100W DC-DC Converter 15 Voltage With Solderability IEC60068-2-20 YN100-48S15-PEC

DC-DC Converters 100W Output 12V YN100-48S15-PEC

 

Key Features

Output power: 100W

Wide input range: 36-72Vdc

High conversion efficiency: Up to 92%

Line regulation to ±0.5%

Load regulation to ±0.5%

Fixed operating frequency

Isolation voltage :1500V

Enable (ON/OFF) control

Output over-load protection

Hiccup mode short circuit protection

Over-temperature protection

Input under-voltage lock-out

Output voltage trim: ±5%

 

Package: Encapsulated

Quarter Brick: 2.30×1.48×0.48in

58.5×37.6×12.3mm

 

Product Overview

These DC-DC converter modules use advanced power

processing, control and packaging technologies to provide

the performance, flexibility, reliability and cost effectiveness

of a mature power component. High frequency Active Clamp

switching provides high power density with low noise and

high efficiency.

 

1. Electric Characteristics

Electrical characteristics apply over the full operating range of input voltage, output load and base plate temperature,unless otherwise specified. All temperatures refer to the operating temperature at the center of the base plate. All data testing at Ta=25oC except especial definition.

 

1.1 Absolute Maximum Ratings

Parameter	Min	Typ	Max	Units	Notes
Input Voltage			78	Vdc	Continuous, non-operating
			75	Vdc	Continuous, operating
			78	Vdc	Operating transient protection,<100mS
Isolation Voltage			2000	Vdc	Input to Output
Operating Temperature	-55		100	℃
Storage Temperature	-65		125	℃
Enable to Vin- Voltage	-0.8		10	Vdc

 

1.2 Input Characteristics

Parameter	Min	Typ	Max	Units	Notes
Input Voltage Range	36	48	72	Vdc	Continuous
Under-Voltage Lockout		35.5	35.9	Vdc	Turn-on Threshold
	32.5	34.0		Vdc	Turn-off Threshold
Maximum Input Current		3.5		A	Full load;36Vdc input
Efficiency		92.5		%	Figures1-4
Dissipation		7	11	W	No load
Disabled Input Current		10		mA	Enable pin low
Recommend External Input Capacitance		100		μF	Typical ESR 0.1-0.2W

 

1.3 Output Characteristics

Parameter	Min	Typ	Max	Units	Notes
Output Voltage Set point	14.85	15.00	15.15	Vdc	Nominal input; No load;25℃
Output Voltage Range	14.80	15.03	15.20	Vdc
Output Current Range	0		6.7	A	Subject to thermal derating; Figures 5 - 8
Line Regulation		±0.05	±0.50	%	Low line to high line; Full load
Load Regulation		±0.09	±0.50	%	No load to full load; Nominal input
Temperature Regulation			±0.02	% / °C	Over operating temperature range
Current Limit	7	7.7	8.7	A	Output voltage 95% of nominal
Short Circuit Current	0.3	7.7	8.5	A	Output voltage <250 mV
Ripple (RMS)		50		mV	Nominal input; Full load;      20 MHzbandwidth; Figure 13
Noise(Peak-to-Peak)		150		mV
Maximum Output Cap.			4000	μF	Nominal input; Full load
Output Voltage Trim		±5		%	Nominal input; Full load; 25°C

 

1.4 Dynamic Response Characteristics

Parameter	Min	Typ	Max	Units	Notes
Change In Output Current (di/dt= 0.1A/μs)		440		mV	50% to 75% to 50% Iout max; Figure 11
Change In Output Current (di/dt= 2.5A/μs)		520		mV	50% to 75% to 50% Iout max; Figure 12
Settling Time		300		μS	To within 1% Vout nom.
Turn-on Time		15		mS	Full load; Vout=90% nom. Figure 9
Shut-down Fall Time		5		mS	Full load; Vout=10% nom. Figure 10
Output Voltage Overshoot				%

 

1.5 Functional Characteristics

Parameter	Min	Typ	Max	Units	Notes
Switching Frequency	187	230	255	KHz	Regulation stage and Isolation stage
Trim(Pin6)					See part 7.3 Voltage Trim(Pin6)
Output Voltage Trim		5		%	Trim up, Trim Pin to Vout(+).
		5		%	Trim down, Trim Pin to Vout(-).
Enable(ON/OFF)Control(Pin2)					See part 7.1
Enable Voltage Enable Source Current			10	Vdc	Enable pin floating
			0.5	mA
Enable (ON-OFF Control) Positive Logic	3.5		10	Vdc	ON-Control, Logic high or floating
	-0.5		0.5	Vdc	OFF-Control, Logic low
Over-Load Protection	105	115	130	%	Current-Mode, Pulse by Pulse Current Limit Threshold,(%Rated Load)
Short-Circuit Protection			65	mΩ	Type: Hiccup Mode, Non-Latching, Auto-Recovery,Threshold,Short-Circuit Resistance
Over-Temperature Protection		105		℃	Type: Non-Latching, Auto-Recovery； Threshold, PCB Temperature
		15		℃	Hysteresis

 

