PKM 4000D Series 36-75 Vdc DC/DC converter Output up to 40 A/72 W Contents Product Program. . . . . . . . . . . . . . . . . . . . . . 2 Quality Statement. . . . . . . . . . . . . . . . . . . . . 2 Limitation of Liability. . . . . . . . . . . . . . . . . . . 2 Mechanical Information. . . . . . . . . . . . . . . . . 3 Absolute Maximum Ratings . . . . . . . . . . . . . 4 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Product Qualification Specification. . . . . . . . 5 Safety Specification . . . . . . . . . . . . . . . . . . . 6 PKM 4418LD PINB - 1.2 V Data . . . . . . . . . . 7 PKM 4618HD PINB - 1.5 V Data . . . . . . . . 10 PKM 4718GD PINB - 1.8 V Data . . . . . . . . 13 EMC Specification. . . . . . . . . . . . . . . . . . . . 16 Operating Information. . . . . . . . . . . . . . . . . 17 Thermal Consideration . . . . . . . . . . . . . . . . 19 Soldering Information . . . . . . . . . . . . . . . . . 20 Delivery Package Information. . . . . . . . . . . 20 Compatibility with RoHS requirements. . . . 20 Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Sales Offices and Contact Information. . . . 21 Safety Approvals Key Features * Industry standard quarterbrick 57.93 x 36.80 x 9.1 mm (2.278 x 1.449 x 0.35 In.) * RoHS compliant * High efficiency, typ. 89.5 % at 1.8 V half load * 1500 Vdc input to output isolation, meets isolation requirements equivalent to basic insulation according to IEC/EN/UL 60950 * More than 3.15 million hours MTBF The PKM 4000D series of high efficiency DC/DC converters are designed to provide high quality on-board power solutions in distributed power architectures used in Internetworking equipment in wireless and wired communications applications. The PKM 4000D series uses patented synchronous rectifi cation technology and achieves an effi ciency up to 89% at full load. Included as standard features are output over-voltage protection, input under-voltage protection, over temperature protection, softstart, output short circuit protection, remote sense, remote control, and output voltage adjust function. These converters are designed to meet high reliability requirements and are manufactured in highly automated manufacturing lines and meet world-class quality levels. Ericsson Power Modules is an ISO 9001/14001 certified supplier. E Datasheet Product Program VO/IO max VI 48/60 PO max Ordering No. 1.2 V/40 A 48 W PKM 4418LD PINB 1.5 V/40 A 60 W PKM 4618HD PINB 1.8 V/40 A 72 W PKM 4718GD PINB 2.5 V/40 A 100 W PKM 4119D PINB See Technical Specification PKM4000D series 3.3 V/35 A 116 W PKM 4110D PINB See Technical Specification PKM4000D series 5.0 V/25 A 125 W PKM 4111D PINB See Technical Specification PKM4000D series 12 V/11 A 132 W PKM 4113D PINB See Technical Specification PKM4000D series Output 1 Option Suffix Baseplate Comment Example PKM4418D PI Increased stand-off and height M PKM4418LD PINBM Lead length 3.69 mm (0.145 in) LA PKM4418LD PINBLA Lead length 4.57 mm (0.180 in) LB PKM4418LD PINBLB Note: As an example a positive logic, increased stand-off and short pin product would be PKM 4110D PIPNBMLA. For more information about the complete product program, please refer to our website: www.ericsson.com/powermodules Quality Statement Limitation of Liability The PKM 4000D DC/DC converters are designed and manufactured in an industrial environment where quality systems and methods like ISO 9000, 6 (sigma), and SPC are intensively in use to boost the continuous improvements strategy. Infant mortality or early failures in the products are screened out and they are subjected to an ATE-based final test. Conservative design rules, design reviews and product qualifications, plus the high competence of an engaged work force, contribute to the high quality of our products. Ericsson Power Modules does not make any other warranties, expressed or implied including any warranty of merchantability or fitness for a particular purpose (including, but not limited to, use in life support applications, where malfunctions of product can cause injury to a person's health or life). PKM 4000D Datasheet EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Mechanical Information Mechanical Information PKM 4000D Datasheet EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Absolute Maximum Ratings Characteristics min typ max Unit Tpcb Maximum Operating Tpcb Temperature (see thermal consideration section) -40 +125 C TS Storage temperature -55 +125 C VI Input voltage -0.5 +100 Vdc VISO Isolation voltage (input to output test voltage) 1500 Vdc Vtr Input voltage transient (Tp 100 ms) 80 Vdc Negative logic (referenced to -In) 15 Vdc VRC Vadj Positive logic (referenced to -In) -0.5 15 Vdc Maximum input -0.5 2xVoi Vdc Stress in excess of Absolute Maximum Ratings may cause permanent damage. Absolute Maximum Ratings, sometimes referred to as no destruction limits, are normally tested with one parameter at a time exceeding the limits of Output data or Electrical Characteristics. If exposed to stress above these