HMC3229 - ANALOG DEVICES - Datasheet.Live

12/18/06

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AFL270XXD SERIES

The AFL Series of DC/DC converters feature high power

density with no derating over the full military temperature

range. This series is offered as part of a complete family

of converters providing single and dual output voltages

and operating from nominal +28V or +270V inputs with

output power ranging from 80W to 120W. For applications

requiring higher output power, individual converters can

be operated in parallel. The internal current sharing

circuits assure equal current distribution among the

paralleled converters. This series incorporates International

Rectifier’s proprietary magnetic pulse feedback

technology providing optimum dynamic line and load

regulation response. This feedback system samples the

output voltage at the pulse width modulator fixed clock

frequency, nominally 550KHz. Multiple converters can

be synchronized to a system clock in the 500KHz to

700KHz range or to the synchronization output of one

converter. Undervoltage lockout, primary and secondary

referenced inhibit, soft-start and load fault protection are

provided on all models.

Description

n160V To 400V Input Range

n±5V, ±12V, and ±15V Outputs Available

nHigh Power Density - up to 70W/in3

nUp To 100W Output Power

nParallel Operation with Power Sharing

nLow Profile (0.380") Seam Welded Package

nCeramic Feedthru Copper Core Pins

nHigh Efficiency - to 87%

nFull Military Temperature Range

nContinuous Short Circuit and Overload

Protection

nOutput Voltage Trim

nPrimary and Secondary Referenced

Inhibit Functions

nLine Rejection > 60dB - DC to 50KHz

nExternal Synchronization Port

nFault Tolerant Design

nSingle Output Versions Available

nStandard Microcircuit Drawings Available

Features

AFL

270V Input, Dual Output

Manufactured in a facility fully qualified to MIL-PRF-

38534, these converters are fabricated utilizing DSCC

qualified processes. For available screening options,

refer to device screening table in the data sheet.

Variations in electrical, mechanical and screening can

be accommodated. Contact IR Santa Clara for special

requirements.

HYBRID-HIGH RELIABILITY

DC/DC CONVERTER

These converters are hermetically packaged in two

enclosure variations, utilizing copper core pins to

minimize resistive DC losses. Three lead styles are

available, each fabricated with International Rectifier’s

rugged ceramic lead-to-package seal assuring long

term hermeticity in the most harsh environments.

PD - 94461C

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AFL270XXD Series

Specifications

Static Characteristics -55°C < TCASE < +125°C, 160V< VIN < 400V unless otherwise specified.

For Notes to Specifications, refer to page 4

Input voltage -0.5V to +500VDC

Soldering temperature 300°C for 10 seconds

Operating case temperature -55°C to +125°C

Storage case temperature -65°C to +135°C

Absolute Maximum Ratings

Parameter

Group A

Subgroups

Test Conditions

Min

Nom

Max

Unit

INPUT VOLTAGE Note 6 160 270 400 V

OUTPUT VOLTAGE

AFL27005D

AFL27012D

AFL27015D

AFL27005D

AFL27012D

AFL27015D

2, 3

VIN = 270 Volts, 100% Load

Positive Output

Negative Output

Positive Output

Negative Output

Positive Output

Negative Output

Positive Output

Negative Output

Positive Output

Negative Output

Positive Output

Negative Output

4.95

-5.05

11.88

-12.12

14.85

-15.15

4.90

-5.10

11.76

-12.24

14.70

-15.30

5.00

-5.00

12.00

-12.00

15.00

-15.00

5.05

-4.95

12.12

-11.88

15.15

-14.85

5.10

-4.90

12.24

-11.76

15.30

-14.70

OUTPUT CURRENT

AFL27005D

AFL27012D

AFL27015D

VIN = 160, 270, 400 Volts - Notes 6, 11

Either Output

12.8

6.4

5.3

OUTPUT POWER

AFL27005D

AFL27012D

AFL27015D

Total of Both Outputs. Notes 6,11

100

MAXIMUM CAPACITIVE LOAD Each Output Note 1 5,000 µF

OUTPUT VOLTAGE

TEMPERATURE COEFFICIENT

IN = 270 Volts, 100% Load - Notes 1, 6

-0.015

+0.015

%/°C

OUTPUT VOLTAGE REGULATION

Line

Load

Cross

AFL27005D

AFL27012D

AFL27015D

1, 2, 3

Note 10

No Load, 50% Load, 100% Load

VIN = 160, 270, 400 Volts.

