Vicor Design Guide

8/13/2019 Vicor Design Guide

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Design GuideDC-DC Converters

4 8 V I N P U T F A M I L Y

12


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w w w . v i c o r p o w e r . c o m

Vicors 2nd Generation of DC-DC converters are a

new class of products providing an infinite range of

standard solutions for power system requirements.

These solutions are available in three different

package sizes, each optimized over a range of

power levels. Each package size shares a common

feature set and control functions with a tailored

power train. The power trains, although not identical,are simply scaled according to the specific output

voltage and power requirements. The end result is

a family of products sharing predictable and

repeatable performance characteristics, varying only

in power level; therefore, when migrating from one

case size to another, there are no hidden

surprises. The 48Vdc input family is available with

outputs from 2.0 to 48 Volts and power levels from

50 to 500 Watts.At the present time, solutions exist

in the following package sizes:

Micro

1.45 x 2.28 x 0.5

Up to 150 Watts

Mini

2.28 x 2.2 x 0.5

Up to 250 Watts

Maxi

4.6 x 2.2 x 0.5Up to 500 Watts

This design guide provides complete electrical,

mechanical, thermal management, mounting and

manufacturing data enabling rapid trouble free

design-in of Vicors 2nd Generation of DC-DC

converters. It includes sections on board layout,

test and measurement and input transient protection

and filtering. Data sheets, including mechanicaldiagrams, are available as PDF files through our

web site and Vicors world-wide technical support

centers may also be accessed via voice,

facsimile and E-mail.

Part Numbering . . . . . . . . . . . . . . . . . . . . . . . . . .1

Table of Available 48V Modules . . . . . . . . . . . . .1

Electrical Specifications Micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Maxi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Control Functions

Primary Control (PC Pin) . . . . . . . . . . . . . . . .8

Paralleling Application Note . . . . . . . . . . . .9

Parallel Operation (PR Pin) . . . . . . . . . . . . .10

Secondary Control (SC Pin) . . . . . . . . . . . .11

Module Do's and Don'ts . . . . . . . . . . . . . . . .12-13

Filtering and Transient Protection

Basic Filtering . . . . . . . . . . . . . . . . . . . . . . . .14

Common-Mode and Differential-Mode . .15

Test and Measurement

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Regulation . . . . . . . . . . . . . . . . . . . . . . . . . .17

Output Ripple and Noise . . . . . . . . . . . . . .18

Soldering Guidelines . . . . . . . . . . . . . . . . . .19

Mechanical Drawings and Pinouts Micro, FM48, IAM48 . . . . . . . . . . . . . . . . . . .20

Mini, FIAM . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Maxi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Mounting & Thermal Management

Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24

Thermal Performance Curves

Micro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Mini . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Maxi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Data Sheets

FM48 - FiltMod . . . . . . . . . . . . . . . . . . . . . . .28

IAM48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

FIAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Vicor Technical Support . . . . . . . . . . . . . . . . . .31

Contents


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Part Numbering48V Input Family of DC-DC Converters

V 48 A 15 C 500 A L

Input Package Output Product Output Pin Style BaseplateVoltage Voltage Grade Power

A = Maxi C = -20C to 100C blank=short blank=slotted

B = Mini T = -40C to 100C L=long 2=threadedC = Micro H = -40C to 100C M=short gold 3=thru-holeM = -55C to 100C N=long gold

Output Voltage (Vdc) Output Power (Watts) Vicor Model Number Package Size

2.0 50 V48C2C50A Micro

2.0 100 V48B2C100A Mini

2.0 160 V48A2C160A Maxi

3.3 75 V48C3V3C75A Micro

3.3 150 V48B3V3C150A Mini3.3 264 V48A3V3C264A Maxi



5.0 100 V48C5C100A Micro

5.0 200 V48B5C200A Mini

5.0 400 V48A5C400A Maxi

12.0 150 V48C12C150A Micro

12.0 250 V48B12C250A Mini

12.0 500 V48A12C500A Maxi15.0 150 V48C15C150A Micro

15.0 250 V48B15C250A Mini

15.0 500 V48A15C500A Maxi

24.0 150 V48C24C150A Micro

24.0 250 V48B24C250A Mini

24.0 500 V48A24C500A Maxi

28.0 150 V48C28C150A Micro

28.0 250 V48B28C250A Mini

28.0 500 V48A28C500A Maxi48.0 150 V48C48C150A Micro

48.0 250 V48B48C250A Mini

48.0 500 V48A48C500A Maxi


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MODULE INPUT SPECIFICATIONS

Parameter Min Typ Max Unit Notes

Operating input voltage 36 48 75 Vdc

Undervoltage turn-on 34.9 35.7 Vdc

Undervoltage turn-off 29.4 30.5 Vdc

Overvoltage turn-off/on 75.7 78.8 82.5 VdcInput surge withstand 100 Vdc 30ohms, 12 modules will require buffer amplifier

MODULE GENERAL SPECIFICATIONS


Remote sense (total drop) n/a

Isolation voltage (in to out) 3000 Vrms Complies with reinforced insulation requirements.

Isolation voltage in to base) 1500 Vrms Complies with basic insulation requirements.

Isolation voltage (out to base) 500 Vrms Complies with operational insulation requirements.

Isolation resistance (in to out) 10 megohms

Weight 2.1(60) 2.3(66)ounces (grams)

Temperature limiting 100 115 C See figures 2, 4, on page 8.

Agency approvals UL, CSA, TV, BABT, CE, VDE UL1950, CSA950, EN60950, VDE 0805, BS7002

IEC60950, (with a fuse in series with the +input)

Electrical SpecificationsMICRO

Electrical characteristics apply over the full operating range of input voltage, output load (resistive) and baseplate

temperature, unless otherwise specified. All temperatures refer to the operating temperature at the center of the baseplate.


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Electrical SpecificationsMICRO

MODULE OUTPUT SPECIFICATIONSParameter Min Typ Max Unit Notes

Output voltage setpoint 1% Vout nom Nom. input; full load, 25C

Line regulation 0.02 0.2 % Low line to high line; full load

Temperature regulation 0.002 0.005 %/C Over operating temp. range

Power sharing accuracy 2 5 % 10% to 100% of full loadProgramming Range 10 110 % Of nominal output voltage.

For trimming below 90% of nom.

a minimum load of 10% of

maximum rated power may be

required

Current limit 115 % Iout max. Output voltage 95% of nominal

Short circuit current 115 % Iout max. Output voltage


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MODULE INPUT SPECIFICATIONS


Operating input voltage 36 48 75 Vdc

Undervoltage turn-on 34.9 35.7 Vdc

Undervoltage turn-off 29.4 30.5 Vdc

Overvoltage turn-off/on 75.7 78.8 82.5 Vdc

Input surge withstand 100 Vdc 30ohms, 12 modules will require buffer amplifier

MODULE GENERAL SPECIFICATIONS


Remote sense (total drop) 0.5 Vdc 0.25V/leg (sense leads must be closed)

Isolation voltage (in to out) 3000 Vrms Complies with reinforced insulation requirements.Isolation voltage in to base) 1500 Vrms Complies with basic insulation requirements.

Isolation voltage (out to base) 500 Vrms Complies with operational insulation requirements.

Isolation resistance (in to out) 10 megohms

Weight 3.7(104) 4(112) ounces(grams)

Temperature limiting 100 115 C See Figures 2, 4 on page 8.

Agency approvals UL, CSA, TV, BABT, CE, VDE UL1950, CSA950, EN60950, VDE 0805, BS7002

IEC60950, (with a fuse in series with the +input)

Electrical SpecificationsMINI

Electrical characteristics apply over the full operating range of input voltage, output load (resistive) and baseplate

temperature, unless otherwise specified. All temperatures refer to the operating temperature at the center of the baseplate.