limits, function and performance may degrade in an unspecified manner. Input TPcb <TPcb max unless otherwise specified Characteristics Conditions min typ 36 max Unit 75 Vdc VI Input voltage range VIoff Turn-off input voltage Ramping from higher voltage 32 Vdc VIon Turn-on input voltage Ramping from lower voltage 34 Vdc CI Input capacitance 5.4 F PIi Input idling power Io= 0, VI = 53 V 3.5 W PRC Input standby power (turned off with RC) VI = 53 V, RC activated 0.1 W Fundamental Circuit Diagram *TPMBUFE 'FFECBDL 4FDPOEBSZ 1SJNBSZ 8 1 7 6 5 7PMUBHF .POJUPSJOH $POUSPM 2 $POUSPM 4 3 PKM 4000D Datasheet EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Product Qualification Specification Characteristics Random Vibration IEC 68-2-34 Eb Frequency Spectral density Duration 10 ... 500 Hz 0.025 g2/Hz 10 min each direction Sinusoidal vibration IEC 68-2-6 Fc Frequency Amplitude Acceleration Number of cycles 10 ... 500 Hz 0.75 mm 10 g 10 in each axis Mechanical shock (half sinus) IEC 68-2-27 Ea Peak acceleration Duration Pulse shape 200 g 3 ms half sine Temperature cycling IEC 68-2-14 Na Temperature Number of cycles -40 ... +100 C 300 Heat/Humidity IEC 68-2-67 Ca Temperature Humidity Duration +85 C 85 % RH 1000 hours Solder heat stability IEC 68-2-20 1A Temperature, solder Duration 260 C 10 s Resistance to cleaning agents IEC 68-2-45 XA Method 2 Water Isopropyl alcohol Glycol ether Method +55 5 C +35 5 C +35 5 C with rubbing Storage test IEC 68-2-2 Ba Temperature Duration 125 C 1000 h Cold (in operation) IEC 68-2-1 Bc Temperature, TA Duration -40 C 2h Duration 1000 h Operational life test PKM 4000D Datasheet EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Safety Specification General information. Isolated DC/DC converters. Ericsson Power Modules DC/DC converters and DC/DC regulators are designed in accordance with safety standards IEC/EN/UL 60 950, Safety of Information Technology Equipment. It is recommended that a fast blow fuse with a rating twice the maximum input current per selected product be used at the input of each DC/DC converter. If an input filter is used in the circuit the fuse should be placed in front of the input filter. In the rare event of a component problem in the input filter or in the DC/DC converter that imposes a short circuit on the input source, this fuse will provide the following functions: IEC/EN/UL60950 contains requirements to prevent injury or damage due to the following hazards: * * * * * * Electrical shock Energy hazards Fire Mechanical and heat hazards Radiation hazards Chemical hazards * Isolate the faulty DC/DC converter from the input power source so as not to affect the operation of other parts of the system. * Protect the distribution wiring from excessive current and power loss thus preventing hazardous overheating. The galvanic isolation is verified in an electric strength test. The test voltage (VISO) between input and output is 1500 Vdc or 2250 Vdc for 60 seconds (refer to product specification). Leakage current is less than 1A at nominal input voltage. On-board DC-DC converters are defined as component power supplies. As components they cannot fully comply with the provisions of any Safety requirements without "Conditions of Acceptability". It is the responsibility of the installer to ensure that the final product housing these components complies with the requirements of all applicable Safety standards and Directives for the final product. 24 V dc systems. The input voltage to the DC/DC converter is SELV (Safety Extra Low Voltage) and the output remains SELV under normal and abnormal operating conditions. Component power supplies for general use should comply with the requirements in IEC60950, EN60950 and UL60950 "Safety of information technology equipment". 48 and 60 V dc systems. If the input voltage to Ericsson Power Modules DC/DC converter is 75 V dc or less, then the output remains SELV (Safety Extra Low Voltage) under normal and abnormal operating conditions. There are other more product related standards, e.g. IEC612047 "Safety standard for power supplies", IEEE802.3af "Ethernet LAN/MAN Data terminal equipment power", and ETS300132-2 "Power supply interface at the input to telecommunications equipment; part 2: DC", but all of these standards are based on IEC/EN/UL60950 with regards to safety. Single fault testing in the input power supply circuit should be performed with the DC/DC converter connected to demonstrate that the input voltage does not exceed 75 V dc. If the input power source circuit is a DC power system, the source may be treated as a TNV2 circuit and testing has demonstrated compliance with SELV limits and isolation requirements equivalent to Basic Insulation in accordance with IEC/EN/UL 60 950. Ericsson Power Modules DC/DC converters and DC/DC regulators are UL 60 950 recognized and certified in accordance with EN 60 950. The flammability rating for all construction parts of the products meets UL 94V-0. Non-isolated DC/DC regulators. The products