VIN = 160, 270, 400 Volts. Note 12

Positive Output

Negative Output

Positive Output

Negative Output

Positive Output

Negative Output

-0.5

-1.0

-8.0

-1.0

-5.0

-1.0

-5.0

+0.5

+1.0

+8.0

+1.0

+5.0

+1.0

+5.0

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AFL270XXD Series

Static Characteristics (Continued)

For Notes to Specifications, refer to page 4

Parameter

Group A

Subgroups

Test Conditions

Min

Nom

Max

Unit

OUTPUT RIPPLE VOLTAGE

AFL27005D

AFL27012D

AFL27015D

1, 2, 3

VIN = 160, 270, 400 Volts, 100% Load,

BW = 10MHz

mVpp

INPUT CURRENT

No Load

Inhibit 1

Inhibit 2

2, 3

1, 2, 3

VIN = 270 Volts

IOUT = 0

Pin 4 Shorted to Pin 2

Pin 12 Shorted to Pin 8

3.00

5.00

INPUT RIPPLE CURRENT

AFL27005D

AFL27012D

AFL27015D

1, 2, 3

VIN = 270 Volts, 100% Load

mApp

CURRENT LIMIT POINT

Expressed as a Percentage

of Full Rated Load

VOUT = 90% VNOM , Current split

equally on positive and negative outputs.

Note 5

115

105

125

115

140

LOAD FAULT POWER

DISSIPATION

Overload or Short Circuit

1, 2, 3

VIN = 270 Volts

EFFICIENCY

AFL27005D

AFL27012D

AFL27015D

1, 2, 3

VIN = 270 Volts, 100% Load

ENABLE INPUTS (Inhibit Function)

Converter Off

Sink Current

Converter On

Sink Current

1, 2, 3

Logical Low on Pin 4 or Pin 12

Note 1

Logical High on Pin 4 and Pin 12 - Note 9

Note 1

-0.5

2.0

0.8

100

µA

SWITCHING FREQUENCY 1, 2, 3 500 550 600 KHz

SYNCHRONIZATION INPUT

Frequency Range

Pulse Amplitude, Hi

Pulse Amplitude, Lo

Pulse Rise Time

Pulse Duty Cycle

1, 2, 3

Note 1

500

2.0

-0.5

700

0.8

100

KHz

ISOLATION 1 Input to Output or Any Pin to Case

(except Pin 3). Test @ 500VDC

100 MΩ

DEVICE WEIGHT Slight Variations with Case Style 85 g

MTBF MIL-HDBK-217F, AIF @ TC = 70°C 300 KHrs

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AFL270XXD Series

Dynamic Characteristics -55°C < TCASE < +125°C, VIN=270V unless otherwise specified.

Notes to Specifications:

1. Parameters not 100% tested but are guaranteed to the limits specified in the table.

2. Recovery time is measured from the initiation of the transient to where Vout has returned to within ±1.0% of

Vout at 50% load.

3. Line transient transition time ≥ 100µs.

4. Turn-on delay is measured with an input voltage rise time of between 100V and 500V per millisecond.

5. Current limit point is that condition of excess load causing output voltage to drop to 90% of nominal.

6. Parameter verified as part of another test.

7. All electrical tests are performed with the remote sense leads connected to the output leads at the load.

8. Load transient transition time ≥ 10µs.

9. Enable inputs internally pulled high. Nominal open circuit voltage ≈ 4.0VDC.

10. Load current split equally between +Vout and -Vout.

11. Output load must be distributed so that a minimum of 20% of the total output power is being provided by one of

the outputs.

12. Cross regulation measured with load on tested output at 20% of maximum load while changing the load on

other output from 20% to 80%.

