BOTTOM

115.030.0

22.0

BBB

*References to the center of guide pin on blind mate connector.

PSUP N/COTFA2A1

Vo2CS

Vo2-S

RTN

1N

1S

1K

P2 1JP1

Vo2+S

Vo2 Vo2

N/C

N/C

N/CVaux

OGOOD

PFVo1 ENA

VauxRTN

Vo2 ENA

A0

SCL

SDA

4N 5N

5S4S

3N2N

2S 3S

4K 5K3K2K

2J 4J 5J3J

N/C

Vo1+S

Vo1-S

Vo1CS

Vo1

RTN

Vo16N

6S

6K

6J P4P3

P4P1

K

J

N

S53 42 61

P3P2

Output Connector Pin Assignments




101.6 (4.0")

25

.0 (

0.9

8")

264.2

(10.4

")

FA

N

17.0

V.R

. h

ole

s

10

.3

RATING LABEL

72.5

PALS Bottom View

#4-40-4PL

Mounting Holes

Marked "A"

75.0

246.0

73.6

FAN

SPRING CLIP

22.0

8.0

264.2

250.0

12.0

13.3

A

A A

A

PALS Top View

NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical componentsin life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of the respectivedivisional president of Power-One, Inc.

TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on thedate manufactured. Specifications are subject to change without notice.


MAR 06, 2006 revised to APR 20, 2006 Page 1 of 11 www.power-one.com

HHS04Z52 DC-DC Converter Data Sheet48 V Input, 52.5 V @ 3.8 A Half-Brick Converter

Applications Next-generation IP Telephony & Power Over LAN (Unit is compliant to IEEE802.3af) Distributed power architectures

Benefits • Simplifies power system design, reduces design

time and technical risk • Reduces PCB area occupied by power

conversion and power management components

Features • RoHS lead solder exemption compliant • 200 Watt output power capability • Standard ½-brick footprint and pinout • Fully regulated 52.5 VDC output • Efficiency up to 92% • Input-to-output isolation: 2,250 VDC • Basic insulation • Output overcurrent protection • Output overvoltage protection • Overtemperature protection • Remote sense • Remote on/off (primary referenced) • Safety: UL60950-3rd/ CSA C22.2 60950-00,

TUV EN60950:2001, IEC60950-1:2001

Description The HHS04Z52 is a DC-DC converter that operates over an input voltage range of 36 to 75 VDC and provides regulated 52.5 V output rated up to 3.8 amps (200 watts) of continuous output current. The output is fully isolated from the input, which allows a positive or negative output voltage configuration. The standard feature set includes remote on/off, remote sensing, undervoltage lockout, overtemperature protection, output overvoltage protection, output trim, and a dedicated pin that connects to the baseplate. The highly efficient topology and thermally-optimized construction allow this unit to provide high output current over a wide operating temperature range while maintaining a safe guardband of electrical and thermal component deratings. The addition of an external heat sink further increases the capacity of the unit. The HHS04Z52 employs 100% surface-mount components for consistency and reliability in the production process.

Model Selection

Model Input

Voltage VDC

Input Current,

Max ADC 1

Output Voltage

VDC

Output Rated Current I rated

ADC

Output Ripple/Noise,

mV p-p 2

Typical Efficiency @

I rated % HHS04Z52-NT 36-75 6.11 52.5 3.8 150 92

NOTES: 1 @ VIN min. 2 (DC to 500 kHz)




1. Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long-term reliability, and cause permanent damage to the converter.