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Temperature regulation 0.002 0.005 %/C Over operating temp. rangePower sharing accuracy 2 5 % 10 to 100% of full load

Programming range 10 110 % Of nominal output voltage.


a minimum load of 10% of

maximum rated power may

be required




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Temperature regulation 0.002 0.005 %/C Over operating temp. rangePower sharing accuracy 2 5 % Of nominal output voltage.


a minimum load of 10% of max.

rated power may be required




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Module Enable/DisableThe module may be disabled by pulling PC below2.3V with respect to -Input. This may be done with anopen collector transistor, relay, or optocoupler.Multiple converters may be disabled with a singletransistor or relay either directly or via ORingdiodes.See Fig.1.

Primary Auxiliary SupplyAt 5.7V, PC can source up to 1.5 mA. In the exampleshown in Figure 3, PC powers a LED to indicate themodule is enabled.

Module AlarmThe module contains watchdog circuitry whichmonitors input voltage, operating temperature andinternal operating parameters. In the event that anyof these parameters are outside of their allowableoperating range, the module will shut down and PCwill go low. PC will periodically go high and themodule will check to see if the fault (as an example,overtemperature) has cleared. If the fault has notbeen cleared, PC will go low again and the cycle willrestart. The SC pin will go low in the event of a faultand return to its normal state after the fault has beencleared. See Fig. 2, 4.

1. Module Enable/Disable 2. PC/SC module alarm logic

(Micro Inset)

3. LED on-state indicator 4. PC/SC module alarm timing.

5. Isolated on-state indicator 6. Secondary side on-state

(Micro inset)

+In

PC

PR

In

Disable

Disable = PC


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Parallel BusPR Pin

Parallel OperationA unique feature has been designed into Vicors2nd Generation converter modules which facilitatesparallel operation for power expansion or redundancy.The PR pin is a bi-directional port that transmits and

receives information between modules. The pulsesignal on the parallel (PR) bus serves to synchronizethe high frequency switching of each converterwhich in turn forces them to load share.These modulespossess the ability to arbitrate the leadership role; i.e.,a democratic array. The module that assumescommand transmits the sync pulse on the parallel buswhile all other modules on the bus listen.

Compatible interface architectures include

the following:

DC coupled single-wire interface. All PR pins aredirectly connected to one another. This interfacesupports current sharing but is not fault tolerant.MinusIn pins must be tied to the same electric potential.

AC coupled single-wire interface. All PR pins areconnected to a single communication bus through.001F (500V) capacitors. This interface supportscurrent sharing and is fault tolerant except for thecommunication bus. See Fig. 7.

Transformer coupled interface. Modules or arrays ofmodules may also be interfaced to share a loadwhile providing galvanic isolation between PR pinsvia a transformer coupled interface. For large arrays,

buffering may be required. The power source for thebuffer circuit may be derived from PC pins. For arraysof four or more modules, the transformer coupledinterfaced is recommended.See Fig. 8.

Parallel operation considerations

Care must be taken to avoid introducing interferingsignals (noise) onto the parallel bus as this mayprevent proper load sharing between modules. Onepossible source of interference is input ripple currentconducted via the plus and minus input power pins.The PR signal and DC power input share a commonreturn which is the negative input pin.Steps should be

taken to de-couple AC components of input currentfrom the parallel bus. The input to each converter(designated as + and - pins on the input side of themodule) should be bypassed locally with a 0.2Fceramic or film capacitor. This provides a shunt pathfor input ripple current. A Y-rated capacitor shouldbe connected between the negative input pinand baseplate of each module, thus creating a shuntpath for common mode components of current.Attention to the PC board artwork should minimizethe parasitic impedance between negative input

pins of parallel modules to insure that all PR pins arereferenced to the same potential. Modules should beplaced physically close to each other and widecopper traces (0.75in., 2oz. copper) should be usedto connect power input pins. A dedicated layer of

copper is the ideal solution.

Some applications require physical separation ofparalleled modules on different boards, and /or inputpower from separate sources. In these cases,transformer coupling of the PR signal, per figure 8,is required to prevent inter-module common modebounce from interfering with the sync pulsetransmission. High speed buffering may be requiredwith large arrays or if the distance between modulesis greater than a few inches. This is due to the fact thaall modules,except the one thats talking, are in thelistening mode. Each listener presents a load to themaster (talker) which is approximately 500 ohmsshunted by 30pF capacitance. Long leads for theinterconnection introduce losses and parasiticreactance on the bus which can attenuate anddistort the sync pulse signal. The bandwidth ofthe bus must be at least 60MHz and the signalattenuation less than 2dB. In most cases transformercoupling without buffering is adequate.Again careful attention must be given to layoutconsiderations. Please consult with applicationsengineering at any Vicor technical support centerfor additional information.

7. AC coupled single-wire interface.

8. Transformer coupled interface.

0.2F

Low inductance

ground plane orbus

+In

PC

PR

In

+In

PC

PR

In

Module 2

Module 10.001F

0.2F

0.001F

+

ParallelBus

0.2F

+In

PC

PR

In

+In

PC

PR

In

Module 2

Module 1

0.2F

T1

T2

+

+

1

2

34

5

6

5

6


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PR Pin ConsiderationsWhen paralleling modules it is important that thePR signal is communicated to all modules within theparallel array. Modules which do not receive aPR pulse in a parallel array will not current shareand may be damaged by running in an overpower condition.

All modules in an array must be of the same type.

Series connection of outputs is generallyaccomplished without connecting the PR pinand allowing each module to regulate its ownoutput voltage. Since the same current passesthrough the output of each module with theseries connection, power sharing is inherent.Series connection of inputs requires specialprecautions, please contact applicationsengineering for assistance.

The + and - Output pins of modules connected in aparallel array must never be allowed to become

open circuited from the output bus or permanentdamage to the module may result.

13. Resister values for Micro voltage drop compensation.

Control Functions and Output ConsiderationsParallel Operation (PR Pin)

Parallel OperationThe PR pin supports paralleling for increased powerwith N+1 (N+M) redundancy and phased arraycapability.Modules of the same input voltage,output voltage, and power level will current share if

all PR pins are suitably interfaced. Figures 9 and 10show connections for the Maxi and Mini modules;Figures 11 and 12show connections forMicro modules.

9. N+1 module array output connections. (Maxi and Mini). 10. ORing diodes connections.(Maxi and Mini).

odule 2

odule 1

odule N+1

+Out

+SSCS

Out

+Out

+SSCS

Out

+Out

+SSCS

Out

Load

+S

S

+S

S

+S

S

+Out

+S

SC

S

Out +Sense from

other modules

in the array

11. N+1 module array output connections. (Micro). 12. Voltage drop compensation (Micro).

Vo R1 R2 R3 R4 Unit

1.8 1K 500 9K 550

2.0 1K 500 N/R 750 2.2 1K 500 1.0K 1.00K 2.5 1K 500 3.125K 1.25K

3.3 1K N/R N/R 2.05K

5.0 10K N/R N/R 3.75K 12.0 10K N/R N/R 10.8K 15.0 10K N/R N/R 13.75K

24.0 10K N/R N/R 22.75K 28.0 10K N/R N/R 26.75K

48.0 * 10K N/R N/R 46.75K

The LM10 is rated for a supply voltage of 45Vdc max. If theoutput voltage exceeds this rating use a 5 to 15V zenerdiode from pin 7 of the LM10 to V. A series resistor shouldbe connected from V+ to the cathode of the zener diode.Theresistor value should be selected to set the zener current to1mA.

+Out

SC

Out

+Out

SC

Out

+Out

SC

Out

LOAD

Plane

GroundPlane

R1

4

2

7

6LoadLM10

+Out

SC

Out

R2

R3

13

8

1.05K

200

R4

1.2K

The +Out and -Out power buses

should be designed to minimize and

balance parasitic impedance from

each module output to the load.

The +Sense pins should be tied to the

same point on the +Out power bus;

the -Sense pins should be tied to the

same point on the -Out power bus.

