45 24Vin / 48Vout / 400Watts Features See Page 8 for Part Numbers and Options * * * * * * * * * * * * * DC-DC Converter Module DC input range: 18 - 36V Input surge withstand: 50V for 100ms DC output: 48V Programmable output: 10 to 110% Regulation: 0.2% no load to full load Efficiency: 89.8% Maximum operating temperature: 100C at full load Power density: 79W/cubic inch Height above board: 0.43 in. (10,9 mm) Parallelable, with N+M fault tolerance Low noise ZCS/ZVS architecture Pin style: See Page 6 Baseplate: See Page 7 Product Overview Shown actual size: 4.6 x 2.2 x 0.5 in 117 x 56 x 12,7 mm (Product shown is for size only. Pin and baseplate style may vary. Pin style 1 and slotted baseplate are shown) Absolute Maximum Ratings This DC-DC converter module uses 2nd Generation power processing, control and packaging technologies to provide the performance, flexibility and cost effectiveness expected of a mature power component. For example, a plated-cavity core transformer couples widely separated primary and secondary windings, resulting in low in-toout parasitic capacitance and noise. High frequency ZCS/ZVS switching, advanced power semiconductor packaging and thermal management provide high power density with low temperature gradients. Extensive use of silicon integration results in 1/3 the part count of a 1st Generation converter. This converter is manufactured in a state-of-the-art automated manufacturing facility on a short-cycle-time robotic line having a capacity of one module every ten seconds. In-line process controls are designed to achieve low defect rates and consistent quality. A comprehensive CIM system controls the dispatching, assembly and testing of each module, enabling small lots to be manufactured as efficiently as hundreds-of-thousands of units. Parameter Rating Unit +In to -In voltage -0.5 to +36 Vdc +In to -In voltage 50 Vdc PC to -In voltage -0.5 to +7.0 Vdc PR to -In voltage -0.5 to +7.0 Vdc +Out to -Out voltage -0.5 to +62.9 Vdc +Sense to -Out voltage -0.5 to +62.9 Vdc 1.0 Vdc -0.5 to +1.5 Vdc -Sense to -Out voltage SC to -Out voltage Isolation voltage (in to out) 3000 Vrms Isolation voltage (in to base) 1550 Vrms Isolation voltage (out to base) 500 Vrms Storage temperature See Page 8 C Operating temperature Notes <100ms 125 Max See Page 8 C Pin soldering temperature 500 (260) F (C) <5 sec; wave solder Pin soldering temperature 750 (390) F (C) <7 sec; hand solder 5 (0.57) in-lbs (N-m) Mounting torque Baseplate 6 each, # 4-40 or M3 Thermal Resistance and Capacity Parameter Min Typ Max Unit Baseplate to sink; flat, greased surface 0.08 C/Watt Baseplate to sink; thermal pad (P/N 20263) 0.07 C/Watt Baseplate to ambient 4.9 C/Watt Baseplate to ambient; 1000 LFM 1.1 C/Watt Thermal capacity 165 Watt-sec/C Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 1 of 9 ELECTRICAL CHARACTERISTICS 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. MODULE OPERATING SPECIFICATIONS Parameter Min Typ Max Unit Operating input voltage 18 24 36 Vdc 50 Vdc <100ms Input surge withstand Notes Output voltage setpoint 47.52 48 48.48 Vdc Nominal input; full load; 25C Output OVP setpoint 53.8 55.8 57.8 Vdc 25C; recycle input voltage to restart ( 1 minute off ) 400 Watts Output power Efficiency 86.6 89.8 % At 100C baseplate temperature Nominal input; 75% of full load; 25C MODULE INPUT SPECIFICATIONS Parameter Min Undervoltage turn-on Typ Max Unit 17.5 17.9 Vdc Notes Undervoltage turn-off 14.77 15.3 Overvoltage turn-off/on 36.3 37.8 39.6 Vdc 11.7 13.5 Watts No load Typ Max Unit Notes Line regulation 0.02 0.2 % Low line to high line; full load Load regulation 0.06 0.2 % No load to full load; nominal input Temperature regulation 0.002 0.005 % / C 58 73 mV Dissipation, standby Vdc MODULE OUTPUT SPECIFICATIONS Parameter Min Ripple and noise, p-p -20 to 100C Nominal input; full load; 25C; 20MHz bandwidth Current limit 8.46 9.55 11.3 Amps Output voltage 95% of nominal Short circuit current 5.81 9.55 11.3 Amps Output voltage <250mV 2 5 % 10 to 100% of full load 110 % Of nominal output voltage. For trimming below 90% of nominal, a minimum load of 10% of maximum rated power may be required. Power sharing accuracy Programming range 10 Note: For important information relative to applications where the converter modules are subject to continuous dynamic loading, contact Vicor applications engineering at 800-927-9474. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 2 of 9 ELECTRICAL CHARACTERISTICS, continued MODULE CONTROL SPECIFICATIONS Parameter Min Typ Max Unit Notes PRIMARY SIDE (PC = Primary Control; PR = Parallel) PC bias voltage current limit 5.50 1.5 5.75 2.1 6.00 3.0 Vdc mA PC current = 1.0 mA PC voltage = 5.5V PC module disable 2.3 2.3 2.6 Vdc Must be able to sink 4 mA. See Fig. 1 4 7 ms 0.5 Vavg UV, OV, OT, module fault. See Figs. 2 and 4 6.1 Volts PR load >30 ohms, < 30 pF PC module enable delay PC module alarm PR emitter amplitude 5.7 5.9 PR emitter current 150 PR receiver impedance 375 500 625 ohms 25C PR receiver threshold 2.4 2.5 2.6 Volts Minimum pulse width: 20ns 12 modules Without PR buffer amplifier mA PR drive capability SECONDARY SIDE (SC = Secondary Control) SC bandgap voltage 1.21 1.23 1.25 Vdc SC resistance 990 1000 1010 ohms SC capacitance SC module alarm Referenced to -Sense 0.033 F 0 Vdc With open trim; referenced to -Sense. See Fig. 6 Unit Notes MODULE GENERAL SPECIFICATIONS Parameter Min Typ Remote sense (total drop) Max Vdc 0.25V per leg (senses must be closed) Isolation voltage (in to out) 3000 0.5 Vrms Complies with reinforced insulation requirements Isolation voltage (in to base) 1550 Vrms Complies with basic insulation requirements Isolation voltage (out to base) 500 Vrms Complies with operational insulation requirements Isolation resistance (in to out) 10 Weight Temperature limiting Agency approvals available 7.3 (210) 100 megohms 8 (227) 115 UL, CSA, TUV, BABT, CE, VDE Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 ounces (grams) C See Figs. 2 and 4 UL1950, CSA950, EN60950, VDE0805, BS7002, IEC60950. With a fuse in series with the +Input 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 3 of 9 CONTROL FUNCTIONS - PC PIN Module Enable/Disable Module Alarm The module may be disabled by pulling PC below 2.3V with respect to the -Input. This may be done with an open collector transistor, relay, or optocoupler. Multiple converters may be disabled with a single transistor or relay either directly or via "OR'ing" diodes. See Figure 1. The module contains "watchdog" circuitry which monitors input voltage, operating temperature and internal operating parameters. In the event that any of these parameters are outside of their allowable operating range, the module will shut down and PC will go low. PC will periodically go high and the module will check to see if the fault (as an example, overtemperature) has cleared. If the fault has not been cleared, PC will go low again and the cycle will restart. The SC pin will go low in the event of a fault and return to its normal state after the fault has been cleared. See Figures 2 and 4. Primary Auxiliary Supply At 5.7V, PC can source up to 1.5mA. In the example shown in Figure 3, PC powers a module enabled LED. +In +In SW1 PC Input Undervoltage Input Overvoltage Overtemperature Module Faults Auto Restart PC 2-20ms typ. f (VIN) Disable SW2 SW3 1K SC -S 5.7Vdc (0-3mA) -In -In +S 50 SW1, 2, & 3 shown in "Fault" position PR PR +Out 1.23 Vdc 6K -Out Disable = PC <2.3V Figure 1--Module enable/disable. Figure 2--PC/SC module alarm logic. +In Fault PC "Module Enabled" PC 40s typ. 5.7V 4k PR SC -In Figure 3--LED on-state indicator. Optocoupler 1.23V 2-20ms typ. Figure 4--PC/SC module alarm timing. +In +Out PC +S SC 4k PR -S -In -Out Figure 5--Isolated on-state indicator. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Alarm 1.00V Figure 6--Secondary side on-state indicator. 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 4 of 9 CONTROL FUNCTIONS - SC PIN Output Voltage Programming The output voltage of the converter can be adjusted or programmed via fixed resistors, potentiometers or voltage DACs. See Figures 7 and 8. +Out +Out +S Error Amp SC 1k 0.033F -S +S RD Trim Down Load Error Amp SC 1k 0.033F -Out RU Trim Up Load -S -Out 1.23V 1.23V RD (ohms) = 1,000 Vout Vnom - Vout RU (ohms) = 1,000 (Vout-1.23) Vnom 1.23 (Vout-Vnom) -1,000 Figure 7--Output voltage trim down circuit. Figure 8--Output voltage trim up circuit. Trim Down Trim Up 1. This converter is not a constant power device - it has a constant current limit. Hence, available output power is reduced by the same percentage that output voltage is trimmed down. Do not exceed maximum rated output current. 1. The converter is rated for a maximum delivered power. To ensure that maximum rated power is not exceeded, reduce maximum output current by the same percentage increase in output voltage. 2. The trim down resistor must be connected to the -Sense pin. 2. The trim up resistor must be connected to the +Sense pin. 3. Do not trim the converter above maximum trim range (typically +10%) or the output over voltage protection circuitry may be activated. Trim resistor values calculated automatically: On-line calculators for trim resistor values are available on the vicor website at: vicorpower.com/tools.html. Resistor values can be calculated for fixed trim up, fixed trim down and for variable trim up or down cases for both 1st and 2nd Generation DC-DC converters. In addition to trimming information, the web site and the Applications Manual also include design tips, applications circuits, EMC suggestions, thermal design guidelines and PDF data sheets for all available Vicor products. Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 5 of 9 CONTROL FUNCTIONS - PR PIN Parallel Operation sharing but is not fault tolerant. Minus In pins must be tied to the same electric potential. See Figure 9. The PR pin supports paralleling for increased power with N+1 (N+M) redundancy and phased array capability. Modules of the same input voltage, output voltage, and power level will current share if all PR pins are suitably interfaced. AC coupled single-wire interface. All PR pins are connected to a single communication bus through 0.001F (500V) capacitors. This interface supports current sharing and is fault tolerant except for the communication bus. See Figure 10. Compatible interface architectures include the following: DC coupled single-wire interface. All PR pins are directly connected to one another. This interface supports current +In +In PC PC 0.001F Module 1 Module 1 PR PR -In -In +In +In PC PR Module 2 (up to 12) PC 0.001F PR -In -In Ground plane Ground plane Figure 9--DC coupled single-wire interface. +Out +S SC -S Module 1 Figure 10--AC coupled single-wire interface. * The +Out and -Out power buses should be designed to minimize and balance parasitic impedance from each module output to the load. +S -S -Out +S +Out +S SC -S Module 2 +S 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. -S -Out -S * 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. +Out +Out +S SC -S -Out * OR'ing diodes may be inserted in series with the +Out pins of each module to provide module output fault tolerance. +S SC -S Module N+1 Module 2 (up to 12) -Out Figure 11--N+1 module array output connections. +Sense from other modules in the array Figure 12--OR'ing diodes connections. PIN STYLES Description Notes Short solder Requires in-board, mounting Long solder On-board mounting for 0.65" boards Short ModuMate SurfMate or in-board socket mounting Long ModuMate On-board socket