Parameter Conditions/Description Min Max Units

Input voltage Continuous 36 75 VDC Operating Temperature Baseplate Temperature 0 110 °C Storage Temperature Ambient -55 125 °C

ON/OFF Control Voltage Referenced to -Vin 20 VDC Output Power 260 W

2. Environmental and Mechanical Specifications Parameter Conditions/Description Min Nom Max Units

Baseplate 0 110 °C Operating Temperature Ambient 1 0 85 °C

Operating Humidity Relative Humidity, Non-cond. 95 % Storage Humidity Relative Humidity, Non-cond. 95 % Water Washing Standard process Yes

Shock Halfsine wave, 3 axes 50 g Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 g

Weight 2.4 (68) Oz(g) Dimensions (Overall) 2.28 L

(58.0 ) 2.4 W (61.0)

0.42 H (10.67)

in (mm)

MTBF (calculated) per MIL-STD-217E, Ta = 30OC, or Bellcore TR-NWT-000332 method 1

- ports count

2 MHrs

1 See Figure 9, Power derating curve.

3. Isolation Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.

Parameter Conditions/Description Min Nom Max Units

Insulation Safety Rating Basic Input to Output 2250 VDC

Input to Baseplate 1500 VDC Isolation Voltage

Output to Baseplate 1500 VDC Isolation Resistance Input to Output 10 MΩ

Input to Output - - 5 nF Input to Baseplate - - 1 nF

Capacitance

Output to Baseplate - - 12.5 nF




4. Safety Regulatory Compliance Safety Agency Standard Approved To: Marking

Underwriters Laboratories UL60950-3RD / CSA60950-00 cULus TUV product Service TUV EN60950:2001 TUV PS Baurt mark

CB report IEC60950-1:2001 N/A.

5. Input Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Input Voltage Continuous 36 48 75 VDC Maximum Input Current Vin =36 V, Iou t= Irated 6.11 ADC

Turn-On Input Voltage (UVLO) Ramping Up 36 37 38 VDC Turn-Off Input Voltage Ramping Down 33.5 35.5 35.9 VDC

Input Reflected Ripple Current Irated, 12µH source inductance BW=20 MHz 1

2.6 2 7.5 mA p-p

Inrush Transient Vin = Vin.max 2 A2s 1 See Figure 1 for measurement method. 2 Vin = 48 V




6. Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Output Voltage - 52.5 - VDC Set-point Accuracy: (Vin = 48 V, Io = 3.8 A) -1.5 - +1.5- % Vout

Output Line Regulation: (Vi = 36 V to 75 V) 100 mV Output Load Regulation: (Io,min to Io,max) 100 mV

Combined Output Voltage Regulation

Includes all above plus Temp.Co. & Aging. 5

50.93 52.5 54.07 VDC

Output Current Irated 0 3.8 ADC TAMB=25 °C, VinNOM, Iout=3.8 A 92 % Efficiency 1

TAMB=25 °C, VinNOM, Iout=0.4 A 89 % Switching Frequency Fixed frequency 300 kHz Output Ripple 2, 3

(DC to 500kHz) (500kHz to 1MHz) (1MHz to 20MHz)

Over line and load Tamb= 0 °C to 85 °C

150 50 30

mVp-p mVp-p mVp-p

Turn-On Time (via application of input voltage)

Time from Vin=UVLO to regulation band

50 100 ms

Rise Time From 10 to 90% of Vout.nom 25 30 ms Turn-on Overshoot Overall input voltage, load, and

temperature conditions 3 %Vout

Dynamic Regulation 4 Peak Deviation

Settling Time

75-100-75% load step change, di/dt=1A/μs

to 1% error band

±0.5 200

±3

500

%Vout μs

Admissible Load Capacitance 0 1,000 μF 1 See Figure 1. 2 See Figure 4 for test setup 3 Output ripple may exceed the specification for Io < 0.2 Amps. 4 Measured @ Remote Sense pins, CLOAD = 200 μF min, Settling Time (Vo, 1% of Vo1) 5 Aging < 7 years, Tamb. = 0 °C to +70 °C




7. Protections Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Overcurrent Protection Type Non-latching – Constant current mode, auto-recovery,

may hiccup during short circuit. Threshold 4.8 7.5 ADC Short Circuit 3.8 ARMS

Overvoltage Protection Type Latching; recycle input voltage to unlatch Threshold Vin = Vin.nom, Iout=Irated 58 65 VDC

Overtemperature Protection Type Non-latching, auto-recovery Threshold Baseplate temperature 112 120 °C Hysteresis 10 °C

