SMV-12-500

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500 Watt, High Efficiency, AC/DC Power Modules SMV-500

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Miniature 4.59” x 2.4” x 0.5.” Size High Power Density up to 90.78W/ Inch ³ High Efficiency up to 90.5% at 230VAC (28V) Low Output Noise Metal Baseplate Thermal Protection Over Voltage Protection Current Limit/Short Circuit Protection Adjustable Output Voltage 60-120% of Vo, Set Remote Sense Power On Signal (ENA) Open Collector (10mA sink current). Low (ON) when output is present Model Number Output Voltage Output Amps Input Range Max. Iin FL Efficiency (Tb=25°C) O/P Set Point SMV-12-500 12 VDC 42 85-264 VAC 6.2A 90.2% @ 230Vin 11.76-12.24VDC SMV-28-500 28 VDC 18 85-265 VAC 6.2A 90.5% @ 230Vin 27.44-28.56VDC DESCRIPTION: AC-DC Converter SMV-xx-500 modules are high power density and high efficiency AC-DC converters designed for uses in telecom and other centralized modular and distributed power applications. All use metal baseplates, planar transformers, and surface mount construction to produce up to 500W maximum. Their surface-mount construction uses an insulated metal substrate baseplate construction, planar transformers and thermally conductive potting compound to produce up to 500W in a full brick package and is well suited for the most rigorous requirements of mil/aero COTS and other thermally challenging applications. All specifications are typical at nominal input, full load, and 25DegC unless otherwise noted

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 ABSOLUTE MAXIMUM RATINGS (MIN TO MAX.) Input Power with No Damage 312 VAC Power Factor Correction 0.95 min HL-LL and Full Load Storage Temperature / Humidity -55 to +125°C / 10 to 95% Operating Temperature (Note 5) -40 to 100°C Operating Humidity 20 to 95% Output Power 500 Watts INPUT SPECIFICATIONS Input Voltage (AC(L) to AC(N) 85-265 VAC Input Frequency 47-440 Hz Input Current FL @ 100 Vin, FL 6.2A max. Inrush Current (Note 3) 40A @ 265VAC OUTPUT SPECIFICATIONS O/P Voltage, Current & Set Point See Model Selection Chart PG. 1 Line/Load Regulation (Note 7) 12 V: 48mV, 28V: 56mV, 48V: 96mV Ripple/Noise p-p max. (Note 1) 10% of Vout Dynamic Response (Note 6) 25% - 50% - 75% Load Peak Deviation: 3% Vo, set Settling Time 300uS Current Limit (Note 2) 105-140% of Rated Load Over Voltage Protection 125-145% Vo, set, Io=0.5A, Inverter Shutdown Method Over Temperature Protection Shutdown: 110°C typ. Auto Recovery: 90°C min. Efficiency (Tb=25°C, FL) 12 Vout: 90.2% @ 110 Vin, 90.2% @ 230Vin 28 Vout: 90.5% @ 110 Vin, 90.4% @ 230Vin 48 Vout: 90.4% @ 110 Vin, 90.5% @ 230Vin See Figs. 4a, 4b & 4C EFFICIENCY CURVES STRUCTURAL DYNAMICS Vibration (Note 4) Shock 196.1mS² ISOLATION SPECIFICATIONS Input-Output 3000VAC, 60S Input-Case 2500VAC, 60S Output-Case 1500VDC, 60S Input-Output Capacitance 2000pF Isolation Resistance 100MΩ @ Tb=25°C & 70%RH Output to Baseplate-500VDC GENERAL SPECIFICATIONS MTBF (Tb=40°C, 80%L, 230 Vin) 12V: 1.6Mhrs, 28V: 1.47 Mhrs, 48V: 1.59 Mhrs Weight 7.2 oz (206g) Safety Approvals UL: UL 60950-1-07, 2nd Edition TUV: EN 60950-1:2006 CE: EN 60950-1:2006 CONTROL SPECIFICATIONS Turn-on Time 3S max., 90% Vo, set, FL Trim Adjustment Range 60-120% w the following Caps. 2000uF/25V (12V); 940uF/35V (28V); 440uF/100V (48V) Tb=25°C See Fig. 1 TRIM CiRCUIT Hold Up Time 20mSec. min. with Cap. 780uF (C10 & C11 in Fig.3) NOTES (SEE NEXT PAGE)