Parameter

Group A

Subgroups

Test Conditions

Min

Nom

Max

Unit

LOAD TRANSIENT RESPONSE

AFL27005D Amplitude

Either Output Recovery

Amplitude

Recovery

AFL27012D Amplitude

Either Output Recovery

Amplitude

Recovery

AFL27015D Amplitude

Either Output Recovery

Amplitude

Recovery

4, 5, 6

Note 2, 8

Load Step 50% ⇔ 100%

Load Step 10% ⇔ 50%

10%

⇒ 50%

50% ⇒ 10%

Load Step 50% ⇔ 100%

Load Step 10% ⇔ 50%

10% ⇒ 50%

50%

⇒ 10%

Load Step 50% ⇔ 100%

Load Step 10% ⇔ 50%

10% ⇒ 50%

50% ⇒ 10%

-450

-750

450

200

450

200

400

750

200

750

200

400

750

200

750

200

400

µs

LINE TRANSIENT RESPONSE

Amplitude

Recovery

Note 1, 2, 3

VIN Step = 160 ⇔ 400 Volts

-500

500

µs

TURN-ON CHARACTERISTICS

Overshoot

Delay

4, 5, 6

VIN = 160, 270, 400 Volts. Note 4

Enable 1, 2 on. (Pins 4, 12 high or

open)

250

120

LOAD FAULT RECOVERY Same as Turn On Characteristics.

LINE REJECTION MIL-STD-461D, CS101, 30Hz to

50KHz

Note 1

60 70 dB

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AFL270XXD Series

Block Diagram

Figure I. AFL Dual Output

Figure II. Enable Input Equivalent Circuit

Pin 4 or

Pin 12

1N4148

100K

290K

150K

2N3904

+5.6V

Disable

Pin 2 or

Pin 8

Circuit Operation and Application Information

The switched voltage impressed on the secondary output

transformer windings is rectified and filtered to provide the

positive and negative converter output voltages. An error

amplifier on the secondary side compares the positive output

voltage to a precision reference and generates an error

signal proportional to the difference. This error signal is

magnetically coupled through the feedback transformer into

the control section of the converter varying the pulse width

of the square wave signal driving the MOSFETs, narrowing

the pulse width if the output voltage is too high and widening

it if it is too low. These pulse width variations provide the

necessary corrections to regulate the magnitude of output

voltage within its’ specified limits.

Because the primary portion of the circuit is coupled to the

secondary side with magnetic elements, full isolation from

input to output is maintained.

Although incorporating several sophisticated and useful

ancilliary features, basic operation of the AFL270XXDseries

can be initiated by simply applying an input voltage to pins 1

and 2 and connecting the appropriate loads between pins 7,

8, and 9. Of course, operation of any converter with high

power density should not be attempted before secure

attachment to an appropriate heat dissipator. (See Thermal

Considerations, page 7)

Inhibiting Converter Output (Enable)

As an alternative to application and removal of the DC voltage

to the input, the user can control the converter output by

providing TTL compatible, positive logic signals to either of

two enable pins (pin 4 or 12). The distinction between these

two signal ports is that enable 1 (pin 4) is referenced to the

input return (pin 2) while enable 2 (pin 12) is referenced to

the output return (pin 8). Thus, the user has access to an

inhibit function on either side of the isolation barrier. Each

port is internally pulled “high” so that when not used, an

open connection on both enable pins permits normal

converter operation. When their use is desired, a logical

“low” on either port will shut the converter down.

The AFL series of converters employ a forward switched

mode converter topology. (refer to Figure I.) Operation of

the device is initiated when a DC voltage whose magnitude

is within the specified input limits is applied between pins 1

and 2. If pins 4 and 12 are enabled (at a logical 1 or open)

the primary bias supply will begin generating a regulated

housekeeping voltage bringing the circuitry on the primary

side of the converter to life. Two power MOSFETs used to

chop the DC input voltage into a high frequency square

wave, apply this chopped voltage to the power transformer.

As this switching is initiated, a voltage is impressed on a

second winding of the power transformer which is then

rectified and applied to the primary bias supply. When this

occurs, the input voltage is excluded from the bias voltage

generator and the primary bias voltage becomes internally

generated.

ERROR

AMP

& REF

OUTPUT

FILTER

INPUT

FILTER

OUTPUT RETURN

+ INPUT

INPUT RETURN

CONTROL

SYNC INPUT

CURRENT

SENSE

ENABLE 2

AMPLIFIER

+ OUTPUT

SYNC OUTPUT

ENABLE 1

CASE

PRIMARY

BIAS SUPPLY

- OUTPUT

OUTPUT

VOTAGE TRIM

FILTER

OUTPUT

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AFL270XXD Series

Figure III. Preferred Connection for Parallel Operation

Synchronization of Multiple Converters

Parallel Operation-Current and Stress Sharing

Internally, these ports differ slightly in their function. In use,

a low on Enable 1 completely shuts down all circuits in the

converter, while a low on Enable 2 shuts down the secondary

side while altering the controller duty cycle to near zero.