should be installed in the end-use equipment, in accordance with the requirements of the ultimate application. Normally the output of the DC/DC converter is considered as SELV (Safety Extra Low Voltage) and the input source must be isolated by minimum Double or Reinforced Insulation from the primary circuit (AC mains) in accordance with IEC/EN/UL 60 950. PKM 4000D Datasheet The input voltage to the DC/DC regulator is SELV (Safety Extra Low Voltage) and the output remains SELV under normal and abnormal operating conditions. It is recommended that a slow blow fuse with a rating twice the maximum input current per selected product be used at the input of each DC/DC regulator. EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4418LD PINB - 1.2 V Data TPcb = -40...+90 C, VI = 36...75V, sense pins connected to output pins unless otherwise specified. Characteristics Output Conditions Unit min typ max 1.2 1.22 V Output voltage initial setting and accuracy VI = 53 V, IOmax, TPcb = 25 C 1.18 Output adjust range IOmax, VI = 53 V, TPcb = 25 C 0.96 1.32 V Output voltage tolerance band 0.1...1 x IOmax 1.16 1.24 V Idling voltage IO = 0 1.18 1.22 V Line regulation IOmax -10 10 mV Load regulation IO = 0.01...1 x IOmax, VI = 53 V -10 10 mV Vtr Load transient voltage deviation 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 130 mV ttr Load transient recovery time 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 100 s tr Ramp-up time ts Start-up time IO Output current POmax Max output power At V = VOnom 48 Ilim Current limit threshold TPcb < TPcbmax 42 52 A Isc Short circuit current TPcb = 25 C 44 58 A VOac Output ripple & noise See ripple and noise, IOmax, VOnom 50 100 mVp-p SVR Supply voltage rejection (ac) TPcb = 25 C, f = 100 Hz sine wave 1 Vp-p, VI = 53 V 60 dB Efficiency - 50% load TPcb = +25 C, VI = 48 V, 0.5 x IOmax 87.5 % Efficiency - 100% load TPcb = +25 C, VI = 48 V, IOmax 85 % Efficiency - 50% load TPcb = +25 C, VI = 53 V, 0.5 x IOmax 87.5 % Efficiency - 100% load TPcb = +25 C, VI = 53 V, IOmax 85 % Pd Power Dissipation TPcb = +25 C, VI = 53 V, IOmax fs Switching frequency 0 ... 1.0 x IOmax VOi VO PKM 4000D Datasheet 0.1...1 x IOmax, VI = 53 V 0.1...0.9 x VOnom 0.1...1 x IOmax, VI = 53 V From VI connected to 0.9 x VOnom 5 15 30 ms 5 20 40 ms 40 A 0 82.5 82.5 145 W 155 11 W 165 kHz EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4418LD PINB Typical Characteristics Output Current Derating Efficiency <> <"> NT MGN NT MGN NT MGN NT MGN NT MGN NT MGN /BU$POW 7 7 7 7 <"> <$> Thermal Resistance Power Dissipation <8> <$8> 7 7 7 7 Available load current vs. ambient air temperature and airflow at Vin = 53 V. DC/DC converter mounted vertically with airflow testconditions as per the Thermal consideration section. Efficiency vs. load current and input voltage at TPcb = +25 C <"> Dissipated power vs. load current and input voltage at TPcb = +25 C <NT> Thermal resistance vs. airspeed measured at the converter. Tested in windtunnel with airflow and test conditions as per the Thermal consideration section. Output Characteristic <7> <"> Output voltage vs. load current at TPcb = +25 C, VI = 53 V. PKM 4000D Datasheet EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4418LD PINB Typical Characteristics Turn-Off Start-Up Turn-off enabled by disconnecting Vin. IO = 40 A resistive load at TPcb = +25 C, Vin = 53 V. Top trace: output voltage (0.5 V/div.). Bottom trace: input voltage (20 V/div.) Time scale: 10 ms/div. Start-up enabled by connecting Vin. IO = 40 A resistive load, TPcb = +25 C, Vin = 53 V. Top trace: output voltage (0.5 V/div.). Bottom trace: input voltage (20 V/div.). Time scale: 10 ms/div. Transient Output Ripple Output voltage response to load current step-change (10-30-10 A) at TPcb = +25 C, Vin = 53 V. Top trace: Input voltage (100 mV/div.). Bottom trace: load current (10 A/div.). Time scale: 0.1 ms/div. Output voltage ripple (20 mV/div.) at TPcb = +25 C, Vin = 53 V, IO = 40 A resistive load with C = 10 F tantalum and 0.1 F ceramic capacitor. Band width = 20 MHz. Time scale: 2 s/div. Output Voltage Adjust Output Voltage Adjust <L0IN> The resistor value for an adjusted output voltage is calculated by using the following equations: Output Voltage Adjust Upwards, Increase: Radj= [4.896 /(1.0208-(1.225/VO))-1 ] kOhm %FDSFBTF *ODSFBTF Output Voltage Adjust Downwards, Decrease: Radj= [5.104 /((1.225/VO) -1.0208)-1 ] kOhm Eg Increase 8% =>Vout = 1.3 Vdc 4.896/1.0208-1.225/1.3-1=61 kOhm Eg Decrease 8% =>Vout = 2.45 Vdc 5.104 /(1.225/1.1)-1.0208)-1=54 kOhm PKM 4000D Datasheet <> Output voltage adjust resistor value vs. percentage change in output voltage. EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4618HD PINB - 1.5 V Data TPcb = -40...