1.6 Isolation Characteristics

Parameter	Min	Typ	Max	Units	Notes
Isolation Voltage	1500			Vdc	Input to Output
	1500			Vdc	Input to Base
	500			Vdc	Output to Base
Isolation Resistance	10			MΩ	At 500VDC to test it when atmospheric pressure and R.H. is 90%
Isolation Capacitance		1000		pF

 

2. General Characteristics

Parameter	Min	Typ	Max	Units	Notes
Weight		2.5(72)		Oz (g)	Encapsulated
MTBF ( calculated )	1			MHrs	TR-NWT-000332; 80% load,300LFM, 40℃ Ta

 

3. Environmental Characteristics

Parameter	Min	Typ	Max	Units	Notes
Operating Temperature	-55		+100	℃	Extended, base PCB temperature
Storage Temperature	-65		+125	℃	Ambient
Temperature Coefficient			±0.02	%/℃
Humidity	20		95	%R.H.	Relative Humidity, Non-Condensing

 

4. Standards Compliance

Parameter	Notes
UL/cUL60950
EN60950
GB4943
Needle Flame Test (IEC 695-2-2)	Test on entire assembly; Board & plastic components UL94V-0 compliant
IEC 61000-4-2

 

5. Qualification Specification

Parameter	Notes
Vibration	10-55Hz sweep, 1 min./sweep, 120 sweeps for 3 axis
Mechanical Shock	100g min, 2 drops in x and y axis, 1 drop in z axis
Cold(in operation)	IEC60068-2-1 Ad
Damp Heat	IEC60068-2-67 Cy
Temperature Cycling	-40°C to 100°C, ramp 15°C/min., 500 cycles
Power/Thermal Cycling	Vin = min to max, full load, 100 cycles
Design Marginality	Tmin-10°C to Tmax+10°C, 5°C steps, Vin = min to max, 0-105% load
Life Test	95% rated Vin and load, units at derating point, 1000 hours
Solderability	IEC60068-2-20

 

6. Typical Wave And Curves

 

Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C.

Figure 2: Efficiency at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (nominal Vin).

 

Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C.

Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (derating input voltage).

 

Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 0 LFM through 400 LFM with air flowing from pin 3 to pin 1 (derating input voltage).

Figure 6: Thermal plot of converter at full load current (100W) with 25°C air flowing at the rate of 200 LFM. Air is flowing across the converter from pin 3 to pin 1 (derating input voltage).

 

Figure 7: Maximum output power-derating curves vs. ambient air temperature for airflow rates of 0 LFM through 400 LFM with air flowing from input to output (nominal input voltage).

Figure 8: Thermal plot of converter at full load current (100W) with 25°C air flowing at the rate of 200 LFM. Air is flowing across the converter from input to output (nominal input voltage).

 

Figure 9: Turn-on transient at full load (resistive load) (20 ms/div).Input voltage pre-applied.  Ch 1: Vout (5V/div).Ch 2: ON/OFF input(2V/div)

Figure 10: Shut-down fall time at full load (20 ms/div). Ch 1: Vout (5V/div).Ch 2: ON/OFF input (2V/div).

 

Figure 11: Output voltage response to step-change in load current (50%-75%-50% of Iout(max); dI/dt = 0.1A/μs). Load cap: 10μF, 100 mΩ ESR tantalum capacitor and 1μF ceramic capacitor. Ch 1: Vout (200mV/div).

Figure 12: Output voltage response to step-change in load current (50%-75%-50% of Iout(max): dI/dt = 2.5A/μs). Load cap: 470μF, 30 mΩ ESR tantalum capacitor and 1μF ceramic cap. Ch 1: Vout (200mV/div).

 

Figure 13: Output voltage ripple at nominal input voltage and rated load current (50mV/div). Load capacitance: 1μF ceramic capacitor and 10μF tantalum capacitor. Bandwidth: 20 MHz.

 

7. Function Specifications

7.1 Enable (ON/OFF) Control (Pin 2)

The Enable pin allows the power module to be switched on and off electronically. The Enable (On/Off) function is useful for conserving battery power, for pulsed power application or for power up sequencing. The Enable pin is referenced to the -Vin. It is pulled up internally, so no external voltage source is required. An open collector (or open drain) switch is recommended for the control of the Enable pin. When using the Enable pin, make sure that the reference is really the -Vin pin, not ahead of EMI filtering or remotely from the unit. Optically coupling the control signal and locating the opto coupler directly at the module will avoid any of these problems. If the Enable pin is not used, it can be left floating (positive logic) or connected to the -Vin pin (negative logic).Figure A details five possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry.

 

Figure A: Various circuits for driving the ON/OFF pin.

Figure B: Internal ON/OFF pin circuitry.

 

7.2 Remote Sensing (Pins 7 and 5)

Remote sensing allows the converter to sense the output voltage directly at the point of load and thus automatically compensates the load conductor distribution & contact losses (Figure C). There is one sense lead for each output terminal, designated +Sense and -Sense. These leads carry very low current compared with the load leads. Internally a resistor is connected between sense terminal and power output terminal. If the remote sense is not used, the sense leads needs to be shorted to their respective output leads(Figure D).

