500HBAW GAPTEC | Alldatasheet

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500HBAW_1.5 series 500W Half-Brick - Single Output DC-DC Converter - Wide Input - Isolated & Regulated GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 1 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. Compliance with RoHS6 EU Directive 2011/65/EU Delivers up to 10A output current High efficiency, typ.93% at Vout 100% load Low output ripple and noise Exceptional thermal performance Industry standard “Half-brick“ footprint Remote On/Off positive logic Fixed switching frequency (270 kHz typical) Remote Sense Input under voltage lockout Output over voltage protection Over temperature protection Output over current protection Adjustable output voltage: 25V~57.6V Meets the voltage and current requirements for ETSI 300-132-2 and complies with and licensed for Basic Insulation rating per IEC60950-1 DC-DC Converter 500 Watt The 500HBAW_1.5 series are half-brick DC-DC converters that provide high efficiency single output. They can operate from 36VDC to 75VDC input and 50V/10A output. The output can be trimmed from 25V to 57.6V. The remote on/off feature on the module can be either negative or positive logic. Negative logic turns the module on during a logic low and off during a logic high. Positive logic turns the modules on during a logic high and off during a logic low. The output voltage trim can be either negative or positive trim logic. Positive trim logic indicates that the output voltage will increase when the TRIM pins are connected to “+Vo1” and decrease when connected to “GND”. Negative trim logic indicates that the output voltage will decrease when the TRIM pins are connected to “+Vo1” and increase when connected to “GND”. Note: 1. Operation under minimum load will not damage the converter; However, they may not meet all specification listed, and that will reduce the life of product. 2. All specifications measured at Ta = 25°C, humidity <75%, nominal input voltage and rated output load unless otherwise specified. 3. In this datasheet, all the test methods of indications are based on corporate standards. Example: 500HBAW_4848S1.5 W = 500 Watt; HB = Half-Brick; A = Pinning; W = Wide input (2:1); 48 = 36-72 Vin; 48 = 48Vout; S = Single Output; 1.5 = 1.5kVDC Isolation Output specifications Item Test condition Min Typ Max Voltage set point Vin=Vin(nom); Io=Io(max) 49.5 50 50.5 VDC Output Current 10 A Line regulation Vin=Vin(min) to Vin(max) lo= lo(max) ±0.2 ±0.5 % Load regulation Io=0 to Io(max);Vin=Vin(nom) ±0.2 ±0.5 % Voltage accuracy ±0.5 ±1.0 % Voltage adj. range Vin=Vin(min) to Vin(max) Io=0 to Io(max) -25 57.6 %Vo Remote sense compensation

1 VDC

110 150 %Io External load capacitance ESR<200mΩ at -40°C, recommend 2~3PCS KY, KZE and KZH series aluminum capacitors in parallel 680 2200 µF Temperature coefficient Ambient Temperature -40°C ~85°C 200 ppm /°C Dynamic response Io(max), di/dt=2.5A/µS 1A(3.5ms)~8A(1.5ms);di/dt=1.5A/µS 1A(3.5ms)~8A(1.5ms), di/dt=1.5A/µS 350/ 100 1.5/ 100 900/ 200 2.2/ 200 mV/ µS µS Ripple & Noise* Measured with 10µF Tantalum external and 1µF ceramic capacitor at output, 100%load, 20MHz bandwidth 120 200 mV Turn-on delay time Time from instant at which Vin=Vin(min) until Vo=10% of Vo(nom) 500 ms Turn-on Rise Time Time for Vo to rise from 10% of Vo(nom) to 90% of Vo(nom) 300 ms Output Voltage Overshoot 5 %Vo * Test ripple and noise by “parallel cable” method. Measured with 10µF Tantalum and 1µF ceramic Input specifications Item Test condition Min Typ Max Units Input voltage • Continuous