8. Feature Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.

Parameter Conditions/Description Min Nom Max Units On/Off

(On/Off signal is low – converter is ON) Converter ON Sink current

-0.5

0.5

1.2 0.75

VDC

mADC

Negative Logic (-N suffix)

On/Off (pin 3) (Primary side ref. to -Vin) Converter OFF

Open circuit voltage 2.5

2.0 20

VDC VDC

Positive Logic 1 Remote Sense 2

Remote Sense Headroom 0.5 VDC Output Voltage Trim 2

Trim Up Vin = Vin.nom, Iout = Irated 0.5 VDC Trim Down Vin = Vin.nom, Iou t= Irated -2.5 VDC

1 Consult factory for availability of this option. 2 Combined output voltage positive adjustment cannot exceed 0.5 VDC.




9. Performance Characteristics

9.1 Efficiency

HHS04Z52-NT, EFFICIENCY VS. LOAD RESPONSE

40

45

50

55

60

65

70

75

80

85

90

95

100

10 20 30 40 50 60 70 80 90 100LOAD %

EFFI

CIE

NC

Y %

EFF.(38V) EFF.(48V) EFF.(75V)

Figure 1. HHS04Z52 Efficiency vs. Output Current

9.2 Startup Characteristics

Figure 2. HHS04Z52 Startup Waveform

Channel 1 – input voltage = 48 V Channel 2 – output voltage Time: 10 ms/div. This waveform demonstrates typical output voltage turn-on delay time and monotonic rise with no overshoot.

9.3 Dynamic Load Response

Figure 3. HHS04Z52 Dynamic Regulation

The load is switched from 2.85 A to 3.8 A at di/dt=1A/μs. Cext=220 μF. (Above performance: 60mV / 180μs) Top waveform – output current Bottom waveform – output voltage, 50mV/div. Time: 200 μs/div.




9.4 Ripple and Noise To improve accuracy and repeatability of ripple and noise measurements, Power-One utilizes the test setup shown in Figure 4.

DUT

LOAD10.1uf

ceramic SCOPE

COPPER STRIPS (2 to 3 inches)

+Vo1

-Vo1

10uFTantalum

Figure 4. Output Ripple & Noise Measurement Test Setup

A BNC connector is used for the measurements to eliminate noise pickup associated with long ground leads of conventional scope probes. The connector, a 0.1 μF ceramic and a 10 μF tantalum capacitors, and the load are located 2-3” away from the converter.

9.5 Overcurrent Protection To provide protection from an output overload or short-circuit condition, the HHS04Z52 is equipped with current-limiting circuitry and can endure the fault condition for an unlimited duration. At the point of current-limit inception, the converter goes into the hiccup mode, causing the output current to be limited both in peak and duration. Because of a lower duty cycle, the RMS value of output current is also low.

Figure 5. HHS04Z52 Output Current With

Output Shorted and Vin=36V. Scale is 5A Per Division

Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation.

9.6 Overvoltage Protection The output overvoltage protection consists of a separate control loop, independent of the primary control loop. This control loop has a higher voltage set point than the primary loop. In a fault condition the converter limits its output voltage and latches off. Figure 6 shows operation of the converter under an overvoltage condition.

Figure 6. Output Voltage of an HHS04Z52 Under a Forced

Overvoltage Condition. Vin=75V, No Load, Co=220µF

10. Feature Descriptions

10.1 ON/OFF The ON/OFF (#5) pin in the HHS04Z52 converter is referenced to the –Vin (#1) pin (see Figure 8). 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 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. (Not available) 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. The user should avoid connecting a resistor between the ON/OFF pin and the +Vin (# 4) pin. 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 really 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. Note: If the ON/OFF pin is not used, it can be connected to the -Vin pin (negative logic).

10.2 Remote Sense The HHS04Z52 converter has 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 the Figure 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 met the output voltage regulation specifications.

10.3 Output Voltage Trim The trim feature allows the user to adjust the output voltage from its nominal value. The HHS04Z52 trims up with a resistor from the Trim (# 7) pin to the +Sense (# 80) pin and trims down with a resistor from the Trim pin to the –Sense (# 6) pin as shown in the Figure 7.