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 NOTES 1.Bandwidth 5Hz to 20MHz and with filter 4.7nF MLCC series 50Ω (12, 28V) 100Ω (48V) min. Output Capacitors: 12V: 1000uF*2, TC≥ -20°C, 1000uF*4 28V: 470uF*2, TC≥ -20°C, 470uF*4, TC≤ -20°C 48V: 220uF*2, TC≥ -20°C, 220uF*4, TC≤ -20°C 2. Current Limit inception point Vo=90% of Vo, set @ Tb-25°C; Auto recovery. 3. Turn on @ 265Vin, External Components are needed for operation Refer to Fig. 3 for application circuit. 5. Temperature measurement shall be taken from the baseplate (Tb). See Fig. 2 for location definition . 6. 0.1A/uS; with cap 940uF/35V (28V); 440uF/100V (48V) Tb=25°C, Vin=200VAC 7. Line = LL-HL, Load = NL-FL, Measured in typical Milli Volts (mV)

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 TRIM CIRCUIT: Output Voltage Adjusted by using external resistor and/or variable resistor: For 28Vout, R=35.7Kohm For 48Vout, R=42.2Kohm Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. Vo trim VR = ( 1.472 ) - 19.532 (UNIT:K/uni03A9) Vo trimVR = 1.103 - 8.488 (UNIT:K/uni03A9)For 12Vout, R=12.7Kohm Draft Rev.3a 07/07/2010 Web Site: http://www.acbel.com5 TRIM CIRCUIT: Output Voltage Adjusted by using external resistor and/or variable resistor: R=33Kohm and VR=20Kohm for 60% to 120% of Vo,set Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. BASEPLATE MEASURE POINT: Fig2 Baseplate Temperature Measure Point. Draft Rev.3a 07/07/2010 Web Site: http://www.acbel.com5 TRIM CIRCUIT: Output Voltage Adjusted by using external resistor and/or variable resistor: R=33Kohm and VR=20Kohm for 60% to 120% of Vo,set Fig1 The schematic of output voltage adjusted by using external resistor and/or variable resistor. BASEPLATE MEASURE POINT: Fig2 Baseplate Temperature Measure Point.

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Rev.3.6 2014/02/26 Web Site: http://www.acbel.com6

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Rev.3.6 2014/02/26 Web Site: http://www.acbel.com7 The Description For Each Region Of Time Sequence：：：：  Region I： (1) The input voltage is under 85Vrms, so the unit has no output and the ENA signal is high (open collector). (2) Input under voltage lockout (UVLO) action. The unit starts the turn on sequence. When the input voltage reaches 85Vac and it delays 300mS, the inrush signal changes from low to high. When the inrush signal is low, the internal transistor of the unit between R terminal and +BC terminal is open. Therefore, the inrush current can be suppressed by external resistor. When the inrush signal is high, the internal transistor of unit is short. Therefore, the external resistor is by- passed by internal transistor. The voltage of bulk capacitors ( ±BC) should be more than 95% of the rectification i nput voltage before inrush signal changes to high. If not, the unit could be damaged by inrush current. (3) When the inrush signal is high and then delays 100mS, the PFC_Ctrl signal changes from low to high. Which means the PFC converter turns on and the ±BC will be boosted to 385Vdc (Typ). (4) When the PFC_Ctrl is high as well as ±BC reaches 360V and then delays 300mS, the DC/DC_Ctrl signal will change from low to high. After the steps mentioned the output voltage of unit starts to increase to specified voltage level. (5) When the output voltage of DC9010-690G reaches 13.7V (Typ) at start up, the ENA signal is pulled low to indicate that unit finished the turn on sequence. The unit finished the turn on sequence through the steps above.  Region II：The over temperature protection (OTP) action. When the baseplate temperature (refer to spec. figure 2) of the unit rises to 110℃ (Typ), both PFC and DC/DC converters turns off and the output shuts down. When the baseplate temperature decreases to 90 ℃(Min), the output au- to-recovers.  Region III：PFC output over voltage protection (OVP) action. When ±BC is over 424V (Typ), the PFC converter turns off. The PFC output voltage auto-recovers if the failure is removed.  Region IV：Output OVP action. The output OVP mode is clamped.

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Rev.3.6 2014/02/26 Web Site: http://www.acbel.com8  Region V：Output over current protection (OCP) action. When t he output current of the unit is over limitation, the output voltage steps down. If the failure mode is removed, the output voltage auto-recovers.  Region VI： (1) Input UVLO action. When the input voltage is under 80Vac (Typ) , the PFC_Ctrl signal changes from high to low, which means that the PFC converter turns off. After ±BC reduces to 300V , the inrush signal changes from high to low at the same time. (2) When the inrush is low and delays 5mS, the DC/D C_Ctrl changes from high to low, which means the DC/DC converter turns off. (3) When the output voltage of DC9010-690G decreases to 13.7V (Typ), the ENA signal changes from low to high. The unit turns off through the steps of region VI.

