F3D480T20A VICOR | Alldatasheet

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Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 1 of 14 vicorpower.com F3D480T20A PRELIMINARY +Out –IN +IN F3D480T20A 8395846576834856 C S NRTL US PFM DC+ PR SC SG –Out BV RSV PC Pb

  • Input: rectified 120/240 Vac sinusoidal
  • Output: 48 Vdc programmable
  • Output power: Up to 200 W
  • 4,242 Vdc reinforced insulation
  • 90% efficiency
  • 375 W/in 3 power density
  • Low profile: 0.25”
  • Surface mount J Lead package
  • Meets EN 61000-3-2 harmonic current limits F3D480T20AV•I Chip PFM Power Factor Module Output Power Designator (POUT x 0.1) A = Analog Control F 3 D 480 T 20 A Power Factor Module Input Designator 3 = 115/230 Vac Product Grade Temperatures (°C) Grade Storage Operating T -40 to150 -40 to125 M -65 to150 -55 to125 Package D = Double VIC w/ J leads Output Voltage Designator (VOUT x10) Part Numbering Product Description The PFM (Power Factor Module) is a V•I Chip power component that converts a rectified 120/240 Vac line to an isolated, regulated DC voltage programmable from 26 V to 48 V. Rated at 200 W, the PFM meets EN61000-3-2 harmonic current limits and is available in a double VIC package measuring only 1.69" (43,0) x 1.26" (32,0) x 0.25" (6,2). The PFM power density is 375 W/in The PFM is the front-end V•I Chip for AC-DC power systems. It requires only a rectifier, input filter and an output capacitor to provide a high density, power factor corrected, 200 W power supply. The high operating frequency and soft switching allow miniaturization of power train components and make EMI filter components smaller than those required by lower frequency, hard switching converters. Output energy storage is accomplished at SELV levels providing packaging and interconnect flexibility not available with conventional AC Front Ends. PFMs may be paralleled with power sharing for added power or redundancy in single or three phase systems. The output voltage can be programmed to meet the requirements of system loads and/or additional downstream conversion devices such as Vicor’s Pre Regulator Modules (PRMs) and Voltage Transformation Modules (VTMs). Actual Size Absolute Maximum Ratings Parameter Min Max Unit Notes Input voltage (+IN to -IN) Operating 90 264 Vrms Rectified AC sinusoidal Non-operating 0 450 Vdc 100 ms Input voltage slew rate 25 V/µs PC to -IN -0.3 7 Vdc BV to -IN -0.3 50 Vdc PR to -OUT -0.3 7 Vdc SC -0.3 1.5 Vdc Output voltage (+OUT to -OUT) -0.5 55 Vdc Output current 6 A Dielectric withstand (input to output) 4,242 Vdc Reinforced insulation

1 Min

Operating junction -55 125 ˚C M-Grade Storage -65 150 ˚C M-Grade Case peak temperature during reflow 225 ˚C MSL 3 Case peak temperature during reflow 245 ˚C MSL 6 L N Input Filter / Rectifier PFM Load48 Vdc 200 W PFM

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 2 of 14 vicorpower.com F3D480T20A PRELIMINARY Parameter Min Typ Max Unit Note Source voltage low range 90 132 Vrms The PFM is not designed to support output load Source voltage high range 180 264 Vrms when the input is 132 to 175 Vrms Source frequency range 47 63 Hz Rectified AC Input Source The PFM operates from a full bridge rectified AC line with the following characteristics: Parameter Min Typ Max Unit Note Set point 47.5 48.0 48.5 Vdc Output may be trimmed down from factory set point Output voltage trim range 26 48 48.0 Vdc via external trim resistor. See page 4, SC pin Output current 0 4.1 A Vout = 48 Vdc Output power 0 200 W V out = 48 Vdc see Fig. 22 for heat sink information OVP set point 56 58 Vdc Line regulation 0.3 1 % Load regulation 0.5 1 % Efficiency 88 90 % 120 Vrms 75% load No load power dissipation 0.75 W Meets Energy Star no load limit Current share accuracy 5 10 % Switching frequency ripple 240 300 mV pk-pk ~1.2 MHz with 10 µF ceramic bypass capacitance Line frequency ripple 350 750 mV rms With 10,000 µF output capacitor 1.12 2.0 V pk-pk Start up time From application of power 2.0 2.5 5.0 S No overshoot Dynamic response Voltage deviation 6 % Of Vout Recovery time 500 mS Output capacitance 1,500 2,200 10,000 µF Required for PFC. Output ripple is a function of output Hold-up capacitance 1,500 2,200 10,000 µF and hold-up capacitance. See Fig.8 for hold-up time. Short circuit protection 5.5 6.0 A Current limited Output Electrical characteristics (Conditions: 25˚C case, 75% rated load and specified input voltage range unless otherwise specified.) Parameter Min Typ Max Unit Note Undervoltage shut down 82 85 Vrms Source voltage Overvoltage shut down 265 275 Vrms Source voltage Power factor 0.94 47 – 63 Hz Inrush current 5 A pk Input (Operating from AC input source)