At the discretion of the power system

designer,a subset of all modules within

an array may be configured as slaves

by shorting SC to -S.

ORing diodes may be inserted in series

with the +OUT pins of each module to

provide module output fault tolerance.

The +Out and -Out power buses should

be designed to minimize and balance

parasitic impedance from each module

output to the load.

At the discretion of the power system

designer,a subset of all modules within

an array may be configured as slaves

by shorting SC to -Out.

Do not use output ORing diodes

with parallel arrays of MicroMods.

See Figure 13.

*


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SC Pin and Output Voltage Trimming

Circuits such as OP-Amps and D/A converters whichdirectly drive the SC pin should be designed to limitthe applied voltage to the SC pin. It is also importantto consider voltage excursions that may occurduring initialization of the external circuitry. Theexternal circuit must be referenced to the -S pin(-Out on Micro).

For systems which require an adjustable outputvoltage, it is good practice to limit the adjustmentrange to a value only slightly greater than thatrequired. This will increase the adjustment resolutionwhile reducing noise pickup.

Contact Applications Engineering if the module is tobe dynamically trimmed.

Trim values calculated automatically

Trimming resistor calculators are available on Vicors web

site at www.vicorpower.com/tools or by requesting a

copy of Vicors Applications Manual on CD ROM.

Resistor values can be calculated for fixed trim up, fixed

trim down and for variable trim up or down.

In addition to trimming information, the web site and

the applications manual on CD ROM also includesdesign tips, applications circuits, EMC suggestions,

thermal design guidelines and PDF data sheets for

all Vicor products.

Control FunctionsSecondary Control (SC Pin)

Output Voltage ProgrammingThe output voltage of the converter can be adjustedor programmed via fixed resistors, potentiometers orvoltage DACs. See fig. 14 and 15.

Trim Down1. This converter is NOT a constant power device; ithas a constant current limit. Hence,available outputpower is reduced by the same percentage thatoutput voltage is trimmed down. Do not exceedmaximum rated output current.

2. The trim down resistor must be connected tothe -sense pin (-out pin on a micro).

Trim Up1. The converter is rated for a maximum deliveredpower. To ensure that maximum rated power is notexceeded, reduce maximum output current by thesame percentage increase in output voltage.

2. The trim up resistor must be connected to the+sense pin (+out pin on a Micro.)

3. Do not trim the converter above maximum trimrange (+10%) or the output over voltage protectioncircuitry may be activated.

14. Output voltage trim down circuit. (Micro inset) 15. Output voltage trim up circuit. (Micro inset)

Load

+Out

+S

SC

S

Out

RDTrim Down

ErrorAmp

1k

1.23V

0.033F

+Out

+S

SC

S

Out

RUTrim Up Load

ErrorAmp

1k

1.23V

0.033F

Load

RDTrim Down

ErrorAmp

1k

1.23V

0.033F

+Out

SC

Out

RUTrim Up

LoadErrorAmp

1k

1.23V

0.033F

+Out

SC

Out

RD (ohms) =1,000 Vout

Vnom - VoutRU (ohms) =

1,000 (Vout-1.23) Vnom-1,000

1.23(Vout - Vnom)


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Do's and Don'ts and General Topics

Safety ConsiderationsFusing

Safety agency conditions of acceptability requirethat the module (+) input terminal be fused and thebaseplate of the converter be connected to earth

ground. The following table lists the acceptable fusetypes and current rating for the 48V input family ofDC-DC converters.

The location of the fuse must be in series with thepositive(+) input lead. Fusing the negative input leaddoes not provide adequate protection as the PRand PC terminals of the converter are referenced tothe - input. If a fuse located in the - input lead wereto open, the PR and PC terminals would rise to thepotential of the + input.This could damage anyconverter or circuitry connected to these pins. Thefuse should not be located in an area with a highambient temperature as this will lower the current

carrying rating of the fuse.

Thermal and Voltage Hazards

Vicor component power products are intended tobe used within protective enclosures.Vicor DC-DCconverters can work comfortably at baseplatetemperatures which could be harmful if contacteddirectly. Voltages and high currents (energy hazard)present at the terminals and circuitry connected tothem may pose a safety hazard if contacted orif stray current paths develop. Systems withremovable circuit cards or covers which mayexpose the converter(s) or circuitry connected to

them should have proper guarding to avoidhazardous conditions.

PC Pin

The PC pin should only be used to disable themodule, provide a bias to input referenced circuitryor communicate status of the module.

The PC pin is referenced to the - Input pin. All circuitswhich connect to the PC pin must use the -input asthe reference.Do not break the connection

between the -input and the circuitry connected tothe PC pin or damage to the module will result.

Circuits which derive their power from the PC pinmust not exceed 1.5mA.

Do not do not drive the PC pin with external circuitry.

Do not attempt to control the output of theconverter by PWM modulation of the PC pin.

For applications where the converter will bedisabled on a regular basis or where capacitanceis added to this pin,please contact Vicorapplications engineering.

High Power Arrays and PR PinTo simplify the implementation of large arrays, asubset of modules within the parallel array may beconfigured as boosters by connecting the SC pin tothe -Sense lead. Modules which are connected asboosters can not assume the role of drivers for N+Mredundant arrays. Modules configured as boostersmay be locally sensed.

Each module within the parallel array must beproperly bypassed with capacitors. Film or ceramictypes should be used across the input of the moduleand between each input lead and the baseplate.Modules which have input sources which are notconnected to SELV sources should use X ratedcapacitors across the input and Y rated capacitorsfrom each lead to the baseplate. When in doubt

about capacitor safety approvals, always consultwith the governing safety regulatory agency or Vicorapplications engineering.

A maximum of 12 modules may be connected inparallel. Please contact Vicor applicationsengineering for recommendations for larger arrays.

The PR pin is referenced to the - Input pin, thereforeall modules within the array must have a commonlow impedance connection between each - Inputpin. Special precautions are necessary if a PWB is notused for interconnection of modules as the wiringimpedance can be significant. Do not allow theconnection between the -input pin and the -inputbus to become disconnected or damageto the module will result.

Coupling transformers should be used to transmitthe PR pulse if long distances between each moduleare anticipated or if the interconnection impedanceof the -input leads is high or questionable. PRcoupling transformers should be used if the PR pulseleaves the PWB. For example,an array constructedof multiple circuit cards plugged into a backplane

Fuse Ratings and Recommended types

Package Output Voltage Fuse

Maxi 2 Buss ABC-8

Maxi 3.3 Buss ABC-12

Maxi 5 Buss ABC-15

Maxi 12, 15, 24, 28, 48 Buss ABC-20

Mini 2, 3.3 Buss ABC-8

Mini 5, 12, 15, 24, 28, 48 Buss ABC-10

Micro 2, 3.3, 5@50W, or 75W Buss PC Tron 5AMicro 5@100W, 12, 15, 24, 28, 48 Buss ABC-8


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with a number of converters on each card wouldbenefit by having a PR coupling transformer at theentry point of each card, however no couplingtransformer would be required between eachconverter on the card.Do not externally drive the PR

pin. Connection to this pin is limited to Vicor modulesonly. Refer to page 10, "Control Functions and OutputConsiderations" for additionalinformation on parallel operation.

Input Source ImpedanceThe impedance of the source feeding the input ofthe module directly affects both the stability andtransient response of the module. In general thesource impedance should be lower than the inputimpedance of the module by a factor of ten.

To calculate the required source impedance, use thefollowing formula:

Z = 0.1 x (VLL)2 / Pin where:

Z is required input impedanceVLL is the low line input voltagePin is the input power of the module

In addition for the 48V input family of converters aminimum of 15uF should be used at the input ofeach converter in applications where the distancebetween the converter and holdup capacitorsexceed six inches (6").

Filters which precede the converter module shouldbe well damped to prevent ringing when the inputvoltage is applied or the load on the output of theconverter is abruptly changed.