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 C1,2,3 250V 1uF Film X Cap C16,17 0.033uF EMI; Ceramic or Film C4,5 4700pf Ceramic Y Caps L1,2 6mH EMI C6,7 1000pf Ceramic Y Caps R1 470K 2W Bleeder C8,9 450V 1uF Film TRF1 10Ω Thermal Fuse C10,11 390uF/450V Electrolytic Bulk Caps; F1 250V 15A FB max. 1200uF C12 1000pf Ceramic Y Cap C13,14 12V: 1000uF/50V Electrolytic 28V: 470uF/50V 48V: 220uF/50V C15 12V: 2.2uF/25V Ceramic 28V, 48V: 2.2uF/100V Application Circuit Instructions F1: This power module has no internal fuse. Use an external fuse to acquire each Safety Standard and to further improve safety. Further, Fast-Blow type fuses must be used per one module. Also, In-rush Surge current flows during line throw-in. Be sure to check I²t rating of external switch and external fuse. Recommended External Fuse: 15A Select fuse based on rated voltage, rated current and surge capability. 1. Voltage Ratings: 100VAC Line: AC125V 200VAC Line: AC250V 2. Current Ratings: Rated current is determined by the maximum input current based on operating conditions and can be calculated using the following formula: Iin (max.) = Pout (Arms) Iin (max.): Maximum Input Current Vin x Eff x PF Pout: Maximum Output Power Vin: Minimum Input Voltage Eff: Efficiency PF: Power Factor C1,2,3: 1uF (Safety Approved “X” Film Capacitor): Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating: 250VAC Note: Connect C3 as near as possible to the input terminals of the power module. C4,5: 4,700pF (Ceramic “Y” Capacitor): Add ceramic capacitor as an EMI/EMS counter measure. Be sure to consider leakage current of your equipment when adding this capacitor. High withstand voltages are applied across this capacitor depending on the application. Select capacitors with high withstand voltage ratings. C6,7: 1,000pF (Ceramic “Y” Capacitor): Add ceramic capacitor as an EMI/EMS counter measure. Be sure to consider leakage current of your equipment when adding this capacitor. High withstand voltages are applied across this capacitor depending on the application. Select capacitors with high withstand voltage ratings. C8,9: 1uF (Film Capacitor): Ripple current flows through this capacitor. When selecting capacitor, be sure to check the allowable maximum ripple current rating. Verify the actual ripple current flowing through this capacitor by doing actual measurement. Recommended Voltage Rating: 450VAC Note: Select capacitor with more than 3A (rms) rating. Connect C8,9 as near as possible to the input terminals of the power module. T F R

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Rev.3.6 2014/02/26 Web Site: http://www.acbel.com10 Fig. 4 Bulk cap ripple current requirement vs. Output load R2R2 R2R2: Inrush current limit. Resistance can be calculated by formula below. Suggest to choose resistance >10ohm. . Vinrms: Input voltage Ir,pk: Inrush current peak value. Sufficient inrush energy withstand capacity is required. Required energy capacity can be calculated below and suggest having some design margin. Cbulk : Bulk capacitance (C10&C11) Vinrms: Input voltage. The selected inrush resistor R2 have to meet the formula below, if the resistor value over the limitation may cause the brick damage. Cbulk: Bulk capacitance (C10&C11) C12C12 C12C12: Part of EMI filter. Choose safety approved Y-cap. C13 C14C13 C14C13 C14C13 C14: E-cap to reduce output ripple and ensure stability. Choose low ESR part and check the ripple current rating higher than application. Suggest at least 470uF*2 if Tb>-20℃ and 470uF*4 if -40℃<Tb<-20℃. C15C15 C15C15: Connect ceramic capacitor near output terminal to reduce output noise. C16 C17C16 C17C16 C17C16 C17: Ceramic or film capacitor for EMI filtering. High voltage rating is required for isolation requirement. pkIr VinR rms 2*= 2)2(*2 rmsbulk VinC bulkC mSR *20 300<

