B R OADBAND T EL C OM P OWER , I NC Low Cost Solutions To Modular Power Supplies BAUART GEPRUFT Flat Transformer Technology Features: (R) TUV Rheinland TYPE APPROVED 18 Vdc to 400 Vdc input 2.1 Vdc to 24.0 Vdc Output A C 200 Watts 105C No de-rating Base Plate Temperature Up To 105C Load/Line Regulation: 0.1% Peak to Peak Output Ripple: 1% B Minimum Load: 0 Ampere Input Undervoltage Lockout Output Over Current Protection D 400 Watts MTBF : Over 700,000 Hours (Per Mil-Std-217E) Output Over Voltage Protection Over temperature Shutdown Very Low Temperature Rise Actual Size: Length: 4.6 in (116.8 mm) Width: 2.4 in (61.0 mm) Height: 0.5 in (12.7 mm) Switching Frequency: 300 kHz (fixed) High Efficiency: up to 90% Output Trimming and Remote Sensing BTCPowerTM Model Numbering System IMT 400 - XX - XX Digital On/Off Control N + 1, Current Sharing Output Power (Watts) 200, 400 Broadband TelCom Power, Inc. 1791 Grand Ave., Santa Ana, CA 92705 Tel: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com Nominal Input Voltage 24, 48, 72, 110, 150, 300 Vdc Output Voltage 2.1, 3.3, 5.0, 12.0, 15.0, 24.0 Vdc August 2000 Applications * Telecommunication systems * Distributed Power systems * Industrial application * Regulated DC power Product Overview The unique transformer technology is the basis of BTCPower's low cost, high performance, and high reliability DC-DC converter line. These converters are designed for telecommunication and industrial applications. The converter design utilizes a push-pull topology operating at a fixed switching frequency of 300 kHz. By using a fixed switching frequency, EMI filtering is made easier, and less expensive. The core technology is a patented, modular, and very low noise Flat TransformerTM which generates extremely low leakage inductance and inter-winding capacitance - a combination not available in conventional transformers. In addition, the Flat Transformer does not create hot spots, therefore, making the converters more reliable. The use of direct bond aluminum base plates, forced current sharing in parallel rectifiers, and the absence of hot spots in the transformers allow the converter to have very low temperature gradients. The converter's internal temperature rise is less than 10 C above base plate temperature, allowing base plate temperature to be raised to 105 C. The converters are manufactured in an ISO 9001 approved facility utilizing advanced automated surface mount technology and state of the art in-process test procedures. Objective The chief objective of the IMT series converters is to reduce costs, while improving high performance and reliability. This will enable "brick" type modular DC-DC converters to be cost effective in the manufacturing of quick turn around custom power supplies. Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 2 IMT 200 and IMT 400 Output Inductor L3 Flat TransformerTM T1 Input Filter choke L1 Thermal CladTM Aluminium Baseplate Input choke L2 Direct bond MOSFETS Q6, Q8 Direct bond parallel Rectifiers are used D10 (Forced equal current sharing due to use of Flat TransformerTM) Competitive Advantages: 1) BTCPower's DC-DC Converters are low cost, and can be delivered in a timely manner because readily available standard off the shelf components are used. No special custom parts are used. 2) BTCPower's DC-DC Converters are extremely reliable because of the lower temperature gradient and even thermal loading: 3) The highly de-rated multiple parallel rectifiers receive exact same shared currents from the use of the Flat Transformer technology. This ensures even thermal loading on the rectifiers. The Flat Transformer technology uses multiple cores. This coupled with the absence of many turns eliminates hot spots in the transformer windings. All heat generating components such as the Flat Transformers, inductors, rectifiers, and Mosfets are directly solder-bonded onto the aluminum base plate for maximum transfer of heat out of the converter. BTCPower's DC-DC Converters utilize simple push pull topology with fewer components. The fixed switching frequency ensures easier and less expensive EMI filtering. In addition, negligible leakage inductance of Flat Transformers reduces the switching losses. Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 3 132 To 240 Watts Model Selection Chart See IMT 200 Series Outline Drawing For Dimensions Output Voltage Output Current (Amperes) (Vdc) Output Power (Watts) Input Voltage (Vdc) Input Current (Amperes) IMT-200-24-3.3 18-36 10.5 3.3 40 132 IMT-200-24-5 18-36 11.0 5 30 150 IMT-200-24-10 18--36 13.5 10 20 200 IMT-200-24-12 18-36 14.5 12 17 204 IMT-200-48-3.3 36-72 7.0 3.3 50 165 IMT-200-48-5 36-72 7.5 5 40 200 IMT-200-48-10 36-72 7.0 10 20 200 IMT-200-48-12 36-72 7.0 12 17 204 IMT-200-72-3.3 50-100 4.5 3.3 50 165 IMT-200-72-5 50-100 5.5 5 40 200 IMT-200-72-10 50-100 5.0 10 20 200 IMT-200-72-12 50-100 5.5 12 17 204 IMT-200-150-3.3 100-200 2.5 3.3 50 165 IMT-200-150-5 100-200 2.5 5 40 200 IMT-200-150-10 100-200 2.5 10 20 200 IMT-200-150-12 100-200 2.5 12 17 204 IMT-200-150-15 100-200 2.0 15 10 150 IMT-200-300-3.3 200-400 .75 3.3 50 165 IMT-200-300-5 200-400 .86 5 40 200 IMT-200-300-10 200-400 .82 10 20 200 IMT-200-300-12 200-400 .83 12 17 204 IMT-200-300-15 200-400 .62 15 10 150 IMT-240-110-10 66-160 4.5 10 24 240 IMT-240-48-24 36-72 7.8 24 10 240 IMT-210-24-14 18-36 14.5 14 15 210 IMT-240-150-24 100-200 2.8 24 10 240 Model Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 4 High Current Series Model Selection Chart See IMT 400 Series Outline Drawing For Dimensions Model Input Voltage (Vdc) Output Voltage (Vdc) Output Current (Amperes) Output Power (Watts) IMT-400-300-5 200-400 5 80 400 IMT-400-300-12 200-400 12 34 408 IMT-400-300-15 200-400 15 27 405 IMT-400-48-5 36-72 5 80 400 IMT-400-48-12 36-72 12 34 408 IMT-400-48-15 36-72 15 27 405 IMT-400-48-24 36-72 24 17 408 IMT-400-300-24 200-400 24 17 408 IMT-380-300-3.8 200-400 3.8 100 380 IMT-360-48-3.6 36-72 3.6 100 360 IMT-250-48-2.5 36-72 2.5 100 250 IMT-210-300-2.1 200-400 2.1 100 210 210 Watts to 408 Watts IMT 400 Series The above models have larger input and output pins. Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 5 Electrical Characteristics 1. Input Voltage -- Please refer to Model Selection Charts: IMT 200 and IMT 400 2. Output Voltage (without trimming) 1% of Nominal -- Please refer to Model Selection Chart. 3. Output Current -- Please refer to Model Selection Chart. 4. Mechanical Parameters Units Dimension mm 116.8(L) x 61.0(W) x 12.7(H) inches 4.6(L) x2.4 (W) x 0.5(H) Weight 226 grams 0.10 Ibs Mounting screw type M3 Suggested screw torque 8.0 m-Kg See mechanical drawing. The following characteristics are measured under the following conditions unless specified otherwise: Ambient Temperature: 25C, Nominal Line and Full Load. 5. Input Characteristics Parameters Minimum Typical Maximum Units 30 35 mA Reflected ripple current No load power consumption 6. Please refer to Table 2 Input ripple rejection (120Hz) 30 35 dB Input ripple rejection (1kHz) 25 30 dB Output Characteristics Parameters Minimum Typical Maximum Units 101 %VNOM Load regulation 0.1 %VNOM 10% to 100% load Line regulation 0.1 %VNOM Low line to high line Setpoint accuracy 99 100 Test Conditions Output ripple & noise p-p 1.0 2.0 %VNOM 20 MHz bandwidth Output temperature drift 0.01 0.02 % /C TBASE= 30 to 90C 25 mV 10% to 100% load Start-up overshoot Transient response:- 75% to 100% load change Settling time 100 200 sec Over/under-shoot 300 500 mV Trimming range Remote sense compensation 2.5 A / us Please refer to Table 2 Trim down to 30% is available 0.1 0.15 V Plus complete trim range Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 6 7. Gate Control Characteristics Parameters Minimum Typical Maximum Units Gate in Voltage for ON state 3.5 5.0 7.0 V Gate in Voltage for OFF state 0.0 1.35 V Test Conditions Active high (or open) in Gate-In Control Pin. Low logic level (0 to 1.8V) will disable the converter. 