+90 C, VI = 36...75V, sense pins connected to output pins unless otherwise specified. Characteristics Output Conditions Unit min typ max 1.5 1.53 V Output voltage initial setting and accuracy VI = 53 V, IOmax, TPcb = 25 C 1.47 Output adjust range IOmax, VI = 53 V, TPcb = 25 C 1.35 1.65 V Output voltage tolerance band 0.1...1 x IOmax 1.44 1.56 V Idling voltage IO = 0 1.44 1.56 V Line regulation IOmax -10 10 mV Load regulation IO = 0.01...1 x IOmax, VI = 53 V -10 10 mV Vtr Load transient voltage deviation 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 120 mV ttr Load transient recovery time 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 100 s tr Ramp-up time ts Start-up time IO Output current POmax Max output power At V = VOnom 60 Ilim Current limit threshold TPcb < TPcbmax 42 52 A Isc Short circuit current TPcb = 25 C 44 58 A VOac Output ripple & noise See ripple and noise, IOmax, VOnom 50 100 mVp-p SVR Supply voltage rejection (ac) TPcb = 25 C, f = 100 Hz sine wave 1 Vp-p, VI = 53 V 68 dB Efficiency - 50% load TPcb = +25 C, VI = 48 V, 0.5 x IOmax 88.5 % Efficiency - 100% load TPcb = +25 C, VI = 48 V, IOmax 86.5 % Efficiency - 50% load TPcb = +25 C, VI = 53 V, 0.5 x IOmax 88.5 % Efficiency - 100% load TPcb = +25 C, VI = 53 V, IOmax 86.5 % Pd Power Dissipation TPcb = +25 C, VI = 53 V, IOmax fs Switching frequency 0 ... 1.0 x IOmax VOi VO PKM 4000D Datasheet 0.1...1 x IOmax, VI = 53 V 0.1...0.9 x VOnom 0.1...1 x IOmax, VI = 53 V From VI connected to 0.9 x VOnom 5 15 30 ms 5 20 40 ms 40 A 0 84 84 145 10 W 155 12 W 165 kHz EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4618HD PINB Typical Characteristics Output Current Derating Efficiency <> <"> NT MGN NT MGN NT MGN NT MGN NT MGN NT MGN /BU$POW 7 7 7 7 <"> <$> Thermal Resistance Power Dissipation <8> <$8> 7 7 7 7 Available load current vs. ambient air temperature and airflow at Vin = 53 V. DC/DC converter mounted vertically with airflow testconditions as per the Thermal consideration section. Efficiency vs. load current and input voltage at TPcb = +25 C <"> Dissipated power vs. load current and input voltage at TPcb = +25 C <NT> Thermal resistance vs. airspeed measured at the converter. Tested in windtunnel with airflow and test conditions as per the Thermal consideration section. Output Characteristic <7> <"> Output voltage vs. load current at TPcb = +25 C, VI = 53 V. PKM 4000D Datasheet 11 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4618HD PINB Typical Characteristics Turn-Off Start-Up Start-up enabled by connecting Vin. IO = 40 A resistive load, TPcb = +25 C, Vin = 53 V. Top trace: output voltage (0.5 V/div.). Bottom trace: input voltage (20 V/div.). Time scale: 10 ms/div. Turn-off enabled by disconnecting Vin. IO = 40 A resistive load at TPcb = +25 C, Vin = 53 V. Top trace: output voltage (0.5 V/div.). Bottom trace: input voltage (20 V/div.) Time scale: 10 ms/div. Transient Output Ripple Output voltage response to load current step-change (10-30-10 A) at TPcb = +25 C, Vin = 53 V. Top trace: Input voltage (100 mV/div.). Bottom trace: load current (10 A/div.). Time scale: 0.1 ms/div. Output voltage ripple (20 mV/div.) at TPcb = +25 C, Vin = 53 V, IO = 40 A resistive load with C = 10 F tantalum and 0.1 F ceramic capacitor. Band width = 20 MHz. Time scale: 2 s/div. Output Voltage Adjust Output Voltage Adjust <L0IN> The resistor value for an adjusted output voltage is calculated by using the following equations: Output Voltage Adjust Upwards, Increase: Radj= [5.917 /(0.8166-(1.225/VO))-1 ] kOhm Output Voltage Adjust Downwards, Decrease: Radj= [4.093 /(1.225-(0.8166/VO))-1 ] kOhm Eg Increase 4% =>Vout = 2.6 Vdc 5.917/(0.8166-(1.225/1.62))=97 kOhm Eg Decrease 2% =>Vout = 2.45 Vdc 4.093 /((1.225/1.38)-0.8166))-1=56.4 kOhm PKM 4000D Datasheet %FDSFBTF *ODSFBTF <> Output voltage adjust resistor value vs. percentage change in output voltage. 12 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4718GD PINB - 1.8 V Data TPcb = -40...+90 C, VI = 36...75V, sense pins connected to output pins unless otherwise specified. Characteristics Output Conditions Unit min typ max 1.8 1.83 V Output voltage initial setting and accuracy VI = 53 V, IOmax, TPcb = 25 C 1.77 Output adjust range IOmax, VI = 53 V, TPcb = 25 C 1.62 1.98 V Output voltage tolerance band 0.1...1 x IOmax 1.74 1.86 V Idling voltage IO = 0 1.77 1.83 V Line regulation IOmax -10 10 mV Load regulation IO = 0.01...1 x IOmax, VI = 53 V -10 10 mV Vtr Load transient voltage deviation 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 150 mV ttr Load transient recovery time 0.1...1.0 x IOmax , VI = 53 V Load step = 0.5 x IOmax 100 s tr Ramp-up time ts Start-up time IO Output current POmax Max output power At V = VOnom 72 Ilim Current limit threshold TPcb < TPcbmax 42 53 A Isc Short circuit current TPcb = 25 C 44 63 A VOac Output ripple & noise See ripple and noise, IOmax, VOnom 50 100 mVp-p SVR Supply voltage rejection (ac) TPcb = 25 C, f = 100 Hz sine wave 1 Vp-p, VI = 53 V 68 dB Efficiency - 50% load TPcb = +25 C, VI = 48 V, 0.5 x IOmax 89.5 % Efficiency - 100% load TPcb = +25 C, VI = 48 V, IOmax 87 % Efficiency - 50% load TPcb = +25 C, VI = 53 V, 0.5 x IOmax 89.5 % Efficiency - 100% load TPcb = +25 C, VI = 53 V, IOmax 87 % Pd Power Dissipation TPcb = +25 C, VI = 53 V, IOmax fs Switching frequency 0 ... 