Input Transients and SurgesThe voltage applied to the input of the module mustnot exceed the ratings outlined in the data sheet.Protection devices such as Zener diodes and MOVsshould be used to protect the module from shortduration transients. These shunt protection devicesare only effective if the source impedance is high

relative to the impedance of the protection devicewhen it is conducting.For voltage surges where theabnormal voltage is present for a long period oftime, shunt protection devices can easily bedamaged by the power dissipated. For this type ofcondition a voltage limiter in series with the inputof the module may be the best solution.Vicorapplications engineering can assist in recommendingthe appropriate type of protection for the module.

Sense Leads (Mini and Maxi only)The sense leads of the module must alwaysterminate either directly to the output pins (localsensing) or at the load (remote sensing).When remote sensing is used, the wiring impedance

in combination with the load impedance can causesignificant loss of phase margin and result inoscillation and possible damage to the module,poor transient response,or activation of the outputovervoltage protection. Long sense leads mayrequire a compensation circuit for stability.

Protection circuitry is required for reversed senseleads. Please contact Vicor applications engineeringfor specific recommendations.

Do not exceed 1V between -S and -Out leads.This isan important consideration if the converter is used ina Hot Swap application.OR'ing diodes, if used,should be located in the +Output lead to avoidexceeding this rating.

Do not exceed the rated power of the converter.Thetotal of the power consumed by the load plus thepower lost in conductors from the converterto the load must be less than the output powerrating of the converter.

Output ConnectionsFor systems which charge batteries, subject themodule to dynamic loading, or loads which havelarge reactive components, please contact Vicor

applications engineering to discuss your application.

Do not externally drive the output of the modulehigher than its nominal or trimmed setpoint voltage.

Modules which are used to charge batteries shoulduse a diode in series with the output of the module.The charge current must be externally controlled toinsure that the module is not operated in excess of itspower rating.

Current carrying conductors should be sized tominimize voltage drops.

Do not use output ORing diodes with parallelarrays of micro modules.

Absolute Maximum RatingsPlease consult individual module data sheets formaximum rating concerning pin-pin voltages,isolation, temperature and mechanical ratings. Refeto "Control Functions,Secondary Control"on page 11 for application information regardingoutput voltage adjustment.


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All switching power supplies generate potentiallyinterfering signals as a result of high frequency, highpower switching. The Vicor power convertertopology, to a large extent, addresses the problem atthe source by the use of a quasi-resonant, zero

current switching topology. The switching currentwaveform is a half sine wave that generates far lessconducted and radiated noise in both frequencyspectrum and magnitude. EMI filtering, if properlydesigned and implemented, reduce the magnitudeof conducted noise an additional 40-60dB, and as aresult, the noise radiated by the power conductors isreduced proportionally.

Conducted noise on the input power lines can occuras either differential-mode or common-mode noisecurrents. Differential-mode noise, largely at lowfrequencies, appears across the input conductors atthe fundamental switching frequency and its

harmonics. Common-mode noise is measuredbetween the converters input conductors andground, having mostly high-frequency content.

Some basic guidelines to follow for successful EMIfiltering are as follows:

1. Keep current loops small. The ability of a conductorto couple energy by induction and radiation isreduced accordingly.

2. For conductor pairs, use wide (low Z) coppertraces aligned above and below each other.

3. Locate filters at the source of interference; i.e., thepower converter.

4. Filter component values should be chosen withconsideration given to the desired frequency rangeof attenuation. For example, capacitors are selfresonant at some frequency, beyond which they lookinductive. Keep bypass capacitor leads as short aspossible.

5. Locate components on the board withconsideration given to proximity of noise sources topotentially susceptible circuits.

The FiltMod is an input line filter module that hasbeen optimized for use with 2nd Gen DC-DCconverters. When used in conjunction with therecommended external components and layout, itwill significantly reduce the differential and

common-mode noise returned to the power source.

The FiltMod meets the requirements of EN55022 B,FCC B, and Bellcore GR-001089-CORE, Issue 2 whenused with any combination of 2nd Generationconverters up to maximum rated power. It canaccommodate up to 75Vdc input (100Vdc for100 ms), and it comes in 8 and 12 Amp versions.It is packaged in a micro-size module.(2.28 x 1.45 x 0.5 inches / 57,9 x 36,8 x 12,7 mm).

In general,DC-DC converters should be properlybypassed, even if no EMI standards need to be met.Bypass Vin and Vout pins to each DC-DC module

baseplate as shown in Figure 16. Capacitor leadlength should be as short as possible. In mostapplications, bypass caps on the input side are 4700pF Y capacitors (Vicor P/N 01000) carrying theappropriate safety agency approval. Bypass caps onthe output side are 0.01F ceramic capacitors ratedat 500V (Vicor P/N 01501).

EMI can be very application dependent.Apackaged filter accessory may not always be theright answer, and the general practice of bypassingVin and Vout may not produce optimal results.You may have to adjust the values depending on

the severity of common mode and differential modenoise.

Input transient suppression should be used inapplications where source transients may beinduced by load changes, blown fuses, etc. The levelof transient suppression required will depend on theexpected severity of the transients. A zener diode,TRANSORB, or MOV (Z1) will provide transientsuppression, act as a voltage clipper for DC inputspikes, and provide reverse input voltage protection.

Filtering and Transient ProtectionEnhanced Common-Mode and Differential-Mode FIltering

2nd Generation48Vdc Input

DC-DC Converters

IN

PR

PC

+IN

OUT

S

SC

+S

+OUT

FM48

IN

+IN

4

3

2

1

7

6

5

16. Typical connection diagram of a FiltMod and a 2nd Generation DC-DC converter.

C2

C3

C5

C4

C1


17/36


The device voltage rating should be chosen abovehigh line voltage limits to avoid conducting duringnormal operation which would result in overheating.

When the FiltMod is used in combination with theIAM48, the overall system meets the input transientimmunity requirements of ETS 300 386-1, Class 2 and

Bellcore, TR-NWT-000499. It also meets the EMIrequirements of EN55022 level B,FCC Level B,andBellcore GR-001089-CORE, Issue 2.

Figure 17 shows an alternate solution based on theuse of FIAM (Filter/Input Attenuation Module). The

FIAM provides similar levels of EMI attenuation,transient protection and inrush current limiting as thecombination Filtmod and IAM48 with the advantageof being housed in a single, mini-sized module.

Figure 19 shows a conducted noise curve from0.15 MHz to 30 MHz of a FIAM used with a

V48A12C500A module, together with therecommended external components. Figure 20shows a conducted noise curve over the samerange when a V48B24C250A module is used.These experimental results are well within the limitsof EN55022 B in both cases.

IAM22nd Generation

48Vdc InputDC-DC Converters

IN

PR

PC

+IN

OUT

S

SC

+S

+OUT

FM48

IN

+IN

IAM48

4

3

2

1

7

6

5

4

3

2

17

6

5

Note: The IAM48 is shown in the on state.To disable, open the connection to pin 3.

IN

NC

NC

+IN

OUT

GND

+ OUT

OUT

NC

Off/On

+OUT

IN

NC

+ IN

18. Typical connection diagram of a IAM48, FiltMod and a 2nd Generation DC-DC converter.

Z1

19. Conducted noise plot: FIAM with V48A12C500A. 20. Conducted noise plot: FIAM with V48B24C250A.

C2

C1

C3

C5

C4

2nd Generation48Vdc Input

DC-DC ConvertersFIAM

IN

PR

PC

+IN

OUT

S

SC

+S

+OUT

IN

EMI

GND

NC

+IN +OUT

NC

NC

ON

OFF

OUTIN

+IN

Note: The FIAM is shown in the on state. To disable,open the connection between ON/OFF and Out.