  • Transient (100ms) 100 VDC VDC Operating Input Voltage 36 48 75 VDC Max. Input Current 100% load Vin=36V 17 A No load Input Current No load Full Input Voltage 200 mA Standby Input Current mA 10 100 mA Input Reflected Ripple Current Peak-to-Peak 12 µH source impedance, add 470µFelectrolytic and 1µF ceramic capacitor at input 150 300 mA Recommended External Input Capacitance Low ESR capacitor recommended 330 µF Inrush Transient 1 A2S Input fuse 20 A Output specifications Item Test condition Min Typ Max Short circuit protection Hiccup Mode Automatic recovery 4 h Efficiency Vin=48V, 100%load ambient temperature 25°C 91.5 93 % Operating temp -40 100 °C Storage temperature -55 125 °C Operating Humidity 90 %RH Storage Humidity 90 %RH Operating Altitude 0 3000 m Storage Altitude 0 3000 m Switching Frequency Vin=Vin(nom); Io=Io(max); Fixed frequency 220 270 320 kHz MTBF Telcordia SR332, 40°C Ta 2,800,000 h FIT 109/MTBF 357 Thermal Stability Time - 30 min Weight 70 75 80 g Safety Compliant to IEC60950-1,UL60950-1,EN60950-1,GB4943 Vibration IEC60068-2-6:10-500Hz sweep,0.75mm excursion,10g acceleration, 10min in each 3 perpendicular directions Transportation ETS300019-1-2 Shock IEC60068-2-27:200g acceleration, duration 3 ms,6 drops in each 3 perpendicular directions

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 2 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice.

500 W Half-Brick - Single Output DC-DC Converter - Wide Input - Isolated & Regulated

500HBAW_1.5 series Part Number Input Voltage [V] Input current [A, max] Output Voltage [VDC] Output Current [A, typ/max] Efficiency* [%, min/typ] 450HBAW_4848S1.5 36-72 2.45 48 8.3/9.1 87/90 * Vin = Vin(nom); Io = Io(max), ambient temperature 25°C Isolation specifications Item Test condition Min Typ Max Units Isolation voltage Tested for 1 minute leak current <10mA

  • Input-output
  • Input-case
  • Output-case 1500 1050 500 VDC VDC VDC Isolation resistance Normal air pressure, 500Vdc, the isolation resistance is no more than 10 MΩ 10 MΩ Isolation Capacitor (Input-Output) 4400 pF Remote control specifications Item Test condition Min Typ Max Units Logic Low Voltage Converter guaranteed logic high when REM pin is left open 0 1.2 V Logic High Voltage Converter guaranteed logic high when REM pin is left open 2.4 20 V Remote On/ Off Current 3 mA Typical Characteristic Curves Converter efficiency vs output current (figure 1) Dynamic Response Derating output current vs local ambient temperature (figure 2) Protection specifications Item Test condition Min Typ Max Units Input under voltage lockout
  • Turn-off threshold
  • Turn-on treshold
  • Hysteresis 1 2 VDC VDC VDC Output over voltage protection Under the converter’s maximum allowable output power. hiccup 58 65 VDC Output over current protection Hiccup mode, automatic recovery Yes Over temperature protection Automatic recovery See OTP section 102 110 120 °C Over temperature protection Hysteresis Automatic recovery See OTP section 2 5 10 °C Product Selection Guide

