HBC DC-DC Series Data Sheet
300-Watt Half-Brick Converters
Features
•
•
•
•
•
•
•
•
•
•
•
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•
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High efficiency up to 94%
3
High power density – 110 W/in
High current rating - 25A
Low profile – 12.7mm height
Input/output isolation: 1500VDC
Basic insulation
Start-up into high capacitive load
Low conducted and radiated EMI
Output overcurrent protection
Output overvoltage protection
Overtemperature protection
Remote sense
Remote on/off (primary referenced), positive
or negative logic option
Adjustable output voltage from 9.6V to 13.2V
UL 1950 Recognition, CSA 22.2 No. 950-95
certification, TUV IEC950
Applications
•
•
•
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Intermediate Bus architectures
Telecommunications equipment
LAN/WAN applications
Data processing applications
Description
The HBC Series of high density bus converters convert a worldwide telecom bus voltage of 36 to 75VDC to a
12V bus at 25A. The output is ideal for powering non-isolated, point-of-load converters such as synchronous
buck converters used commonly in intermediate bus architectures.
The unit's open-frame, two-board construction provides ideal thermal transfer for maximum reliability. Power
devices are mounted on an Insulated Metal Substrate (IMS) base plate with very low thermal impedance. The
control PCB is physically isolated from the hotter IMS board, providing lower overall component temperatures for
high reliability. The standard feature set includes remote on/off, remote output voltage sensing, positive output
trim, input undervoltage lockout, and overtemperature shutdown with hysteresis.
Model Selection
Model
Input
Voltage
VDC
Input
Current,
Max
ADC
Output
Voltage
Vout,
VDC
Output rated
Current
I
rated,
ADC
Output
Ripple/Noise,
mV p-p
Typical
Efficiency @
I
rated,
%
HBC25ZH
36-75
10
12.0
25
150
92
REV. DEC 15, 2003
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Page 1 of 7
HBC DC-DC Series Data Sheet
300-Watt Half-Brick Converters
Absolute Maximum Ratings
Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long-
term reliability, and cause permanent damage to the converter.
Parameter
Input voltage
Operating Temperature
Storage Temperature
ON/OFF Control Voltage
Referenced to -Vin
Conditions/Description
Continuous
Transient, 100ms
Base Plate Temperature
Min
Max
75
100
110
125
7
Units
VDC
VDC
°C
°C
VDC
-40
-55
Environmental and Mechanical Specifications
All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.
Parameter
Shock
Sinusoidal Vibration
Weight
Water Washing
MTBF
Conditions/Description
Halfsine wave, 3 axes
GR-63-CORE, Section 5.4.2
Standard process
Per Bellcore TR-NWT-000332
Min
50
1
Nom
Max
Units
g
g
gm
kHrs
2.6/73
Yes
1,100
Isolation Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted.
Parameter
Insulation Safety Rating
Isolation Voltage
Isolation Voltage
Isolation Resistance
Isolation Capacitance
Conditions/Description
Input to output, output to base plate
Input to base plate
Min
1500
1500
10
1000
Nom
Basic
Max
Units
VDC
VDC
MOhm
pF
Input Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise noted.
Parameter
Input Voltage
Turn-On Input Voltage
Turn-Off Input Voltage
Turn-On Time for turn-on via
application of input voltage
Turn-On Time for turn-on via
ON/OFF signal
Input Reflected Ripple Current
Inrush Transient
Conditions/Description
Continuous
Ramping Up
Ramping Down
Time from Vin=UVLO to regulation
band
Time from ON/OFF signal to
regulation band
Full Load, 12µH source inductance
Vin=Vin.max
Min
36
33
31
Nom
48
Max
75
36
33
85
25
200
0.25
Units
VDC
VDC
VDC
mS
mS
mA p-p
As
2
60
10
REV. DEC 15, 2003
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Page 2 of 7
HBC DC-DC Series Data Sheet
300-Watt Half-Brick Converters
Output Specifications
All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.
Parameter
Output Voltage Setpoint Accuracy
Output Current*
Line Regulation
Load Regulation
Total output voltage regulation
Remote Sense Headroom
Dynamic Regulation
Peak Deviation
Settling Time
Admissible Load Capacitance
Output Current Limit Threshold**
Switching Frequency
Overvoltage Protection,
Latching
Trim Range
Conditions/Description
Vin=Vin.nom, Full Load
See selection chart for I
rated
Vin.min to Vin.max, I
rated
Vin=Vin.nom, 10% to 100%I
rated
Over all input voltage, load, and
temperature conditions
75-100% load step change
to 1% error band
I
rated
, Nom Vin
Vout≤0.97Vout.nom
Over all input voltage and load
conditions
I
rated
, Vin=Vnom
110
400
115
80
125
110
600
600
1,000
15,000
150
mV
µs
µF
%I
rated
kHz
%Vout
%Vout
Min
-2
0
Nom
Max
2
25
0.5
1.0
4
5%
Units
%Vout
A
%Vout
%Vout
%Vout
%Vout
-4
** Overcurrent protection is non-latching with auto recovery.
Feature Specifications
All specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted.
Parameter
Shutdown (ON/OFF)
Negative Logic
Converter ON
Source Current
Converter OFF
Open Circuit Voltage
Positive Logic
Converter ON
Open Circuit Voltage
Converter OFF
Source Current
Overtemperature Protection
Conditions/Description
On/Off signal is low – converter is ON
-0.5
ON/OFF pin is connected to -Vin
2.5
ON/OFF pin is floating
On/Off signal is low–converter is OFF
2.5
ON/OFF pin is floating
-0.5
ON/OFF pin is connected to -Vin
Base Plate Temperature
120
0.8
0.5
7
5
7
5
0.8
0.5
130
VDC
MADC
VDC
VDC
VDC
VDC
VDC
mADC
°C
Min
Nom
Max
Units
REV. DEC 15, 2003
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Page 3 of 7
HBC DC-DC Series Data Sheet
300-Watt Half-Brick Converters
Efficiency Curves
95
EFFICIENCY %
90
85
36V
For output decoupling we recommend using a
10µF low ESR tantalum capacitor
(AVX TPSC106M025R0500 is used in our test
setup) and a 1µF ceramic capacitor. Note, that
the capacitors do not substitute the filtering
required by the load.