Externally, the use of either port is transparent to the user

save for minor differences in idle current. (See specification

table).

When operating multiple converters, system requirements

often dictate operation of the converters at a common

frequency. To accommodate this requirement, the AFL

series converters provide both a synchronization input and

output.

high level of +2.0V. The sync output of another converter

which has been designated as the master oscillator provides

a convenient frequency source for this mode of operation.

When external synchronization is not indicted, the sync in

pin should be left unconnected thereby permitting the

converter to operate at its’ own internally set frequency.

The sync output signal is a continuous pulse train set at

550 ± 50KHz, with a duty cycle of 15 ± 5.0%. This signal is

referenced to the input return and has been tailored to be

compatible with the AFL sync input port. Transition times

are less than 100ns and the low level output impedance is

less than 50Ω. This signal is active when the DC input

voltage is within the specified operating range and the

converter is not inhibited. This synch output has adequate

drive reserve to synchronize at least five additional

converters. A typical synchronization connection option is

illustrated in Figure III.

Power

Input

(Other Converters)

Share Bus

AFL

- Output

Enable 2

+ Output

Return

Trim

Vin

Rtn

Case

Enable 1

Sync Out

Sync In

AFL

- Output

Enable 2

+ Output

Return

Trim

Vin

Rtn

Case

Enable 1

Sync Out

Sync In

AFL

- Output

Enable 2

+ Output

Return

Trim

Vin

Rtn

Case

Enable 1

Sync Out

Sync In

Optional

Synchronization

Connection

to Positive Load

to Negative Load

Figure III. illustrates the preferred connection scheme for

operation of a set of AFL converters with outputs operating

in parallel. Use of this connection permits equal current

sharing among the members of a set whose load current

exceeds the capacity of an individual AFL. An important

feature of the AFL series operating in the parallel mode is

that in addition to sharing the current, the stress induced by

temperature will also be shared. Thus if one member of a

paralleled set is operating at a higher case temperature, the

current it provides to the load will be reduced as

compensation for the temperature induced stress on that

device.

The sync input port permits synchronization of an AFL

converter to any compatible external frequency source

operating between 500KHz and 700KHz. This input signal

should be referenced to the input return and have a 10% to

90% duty cycle. Compatibility requires transition times less

than 100ns, maximum low level of +0.8V and a minimum

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AFL270XXD Series

A conservative aid to estimating the total heat sink surface

area (AHEAT SINK) required to set the maximum case

temperature rise (∆T) above ambient temperature is given

by the following expression:

A HEAT SINK ≈⎧

⎨

⎩

⎫

⎬

⎭−

−

∆T

P80 30

085

143

where

∆

Eff

OUT

==−

⎧

⎨

⎩

⎫

⎬

⎭

Case temperature rise above ambient

Device dissipation in Watts 11

∆T = 85 - 25 = 60°C

and the required heat sink area is

From the Specification Table, the worst case full load

efficiency for this device is 83% @ 100 watts: thus, power

dissipation at full load is given by

Because of the incorporation of many innovative

technological concepts, the AFL series of converters is

capable of providing very high output power from a package

of very small volume. These magnitudes of power density

can only be obtained by combining high circuit efficiency

with effective methods of heat removal from the die junctions.

This requirement has been effectively addressed inside the

device; but when operating at maximum loads, a significant

amount of heat will be generated and this heat must be

conducted away from the case. To maintain the case

temperature at or below the specified maximum of 125°C,

this heat must be transferred by conduction to an

appropriate heat dissipater held in intimate contact with the

converter base-plate.

When operating in the shared mode, it is important that

symmetry of connection be maintained as an assurance of

optimum load sharing performance. Thus, converter outputs

should be connected to the load with equal lengths of wire of

the same gauge and should be connected to a common

physical point, preferably at the load along with the converter

output and return leads. All converters in a paralleled set

must have their share pins connected together. This

arrangement is diagrammatically illustrated in Figure III.

showing the output and return pins connected at a star

point which is located close as possible to the load.