TRANSORB P/N

20461-120

17. Typical connection diagram of a FIAM and a 2nd Generation DC-DC converter.


18/36


Test & MeasurementEfficiency

Efficiency is defined as the ratio of delivered outputpower to converter input power and is a basic figureof merit that can be used to relate power dissipationdirectly to converter output power. It is a function ofinput voltage, input voltage range, temperature,

output voltage and output power or current.Efficiency affects the design and size of the coolingsystem as well as the power system componentsneeded to power the system fuses, filters,batteries,etc.

Efficiency is also a key parameter in battery backedup systems found in central offices, customerpremises and remote sites. The higher the efficiency,the longer a system will continue to operate from a

battery given a fixed Ampere-hour capacity. Asystem with an efficiency rating of 85% will reducethe dissipation by approximately a factor of1/2 versus a system with 75% efficiency.

The accuracy of efficiency measurements, like otherparameters, are affected by technique andequipment. Separate DVMs for input and outputvoltage measurements are required as are accuratecurrent measuring devices for both input andoutput current.

Basic Measurement Technique1. Make all connections unpowered.

2. Set Vin for 48Vdc measured at input pins.

3. Set electronic load for full load current andrecord measurement.

4. Measure input current.

5. Measure output voltage at output pins and

record measurement.

6. Calculate efficiency.

Efficiency Measurement

DO

DON'T

-Out

-S

SC

+S

+Out+In

PC

PR

-In

2nd GenerationDC-DC Converters

48Vdc Input

+ DVM

ELECTRONICLOADDVM

ELECTRONICPOWER SUPPLY

-Out

-S

SC

+S

+Out+In

PC

PR

-In

2nd GenerationDC-DC Converters

48Vdc Input

+DVM DVM

Eff. (in %) = Vout x Iout x 100Vin x Iin


19/36


Test & MeasurementRegulation

Regulation is the ability of a power supply or aDC-DC converter to maintain an output voltagewithin a specified tolerance independent ofchanging conditions of input voltage and /or outputload. Regulation measurements usually involve

changing input voltage or output load conditionswhile measuring the output voltage. Measurementtechniques can adversely affect the accuracy of themeasurement, so the following guidelines should beobserved.

Guidelines Make all voltage measurements as close to the

input and output pins as possible.

Use an electronic load with appropriate sizedconductors.

Do not use the integral volt meter of the electronic

load to measure output voltage; use a separateDVM.

Be certain to properly cool the DC-DC converteras the tests are run. A small cooling fan directedon the module is usually sufficient for tests of ashort duration.

Make certain to use test equipment in goodworking order and properly calibrated.

Make all connections including local sense if

applicable,observing correct polarity beforeturning on voltage source.

Measurement ProcedureLine Regulation1. Set input voltage for 48Vdc.2. Set output load for 75% of maximum rated

load current.

3. Measure output voltage and record.

4. Reduce input voltage to 36Vdc and measureoutput voltage and record result.

5. Increase input voltage to 75Vdc and measureoutput voltage and record result.

The difference in readings is a measure of lineregulation as a percent of output voltage

(at nominal input voltage).Vset point ________ 75% load, 48Vdc input

Vout low line (LL) ________ 75% load, 36Vdc input

Vout high line (HL) ________ 75% load, 75Vdc input

100 x (VoutLL - VoutHL) /Vset point = % Line Regulation

Measurement ProcedureLine Regulation1. Return all settings to nominal (i.e. 48 Vdc input,

75% maximum load).

2. Measure and record output voltage.

3. Increase the electronic load setting to 100% ofrated output.


5. Decrease the load setting to zero Amps.


The difference in readings is a measure of loadregulation as a percent of output voltage atrated load.

Vset point ________ 75% load, 48Vdc input

VoutNL ________ No load, 48Vdc input

VoutFL (Full Load) ________ 100% load, 48Vdc input

(VoutNL VoutFL) /Vset point x 100 = % Load Regulation


20/36


Test & MeasurementOutput Ripple and Noise

Output ripple & noise is defined as the sum ofperiodic and random deviations (PARD) present onthe DC output. The periodic (ripple) portion is theunwanted AC content superimposed on the DCoutput and harmonically related to the frequency of

the input line or switching frequency of theconverter. Noise is the aperiodic (random) contentunrelated to the line or switching frequency.

Ripple & noise is measured over a definedbandwidth and is usually expressed as a peak topeak value and will vary with input line voltageand load current. Measurement of ripple and noise isadversely affected by the use of a ground probebecause of inductance not present on the signallead. These differing impedances convert

common-mode signals to differential signals which

are summed with the true differential signal onthe scope display.

To check for common-mode noise, place theoscilloscope probe and the ground lead of theprobe (tied together) to either output pin,positive ornegative. If the noise is common-mode, you will seenoise even thought you are looking at the same

point. This component of noise represents the errorin the differential noise measurement.Thecommon-mode component can be reducedsubstantially by eliminating the probe ground leadand measuring with the scope barrel or with acoaxial adapter. See illustration.

To ScopeInsert probe into female receptacle

(E.F. Johnson #129-0701-301)for proper output differentialnoise measurement technique

Ground ring on probe


21/36


Test & MeasurementSoldering Guidelines

Wave Soldering. Preheating of the PCB is generallyrequired for wave soldering operations to ensureadequate wetting of the solder to the PCB.Therecommended temperature for PCB topside is95-120C prior to the molten wave.Thick, multilayer

PCBs should be heated toward the upper limit of thisrange, while simple two layer PCBs should be heatedto the lower limit. These parameters are consistentwith generally accepted requirements for

circuit card assembly.

The power module is often much more massive thanother components mounted to the PCB. During wavesolder preheating, the pins will dissipate much of theirabsorbed heat within the module. The best way toimprove the soldering of the module is to increasethe dwell time in the molten wave. Approximately 5

seconds of exposure to the molten wave is requiredto achieve an acceptable solder joint.

These guidelines were established for a moltenwave temperature of 465-500 F which is theapproximate operational range in current PCAoperations. PCAs with SMT components on thebottomside are normally run at the lower end ofthis range.

Hand Soldering. A tip temperature of 700-750 F isrecommended. The time will vary depending on thePCB thickness and the amount of copper adjacentto the pin pads. Thicker PCBs with more copperaround the solder pads will require more timebecause of the heatsinking effect of the PCB andcopper.A larger (higher wattage) soldering tipcan be used to compensate for this situation. Tiptemperature, however, should not be increasedabove 750F.

A general time guideline for hand soldering of

module pins is as follows:

Maxi signal pins 3 to 5 secondsMaxi corner pins 5 to 8 seconds

Mini signal pins 3 to 5 seconds

Mini corner pins 4 to 7 secondsMicro signal pins 2 to 4 seconds

Micro corner pins 3 to 5 seconds

It is recommended that a no-clean flux be usedwhen soldering. If this is not possible the followingprecautions must be followed to prevent damage tothe module.

Post Solder Cleaning.Vicor modules are nothermetically sealed and must not be exposed toliquid, including but not limited to cleaning solvents,aqueous washing solutions or pressurized sprays.Cleaning the back side of the PCB is acceptableprovided no solvent contacts the body of themodule.Vicor modules should be soldered usingno-clean flux solder in order to prevent residuebuildup on the module.


22/36


Mechanical DrawingsMICRO, FM48(Fi ltMod), IAM48

567

4321

(REF)

0.080

2,03DIA. (7X)

0.21

5,2

0.27

6,9(2X)

1.04

26,4

1.45

36,8

0.275

6,99

0.800

20,32

0.525

13,34

0.400

10,16

0.12*

3,1

0.20**

5,08

FULL R (6X)

0.15

3,81CHAMFER

(REF.)