8. Isolation Characteristics Parameters Typical Maximum 3,750 Vac Isolation (Input to baseplate) 2,500 Vac 500 Vac Capacitance (Input to output) 10 Insulation resistance (Input to output) 50 Test Conditions Units Isolation (Input to output) Isolation (output to baseplate) 9. Minimum 15 pF M Protection Characteristics Parameters Minimum Typical Maximum Units OVP (Over Voltage Protection) setpoint 120 125 140 %VNOM OCP (Over Current Protection) setpoint 110 115 120 %Full load 90 100 105 C OTP (Over Temp. Protection) setpoint Test Conditions Base plate temp. Please refer to Table 2 Long-term short-circuited current OTP will occur Once the protection circuit is activated, the converter will shut down. To reset the converter, remove the fault and turn the power off. Then turn the power on again (non auto-recovery type). 10. Thermal Characteristics Parameters Efficiency Minimum Typical Maximum Test Conditions Units Please refer to Table 2 Thermal resistance (without heat sink) 5.0 C / W Free air Thermal resistance (with heat sink) 3.0 C / W See Heat sink dimension 11. Environmental Parameters Storage Temperature Minimum -40 Maximum Units 125 C 105 C -25 Operating Temperature - 40 is available as an option Storage Humidity 0 95 % Operating Humidity 0 95 % Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 7 Safety Compliance * UL : 1950 * TUV : EN60950 (R) * CSA : 950 * CE : Marked BAUART GEPRUFT TUV Rheinland TYPE APPROVED Mechanical Drawing: IMT 200 Outline Drawing 0.08"(2mm) Dia (2) places - Solder plate over copper alloy 4.60"(116.8mm) 4.20"(106.7mm) 4 9 3 8 2 6 1 5 2.00" (50.8mm) 0.70"(17.8mm) 0.30"(7.6mm) 7 0.30"(7.6mm) 0.70"(17.8mm) 0.04"(1mm) Dia (7) places - Solder plate over copper alloy PIN # 1 2 3 4 5 6 7 8 9 4.20"(106.7mm) Function + In Gate In NC - In +Out +Sense Trim -Sense -Out 2.40"(61mm) 0.22"(5.6mm) 0.06"(1.5mm) 0.50" 0.025" (12.7mm 0.6mm) Mechanical Drawing: IMT 400 Outline Drawing 0.18"(4.5mm) Dia (2) places - Solder plate over copper alloy 4.60"(116.8mm) 4.20"(106.7mm) 2.00" (50.8mm) 4 9 3 8 2 6 1 5 0.70"(17.8mm) 0.30"(7.6mm) 7 0.30"(7.6mm) 0.70"(17.8mm) 0.08"(2mm) Dia (7) places - Solder plate over copper alloy 4.20"(106.7mm) PIN # 1 2 3 4 5 6 7 8 9 Function + In Gate In NC - In +Out +Sense Trim -Sense -Out 2.40"(61mm) 0.22"(5.6mm) 0.06"(1.5mm) 0.50" 0.025" (12.7mm 0.6mm) Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 8 Thermal Consideration: IMT 200 Series Graph A shows the output power derating (in watts) with heat sink and without heat sink at various ambient temperatures in still air condition. If an appropriate forced air is used with or without a heat sink, there is no power deration as illustrated in Graph B. In such a case, the converter can be operated at its full output power rating. For IMT 200 Series 200 180 250 160 200 Power Output (watts) Power Output (watts) For IMT 200 Series 140 120 100 with heat sink 80 60 40 20 without heat sink 0 0 40 60 80 20 100 120 150 100 50 20 0 0 Operating Temperature in C 20 40 60 80 100 120 Operating Temperature in C Graph A: Output Power Derating in Still Air Graph B: Output Power With Forced Air Heat Sink 2.44" (62.00 mm) 0.78" (20.00 mm) Heat Sink material Heat Sink Dimensions (WxHxL) : Aluminum Extrusion : 2.44" x 0.78" x 4.6" (62 x 20 x 117 in mm) Weight : 135 g (0.06 Ibs) Thermal Impedance = 3.0C / W The converter can be operated at full-load with appropriate forced air cooling or by using a lower thermal resistance heat sink. Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 9 Reliability (thermal cycling) (125) 120 Temperature in C 100 80 -15C / Min. 60 40 20 +15C / Min. 0 -20 -40 (- 40) 10 20 30 40 50 60 70 80 Time in Minutes Thermal cycling is in accordance with MIL-STD-883E. A minimum of 10 cycles is used during the test. Gate Control A remote on-off Control Pin is provided to enable or disable the converter. When the Gate-In Pin 2 is at logic high (2.8 to 7V) or open circuited, the converter is enabled. At logic low (<2.8V) the converter is then disabled. If the control signal has a common return with the primary side, one can use a NPN transistor circuit to enable/disable the converter. If the control signal is from the secondary, or anywhere else, an optical couple circuit can be used. 390 Gate In(P2) 200K CTL signal + = - CTL signal - Gate In(P2) + -IN (P4) -IN (P4) Output Trimming Approximately 10% output voltage trimming can be achieved by adding a potentiometer. The recommended circuit connection technique is shown below: The suggested minimum resistance value is 5.1 K. + OUT (P5) TRIM (P7) - OUT (P9) Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 10 Table 2A. Electrical Characteristics Model No load Power Consumption (Watts) Output Voltage Trimming Range (%VNOM) Long-term Short-circuited Current (Amperes) Typical Efficiency (%) Max. Max. -5 +8 0.10 75 0.6 -5 +8 0.10 82 0.5 0.8 -8 +8 0.10 82 IMT-200-24-12 0.5 0.8 -8 +8 0.10 85 IMT-200-48-3.3 0.5 0.8 -6 +9 0.10 75 IMT-200-48-5 0.5 0.8 -8 +8 0.10 82 IMT-200-48-10 0.5 0.8 -8 +10 0.10 85 IMT-200-48-12 0.6 0.9 -8 +10 0.10 87 IMT-200-72-3.3 0.5 0.8 -6 +9 0.05 78 IMT-200-72-5 0.5 0.8 -8 +10 0.05 82 IMT-200-72-10 0.6 0.9 -8 +10 0.05 85 IMT-200-72-12 0.6 0.9 -8 +10 0.05 86 IMT-200-150-3.3 0.5 0.9 -6 +9 0.02 75 IMT-200-150-5 0.5 0.9 -8 +10 0.02 80 IMT-200-150-10 0.5 0.9 -8 +10 0.02 83 IMT-200-150-12 0.8 1.2 -8 +10 0.02 85 IMT-200-150-15 0.8 1.2 -8 +10 0.02 83 IMT-200-300-3.3 1.0 1.5 -6 +9 0.01 72 IMT-200-300-5 1.0 1.5 -6 +9 0.01 78 IMT-200-300-10 1.0 1.5 -8 +10 0.01 80 IMT-200-300-12 1.0 1.5 -8 +10 0.01 81 IMT-200-300-15 1.0 1.5 -8 +10 0.01 80 IMT-210-300-2.1 1.2 1.8 -8 +10 0.01 70 IMT-240-110-10 0.6 0.9 -8 +10 0.02 85 Typical Max. * Min. IMT-200-24-3.3 0.4 0.6 IMT-200-24-5 0.4 IMT-200-24-10 * Trim down to - 30% is available as an option. Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 11 Table 2B. Electrical Characteristics Model No load Power Consumption (Watts) Output Voltage Trimming Range (%VNOM) Long-term Short-circuited Current (Amperes) Typical Efficiency (%) Typical Max. Min. Max. Max. IMT-360-48-3.6 0.5 -30 +10 0.10 75 IMT-250-48-2.5 0.93 -20 +10 0.10 72 IMT-210-300-2.1 1.07 -9.5 +11 0.01 70 IMT-380-300-3.8 1.13 -30 +10 0.10 72 IMT-400-48-24 0.93 -30 +10 0.10 86 IMT-400-48-5 0.53 -30 +10 0.10 80 IMT-400-300-5 0.91 -30 +10 0.01 81 IMT-210-24-14 0.76 -30 +10 0.05 84 IMT-240-48-24 1.4 -30 +10 0.04 85 IMT-240-150-24 3.1 -30 +10 0.01 88 Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 12 IMT - 200 Application Circuits 1 + In Gate In NC + - IMT - 200 IMT - 400 - Out -S Trim +S + Out IMT - 200 IMT - 400 - Out -S Trim +S + Out - In + - + In Gate In NC - In + - + In Gate In NC - In IMT - 200 IMT - 400 - Out -S Trim +S + Out Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 13 Application Circuit 2 N + 1 and Paralleling Circuit + OUT +S MODULE # 1 TRIM -S - OUT V+ SB ADJ + SEN - SEN SENSE BUS PARA # 1 + OUT +S MODULE # 2 TRIM -S - OUT V+ SB ADJ + SEN - SEN PARA # 2 + OUT +S MODULE # 3 TRIM -S - OUT +VOUT SENSE BUS +VOUT V+ SB ADJ + SEN - SEN PARA # 3 SENSE BUS External current share circuit can be used to parallel IMT 200 and IMT 400 modules using trim pin. A detailed application note on Current Sharing is available. Please request for AN01 or download from our website Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 14 Current Share Module PN: CS01 Outline Drawing 0.6600 0.4350 V+ 0.1300 SB ADJ -SEN +SEN 0.1300 0.0800 Resistance Value of Sense Bus Vs. Different Outputs Vo Io Resistance of Sense Bus 3.3V 50A 0.66m 3.3V 40A 0.825m 5V 40A 1.25m 5V 30A 1.67m 10V 20A 5m 12V 17A 7m 15V 10A 15m Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 15 Broadband TelCom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-48888 Fax: 714-259-8887 Toll Free: 1-888-411-2645 www.btcpower.com E-mail: sales@btcpower.com A C B D Broadband Telcom Power, Inc. 1719 South Grand Ave., Santa Ana, CA 92705 Tel.: 714-259-4888 Fax: 714-259-8887 www.btcpower.com E-mail: sales@btcpower.com 16