Figure 7. HHS04Z52 Converter Trim Schematic

The equations below determine the trim resistor value required to achieve a ΔV change in the output voltage.

Ω⎟⎠⎞

⎜⎝⎛

ΔΔ+

−ΔΔ+

= kVoRup%

%)2100(%225.1

%)100(

Ω⎟⎠⎞

⎜⎝⎛ −Δ

= kRdown )2%

100

where ΔV% is the output voltage change expressed in percent of the nominal output voltage, Vo. 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.




11. Application Information

11.1 Typical Input and Output Connections Figure 8 shows the recommended connections for the HHS04Z52 converter.

+Vo

+Sense

Trim

-Sense

-Vo-Vi

+Vi

On/Off

Fuse

C1 C2 C3

HHS04Z52

Figure 8. Typical Application of the HHS04Z52

The HHS04Z52 converter does 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 μF electrolytic capacitor with the ESR < 0.7 Ω is recommended. 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 10μF low ESR tantalum (AVX TPSC106M025R0500 is used in Power-One test setup) and a 0.1 μF ceramic capacitor. Note that the capacitors do not substitute the filtering required by the load.

11.2 Thermal Considerations The HHS04Z52 converters are designed for both natural and 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 115 °C to ensure reliable long-term operation of the converters. Contact Power-One for the complete list of the derating criteria. The graph in Figure 9 shows the maximum output current of the HHS04Z52 converter at different ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4).

0

0.5

1

1.5

2

2.5

3

3.5

4

25 40 55 70 85

Ambient Temperature (Deg C)

Load

Cur

rent

(A)

NC (25 - 35 LFM) 100 LFM 200 LFM 300 LFM 400 LFM

Figure 9. HHS04Z52 Derating Curves

For example, from Figure 9, the HHS04Z52 operating at 62 °C Ambient can deliver up to 3.8 A reliably with 200 LFM forced air, or with 300 LFM to 73 °C.




11.3 Safety Considerations The HHS04Z52 converter features 2,250 VDC isolation from the input to output. The input-to-output resistance is greater than 10MΩ. 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 end-use 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 HHS04Z52 converter has no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 8. 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.

In order for the output of the HHS04Z52 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 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 HHS04Z52 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.




12. Mechanical Drawing

Note: A highly puncture-resistant insulator sheet is attached to the module (pin side) as a standard feature on each unit (not shown). This adds a protective barrier layer between the converter and the host board.

Mechanical Tolerances

Inches Millimeters X.XX ± 0.020 X.X ± 0.5

X.XXX ± 0.010 X.XX ± 0.25

Pin ± 0.002 ± 0.05

13. Ordering Information Options Suffixes to add to part number

Positive- not available (note 1) Remote ON/OFF Negative - Add “N” suffix

Trim Positive - “T” suffix (required) 0.18”- Standard, no suffix required 0.145”- Add “7” suffix

Pin Length

0.110”- Add “8” suffix (note 1) Host board Insulator Standard, no suffix required (see note above)

1 Consult factory 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.

Pin Function 1 -Vin 2 Case 3 On/Off 4 +Vin 5 -Vo 6 -Sense 7 Trim 8 +Sense 9 +Vo

(PIN SIDE)



HHS05Z55 DC-DC Converter Data Sheet48 V Input, 53. 7V @ 4.85 A Half-Brick Converter

Applications Next-generation IP Telephony & Power Over Ethernet (Unit is compliant to IEEE802.3af) Distributed power architectures

Benefits • Simplifies power system design, reduces design

time and technical risk • Reduces PCB area occupied by power conversion

and power management components

Features • RoHS lead solder exemption compliant • 260-Watt output power capability • Standard ½-brick footprint and pinout • Fully-regulated 53.7 VDC output • Efficiency to 93% • Input-to-output isolation: 2,250 VDC • Basic insulation • Output overcurrent protection • Output overvoltage protection • Overtemperature protection • Remote sense • Remote on/off (primary referenced) • Safety: UL60950-3rd/ CSA C22.2 60950-00,