(6X)

0.65

16,5

0.49

12,4

1.30

33,0

2.28

57,9

1.45

36,8

0.13

3,3

0.06

1,5R (3X)

0.01

X 45

Use a

4-40 Screw (6x)

Torque to:

5 in-lbs

0.57 N-m

0.54

13,7

0.43

10,9

Long Pin0.62

15,7

Short Pin(7X)

(7X)

Slotted (Style 1)

or

Threaded (Style 2)4-40 UNC-2B (6X)

or

Thru Hole (Style 3)#30 Drill Thru (6X)(0.1285)

(ALLMARKINGSTHISSURFACE)

ALUMINUMBASEPLATE

12,7 0,5

0.50 0.02

* Style 1 baseplate only** Style 2 & 3 baseplates

*** Reserved for Vicor accessories. Not for mounting

Center line

style 2 & 3

baseplates only

(4X)***

0.490 .015

12,45 0,38(REF)

2.00050,80

0.235.0155,970,38

(REF)

0.350.0158,890,38

(REF)

1.2732,3

0.092,3

Pin CL

Pin CL

CL

Converter PinsMicro FM48(FiltMod) IAM48

No. Function Label Function Label Function Label

1 +In + +Vin +V -Vout -V

2Primary

PC N/C N/C N/C N/CControl

3 Parallel PR N/C N/C Off/On Off/On

4 -In - -Vin -V +Vout +V

5 -Out - -Vout -V +Vin +V

6

Secondary

SC Ground GND N/C N/CControl

7 +Out + +Vout +V -Vin -V

2 3

6

1

7

4

5

PLATED

THRU HOLE

DIA

0,08

*DENOTES TOL = 0.003

0.133

3,38

1.734**

44,04

.400*

10,161.140**

28,96

0.170*

4,32

0.800*

20,32

0.525*

13,34

0.275*

6,99

2.000*

50,80

0.06

1,5R (4X)

INBOARD

SOLDER

MOUNT

SHORT PIN STYLE

0.094 0.0032,39 0,08

0.43

10,9

(7X)

**PCB WINDOW

PCB THICKNESS0.062 0.010

1,57 0,25

0.53

13,5

ONBOARD

SOLDER

MOUNT

LONG PIN STYLE

0.094 0.0032,39 0,08

PINS STYLES

SOLDER:TIN/LEAD

HOT SOLDER DIPPED

MODUMATE: GOLD PLATED COPPER

ALUMINUM

BASEPLATE

ALL MARKINGS

THIS SURFACE

PCB Mounting Specifications


23/36


Mechanical DrawingsMINI, FIAM

PCB Mounting Specifications

(2X)

0.01

0.358,8

0.20**5,1

0.12*3,1

DIA,(7X)

0.150

3,81

(REF)

DIA,(2X)0.0802,03

431

9 8

2

7 6 5

0.235,8

0.40010,16

1.40035,56

1.00025,40

0.70017,78

2.2055,91.7444,2

FULL R (6X)

(6X)

(REF.)

0.153,81

1.3033,0

2.28

57,9

2.2055,9

0.130

3,30

0.49

12,4

0.6516,5

0.061,5

R (3X)

X 45

CHAMFER

Use a 4-40 ScreTorque to:

5 in-lbs.57 N-m

0.54

13,7

0.4310,9

Long Pin0.62

15,7

Short Pin(9X)

(9X)Slotted

or

Threaded4-40 UNC-2B (6X)

or

Thru Hole#30 Drill Thru (6X)(0.1285)

(ALLMARKINGS

THISSURFACE)

ALUMINUMBASEPLATE

0.50 0.0212,7 0,5



Center line

style 2 & 3

baseplates only

(4X)***0.300 0.0157,62 0,38

0.300 0.0157,62 0,38

1.90048,26

2.00050,80

0.102,5

Pin CL

Pin CL

CL

ALL MARKINGSTHIS SURFACE

PINS STYLES

SOLDER:TIN/LEAD

HOT SOLDER DIPPED

ALUMINUM

BASEPLATE

ries

0.195

4,951.400*

35,56

1.000*

25,40

0.700*

17,78

0.400*

10,16

1.790

45,470.06

1,5R (4X) 0.158

4,01

56789

1 2 3 4

0.003

0,08

* DENOTES

TOL =

PCB THICKNESS0.0620.010

1,57 0,25

SHORT PIN STYLE

0.094 0.003

2,39 0,08

INBOARDSOLDERMOUNT

0.43

10,9

0.53

13,5

1.900*

48.26

1.900*

48,26

1.584*

40,23

0.164 0.003

4,16 0,08

LONG PIN STYLE

0.094 0.003

2,39 0,08

ONBOARDSOLDERMOUNT

0.164 0.003

4,16 0,08

PLATEDTHRU HOLE

DIA

(7X)

(2X)

Converter PinsMini

No. Function Label

1 +In +

2 Primary PCControl

3 Parallel PR

4 -In -

5 -Out -

6 -Sense -S7

SecondarySCControl

8 +Sense +S

9 +Out +

FIAMNo. Function Label

1 + In +

2 No Connect ion NC

3 Ground EMI/GRD

4 In

5 Out

6 ON/OFF ON/OFF

7 No Connect ion NC

8 No Connect ion NC

9 + Out +


24/36


Mechanical DrawingsMAXI

PCB Mounting Specifications (Pin Style 1)

1.74

44,2

2.20

55,9

56789

4321

0.23

5,8(REF)

0.180

4,57

0.080

2,03

1.400

35,56

1.000

25,40

0.700

17,78

0.400

10,16

DIA,(7X)

DIA,(2X)

4-40 UNC-2BThru (4X)***

(Style 2 and 3 only)

Slotted

or

Threaded4-40 UNC-2B (6X)

or

Thru Hole#30 Drill Thru (6X)(0.1285)

0.50

12,7

0.06

1,5 2.20

55,9(REF)

1.80

45,7

4.60

116,8

3.60

91,4

0.13

3,3

FULL R (6X)

(6X)

R (3X)

CHAMFER

0.15

3,81X 45

0.54

13,7

0.43

10,9

0.38

9,6

0.20**

5,08

0.12*

3,1

(2X)

0.01

Use a

4-40 Screw (6x)

Torque to:

5 in-lbs

0.57 N-m

Long Pin0.62

15,7

Short Pin(9X)

(9X)

(ALLMARKINGSTHISSURFACE)

ALUMINUMBASEPLATE

0.50 0.02

12,7 0,5



Center line

4.200

106,68

0.3000.015

7,620,38

0.3000.015

7,620,38

2.00

50,8

0.10

2,5

Pin CL

Pin CL

CL

ALL MARKINGS

THIS SURFACE

PINS STYLES

SOLDER:TIN/LEAD

HOT SOLDER DIPPED

MODUMATE: GOLD PLATED COPPER

ALUMINUM

BASEPLATE

0.195

4,95

1.400*

35,56

1.000*

25,40

0.700*

17,78

0.400*

10,16

3.844

97,64

4.200*

106,68

1.790

45,470.06

1,5R (4X) 0.178

4,52

56789

1 2 3 4

0.003

0,08

* DENOTES

TOL =

PLATEDTHRU HOLE

DIA

PCB THICKNESS0.062 0.010

1,57 0,25

SHORT PIN STYLE

0.094 0.003

2,39 0,08

0.194 0.003

4,93 0,08

LONG PIN STYLE

0.094 0.003

2,39 0,08

0.194 0.003

4,93 0,08

INBOARD

SOLDERMOUNT

0.43

10,9

ONBOARD

SOLDERMOUNT

(7X)

(2X)

0.53

13,5

Converter Pins

No. Function Label

1 +In +

2 Primary PC

Control

3 Parallel PR

4 -In -

5 -Out -

6 -Sense -S7 Secondary SC

Control

8 +Sense +S

9 +Out +


25/36


MOUNTING OPTIONS

NO THRU-HOLE THREADED NO THRU-HOLE THREADED NO THRU-HOLE THREADED

HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK

19126 19126 19127 19126 19126 19127 19126 19126 19127

(100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs)

Kit 19226 Kit 18150 Kit18151 Kit 19226 Kit18166 Kit 18167 Kit 19226 Kit 18166 Kit18167

19132 19132 19133 19132 19132 19133 19132 19132 19133

(100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs) (100 pcs)

Kit 19227 Kit 18156 Kit 18157 Kit 19227 Kit 18172 Kit 18173 Kit 19227 Kit 18172 Kit 18173

Mounting and Thermal Management Hardware

ThermMate, Thermal Pads - Maxi. Mini and Micro

BoardPin HeightThickness

Mounting ConnectionStyle

2Above BoardNominal

(Min./Max.)