Care has to be taken when making output connections. If the output terminals should disconnect before the sense lines, the full load current will flow down the sense lines and damage the internal sensing resistors. Be sure to always power down the converter before making any output connections. The maximum compensation voltage for line drop is up to 0.5V.

 

Figure C: Remote Sense Connection.

Figure D: Remote Sense is not Used.

 

7.3 Voltage Trim (Pin 6)

Output voltage can be adjusted up or down with an external resistor. There are positive trim logic and negative trim logic available. For positive logic, the output voltage will increase when an external trimming resistor is connected between the Trim and +Vout/+Sense pin. The output voltage will decrease when an external trimming resistor is connected between Trim and -Vout/-Sense pin. A multi-turn 20KΩ trim pot can also be used to adjust the output voltage up or down(Figure E & F).

Trim-Up	Trim Pin to +Sense	Trim Pin to -Sense
Trim-Down	Trim Pin to -Sense	Trim Pin to +Sense

 

Figure E:Positive Trim Logic.

Figure F: Trim Pot Connection.

 

7.4 Protection Features

 ·Input Under-Voltage Lockout: The converter is designed to turn off when the input voltage is too low, helping avoid an input system instability problem, The lockout circuitry is a comparator with DC hysteresis. When the input voltage is rising, it must exceed the typical Turn-On Voltage Threshold value(listed on the specification page) before the converter will turn on. Once the converter is on, the input voltage must fall below the typical Turn-Off Voltage Threshold value before the converter will turn off.

·Output Current Limit: The maximum current limit remains constant as the output voltage drops. However, once the impedance of the short across the output is small enough to make the output voltage drop below the specified Output DC Current-Limit Shutdown Voltage, the converter into hiccup mode indefinite short circuit protection state until the short circuit condition is removed. This prevents excessive heating of the converter or the load board.

·Over-Temperature Shutdown: A temperature sensor on the converter senses the average temperature of the module. The thermal shutdown circuit is designed to turn the converter off when the temperature at the sensed location reaches the Over-Temperature Shutdown value. It will allow the converter to turn on again when the temperature of the sensed location falls by the amount of the Over-Temperature Shutdown Restart Hysteresis value.

8. Typical Application And Design Consideration

 

8.1 Typical Application Circuit

Figure G: Typical application circuit (negative logic unit, permanently enabled).

 

8.2 Input Filtering

DC-DC converters, by nature, generate significant levels of both conducted and radiated noises. The conducted noises included common mode and differential mode noises. The common mode noise is directly related to the effective parasitic capacitance between the power module input conductors and chassis ground. The differential mode noise is across the input conductors. It is recommended to have some level of EMI suppression to the power module. Conducted noise on the input power lines can occur as either differential or common-mode noise currents. The required standard for conducted emissions is EN55022 Class A (FCC Part15). (See Figure H).

 

 

Figure H: Input Filtering.

9. Test Method 9.1 Output Ripple & Noise Test The output ripple is composed of fundamental frequency ripple and high frequency switching noise spikes. The fundamental switching frequency ripple (or basic ripple) is in the 100KHz to 1MHz range; the high frequency switching noise spike (or switching noise) is in the 10 MHz to 50MHz range. The switching noise is normally specified with 20 MHz bandwidth to include all significant harmonics for the noise spikes. The easiest way to measure the output ripple and noise is to use an oscilloscope probe tip and ground ring pressed directly against the power converter output pins, as shown below. This makes the shortest possible connection across the output terminals. The oscilloscope probe ground clip should never be used in the ripple and noise measurement. The ground clip will not only act as an antenna and pickup the radiated high frequency energy, but it will introduce the common-mode noise to the measurement as well. The standard test setup for ripple & noise measurements is shown in Figure I. A probe socket (Tektronix, P.N. 131.0258-00) is used for the measurements to eliminate noise pickup associated with long ground clip of scope probes.

 

Figure I: Ripple & Noise Standard Testing Means.

10. Physical Information  

 

10.1 Mechanical Outline

 

 

Notes:   

1. Pins 4, 8 are 0.060” (1.52mm) dia. with 0.085” (2.16mm) dia. standoff shoulders.

2. All other pins are 0.040” (1.02mm) dia. with 0.065” (1.65mm) dia. standoff shoulders.

3. Tolerances: x.xx ±0.02 in. (x.x±0.5mm)

           x.xxx ±0.010 in. (x.xx±0.25mm)

 

10.2  Pin Designations

Pin No.	Name	Function
1	Vin(+)	Positive input voltage
2	Enable	TTL input to turn converter on and off, referenced to Vin(-), with internal pull up.
3	Vin(-)	Negative input voltage
4	Vout(-)	Negative output voltage
5	Sense(-)	Negative remote sense. Sense(-) may be connected to Vout(-) or left open.
6	Trim	Output voltage trim. Leave Trim pin open for nominal output voltage.
7	Sense(+)	Positive remote sense. Sense(+) may be connected to Vout(+) or left open.
8	Vout(+)	Positive output voltage