TUV EN60950:2001, IEC60950-1:2001

Description The HHS05Z55 dc-dc converter operates over an input voltage range of 36 to 75 VDC and provides a regulated 53.7 V output rated to 4.85 amps (260 watts) of continuous output current. The output is fully isolated from the input, which allows a positive or negative output voltage configuration. The standard feature set includes remote on/off, remote sensing, undervoltage lockout, overtemperature protection, output overvoltage protection, output trim, and a dedicated pin that connects to the baseplate. The highly efficient topology and thermally-optimized construction allow this unit to provide high output current over a wide operating temperature range while maintaining a safe guardband of electrical and thermal component deratings. The addition of an external heat sink further increases the capacity of the unit. The HHS05Z55 employs 100% surface-mount components for consistency and reliability in the production process.

Model Selection

Model Input

Voltage VDC

Input Current,

Max ADC 1

Output Voltage

VDC

Output Rated Current I rated

ADC

Output Ripple/Noise,

mV p-p 2

Typical Efficiency @

I rated % HHS05Z55-NT 36-75 7.9 53.7 4.85 150 92.5

NOTES: 1 @ VIN min. 2 (DC to 500 kHz)




Absolute Maximum Ratings Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long-term reliability, and cause permanent damage to the converter.

Parameter Conditions/Description Min Max Units

Input Voltage Continuous 36 75 VDC Operating Temperature Ambient 0 85 °C Storage Temperature Ambient -55 125 °C

ON/OFF Control Voltage Referenced to -Vin 20 VDC Output Power 260 W

1. Environmental, Mechanical Specifications & Reliability Parameter Conditions/Description Min Nom Max Units

Baseplate 0 110 °C Operating Temperature Ambient 1 0 85 °C

Operating Humidity Relative Humidity, Non-cond. 95 % Storage Humidity Relative Humidity, Non-cond. 95 % Water Washing Standard process Yes

Shock Half sinewave, 3 axes 50 g Sinusoidal Vibration GR-63-CORE, Section 5.4.2 1 g

Weight 2.4 (68) Oz(g) Dimensions (Overall) 2.28 L

(58.0 ) 2.4 W (61.0)

0.42 H (10.67)

in (mm)

MTBF (calculated) per Bellcore TR-NWT-000332

Method I, Case 3, Quality level 2

“Limited Stress - Parts Count”

Conditions: GB, TAMBIENT =30 OC, TBASEPLATE =40 OC. Stress = measured.

Assumptions: Additional ΔΤ adjustments made, based on

measurements at full load conditions.

3.2 MHrs


Method I, Case 3, Qual level 2

“Limited Stress - Parts Count”

Conditions: GB, TAMBIENT =50 OC, TBASEPLATE =70 OC. Stress = measured.

Assumptions: Additional ΔΤ adjustments made, based on

measurements at full load conditions.

1.8 MHrs


Method I, Case 2, Quality level 2

“Parts Count” method, Conditions: GB, TA = 40 OC,

Stress @ 50%

2.98 MHrs

Service Life (calculated) TA=30 OC 7 Years 1 See Figures 12 - 13, “power derating curves”.




2. Isolation Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Insulation Safety Rating Basic Input to Output 2250 VDC

Input to Baseplate 1500 VDC Isolation Voltage

Output to Baseplate 1500 VDC Isolation Resistance Input to Output 10 MΩ

Input to Output - - 5 nF Input to Baseplate - - 1 nF

Capacitance

Output to Baseplate - - 12.5 nF

3. Safety Regulatory Compliance Safety Agency Standard Approved To: Marking

CSA UL60950-3RD / CSA C22.2 60950-00 cCSAs TUV product service TUV EN60950-1:2001 TUV PS Baurt mark

CB report IEC60950-1:2001 N/A. May use CE mark Conducted Emissions (with external EMI filter) CISSPR 22 class B

4. Input Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Input Voltage Continuous 36 48 75 VDC Maximum Input Current Vin =36 V, Iout = Irated 7.9 ADC