1.0 x IOmax VOi VO PKM 4000D Datasheet 0.1...1 x IOmax, VI = 53 V 0.1...0.9 x VOnom 0.1...1 x IOmax, VI = 53 V From VI connected to 0.9 x VOnom 5 10 25 ms 5 10 30 ms 40 A 0 84.5 84.5 145 13 W 155 14 W 165 kHz EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4718GD PINB Typical Characteristics Output Current Derating Efficiency <> <"> NT MGN NT MGN NT MGN NT MGN NT MGN NT MGN /BU$POW 7 7 7 7 <"> <$> Thermal Resistance Power Dissipation <8> <$8> 7 7 7 7 Available load current vs. ambient air temperature and airflow at Vin = 53 V. DC/DC converter mounted vertically with airflow testconditions as per the Thermal consideration section. Efficiency vs. load current and input voltage at TPcb = +25 C <"> Dissipated power vs. load current and input voltage at TPcb = +25 C <NT> Thermal resistance vs. airspeed measured at the converter. Tested in windtunnel with airflow and test conditions as per the Thermal consideration section. Output Characteristic <7> <"> Output voltage vs. load current at TPcb = +25 C, VI = 53 V. PKM 4000D Datasheet 14 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 PKM 4718GD PINB Typical Characteristics Turn-Off Start-Up Start-up enabled by connecting Vin. IO = 40 A resistive load, TPcb = +25 C, Vin = 53 V. Top trace: output voltage (1 V/div.). Bottom trace: input voltage (20 V/div.). Time scale: 10 ms/div. Turn-off enabled by disconnecting Vin. IO = 40 A resistive load at TPcb = +25 C, Vin = 53 V. Top trace: output voltage (1 V/div.). Bottom trace: input voltage (20 V/div.) Time scale: 10 ms/div. Transient Output Ripple Output voltage response to load current step-change (10-30-10 A) at TPcb = +25 C, Vin = 53 V. Top trace: Input voltage (100 mV/div.). Bottom trace: load current (10 A/div.). Time scale: 0.1 ms/div. Output voltage ripple (20 mV/div.) at TPcb = +25 C, Vin = 53 V, IO = 40 A resistive load with C = 10 F tantalum and 0.1 F ceramic capacitor. Band width = 20 MHz. Time scale: 2 s/div. Output Voltage Adjust Output Voltage Adjust <L0IN> The resistor value for an adjusted output voltage is calculated by using the following equations: Output Voltage Adjust Upwards, Increase: Radj= 5.11 [1.8(100+%) / 1.225%- (100+2%) /% ] kOhm %FDSFBTF *ODSFBTF Output Voltage Adjust Downwards, Decrease: Radj= 5.11 [(100 / %-2) ] kOhm Eg Increase 4% =>Vout = 2.6 Vdc 5.11 [1.8(100+4)/(1.225x4)-(100+2x4)/4]=57.25 kOhm Eg Decrease 2% =>Vout = 2.45 Vdc 5.11 x(100/2-2)=245.3 kOhm PKM 4000D Datasheet <> Output voltage adjust resistor value vs. percentage change in output voltage. 15 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 EMC Specification The conducted EMI measurement was performed using a module placed directly on the test bench. The fundamental switching frequency is 150kHz. Printed Circuit Board 5H 50 + in LISN Power Module out rcvr DC Power Source Conducted EMI Input termonal value (typ) . 50 ohm temination Filter (if used) - in 5H 50 out LISN 1 m Twisted Pair rcvr Resistive Load Optional Connection to Earth Ground 50 ohm input EMC Reciver Computer Test set-up. Layout Recommendation The radiated EMI performance of the DC/DC converter will be optimised by including a ground plane in the Pcb area under the DC/DC converter. This approach will return switching noise to ground as directly as possible, with improvements to both emissions and susceptibility. If one ground trace is used, it should be connected to the input return. Alternatively, two ground traces may be used, with the trace under the input side of the DC/DC converter connected to the input return and the trace under the output side of the DC/DC converter connected to the output return. PKM 4110D without filter. External filter (class B) Required external input filter in order to meet class B in EN 55022, CISPR 22 and FCC part 15J. $ 7JO C1 $ $ $ $ Make sure to use appropriate safety isolation spacing between these two return traces. The use of two traces as described will provide the capability of routing the input noise and output noise back to their respective returns. $ $ ' $' $O' $' - -$PNNPONPEFJOEVDUPS ) Output ripple and noise The circuit below has been used for the ripple and noise measurements on the PKM 4000D Series DC/DC converters. The capacitors are ceramic type. Low ESR is critical for achieving these results. Ceramic Capacitor Tantalum Capacitor +Vout +Sense Trim 0.1uF + 10uF Load -Sense -Vout BNC Connector to Scope * Conductor from Vout to capacitors = 50mm [1.97in] Output ripple and noise test setup PKM 4110D with filter. PKM 4000D Datasheet 16 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Operating Information Input Voltage Remote Sense The input voltage range 36...75 Vdc meets the requirements of the European Telecom Standard ETS 300 132-2 for normal input voltage range in -48 V and -60 V DC systems, -40.5...-57.0 V and -50.0...