0.063In-Board Solder 1

(0.055/0.071)

0.094In-Board Solder 2

(0.084/0.104)

0.063On-Board Solder 2

(0.055/0.071)

STANDOFFS1Maxi Mini Micro

ALL KITS INCLUDE MOUNTING HARDWARE FOR ONE MODULE.

1. Kits for maxi size module with heat sink include sixstandoffs and necessary #4-40 UNC hardware.Kits for maxi size module with no heatsink, and allkits for mini and micro size modules include fourstandoffs and necessary #4-40 UNC hardware.

2. Pin style 1: Short 0.110 (2,8mm)Pin style 2: Long 0.200 (5,1mm)

Threaded Heat Sink Thru-Hole Heat

SLOTTED BASEPLATE

0.13 Wide Slot (6 Places)

Micro module shown actual size.

Do not drill or modify the baseplate.

When mounting the module to a heatsink use the

proper type and quantity of thermal compound.Use the recommended quantity and type offasteners. Tighten the fasteners in sequence (seefigure below) to the recommended torque value.

ThermMate Thermal Pads (10 pieces per package)For use with Vicor modules, ThermMate thermal padsare a dryalternative to thermal compound andare pre-cut to the outline dimensions of the module.*

Thermal Pad Part No. Part No. ThicknessMaxi (10 pieces) 20263 0.007"Mini (10 pieces) 20264 0.007"Micro (10 pieces) 20265 0.007"

* Slots in thermal pads are 0.205" 0.005".This is slightly largerthan the slots in the module baseplate (0.130" 0.005").

20263

20265 20264

.45"

.53"

6

3

2

1

4

5

1

3

4

2

1

3

4

2


26/36


Thermal HardwareHeat Sinks

Longitudinal FinsThreaded Thru-hole

MAXI

0.4 Fin - 17483

0.9 Fin - 15975

MINI

0.4 Fin - 17485

0.9 Fin - 15989

MICRO

0.4Fin - 16285

0.9Fin - 15971

MAXI

0.4 Fin - 18038

0.9 Fin - 17443

MINI

0.4Fin - 18039

0.9Fin - 17537

MICRO

0.4 Fin - 18030

0.9 Fin - 17539

Transverse Fin sThreaded Thru-hole

MAXI

0.4 Fin - 17510

0.9 Fin - 15960

MINI

0.4 Fin - 16297

0.9 Fin - 15985

MICRO

0.4 Fin - 16299

0.9 Fin - 15987

MAXI

0.4 Fin - 18068

0.9 Fin - 17570

MINI

0.4 Fin - 18073

0.9 Fin - 17572

MICRO

0.4Fin - 18074

0.9Fin - 17574


27/36


0

20

40

60

80

100

120

140

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

Ambient Temperature (deg C)

OutputPower(Watts)

Thermal Performance CurvesMICRO

0

5

10

15

20

25

30

35

40

45

50

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100


OutputPower(Watts)

0

5

10

15

20

25

30

35

40

45

50

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100


OutputPower(Watts)

0

5

10

15

20

25

30

35

40

45

50

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100


OutputPower(W

atts)

0

10

20

30

40

50

60

70

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100


OutputPower(Watts)

0

10

20

30

40

50

60

70

0 510

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100


OutputPower(Watts)

0

10

20

30

40

50

60

70

0 510

15

20

25

30

35

40

45

50

55

60

65

70

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OutputPower(Watts)

Slotted Baseplate 0.4'' Heat Sink 0.9'' Heat Sink

2V(1.8)

3.3V(2.5)

5V

12-48V

bm=.15C/W Baseplate 0.9'' Longitudinal Fins 0.9'' Transverse Fins 0.4'' Longitudinal Fins 0.4'' Transverse Fins

Free Air 10.90 5.37 5.04 7.77 7.76

200 LFM 6.90 2.51 2.31 3.87 3.58

400 LFM 4.78 1.79 1.68 2.68 2.52

600 LFM 3.74 1.42 1.31 2.13 2.01

800 LFM 3.15 1.20 1.10 1.78 1.67

1000 LFM 2.79 1.06 0.97 1.48 1.45

1200 LFM 2.49 0.93 0.88 1.32 1.29

Free Air 200 LFM 400 LFM 600 LFM

800 LFM 1000 LFM 1200LFM


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Thermal Performance CurvesMINI

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OutputPower(Watts)


2V(1.8)

3.3V(2.5)

5V

12-48V

bm=.15C/W Baseplate 0.9'' Longitudinal Fins 0.9'' Transverse F ins 0.4'' Longitudinal Fins 0.4'' Transverse Fins

Free Air 7.94 4.10 3.93 6.28 6.34

200 LFM 4.50 1.72 1.93 2.81 3.00

400 LFM 3.20 1.26 1.38 1.98 2.09

600 LFM 2.52 1.02 1.06 1.55 1.59

800 LFM 2.15 0.86 0.89 1.24 1.31

1000 LFM 1.89 0.75 0.77 1.05 1.11

1200 LFM 1.69 0.68 0.70 0.94 0.99


800 LFM 1000 LFM 1200LFM


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Thermal Performance CurvesMAXI

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PowerOutput(Watts)


2V(1.8)

3.3V(2.5)

5V

12-48V

bm=.15C/W Baseplate 0.9'' Longitudinal Fins 0.9'' Transverse Fins 0.4'' Longitudinal Fins 0.4'' Transverse Fins

Free Air 4.98 2.89 2.24 3.72 3.49

200 LFM 3.23 1.30 1.02 2.14 1.53

400 LFM 2.17 0.90 0.72 1.48 1.08

600 LFM 1.73 0.72 0.60 1.10 0.87

800 LFM 1.46 0.59 0.51 0.86 0.70

1000 LFM 1.27 0.51 0.44 0.71 0.60

1200 LFM 1.14 0.46 0.41 0.61 0.55


800 LFM 1000 LFM 1200LFM


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28 w w w . v i c o r p o w e r . c o m28 w w w . v i c r . c o mThe latest data sheets for individual models are available on the Vicor website at www.vicorpower.com

See page 20 for the FM48 mechanical drawing.

Note: For alternative product grades, change the C in the part number to T.

Parameter Min Typ Max RemarksInput Voltage 36Vdc 48Vdc 76VdcSafety Approvals UL 1950, CSA 22.2-950, EN 60950Dielectric Withstand 1,500Vrms Input /Output to baseEMI/ RFI Bellcore GR-001089-Core Issue 2 When used with Vicor 2nd

EN 55022 Level B Generation 48Vin DC-DCFCC Part 15 Level B converters

Output CurrentFM4808C12 8A Delivered current to anyFM4812C12 12A combination of Vicors 2nd Gen.

48Vin DC-DC converter

Reverse polarity protectionNo damage to unit, externalfusing required

Weight 2.1 ounces (60 grams)

Parameter C-Grade T-GradeStorage temp. 40C to +125C 40C to +125COperating temp. (baseplate) 20C to +100C 40C to +100CWarranty 2 years 2 years

Product Grade Specifications

FM48-FiltMod Specifications(typical at TBP = 25C, nominal line, 75% load, unless otherwise specified)

Typical Transient, Surge Protection and Filtering Solution

IAM22nd Generation

48Vdc Input

DC-DC Converters

IN

PR

PC

+IN

OUT

S

SC

+S

+OUT

FM48

IN

+IN

IAM48

4

3

2

1

7

6

5

4

3

2

17

6

5

Note: The IAM48 is shown in the on state.To disable, open the connection to pin 3.