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 3 of 14 vicorpower.com F3D480T20A PRELIMINARY Electrical (cont.) (conditions: 25˚C case, 75% rated load and specified input voltage range) Control Pins (See page 4 for pin description) Pin Min Typ Max Unit Note BV (Bias Voltage) -0.5 48 V Referenced to -IN PC (Primary Control) DC voltage 4.8 5.0 5.2 Vdc Referenced to -IN Module disable threshold 2.3 2.4 Vdc Module enable threshold 2.5 2.6 Vdc Disable hysteresis 100 mV Current limit 2.0 2.7 3.5 mA PC pulled low Analog control PR (Parallel Port) Voltage 0.6 7.5 V Refer enced to SG, see PR pin pg.4 Source current 1 mA External capacitance 100 pF SC (Secondary Control) Voltage 1.23 1.24 1.25 Vdc Referenced to SG Internal capacitance 1.0 nF External capacitance 0.7 µF Electromagnetic Compatibility (configured as illustrated in Fig. 18 ) Harmonic currents EN 61000-3-2, Amendment 14 See Fig. 11 Line disturbance / immunity EN 61000-4-11 Interruptions and brownouts Transient / surge immunity EN 61000-4-5 2 kV–50 µs line or neutral to earth 1 kV–50 µs line to neutral Conducted emissions EN 55022, Level B With filter ( see Fig. 18 ) Flicker / inrush EN 61000-3-3 Parameter Min Typ Max Unit Note Over temperature shut down 125 130 135 °C Junction temperature Junction-to-case thermal impedance 0.6 °C/W Case-to-ambient thermal impedance 2.3 °C/W 46 mm x 46 mm x11mm heatsink #31474 with 300 LFM Dielectric withstand 4,242 Vdc Input to output Insulation resistance 10 M ohms Input to output Capacitance 110 pF Input to output Leakage current 30 µA Line fuse Rating 250 Vac Always ascertain and observe applicable safety, 4A regulatory and agency specifications Mechanical Weight 1.0 / 30 oz / g Length 1.69 / 43 in / mm Width 1.26 / 32 in / mm Height 0.25 / 6.2 in / mm Reflow parameters Contact Vicor for information regarding soldering of the PFM to printed circuit boards. Resistance to cleaning IEC 68-2-45 XA Water +55 ±5˚C Solvents Method 1 Isopropyl alcohol +35 ±5˚C Agency approvals (pending) cTÜVus UL/CSA 60950, EN 60950 CE Low voltage directive General

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 4 of 14 vicorpower.com F3D480T20A PRELIMINARY Primary side +IN / -IN – DC voltage The PFM operates from a full wave rectified AC voltage within the limits shown on page 2. PFMs have internal over / undervoltage lockout functions that prevent operation outside of the specified rms input range. PFMs will turn on when the input voltage rises above its undervoltage lockout. If the input voltage exceeds the overvoltage lockout, PFMs will shut down until the overvoltage fault clears. BV - bias voltage A 47 µF 50 V electrolytic capacitor must be connected between this port and –IN to provide energy storage for the primary bias circuit. RSV – reserved PC – primary control The PFM voltage output is enabled when the PC pin is open circuit (floating). To disable the PFM output voltage, the PC pin is pulled to –IN. Open collector optocouplers, transistors, or relays can be used to control the PC pin. When using multiple PFMs in a high power array, the PC ports should be tied together to synchronize their turn on. Secondary side DC+ A hold-up capacitor should be connected between this port and SG to provide output hold-up in the event of an input power failure. For 10 ms hold-up at full load, a 2,200 µF 50 V electrolytic capacitor is recommended. DC+ should not be back driven. PR – parallel port (analog control models only) The PR port signal, which is proportional to the PFM output power, supports current sharing among PFMs. To enable current sharing, PR ports should be interconnected. No bypass capacitance should be used when interconnecting PR ports and steps should be taken to minimize stray capacitance and noise coupling into this line (e.g, by minimizing the width of PR port interconnect traces that lay over, or in proximity to, signal grounds or power / ground planes). The PR port is referenced to SG. Pin/Control Functions BOTTOM VIEW +OUT -OUT +IN B V RSV PC -IN Power Factor Module (PFM) DC+ PR SC SG SC – secondary control (analog control models only) The output voltage may be programmed, margined or trimmed down by connecting a voltage source or resistor between the SC port and SG port. The slew rate of the output voltage may be reduced by controlling the rate-of-rise for the voltage at the SC port ( e.g. to limit inrush into a capacitive load). The following expression should be used to calculate the required set point resistor value. No resistor is required if the user desires a nominal 48 V output. Where: R = the set point resistor Vo = the desired output voltage set point Example: Vo R