-72 V respectively. At input voltages exceeding 75 V, the power loss will be higher than at normal input voltage and TPcb must be limited to absolute max +110 C. The absolute maximum continuous input voltage is 80 Vdc. All PKM 4000D Series DC/DC converters have remote sense that can be used to compensate for moderate amounts of resistance in the distribution system and allow for voltage regulation at the load or other selected point. The remote sense lines will carry very little current and do not need a large cross sectional area. However, the sense lines on the Pcb should be located close to a ground trace or ground plane. In a discrete wiring situation, the use of twisted pair wires or other technique to reduce noise susceptibility is highly recommended. The remote sense circuitry will compensate for up to 10% voltage drop between the sense voltage and the voltage at the output pins. The output voltage and the remote sense voltage offset must be less than the minimum over voltage trip point. If the remote sense is not needed the -Sense should be connected to -Out and +Sense should be connected to +Out. Turn-Off Input Voltage The PKM 4000D Series DC/DC converters monitor the input voltage and will turn on and turn off at predetermined levels. The minimum hysteresis between turn on and turn off input voltage is 1 V where the turn on input voltage is the highest. Remote Control (RC) The PKM 4000D Series DC/DC converters have a remote control +In function referenced to the primary RC side (- In), with negative and positive -In logic options available. The RC function allows the converter to be Circuit configuration turned on/off by an external device for RC function like a semiconductor or mechanical switch. The RC pin has an internal pull up resistor to + In. The needed maximum sink current is 1 mA. When the RC pin is left open, the voltage generated on the RC pin is 3.5 - 6.0 V. The maximum allowable leakage current of the switch is 50 A. Output Voltage Adjust (Vadj) All PKM 4000D Series DC/DC converters have an Output Voltage adjust pin (Vadj). This pin can be used to adjust the output voltage above or below Output voltage initial setting. When increasing the output voltage, the voltage at the output pins (including any remote sense offset) must be kept below the overvoltage trip point, to prevent the converter from shut down. Also note that at increased output voltages the maximum power rating of the converter remains the same, and the output current capability will decrease correspondingly. To decrease the output voltage the resistor should be connected between Vadj pin and -Sense pin. To increase the voltage the resistor should be connected between Vadj pin and +Sense pin. The resistor value of the Output voltage adjust function is according to information given under the output section. The standard converter is provided with "negative logic" remote control and the converter will be off until the RC pin is connected to the - In. To turn on the converter the voltage between RC pin and - In should be less than 1 V. To turn off the converter the RC pin should be left open, or connected to a voltage higher than 2 V referenced to - In. In situations where it is desired to have the converter to power up automatically without the need for control signals or a switch, the RC pin can be wired directly to - In. The second option is "positive logic" remote control, which can be ordered by adding the suffix "P" to the end of the part number. The converter will turn on when the input voltage is applied with the RC pin open. Turn off is achieved by connecting the RC pin to the - In. To ensure safe turn off the voltage difference between RC pin and the - In pin shall be less than 0.8 V. The converter will restart automatically when this connection is opened. PKM 4000D Datasheet +Out +Out +Sense +Sense Load Vadj Radj Load Vadj Radj -Sense -Sense -Out -Out Decrease Increase Circuit configuration for output voltage adjust 17 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Operating Information Current Limit Protection Maximum Capacitive Load The PKM 4000D Series DC/DC converters include current limiting circuitry that allows them to withstand continuous overloads or short circuit conditions on the output. The output voltage will decrease towards zero for output currents in excess of max output current (Iomax). The converter will resume normal operation after removal of the overload. The load distribution system should be designed to carry the maximum output short circuit current specified. When powering loads with significant dynamic current requirements, the voltage regulation at the load can be improved by addition of decoupling capacitance at the load. The most effective technique is to locate low ESR ceramic capacitors as close to the load as possible, using several capacitors to lower the effective ESR. These ceramic capacitors will handle short duration high-frequency components of dynamic load changes. In addition, higher values of electrolytic capacitors should be used to handle the mid-frequency