IN

NC

NC

+IN

OUT

GND

+ OUT

OUT

NC

Off/On

+OUT

IN

NC

+ IN

Shown actual size:2.28 x 1.45 x 0.5 in

57,9 x 36,8 x 12,7 mm

Data Sheet

FM48TM

FiltMod

Input Filter Module

Features

Low profile mounting option

EMI filtering

8 and 12 Amp versions

CE Marked

Micro-size package

Products Highlights

The FM48 input filter module enables

designers to meet the conducted

emission limits of EN55022 Level Band FCC Level B when used with

Vicors 48 Volt 2nd Generation of

DC-DC converters. FiltMods accept

an input voltage of 36 to 76Vdc with

a transient withstand capability of

100Vdc for 100 msec. The FiltMods are

packaged in an industry standard

quarter-brick module measuring

2.28" x 1.45" x 0.5" and are available

in either 8 or 12 Ampere capacity.

Both versions may be on-board or

in-board mounted for height critical

applications. The FiltMods can beteamed with Vicors IAM48 for

transient and surge protection.

Compatible Products

IAM48 2nd Generation 48V input

DC-DC converters

Part Numbers

FM4808C11: 8 Amp Short Pins

FM4808C12: 8 Amp Long Pins

FM4812C11: 12 Amp Short Pins

FM4812C12: 12 Amp Long Pins

Conducted Noise

FM4812C12 and Model V48A12C500A

DC-DC converter.

FM4812C12 and Model V48B24C250A

DC-DC converter.


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The latest data sheets for individual models are available on the Vicor website at www.vicorpower.com

See page 20 for the IAM48 mechanical drawing.

Parameter Min Typ Max Remarks

Input voltage 36Vdc 48Vdc 76Vdc Continuous

Inrush limiting 14mA/F 6A with 330F capacitor

(See Fig 1)

Safety approvals UL 1950, CSA 22.2-950, EN 60950

Transient immunity

Telcordia-GR-499-CORE Section 132 200V 1sec durationETS 300 386-1 Class 2 200V 5.0sec rise time, 50sec

duration surge

250V 1-100 nsec burst

When used with Vicor

FM-48 filter module

Dielectric withstand 1,500Vrms Input/Output to base

Output current Delivered current to any

IAM4810C12 10A combination of Vicors 2nd

IAM4820C12 20A Gen. 48Vin DC-DC converters

Efficiency 97%Internal voltage drop is

1.1V max.@ 20A, 100C basepl

ON/OFF control

ENABLE(ON) 0.0Vdc 1.0Vdc Referenced to Vout.

DISABLE(OFF) 3.5Vdc 5.0Vdc 100K internal pull-up resistor

Reverse polarity protectionNo damage to module, externa

fuse required

External capacitance See Fig 3

IAM4810C12 10F 150F 100V

IAM4820C12 100F 330F 100V

Weight 1.7 ounces (50 grams)

Warranty 2 years

Features Wide input voltage range

High surge withstand

97% Efficiency

Input reverse polarity protection

On/Off control feature

MicroMod package

Primary Function

Inrush current limiting

Input transient protection

Products Highlights

The 2nd Generation IAM48 is a

component level, DC input front-end

designed to occupy minimum board

space while providing maximum

transient protection for todays

sophisticated electrical systems. The

IAM48, in combination with Vicors

48V input 2nd Generation DC-DC

converters, provides a highly efficient,

high density power system with

outputs from 1 to 100Vdc.

When the IAM48 is used with the

Vicor FM48-FiltMod, the

combination meets the conducted

EMI specifications of Telcordia,

FCC and European Norms.

Compatible Products

FM48-FiltMod

2nd Generation 48V inputDC-DC converters

Part Numbers

Shown actual size:

2.28 x 1.45 x 0.5 in

57,9 x 36,8 x 12,7 mm

IAM48 Specifications(typical at TBP = 25C, nominal line, unless otherwise specified)

Data Sheet

IAM48TM

Input Power

Conditioning Module

Parameter Rating Unit Notes

+In to In 80 Vdc Continuous

+In to In 100 V 100ms

+Out to Out 75 Vdc Continuous

Mounting torque 5(0.57) in-lbs 6 each, #4-40 or M3

Pin soldering temperature 500 (260) F(C)


32/36


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Vicor Technical Support

Vicors technical support team is staffed withapplications engineers to provide the product andapplication information and technical assistancecustomers need concerning Vicor products and

power solutions. Our facilities house electronicslaboratories where Vicor applications engineers canevaluate specific customer design issues and offer awide range of component-based power solutionsthat include distributed power, current sharing,N + 1redundancy, thermal management, and compliancewith safety and performance standards.

Applications engineers ...

Answer technical questions (by phone, fax, E-mail,

or the Vicor web site).

Assist with component-based power system design

Support user needs through visits to Vicor andcustomer facilities.

Help select the most appropriate product for

your application.

If you have a specific technical question, you maycall or e-mail an applications engineer located atone of our global offices.

USAVicor Corporation(Corporate Headquarters)

25 Frontage RoadAndover, MA 01810-5413

For General Information

Tel: 978-470-2900Fax: 978-475-6715

For Technical Support

Tel: 800-927-9474Fax: 978-749-3341E-mail: [email protected]

For Sales Support (Vicor Express)

In U.S.and Canada: 800-735-6200Fax: 978-475-6715E-mail: [email protected]

Vicor Corporation377 E. Butterfield RoadLombard, IL 60148Tel: 630-769-8780Fax: 630-769-8782

Vicor Westcor Division560 Oakmead ParkwaySunnyvale, CA 94086-4049Tel: 408-522-5280Fax: 408-774-5555

Latin AmericaCall the number below andask the operator to connectyou to 800-735-6200.Argentina: 001-800-200-1111Brazil: 000+8010Mexico: 95-800-462-4240

EuropeVicor France6, Parc Ariane

Btiment "Le Mercure"78284 Guyancourt CedexFranceTel: +33-1-3452-18300800 419 419 (in France)Fax: +33-1-3452-2830E-mail: [email protected]

Vicor GermanyAdalperostrae 2985737 Ismaning, GermanyTel: +49-89-962439-0

0800 018 29 18 (in Germany)Fax: +49-89-962439-39E-mail: [email protected]

Vicor ItalyVia Milanese,2020099 Sesto S. GiovanniMilano, ItalyTel: +39-02-2247-2326800 899 677 (in Italy)Fax: +39-02-2247-3166E-mail: [email protected]

Vicor U.K.Coliseum Business CentreRiverside Way, Camberley

Surrey GU15 3YLEnglandTel: +44-1276-678-222

In UK: 0800-980-8427In Denmark: 80 88 11 41In Norway: 800 11083In Sweden: 020 798236

Fax: +44-1276-681-269E-mail: [email protected]

Asia-PacificVicor Japan Co., Ltd.6F, POLA 3rd Bldg.8-9-5, Nishi-gotandaShinagawa-kuTokyo 141-0031 JapanTel: +81-3-5487-3880Fax: +81-3-5487-3885www.vicor-asia.com

Vicor Hong KongRm 511, Tower 1, Silvercord30 Canton RoadTsim Sha TsuiHong Kongwww.vicr.com.cnTel: +852-2956-1782Fax: +852-2956-0782


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Notes Page


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Information furnished by Vicor is believed to be accurate and reliable. However,no responsibility is assumed by

Vicor for its use. No license is granted by implication or otherwise under any patent or patent rights of Vicor. Vicor

components are not designed to be used in applications, such as life support systems, wherein a failure or

malfunction could result in injury or death.All sales are subject to Vicors Terms and Conditions of Sale, which are

available upon request. Specifications are subject to change without notice.


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