Turn-On Input Voltage (UVLO) 1 Ramping Up 36 37 38 VDC

Turn-Off Input Voltage 1 Ramping Down 34.7 35.5 35.9 VDC

Input Reflected Ripple Current Irated, 12 µH source inductance BW=20 MHz 3

2.6 2 7.5 mA p-p

Inrush Transient Vin = Vin.max 2 A2s 1 . See Figure 1 2 Vin = 48 Vin. 3 See Figure 7 for measurement method




5. Output Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Combined Output Voltage Regulation Includes all below & Aging. 5 53.3 53.7 54.1 VDC Set-point Accuracy: (Vin = 48V, Io = 4.85 A) 53.34 53.7 54.04 VDC

Line Regulation: (Vi = 36 V to 75 V) 100 mV Load Regulation: (Io,min to Io,max) 100 mV

Temperature Regulation (TAMB = 0 OC to 70 OC) 100 mV Output Current Irated 0 4.85 ADC

VinNOM, Iout = 4.85A 92.5 93.4 % VinNOM, > 50% Iout 91 92.5 %

Efficiency 1

(TAMB=25°C)

VinNOM, 10 to 50% Iout 83 87 % Switching Frequency Fixed frequency 250 300 350 kHz

Over line and load, TAMB= 0 °C to 85 °C

(DC to 500 kHz)

150 0.28

mVp-p % Vo

(500 kHz to 1 MHz)

50 0.1

mVp-p % Vo

Output Ripple 2, 3

(1 MHz to 20 MHz) 30 mVp-p

Turn-On Time 6 (via application of input voltage)

Time from Vin = UVLO to regulation band

30 50 ms

Rise Time From 10 to 90% of Vout.nom 5 20 30 ms Turn-on Overshoot Overall input voltage, load, and

temperature conditions 0 3 %Vout

Dynamic Regulation 4 Peak Deviation

Settling Time

25% load step change (4.85 A – 3.64 A – 4.85 A),

di/dt=1A/μs

±0.2 200

±3

500

%Vout

μs Admissible Load Capacitance 200 1,000 μF

1 See Figure 3 for efficiency at elevated temperatures. 2 See Figure 6 for test setup 3 Output ripple may exceed the specification for Io < 0.2 Amps. 4 Measured @ Remote Sense pins, CLOAD = 220 μF min, Settling Time (Vo, 1% of Vo) – refer to Figure 5. 5 Aging < 7 years, Tamb. = 0 OC to +70 OC 6 See Figure 4




6. Protections Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.


Overcurrent Protection Type Non-latching – Constant current mode, auto-recovery,

may hiccup during short circuit. Threshold 5.7 9.0 ADC Short Circuit 1 Hiccup Mode 9.0 ARMS

Overvoltage Protection Type Latching; recycle input voltage to unlatch Threshold 2 Vin = Vin.nom, Iout=IRATED 58 60 65 VDC

Overtemperature Protection Type Non-latching, auto-recovery Threshold Baseplate temperature 112 120 °C Hysteresis 10 °C

1 See Figure 8 2 See Figure 9

7. Feature Specifications All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.

Parameter Conditions/Description Min Nom Max Units On/Off

(On/Off signal is low – converter is ON) Converter ON Sink current

-0.5

0.5

1.2 0.75

VDC

mADC

Negative Logic (-N suffix)

On/Off (pin 3) (Primary side ref. to -Vin) Converter OFF

Open circuit voltage 2.5

2.0 20

VDC VDC

Positive Logic 1 Remote Sense 2

Remote Sense Headroom 0.5 VDC Output Voltage Trim 2

Trim Up Vin = Vin.nom, Iout = Irated 0.5 VDC Trim Down Vin = Vin.nom, Iout = Irated -2.5 VDC

1 Not presently available 2 Combined output voltage positive adjustment cannot exceed 0.5 VDC. See section 10.3 “Output Voltage Trim”




8. Performance Characteristics

9.1 UVLO Operation

Figure 1. HHS05Z55 Input UVLO Characteristics

9.2 Efficiency

84

86

88

90

92

94

96

0 1 2 3 4 5

Iout (A)

%

42Vin 50Vin

Figure 2.