components. It is equally important to use good design practise when configuring the DC distribution system. Low resistance and low inductance Pcb layouts and cabling should be used. Remember that when using remote sensing, all resistance, inductance and capacitance of the distribution system is within the feedback loop of the converter. This can affect on the converters compensation and the resulting stability and dynamic response performance. As a "rule of thumb", 100F/A of output current can be used without any additional analysis. For example with a 25A converter, values of decoupling capacitance up to 2500 F can be used without regard to stability. With larger values of capacitance, the load transient recovery time can exceed the specified value. As much of the capacitance as possible should be outside the remote sensing loop and close to the load. The absolute maximum value of output capacitance is 10 000 F. For values larger than this, please contact your local Ericsson Power Modules representative. Over Voltage Protection (OVP) The PKM 4000D Series DC/DC converters include output overvoltage protection. In the event of an overvoltage condition due to malfunction in the voltage monitoring circuits, the converter's PWM will automatically dictate minimum duty-cycle thus reducing the output voltage to a minimum. Over Temperature Protection (OTP) The PKM 4000D Series DC/DC converters are protected from thermal overload by an internal over temperature shutdown circuit. When the Pcb temperature (TC reference point) exceeds the temperature trig point (120 C) for the OTP circuit the converter will cut down output power. The converter will go into hiccup mode until safe operational temperature is restored. Input And Output Impedance The impedance of both the power source and the load will interact with the impedance of the DC/DC converter. It is most important to have a low characteristic impedance, both at the input and output, as the converters have a low energy storage capability. The PKM 4000D Series DC/DC converters have been designed to be completely stable without the need for external capacitors on the input or the output circuits. The performance in some applications can be enhanced by addition of external capacitance as described under maximum capacitive load. If the distribution of the input voltage source to the converter contains significant inductance, the addition of a 100F capacitor across the input of the converter will help insure stability. This capacitor is not required when powering the DC/DC converter from a low impedance source with short, low inductance, input power leads. PKM 4000D Datasheet Parallel Operation The PKM 4000D Series DC/DC converters can be paralleled for redundancy if external o-ring diodes are used in series with the outputs. It is not recommended to parallel the PKM 4000D Series DC/DC converters for increased power without using external current sharing circuits. 18 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Thermal Consideration General Calculation of ambient temperature The PKM 4000D series DC/DC converters are designed to operate in a variety of thermal environments, however sufficient cooling should be provided to help ensure reliable operation. Heat is removed by conduction, convection and radiation to the surrounding environment. Increased airflow enhances the heat transfer via convection. The available load current vs. ambient air temperature and airflow at Vin =53 V for each model is according to the information given under the output section. The test is done in a wind tunnel with a cross section of 305 x 305 mm, the DC/DC converter vertically mounted on a 16 layer Pcb with a size of 254 x 254 mm, each layer with 35 m (1 oz) copper. Proper cooling can be verified by measuring the temperature of selected devices. Peak temperature can occur at positions P1 - P4. The temperature at these positions should not exceed the recommended max values. By using the thermal resistance the maximum allowed ambient temperature can be calculated. Note that the recommended max value is the absolute maximum rating (non destruction) and that the electrical output data is guaranteed up to TPcb +90 C. B. 8 W x 4.8 C/W = 38.4 C Position Device TC P1 Pcb P2 Transistor Tsurface 120 C P3 Transistor Tsurface 120 C P4 Transformer Tsurface 130 C 1.The power loss is calculated by using the formula ((1/) - 1) x output power = power losses. = efficiency of converter. E.g 90% = 0.90 2.Find the value of the thermal resistance for each product in the diagram by using the airflow speed at the output section of the converter. Take the thermal resistance x powerloss to get the temperature increase. 