42 V 211 kΩ

36 V 90.3 kΩ SG – signal return (analog control models only) This port should be used as reference for the SC, PR, and DC+ ports. Care must be taken to insure there are no low impedance paths between -OUT and SG. Such a path could allow current to bypass the internal current sense resistor. + OUT / -OUT – voltage output These ports provide the isolated DC output voltage. The –OUT pin is separated from the SG (Signal Return) pin by the internal current sensing resistor. Safety consideration Care must be exercised to insure appropriate spacing, clearance and creepage distances are maintained between line side terminals and secondary SELV terminals. μP 1 nF ref 1.25 V 1.25 V Full Scale SC SG 30.1 kΩ Figure 2—Functional block diagram Figure 1— PFM pin out Table 1

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 7 of 14 vicorpower.com F3D480T20A PRELIMINARY 50 100 150 200 Output Power (W) Hold-up Time (mS) Figure 8 — Hold up time with 2,200 µF output and hold-up capacitors with 48 Vdc output Electrical (conditions: 25˚C case, 75% rated load and specified input voltage range) 100 120 140 160 180 200 220 26 37 48 Output Voltage Output Power Figure 7 — Output power rating vs. trimmed output voltage Figure 12 — PFM test circuit BV RSV PC PR SC PFM +In -In DC+ SG -OUT +OUT Load 0.5 μF 600 V 47 μF 50 V 2,200 μF 50 V 2,200 μF 50 V 120 / 240 Vac Rectified Optional Hold-up Cap. Output Cap. 4.0 A Figure 9 — Efficiency vs. Output Power (120 Vrms, 48 Vdc) 50 75 100 125 150 175 200 Output Power (W) Efficiency (%) Figure 10 — Power Dissipation vs. Output Power (120 Vrms, 48 Vdc) 0.0 5.0 10.0 15.0 20.0 25.0 50 75 100 125 150 175 200 Output Power (W) Power Dissipation (W) Figure 11 — Harmonic Current vs. EN61000-3-2 limits (115 Vrms

180 W Out)

0.00 0.50 1.00 1.50 2.00 2.50 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Amperes Measured Value Limit

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 9 of 14 vicorpower.com F3D480T20A PRELIMINARY PFM Applications Electrical (cont.) BV RSV PC PR SC PFM +In -In DC+ SG -OUT +OUT HOLD-UP CAP Ref Des Description C3 C2 Connect to a copper shield plane under the PFM L N F1 Fuse, 3.15 A, 5x20 F2 Fuse 6 A C1 47 μF, 50 V 30707-476 C2, C3 4.7 nF, 250 V, Y2 19726-972 C4, C5 2,200 μF, 50 V C6 88 μF 63 V L1 Dual winding inductor, 0.1 nH / winding 29852-R10 L2 Ferrite bead, 6 A 33 ohm @ 100 MHz 29187-33R0 Ros 2.9 K Ω R CD 32.4 Ω R1 1/16 Watt for adj. see SC pin p.11 R2 1/16 Watt 10 Ω Vicor P/N 120 / 240 Vac Filter/ Rectifier P048F048T24AL V048F015T100 Refer to Fig.18

1.2 Vdc

-In PC VC TM +In -Out +Out VTM +Out -Out K Ro +Out –Out +In –In VC PC TM IL VH PR NC SG SC PRM-AL OS NC CD L O A D Factorized Bus (Vf) ROS RCD Figure 17 — Typical FPA (Factorized Power Architecture) from the wall plug to the point of load. See PRM data sheet (P048F048T24AL) for other output voltage / current options.

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 11 of 14 vicorpower.com F3D480T20A PRELIMINARY Load

48 Vdc

400 Watts

L N 120 / 240 Vac Input Filter / Rectifier PFM PFM Electrical (cont.) PFM Applications The block diagram below shows a 400 Watt PFC front end with two PFMs in a parallel configuration. Higher power can be achieved by adding additional PFMs. Figure 21 — Two PFMs operated in parallel for additional power. BCM NSNP niPOL L niPOL L L N 120 / 240 Vac VTMInput Filter / Rectifier PFM NSNP Output 1 Output 2 PRM VTM NSNP L Output 3 Output 4 Figure 20 — Typical application using Factorized Power Architecture (FPA) The block diagram below shows an example of a Factorized Power system from the wall plug to the point-of-load. The PFM directly regulates a primary high power output through a VTM to provide voltage division. A secondary output is independently regulated with a PRM. Auxiliary outputs are derived through a V•I Chip Bus Converter Module (BCM) and non-isolated POL converters.