As a consequence of the topology utilized in the current

sharing circuit, the share pin may be used for other functions.

In applications requiring only a single converter, the voltage

appearing on the share pin may be used as a “totall current

monitor”. The share pin open circuit voltage is nominally

+1.00V at no load and increases linearly with increasing

total output current to +2.20V at full load. Note that the

current we refer to here is the total output current, that is,

the sum of the positive and negative outout currents.

1Sil-Pad is a registered Trade Mark of Bergquist, Minneapolis, MN

Thermal Considerations

Since the effectiveness of this heat transfer is dependent

on the intimacy of the baseplate/heatsink interface, it is

strongly recommended that a high thermal conductivity heat

transferring medium is inserted between the baseplate and

heatsink. The material most frequently utilized at the factory

during all testing and burn-in processes is sold under the

trade name of Sil-Pad® 4001. This particular product is an

insulator but electrically conductive versions are also

available. Use of these materials assures maximum surface

contact with the heat dissipater thereby compensating for

any minor surface variations. While other available types of

heat conductive materials and thermal compounds provide

similar effectiveness, these alternatives are often less

convenient and can be somewhat messy to use.

As an example, assume that it is desired to operate an

AFL27015D while holding the case temperature at TC ≤

+85°C in an area where the ambient temperature is held to

a constant +25°C; then

()

P=• −

⎧

⎨

⎩

⎫

⎬

⎭=• =100 1

1 100 0 205 20 5

..W

A = 60

80 20.5

inHEAT SINK 0.85

•

⎧

⎨

⎩

⎫

⎬

⎭−=

−143

30 563

Thus, a total heat sink surface area (including fins, if any) of

56 in2 in this example, would limit case rise to 60°C above

ambient. A flat aluminum plate, 0.25" thick and of approximate

dimension 4" by 7" (28 in2 per side) would suffice for this

application in a still air environment. Note that to meet the

criteria in this example, both sides of the plate require

unrestricted exposure to the +25°C ambient air.

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AFL270XXD Series

Figure V. Connection for VOUT Adjustment

Input Filter

Undervoltage Lockout

The AFL270XXD series converters incorporate a single

stage LC input filter whose elements dominate the input

load impedance characteristic during the turn-on sequence.

The input circuit is as shown in Figure IV.

Figure IV. Input Filter Circuit

A minimum voltage is required at the input of the converter

to initiate operation. This voltage is set to 150V ± 5.0V. To

preclude the possibility of noise or other variations at the

input falsely initiating and halting converter operation, a

hysteresis of approximately 10V is incorporated in this circuit.

Thus if the input voltage droops to 140V ± 5.0V, the converter

will shut down and remain inoperative until the input voltage

returns to ≈ 150V.

Output Voltage Adjust

Connect Radj to + to increase, - to decrease

By use of the trim pin (10), the magnitude of output voltages

can be adjusted over a limited range in either a positive or

negative direction. Connecting a resistor between the trim

pin and either the output return or the positive output will

raise or lower the magnitude of output voltages. The span

of output voltage adjustment is restricted to the limits shown

in Table I.

Table 1. Output Voltage Trim Values and Limits

Note that the nominal magnitude of output voltage resides in

the middle of the table and the corresponding resistor value

is set to ∞. To set the magnitude greater than nominal, the

adjust resistor is connected to output return. To set the

magnitude less than nominal, the adjust resistor is connected

to the positive output. (Refer to Figure V.)

For output voltage settings that are within the limits, but

between those listed in Table I, it is suggested that the

resistor values be determined empirically by selection or by

use of a variable resistor. The value thus determined can

then be replaced with a good quality fixed resistor for

permanent installation.

When use of this adjust feature is elected, the user should

be aware that the temperature performance of the converter

output voltage will be affected by the temperature

performance of the resistor selected as the adjustment

element and therefore, is advised to employ resistors with a

tight temperature coefficient of resistance.