mounting Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 6 of 9 MECHANICAL DRAWINGS 0.50 0.02 12,7 0,5 MODULE OUTLINE No. Converter Pins Function Label +In + 2 Primary Control PC 3 Parallel PR 4 -In - 5 -Out - 6 -Sense -S 7 Secondary Control SC 8 +Sense +S 9 +Out + 2.20 55,9 0.23 (REF) 5,8 1.74 44,2 1 0.3000.015 7,620,38 0.01 2 PINS: TIN/LEAD HOT SOLDER DIP 9 3 6 or 4-40 UNC-2B (6X) FULL R (6X) 3.60 91,4 0.13 (6X) 3,3 5 0.43 10,9 0.180 DIA,(2X) 4,57 0.080 DIA,(7X) 2,03 0.700 17,78 1.000 25,40 1.400 35,56 Threaded (Style 2) 1.80 45,7 4.60 116,8 4.200 106,68 7 0.10 2,5 0.10 X 45 2,5 CHAMFER ALUMINUM BASEPLATE 8 2.00 50,8 0.38 (2X) 9,6 4 0.400 10,16 Slotted (Style 1) 0.50 12,7 4-40 UNC-2B 0.12* 0.20** Thru (4X)*** 3,1 5,08 (Style 2 and 3 only) (ALL MARKINGS THIS SURFACE) 1 0.3000.015 7,620,38 R 0.06 (3X) 1,5 Use a 4-40 Screw (6x) Torque to: 5 in-lbs 0.57 N-m 2.20 55,9 (REF) 0.54 (9X) Pin Style 1&S 13,7 (Short Pin) 0.62 (9X) Pin Style 2&N 15,7 (Long Pin) or Thru Hole (Style 3) * Style 1 baseplate only ** Style 2 & 3 baseplates *** Reserved for Vicor accessories Not for mounting #30 Drill Thru (6X) (0.1285) PCB MOUNTING SPECIFICATIONS PCB THICKNESS R 0.062 0.010 1,57 0,25 PLATED THRU HOLE DIA 1.790 45,47 0.06 (4X) 1,5 INBOARD SOLDER MOUNT ONBOARD SOLDER MOUNT PIN STYLE 1&S PIN STYLE 2&N (7X) 0.094 0.003 2,39 0,08 0.094 0.003 2,39 0,08 (2X) 0.194 0.003 4,93 0,08 0.194 0.003 4,93 0,08 ALL MARKINGS THIS SURFACE 0.178 4,52 1 2 3 4 ALUMINUM BASEPLATE 4.200* 106,68 PINS STYLES STYLE 1 & 2: TIN/LEAD HOT SOLDER DIPPED STYLE S & N: GOLD PLATED COPPER 3.844 97,64 9 8 7 6 5 Unless otherwise specified, dimensions are in inches mm Decimals 0.400* 10,16 0.195 4,95 0.XX 0.700* 17,78 1.000* 25,40 1.400* 35,56 0.43 10,9 0.53 13,5 0,25 0.XXX * DENOTES 0.003 TOL = 0,08 Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Tol. Angles 0.01 1 0.005 0,127 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 Page 7 of 9 PART NUMBERS & OPTIONS 24Vin / 48Vout / 400Watts Part Number Pins Base VI-982437 VI-982438 VI-982439 VI-982440 VI-982441 VI-982442 VI-982443 VI-982444 VI-982445 VI-982446 VI-982447 VI-982448 VI-982449 VI-982450 VI-982451 VI-982452 VI-982453 VI-982454 VI-982455 VI-982456 VI-982457 VI-982458 VI-982459 VI-982460 VI-982461 VI-982462 VI-982463 VI-982464 VI-982465 VI-982466 VI-982467 VI-982468 VI-982469 VI-982470 VI-982471 VI-982472 Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Short Solder Long Solder Short ModuMate Long ModuMate Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Slotted Slotted Slotted Slotted Threaded Threaded Threaded Threaded Thru-hole Thru-hole Thru-hole Thru-hole Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 Minimum Grade Operating Temp C -20C C -20C C -20C C -20C C -20C C -20C C -20C C -20C C -20C C -20C C -20C C -20C T -40C T -40C T -40C T -40C T -40C T -40C T -40C T -40C T -40C T -40C T -40C T -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C H -40C Max Operating Temp 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 100C 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Minimum Storage Temp -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -40C -55C -55C -55C -55C -55C -55C -55C -55C -55C -55C -55C -55C Rev. 5.2 Page 8 of 9 Vicor's comprehensive line of power solutions includes modular, high density DC-DC converters and accessory components, configurable power supplies, and custom power systems. 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 Vicor's Terms and Conditions of Sale, which are available upon request. Specifications are subject to change without notice. 45 Component Solutions for Your Power System Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 Email Vicor Express: vicorexp@vicr.com Technical Support: apps@vicr.com Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 24Vin/48Vout/400W DC-DC Converter Set your site on VICOR at www.vicorpower.com Rev. 5.2 02/03