3. Max allowed calculated ambient temperature is: Max TPcb of DC/DC converter - temperature increase. E.g PKM 4718GD PINB at 1m/s: A. (( 1 ) - 1) x 72 W = 8 W 0.90 C. 120 C - 38.4 C = max ambient temperature is 81.6 C The real temperature will be dependent on several factors, like Pcb size and type, direction of airflow, air turbulence etc. It is recommended to verify the temperature by testing. Recommended max value 120 C Input side 1 1 1 "JSGMPX 1 Output side PKM 4000D Datasheet 19 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Soldering Information Reliability The PKM4000D Series DC/DC converters are intended for through hole mounting on a PCB. When wave soldering is used max temperature on the pins is specified to 260C for 10 seconds. Maximum preheat rate of 4C/s and temperature of max 130C is suggested. When hand soldering, care should be taken to avoid direct contact between the hot soldering iron tip and the pins for more than a few seconds in order to prevent overheating. The Mean Time Between Failure (MTBF) of the PKM 4000D series DC/DC converter is calculated at full output power and an operating ambient temperature (TA) of +40C. Different methods could be used to calculate the predicted MTBF and failure rate which may give different results. Ericsson Power Modules currently uses two different methods, Ericsson failure rate data system DependTool and Telcordia SR332. No-clean flux is recommended to avoid entrapment of cleaning fluids in cavities inside of the DC/DC power module. The residues may affect long time reliability and isolation voltage. Predicted MTBF for the PKM 4000D series products is: 3.15 million hours according to DependTool. 1.67 million hours according to Telcordia SR332, issue 1, Black box techique. Delivery Package Information The Ericsson failure rate data system is based on field tracking data. The data corresponds to actual failure rates of components used in Information Technology and Telecom (IT&T) equipment in temperature controlled environments (TA = -5...+65C). Telcordia SR332 is a commonly used standard method intended for reliability calculations in IT&T equipment. The parts count procedure used in this method was originally modeled on the methods from MIL-HDBK217F, Reliability Predictions of Electronic Equipment. It assumes that no reliability data is available on the actual units and devices for which the predictions are to be made, i.e. all predictions are based on generic reliability parameters. PKM 4000D series standard delivery package is a 20 pcs box. (one box contains 1 full tray and 1 hold down tray) Clamshell Specification Material: Max surface resistance: Color: Capacity: Loaded tray stack pitch: Weight: Polystyrene (PS) 10 MOhm/sq black 20 pcs/tray 38 mm (1.50 In) 138 g (typ) Compatibility with RoHS requirements The products are compatible with the relevant clauses and requirements of the RoHS directive 2002/95/EC and have a maximum concentration value of 0.1% by weight in homogeneous materials for lead, mercury, hexavalent chromium, PBB and PBDE and of 0.01% by weight in homogeneous materials for cadmium. Exemptions in the RoHS directive utilized in Ericsson Power Modules products include: * Lead in high melting temperature type solder (used to solder the die in semiconductor packages) * Lead in glass of electronics components and in electronic ceramic parts (e.g. fill material in chip resistors) * Lead as an alloying element in copper alloy containing up to 4% lead by weight (used in connection pins made of Brass) PKM 4000D Datasheet 20 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007 Sales Offices and Contact Information Company Headquarters Italy, Spain (Mediterranean) Ericsson Power Modules AB LM Ericssons vag 30 SE-126 25 Stockholm Sweden Ericsson Power Modules AB Via Cadorna 71 20090 Vimodrone (MI) Italy Phone: +46-8-568-69620 Fax: +46-8-568-69599 Phone: +39-02-265-946-07 Fax: +39-02-265-946-69 China Japan Ericsson Simtek Electronics Co. 33 Fuhua Road Jiading District Shanghai 201 818 China Ericsson Power Modules AB Kimura Daini Building, 3 FL. 3-29-7 Minami-Oomachi, Shinagawa-ka Tokyo 140-0013 Japan Phone: +86-21-5990-3258 Fax: +86-21-5990-0188 Phone: +81-3-5733-5107 Fax: +81-3-5753-5162 Germany, Austria North and South America Ericsson Power Modules AB Muhlhauser Weg 18 85737 Ismaning Germany Ericsson Inc. Power Modules 6300 Legacy Dr. Plano, TX 75024 USA Phone: +49-89-9500-6905 Fax: +49-89-9500-6911 Phone: +1-972-583-5254 +1-972-583-6910 Fax: +1-972-583-7839 Hong Kong (Asia Pacific) Ericsson Ltd. 12/F. Devon House 979 King's Road Quarry Bay Hong Kong All other countries Contact Company Headquarters or visit our website: www.ericsson.com/powermodules Phone: +852-2590-2453 Fax: +852-2590-7152 Information given in this data sheet is believed to be accurate and reliable. No responsibility is assumed for the consequences of its use nor for any infringement of patents or other rights of third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Ericsson Power Modules. These products are sold only according to Ericsson Power Modules' general conditions of sale, unless otherwise confirmed in writing. Specifications subject to change without notice. PKM 4000D Datasheet 21 EN/LZT 146 201 R3A (c) Ericsson Power Modules, February 2007