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 12 of 14 vicorpower.com F3D480T20A PRELIMINARY Thermal Management 0 200 400 600 800 1000 1200 Air Velocity (LFM) Thermal Resistance (C/W) Case-to-ambient thermal resistance with Heatsink #31474 Figure 22 — Case to ambient thermal resistance vs. airflow using heatsink #31474 (46mm x 46mm x 11mm) with MCMStrate 2 mil interface PFM

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 13 of 14 vicorpower.com F3D480T20A PRELIMINARY Mechanical Drawings 3.01 0.118 36.99 1.456 3.01 0.118 8.56 0.3371.22 0.048(3) 14.94 0.588 22.54 0.887 16.94 0.66712.94 0.509 11.10 0.437 C L INPUT C L BOTTOM VIEW 1.10 0.043(6) OUTPUT 30.00 1.181 28.00 1,102 26.00 1.024 20.00 0.787 24.00 0.945 22.00 0.866 8.10 0.319(2) 10.00 0.394 6.2 0.25 32.0 1.260 43.0 1.69 OUTPUT INPUT TOP VIEW (COMPONENT SIDE) NOTES: 1- DIMENSIONS ARE mm/in 2- UNLESS OTHERWISE SPECIFIED, TOLERANCES ARE: 3.26 0.128 36.74 1.446 1.38

0.054 TYP

+IN –IN BV RSV PC 1.48 0.058(12) 30.00 1.181 (2) 28.00 1.102 (2) 26.00 1.024 (2) 24.00 0.945 (2) 22.00 0.866(2) 20.00 0.787 (2) 10.00 0.394 (2) 8.48 0.334(4) 1.60 0.063(6) 8.94 0.352(2) 22.54 0.887 (2) 16.94 0.667(2) 14.94 0.588(2) 12.94 0.509(2) 11.48 0.452(2) DC+ PR SC SG 3.26 0.128 0.51

0.020 TYP

–OUT +OUT NOTES: 1- DIMENSIONS ARE mm/in 2- UNLESS OTHERWISE SPECIFIED, TOLERANCES ARE: RECOMMENDED LAND PATTERN (COMPONENT SIDE SHOWN) Figure 23 — PFM outline drawing Figure 24 — PFM PCB land and layout information

Tel: 800-735-6200 Power Factor Module Rev. 1.0 Page 14 of 14 vicorpower.com F3D480T20A 10/05 PRELIMINARY Vicor Corporation

25 Frontage Road

Andover, MA, USA 01810 Tel: 800-735-6200 Technical Support: 800-927-9474 Fax: 978-475-6715 email Vicor Express: vicorexp@vicr.com Technical Support: apps@vicr.com Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. 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. Intellectual Property Notice Vicor and its subsidiaries own Intellectual Property (including issued U.S. and Foreign Patents and pending patent applications) relating to the products described in this data sheet. Interested parties should contact Vicor's Intellectual Property Department. Warranty Vicor products are guaranteed for two years from date of shipment against defects in material or workmanship when in normal use and service. This warranty does not extend to products subjected to misuse, accident, or improper application or maintenance. Vicor shall not be liable for collateral or consequential damage. This warranty is extended to the original purchaser only. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY, VICOR MAKES NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Vicor will repair or replace defective products in accordance with its own best judgement. For service under this warranty, the buyer must contact Vicor to obtain a Return Material Authorization (RMA) number and shipping instructions. Products returned without prior authorization will be returned to the buyer. The buyer will pay all charges incurred in returning the product to the factory. Vicor will pay all reshipment charges if the product was defective within the terms of this warranty. Information published by Vicor has been carefully checked and is believed to be accurate; however, no responsibility is assumed for inaccuracies. Vicor reserves the right to make changes to any products without further notice to improve reliability, function, or design. Vicor does not assume any liability arising out of the application or use of any product or circuit; neither does it convey any license under its patent rights nor the rights of others. Vicor general policy does not recommend the use of its components in life support applications wherein a failure or malfunction may directly threaten life or injury. Per Vicor Terms and Conditions of Sale, the user of Vicor components in life support applications assumes all risks of such use and indemnifies Vicor against all damages.