HHS05Z55 operating at 70 OC Ambient, 200 LFM airflow (-Vin to + Vin)

w/ CoolerMaster heat sink (4” X 2.4” X 0.3”, P/N 700-17522-01 REV A)

84

86

88

90

92

94

96

0 1 2 3 4 5

Iout (A)

( % )

48Vin@25DegC

Figure 3.

HHS05Z55 operating at 25 OC Ambient, 200 LFM airflow (-Vin to +Vin) w/o heat sink. Unit temperature allowed to stabilize at each

recorded datapoint.

9.3 Startup Characteristics

Figure 4. HHS05Z55 Startup Waveform

Channel 1 – input voltage = 48V Channel 2 – output voltage Time: 20 ms/div. This waveform demonstrates typical output voltage turn-on delay time and monotonic rise with no overshoot.




9.4 Dynamic Load Response

Figure 5. HHS05Z55 Dynamic Regulation

The load is switched from 4.85 A to 3.65 A at di/dt=1A/μs. Cext = 200 μF. (Above performance: 158 mV / 200μs) Top waveform – output voltage, 200 mV/div. Bottom waveform – output current Time: 2 ms/div

9.5 Ripple and Noise To improve accuracy and repeatability of ripple and noise measurements, Power-One utilizes the test setup shown in Figure 6.

DUT

0.1ufceramic SCOPE

+Vo1

-Vo1

10uF @ 35VESR=0.3 Tantalum

LOAD1

Shielded Cable (3 to 4 inches)

+Vin

+Vin

Figure 6. Output Ripple & Noise Measurement Test Setup

A BNC connector is used for the measurements to eliminate noise pickup associated with long ground leads of conventional scope probes. The connector, a 0.1 μF ceramic a 10 μF tantalum capacitors and the load are located 2-3” away from the converter.

9.6 Input Reflected Ripple . Figure 7 Input Reflected Ripple Current Test Set-up Note: Measure input reflected-ripple current with a simulated inductance (Ltest) of 12 µH. Capacitors offset possible battery impedance. Measure current as shown above

9.7 Overcurrent Protection To provide protection from an output overload or short-circuit condition, the HHS05Z55 is equipped with current-limiting circuitry and can endure the fault condition for an unlimited duration. At the point of current-limit inception, the converter enters constant current mode, causing the output current to be limited. Heavy overload or short circuit will result in a hiccup current limit mode and restrict current both in peak and duration. Because of a lower duty cycle, the RMS value of output current is also low.

Figure 8. HHS05Z55 Output Current With

Output Shorted and Vin = 36V. Scale is 5 A Per Division Measurement: 6.83 ARMS

Once the output current is brought back into its specified range, the converter automatically exits the protection mode and continues normal operation.

BATTERY

Cs 220 uFESR < 0.1 OHM

@ 20 ºC, 100kHz

Ltest12 uH

22 uFESR < 0.7 OHM

@ 20 ºC, 100 kHz

Vi(+)

Vi(-)

TO OSCILLOSCOPE




9.8 Overvoltage Protection The output overvoltage protection consists of a separate control loop, independent of the primary control loop. This control loop has a higher voltage set point than the primary loop. In a fault condition the converter limits its output voltage and latches off. Figure 9 shows operation of the converter under an overvoltage condition.

Figure 9. Output Voltage of an HHS05Z55 Under a Forced

Overvoltage Condition. Vin=75V, No Load, Co=220µF

9. Feature Descriptions

10.1 ON/OFF The ON/OFF (#3) pin in the HHS05Z55 converter is referenced to the –Vin (#1) pin. 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 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. (Not available) 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. The user should avoid connecting a resistor between the ON/OFF pin and the +Vin (# 4) pin.

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 really 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. Note: If the ON/OFF pin is not used, it can be connected to the -Vin pin (negative logic).

10.2 Remote Sense The HHS05Z55 converter has 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 Figure 10. 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, may not meet the output voltage regulation specifications and the output voltage will be approximately 0.75 volts higher than nominal.