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 3 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. 500HBAW_1.5 series Design considerations Safety considerations Test configurations Input Reflected Ripple Current Test Setup (figure 7) Input filtering The power module should be connected to a low acimpedance input source. Highly inductive source impedances can affect the stability of the power module. For the test configuration in Figure7 a 470µF electrolytic capacitor and a 1µF ceramic capacitor, mounted close to the power module helps ensure stability of the unit. For safety-agency approval of the system in which the power module is used, the power module must be installed in compliance with the spacing and separation requirements of the end-use safety agency standard, i.e. UL60950-1, CAN/CSA-C22.2, No. 60950-1 and EN60950-1:2001(+A11) and IEC60950-1:2005, if the system in which the power module is to be used must meet safety agency requirements. These converters have been evaluated to the spacing requirements for Basic Insulation, per the above safety standards. For all input voltages, other than DC mains, where the input volta- ge is less than 60Vdc, if the input meets all of the requirements for SELV, the output is considered to remain with SELV limits. Signal component failure and fault tests were performed in the power converters. If the input source is non-SELV (ELV or hazardous voltage greater than 60Vdc and less than or equal to 75Vdc), for the module’s output to be considered as meeting the requirements for safety extra-low voltage (SELV), all of the following must be true. 1. The input source is to be provided with reinforced insulation from any other hazardous voltage, including the AC mains. 2. One VIN pin and one VOUT pin are to be grounded, orboth the input and output pins are to be kept floating. 3. The input pins of the module are not operatoraccessible. 4. Another SELV reliability test is conducted on the whole system as required by the safety agencies, to verify that under a single fault, hazardous voltages do not appear at the module’s output. All flammable materials used in the manufacturing of these modules are rated 94V-0. To preserve maximum flexibility, internal fusing is not included, however, to achieve maximum safety and system protection, always use an input line fuse. The safety agencies require a time delay fuse with a maximum rating of 30A. Based on the information provided in this data sheet on inrush energy and maximum dc input current, the same type of fuse with a lower rating can be used. Refer to the fuse manufacturer’s data sheet for further information. Output Ripple and Noise Test Setup (figure 8) Typical Start-up using Input Voltage (figure 6)Typical Output Ripple and Noise (figure 5) Vin = Vin, nom; Io=Io, max) Note: Measure input reflected ripple current with a simulated source inductance of 12µH. The measurement points for input reflected ripple current is showed above. Note: Scope measurements should be made using a BNC socket with a 1µF ceramic capacitor and a 10µF tantalum capacitor. Position the oscilloscope probe between 51mm and 76mm (2in and 3in) from the module

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 4 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. 500HBAW_1.5 series Feature descriptions Remote on/off The REM pin is used to turn the power converter remote on or off via a system signal. Two remote on/off logic are available. Negative logic turns the module on when the REM pin is at logic low and off when it is at logic high. Positive logic turns the module on during logic high and off during logic low. To turn the power module on and off, the user must supply a switch to control the voltage between the REM pin and -Vin terminal (see Figure 9). A logic low is VREM =0 to 0.8 V. During logic high, the maximum VREM voltage generated by the power module is 20V. If not using the remote on/off feature, perform one of the following to turn the converter on: For negative logic, short REM pin to -Vin. For positive logic, leave REM pin open. Remote sense Remote sense minimizes the effects of distribution losses by regulating the voltage at the remote sense connections (see Figure 10). The voltage between the remote sense pins and the output terminals must not exceed the output voltage sense range. The voltage between the +Vo1 and GND terminals must not exceed the minimum output overvoltage protection value shown in the Electrical Specifications table. This limit includes any increase in voltage due to remote sense compensation and output voltage programming (trim). If not using the remote sense feature to regulate the output at the point of load, then connect +S to +VO1 and -S to GND. Although the output voltage can be increased by both the remote sense and by the trim, the maximum increase for the output voltage is not the sum of both. The maximum increase is the larger of either the remote sense or the trim. The amount of power delivered by the module is defined as the voltage at the output terminals multiplied by the output current. When using remote sense and trim, the output voltage of the module can be increased, which at the same time the output current would increase the power output of the module. Care should be taken to ensure that the maximum output power of the module remains at or below the maximum rated power. Output Voltage Programming Resistance adjustment mode Output voltage trim allows the user to increase or decrease the output voltage set point of a module. This is accomplished by connecting an external resistor between the TRIM pin and either the +S or -S pins. If not using the trim feature, leave the TRIM pin open. To increase the output voltage, refer to figure 12. A trim resistor, Rtrimup, connected between the TRIM and +S pin. The maximum trim up voltage can reach up to 57.6V at input voltage from 36-75V. See figure 11. Trimming beyond 57.6V is not an acceptable design practice, as this condition could cause unwanted triggering of the output over-voltage protection (OVP) circuit .When trimming up, care must be taken not to exceed the converter’s maximum allowable output power. To decrease the output voltage (see Figure13.), a trim resistor, Rtrimdown, should be connected between the TRIM and -S, with a value of Figure 11 Max. adjustable output voltage vs. input voltage Figure12. Circuit Configuration to Increase Output Voltage. Figure13. Circuit Configuration to Decrease Output