Shutdown Feature Description
The ON/OFF pin in the HBC Series converters
functions as a normal soft shutdown.
It is
referenced to the –Vin pin (see Figure 2). With
the positive logic, when the ON/OFF pin is pulled
low, the output is turned off and the unit goes into
a very low input power mode.
With negative logic, when the ON/OFF pin is
pulled low, the unit is turned on.
An open collector switch is recommended to
control the voltage between the ON/OFF pin and
the -Vin pin of the converter. The ON/OFF pin is
pulled up internally, so no external voltage source
is required. The user should avoid connecting a
resistor between the ON/OFF pin and the +Vin
pin.
When the ON/OFF pin is used to achieve remote
control, the user must take care to ensure that the
pin reference for the control is really the -Vin pin.
The control signal must not be referenced ahead
of EMI filtering, or remotely from the unit.
Optically coupling the information and locating the
optical coupler directly at the module will solve
any of these problems.
Note:
If the ON/OFF pin is not used, it can be left floating (positive
logic), or connected to the -Vin pin (negative logic).
80
75
0
20
48V
75V
40
60
LOAD %
80
100
Figure 1. HBC25ZH Efficiency vs. Output Load
Typical Application
Figure 2 shows the recommended connections for the
HBC Series converter.
HBC25ZH
Fuse
+Vi
+Vo
+Sense
C1
O n/O ff
Trim
C2
C3
-Sense
-Vi
-Vo
OUTPUT VOLTAGE TRIM
Figure 2. Typical Application of HBC Series
Industry Standard Positive Trim (suffix –T)
The HBC Series converters do not require any external
components for proper operation. However, if the
distribution of the input voltage to the converter contains
significant inductance, the capacitor C1 may be
required to enhance performance of the converter. A
minimum of a 68µF electrolytic capacitor with the
ESR<0.7Ω is recommended for the HBC Series.
Refer to the “Inrush Current Control Application Note”
on www.power-one.com for suggestions on how to limit
the magnitude of the inrush current.
The -T option units trim up with a resistor from the
Trim (#7) pin to the +Sense (#8) pin and trim
down with a resistor from the Trim (#7) pin to the
–Sense (#6) pin as shown in Figure 3.
REV. DEC 15, 2003
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Page 4 of 7
HBC DC-DC Series Data Sheet
300-Watt Half-Brick Converters
to receive safety agency approval, certain rules
must be followed in the design of the system. In
particular, all of the creepage and clearance
requirements of the end-use safety requirements
must be observed. These documents include
UL60950 - CSA60950-00 and EN60950, although
other or additional requirements may be needed
for specific applications.
The HBC Series converters have no internal fuse.
The external fuse must be provided to protect the
system from catastrophic. The user can select a
fuse based upon the highest inrush transient at
the maximum input voltage and the maximum
input current of the converter, which occurs at the
minimum input voltage. Both input traces and the
chassis ground trace (if applicable) must be
capable of conducting a current of 1.5 times the
value of the fuse without opening. The fuse must
not be placed in the grounded input line, if any.
In order for the output of the HBC Series
converter to be considered as SELV (Safety Extra
Low Voltage) or TNV-1, according to all IEC60950
based standards, one of the following
requirements must be met in the system design:
•
•
If the voltage source feeding the module is
SELV or TNV-2, the output of the converter
may be grounded or ungrounded.
If the voltage source feeding the module is
ELV, the output of the converter may be
considered SELV only if the output is
grounded per the requirements of the
standard.
If the voltage source feeding the module is a
Hazardous Voltage Secondary Circuit, the
voltage source feeding the module must be
provided with at least basic insulation
between the source to the converter and any
hazardous voltages.
The entire system,
including the HBC converter, must pass a
dielectric withstand test for reinforced
insulation. Design of this type of systems
requires expert engineering and under-
standing of the overall safety requirements
and should be performed by qualified
personnel.
Figure 3. HBC Series Positive Trim Schematic
The equations below determine the trim resistor value
required to achieve a
∆V
change in the output voltage.
⎛
Vo
(100
+ ∆
%) (100
+
2
∆
%)
⎞
Rup
= ⎜
−
⎟
k
Ω
∆
%
⎝
1.225
∆
%
⎠
⎛
100
⎞
Rdown
= ⎜
−
2)
⎟
k
Ω
⎝ ∆
%
⎠
where
∆V%
is the output voltage change expressed in
percents of the nominal output voltage, Vo.
Notes:
1. When the output voltage is trimmed up, the output power from
the converter must not exceed its maximum rating. The power is
determined by measuring the output voltage on the output pins,
and multiplying it by the output current.
2.
In order to avoid creating apparent load regulation degradation, it
is important that the trim resistors are connected directly to the
remote sense pins, and not to the load or to traces going to the
load.
The output voltage increase can be accomplished by either the
trim or by the remote sense or by the combination of both. In
any case the absolute maximum output voltage increase shall
not exceed 10% of the nominal output voltage
•
3.
Safety Considerations
The HBC Series converters feature 1500 Volt DC
isolation from input to output. The input to output
resistance is greater than 10MΩ. These converters are
provided with basic insulation between input and output
circuits according to all IEC60950 based standards.
Nevertheless, if the system using the converter needs
REV. DEC 15, 2003
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