10.3 Output Voltage Trim The trim feature allows the user to adjust the output voltage from its nominal value. The HHS05Z55 (-T suffix) trims 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 Figure 10.

Figure 10. HHS05Z55 [“T” suffix] Converter Trim Schematic

The equations below determine the trim resistor value required to achieve a ΔV change in the output voltage.

Ω⎟⎠⎞

⎜⎝⎛

ΔΔ+

−Δ

Δ+= kVoRup

%%)2100(

%225.1%)100(

Ω⎟⎠⎞

⎜⎝⎛ −

Δ= kRdown )2

%100

where ΔV% is the output voltage change expressed in percent of the nominal output voltage, Vo. 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 table 8 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.

10. Application Information

11.1 Typical Input and Output Connections Figure 10 shows the recommended connections for the HHS05Z55 converter.

+Vo

+Sense

Trim

-Sense

-Vo-Vi

+Vi

On/Off

Fuse

C1 C2 C3

HHS04Z52

Figure 11. Typical Application of the HHS05Z55

The HHS05Z55 converter does require an external output capacitor for optimum operation. A 200 μF low impedance capacitor is recommended. If the distribution of the input voltage to the converter contains significant inductance, capacitor C1 may be required to enhance performance of the converter. A minimum of a 68 μF electrolytic capacitor with the ESR < 0.7Ω is recommended. 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 low ESR 10 μF, and 0.1 μF ceramic capacitors. Note that the capacitors do not substitute for the filtering required by the load.




11.2 Thermal Considerations The HHS05Z55 converters are designed for both natural and 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 125 °C to ensure reliable long-term operation of the converters. Contact Power-One for the complete list of the derating criteria. The graph in Figure 12 shows the maximum output current of the HHS05Z55 converter (with no attached heatsink) at various ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4).

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

25 40 55 70 85

Ambient Temperature (Deg C)

Load

Cur

rent

(A)


Figure 12. HHS05Z55 Derating Curves (@ Vin = 48 VDC, w/o supplemental heat sink)

The graph in Figure 13 shows the maximum output current of the HHS05Z55 converter with the available Power-One 0.45” height heat sink attached. (option # “-2V”) at various ambient temperatures under both natural and forced convection. (longitudinal airflow direction, from pin 1 to pin 4)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

25 40 55 70 85Ambient Temperature (Deg C)

Load

Cur

rent

(A)


Figure 13. HHS05Z55 Derating Curves (@ Vin = 48 VDC, w/ supplemental 0.45” height heat sink)




11.3 Safety Considerations The HHS05Z55 converter features 2,250 VDC isolation from the input to output. The input to output resistance is greater than 10MOhm. 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 end-use 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 HHS05Z55 converter has no internal fuse. An external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 11. 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.

In order for the output of the HHS05Z55 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 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 HHS05Z55 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.




11. Mechanical Drawing

Note: Kapton HN, a non-porous, highly puncture-resistant plastic film (0.002” thickness) with 6 kV/mil dielectric strength is secured to the module (pin side) as a standard feature on each unit. This adds a protective insulative barrier layer between the converter and the host board.

Mechanical Tolerances

Inches Millimeters X.XX ± 0.02 X.X ± 0.5

X.XXX ± 0.010 X.XX ± 0.25 Pin Dia.

± 0.002 ± 0.05

12. Ordering Information Options Suffixes to add to part number

Positive- not available (note 1) Remote ON/OFF Negative - Add “N” suffix

Trim Positive - “T” suffix (required) 0.18”- Standard, no suffix required 0.145”- Add “7” suffix

Pin Length

0.110”- Add “8” suffix (note 1) Host board Insulator Standard, no suffix required (see drawing note above)

1 Consult factory 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.

Pin Function 1 -Vin 2 Case 3 On/Off 4 +Vin 5 -Vo 6 -Sense 7 Trim 8 +Sense 9 +Vo

(PIN SIDE)


PALS AC-DC Series Data Sheet Power-over-Ethernet · PALS AC-DC Series Data Sheet JUL 06, 2006...

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