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 5 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. 500HBAW_1.5 series Voltage adjustment mode The output voltage can also be trimmed by potential applied at the trim pin. An external trim resistor is connected between trim pin and Vtrim. See Figure 14. The relationship between Vtrim and Vo is described as below: Rtrim =The external trim resistor [kΩ] When Rtrim=0 kΩ V trim = 0.0496 * Vout - 1.24 trim The trim curve is shown as Figure 15. When Rtrim=1 kΩ V trim = 0.0744 * Vout - 2.48 The trim curve is shown as Figure 16. When Rtrim=2kΩ V trim = 0.0992 * Vout - 3.72 The trim curve is shown as Figure 17.

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 6 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. 500HBAW_1.5 series Protection features Thermal considerations Over current Protection To provide protection in an output overload fault condition, the module is equipped with internal current limiting circuitry, and can endure current limiting continuously. At the point of current limit inception, the unit enters hiccup mode. The unit is configured with the auto-restart function, it will remain in the hiccup mode as long as the overcurrent condition exists, it operates normally once the output current is reduced back into its specified range. Output Overvoltage Protection The output over voltage protection consists of circuitry that monitors the voltage on the output terminals. When the output voltage exceeds the overvoltage protection threshold, the module will operate in a hiccup mode until overvoltage cause is cleared. The power modules operate in a variety of thermal environments; however, sufficient cooling should be provided to help ensure reliable operation of the unit. Considerations include ambient temperature, airflow, module power dissipation, and the need for increased reliability. A reduction in the operating temperature of the module will result in an increase in re - liability. Over temperature Protection To provide protection under certain fault conditions, the module is equipped with a thermal shutdown circuit. The module will shutdown when the aluminum baseplate temperature exceeds OTP set value, but the thermal shutdown is not intended as a guarantee that the module will survive when the temperatures beyond its rating. The module will automatically restarts after it cools down. Input Undervoltage Lockout Input under-voltage lockout is standard with this converter, when input voltages below the input under-voltage lockout limit, the module operation is disabled. It will only begin to operate once the input voltage is raised above the undervoltage lockout turn-on threshold Through-Hole Soldering Information The product is intended for through-hole mounting in a PCB. When wave soldering is used, the temperature on the pins is specified to maximum 270 °C for maximum 10 seconds. Maximum preheat rate of 4 °C/s and temperature of max 150 °C is suggested, when hands 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. A no-clean (NC) flux is recommended to avoid entrapment of A noclean (NC) 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. EMC Considerations The Figure 18 shows a suggested configuration to meet the conducted emission limits of EN55022 Class B. Component parameters C1 C2 C3 C4 C5 1uF SMD ceramic capacitor C6 0.1uF SMD ceramic capacitor L1 L2 470uH Common-mode inductance C9 C10 C11 C12 0.22uF Isolation voltage SMD capacitor C7 470µF electrolytic capacitor C8 1000µF electrolytic capacitor Figure13. EMC testing typical application circuit Figure18. EMC testing typical application circuit

GAPTEC-Electronic GmbH & Co. KG sales@gaptec-electronic.com – www.gaptec-electronic.com Page 7 of 7 500HBAW_1.5 – Rev. 2020-1.0 Specifications subject to change without notice. 500HBAW_1.5 series Outline Diagram Dimensions are in millimeters and (inches). Tolerances: x mm ± 1 mm(x.x in. ± 0.04in.) Pin S Function 1 +Vin Positive input voltage

2 REM Remote control

3 FG Case

4 -Vin Negative input voltage

5 GND Negative output voltage

6 -S Negative remote compensation

7 TRIM Output voltage trim

8 +S Positive remote compensation 9 +Vo1 Positive output voltage Figure19. Outline Diagram Pin options L(Pin length) standard 3.6(0.14) Z1 2.8(0.11) Z2 4.6(0.18) Z3 -5.8(0.23) Z4 6.4(0.25) Dimensions are in millimeters and (inches). Figure20. Recommended Pad Layout Recommended Pad Layout