8.4µH

Pin 1

Pin 2

0.54µfd

AFL27005D AFL27012D AFL27015D

Vout R

adj V

out R

adj V

out R

adj

5.5 0 12.5 0 15.5 0

5.4 12.5K 12.4 47.5K 15.4 62.5K

5.3 33.3K 12.3 127K 15.3 167K

5.2 75K 12.2 285K 15.2 375K

5.1 200K 12.1 760K 15.1 1.0M

5.0 ∞ 12.0 ∞ 15.0 ∞

4.9 190K 11.7 975K 14.6 1.2M

4.8 65K 11.3 288K 14.0 325K

4.7 23K 10.8 72.9K 13.5 117K

4.6 2.5K 10.6 29.9K 13.0 12.5K

4.583 0 10.417 0 12.917 0

Enable 2

Trim

- Vout

Return

+ Vout

Loads

ADJ

AFL270xxD

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AFL270XXD Series

Mechanical Outlines

Case X

Case W

Pin Variation of Case Y

1.260 1.500

2.500

2.760

3.000

ø 0.128

0.250

1.000

Ref 0.200 Typ

Non-cum

0.050

0.220

ø 0.040

0.238 max

0.380

Max

2.975 max

712

0.050

0.220

0.250

1.000

ø 0.040

0.525

0.380

Max

2.800

0.42

Case Y Case Z

Pin Variation of Case Y

1.500 1.750

2.500

0.25 typ

1.150

0.050

0.220

712

1.750 0.375

2.00

0.250

1.000

Ref 0.200 Typ

Non-cum

ø 0.040

0.300

ø 0.140

0.238 max

0.380

Max

2.975 max

0.050

0.220

0.250

1.000

Ref

ø 0.040

0.525

0.380

Max

2.800

0.36

BERYLLIA WARNING: These converters are hermetically sealed; however they contain BeO substrates and should not be ground or subjected to any other

operations including exposure to acids, which may produce Beryllium dust or fumes containing Beryllium

Tolerances, unless otherwise specified: .XX = ±0.010

.XXX = ±0.005

10 www.irf.com

AFL270XXD Series

Pin Designation

Pin # Designation

1 + Input

2 Input Return

3 Case Ground

4 Enable 1

5 Sync Output

6 Sync Input

7 + Output

8 Output Return

9 - Output

10 Output Voltage Trim

11 Share

12 Enable 2

Standard Microcircuit Drawing Equivalence Table

Standard Microcircuit IR Standard

Drawing Number Part Number

5962-95501 AFL27005D

5962-99518 AFL27012D

5962-95532 AFL27015D

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AFL270XXD Series

Part Numbering

WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 322 3331

IR SANTA CLARA: 2270 Martin Av., Santa Clara, California 95050, Tel: (408) 727-0500

Visit us at www.irf.com for sales contact information.

Data and specifications subject to change without notice. 12/2006

Notes:

 Best commercial practice

 Sample tests at low and high temperatures

 -55°C to +105°C for AHE, ATO, ATW

Device Screening

Requirement MIL-STD-883 Method No Suffix ES

HB CH

Temperature Range -20°C to +85°C -55°C to +125°C

-55°C to +125°C -55°C to +125°C

Element Evaluation MIL-PRF-38534 N/A N/A N/A Class H

Non-Destructive

Bond Pull

Internal Visual 2017

Yes Yes Yes

Temperature Cycle 1010 N/A Cond B Cond C Cond C

Constant Acceleration 2001, Y1 Axis N/A 500 Gs 3000 Gs 3000 Gs

PIND 2020 N/A N/A N/A N/A

Burn-In 1015 N/A 48 hrs@hi temp 160 hrs@125°C 160 hrs@125°C

Final Electrical MIL-PRF-38534 25°C 25°C

-55°C, +25°C, -55°C, +25°C,

( Group A ) & Specification +125°C +125°C

PDA MIL-PRF-38534 N/A N/A N/A 10%

Seal, Fine and Gross 1014 Cond A Cond A, C Cond A, C Cond A, C

Radiographic 2012 N/A N/A N/A N/A

External Visual 2009

Yes Yes Yes

N/A N/A2023 N/A N/A

AFL 270 05 D X /CH

Model

Input Voltage

28 = 28V

50 = 50V

120 = 120V

270 = 270V

Output Voltage

Output

D = Dual

Case Style

W, X, Y, Z

Screening Level

(Please refer to Screening Table)

No suffix, ES, HB, CH

05 = ±5V

12 = ±12V

15 = ±15V