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 C10,11 (390uF x 2 PCs in parallel; Electrolytic Bulk Capacitors) Boost voltage bulk capacitor is determined by boost voltage ripple voltage, ripple current and hold-up time. Select capacitor value such that boost voltage ripple voltage does not exceed 15Vp-p. Recommended Voltage Rating: 450VDC Recommended Total Capacitor: 390uF to 1,200uF Notes: 1) When ambient temperature is -20ºC or less, AC ripple of boost voltage, output ripple voltage and start-up characteristics might increase or be affected due to ESR characteristics of the bulk capacitors. Therefore, verify above characteristics by actual evaluation. 2) Do not connect capacitors with more than the above capacitance value as this would result in power module damage. C12: 1,000pF (Ceramic “Y” Capacitor): Part of EMI filter. Choose safety approved “Y” capacitor. C13,14: 470uF/50V x 2 PCs in parallel; (220uF/100V for 48V Output) Electrolytic Capacitor: Take note of the maximum allowable ripple current of the electrolytic capacitor used. Especially for sudden load current changes, verify actual ripple current and make sure that allowable maximum ripple current is not to be exceeded. Note: Connect capacitors within 50mm from the output terminals +V and -V of the power module. C15: 2.2uF/100V (Ceramic Capacitor): Connect chip ceramic capacitor within 50mm from the output terminals +V and -V of the power module to reduce output spike noise. Also, note that output spike voltage may vary depending on the wiring pattern of the printed circuit board. C16,17: 0.033uF (Ceramic or Film Capacitor): Connect ceramic or film capacitor as EMI/EMS counter measure and to reduce spike noise. Note: High Voltage is applied across this capacitor during withstand voltage test depending on the applicatiion. Connect these capacitors as near as possible to the output terminals of the power module. L1,2: 6mH: Add common mode choke coil as EMI/EMS counter measure. When using multiple modules, connect coil to each module. Note: Depending on the input filter used, noise might increase or power module might malfunction due to filter resonance. R1: 470KΩ (Bleeder Resistor): Connect bleeder resistor across ACL and ACN terminals. TFR1: 10 to 100Ω: By connecting a thermal fuse resistor across R and +BC terminals as shown in fig. 3, in-rush current during line throw-in can be suppressed. Failures due to in-rush current such as melting of external fuse, welding of relay or switch connecting joints or shutdown of No Fuse Breakers (NFB) can occur. Therefore, be sure to connect this external thermal fuse resistor. Note: This module will not operate without this external resistor. Selection Method of External Resistor TFR1: 1) Calculating Resistance Value for TFR1: Resistance can be calculated by the following formula: R = Vin (Ω) R: Resistance Value for External TFR1 Irush Vin: Input Voltage converted to DC value = Input Voltage (rms) x √2 Irush: Input surge current value 2) Required Surge Current Rating: Sufficient surge current withstand capability is required for external TFR1. Required Surge Current Rating can be selected by I²t. (Current squared multiplied by time) I²t = Co x Vin²(A²s) I²t: Current squared multiplied by time 2 x R Co: Booster Voltage Bulk Capacitance Vin: Input Voltage converted to DC value = Input Voltage (rms) x √2 R: Resistance Value for External TFR1

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 Draft Rev:3.3 2013/07/31 Web Site: http://www.acbel.com11 INPUT VOLTAGE DROPOUT TRANSIENT IMMUNITY: The output voltage should immune input voltage drop out. The allowable dropout time is related to outpu t power and bulk capacitance (C10&C11) and Vo. Dropout time is longer with higher capacitance or lower output power. But the maximum allowable dropout time is 60mS60mS60mS60mS regardless of capacitance and output power. Th e formula of allowable dropout time is shown below. Cbulk: Bulk capacitance (uF) F o r V o ≦ 1 2 V Po: Output power (W) Tholdup: Allowable dropout time (mS) For Vo>12V For example, if required dropout time is 20mS at Po=500W, Vo=12V, the Cbulk capacitance must higher than 475uF, Note that capacitance tolerance need to take into account and must fulfill the minimum capacitance 390*2uF requirement for -40degC operation. Note that the maximum allowable dropout time is 60mS even the calculation result over 60mS. 9 2. 0 * )320385( 1000*)*(2 22 −= holdupo bulk TPC 1000*)*(2 22 Vo TPC holdupo bulk Draft Rev:3.3 2013/07/31 Web Site: http://www.acbel.com12 EFFICIENCY CURVE: DC9011-000G Efficiency Curve @ 12Vo, Tb=25degC 0 10 20 30 40 50 60 70 80 90 100 Efficiency 230V 110V Fig.5 Efficiency curve OUTLINE DRAWING: Fig.5 Outline drawing (12V): Fig. 4a Efficiency curve SMV-12-500 EFFICIENCY CURVE

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 EFFICIENCY CURVE: At 4 SMV-48-500 Efficiency Curve 8V o, T b= 2 5de gC 01 02 03 04 05 06 07 08 09 01 00 Output Load % E ci en cy 11 0 Vi n 23 0 Vi n Fig. 4b E ciency curve (48V): SMV-28-500 Effi ci en cy C ur ve @ Vo = 2 8V , Tb = 2 5 ˚C 01 02 03 04 05 06 07 08 09 01 00 Ou tp ut L oa d (% ) Effi ci en cy ( %) 110Vac 230Vac (28V): Fig. 4b Efficiency curve Fig. 4c Efficiency curve

WWW.ASTRODYNETDI.COM ASTRODYNE USA: 1-800-823-8082 ASTRODYNE PACIFIC: 886-2-26983458 MECHANICAL DIMENSIONS