TXS100ZA-R [BEL]
DC-DC Regulated Power Supply Module, 1 Output, 150W, Hybrid, 2.400 X 3.450 INCH, 0.500 INCH HEIGHT, 3/4 BRICK PACKAGE-14;
| 型号： | TXS100ZA-R |
| 厂家： | 
BEL FUSE INC. |
| 描述： | DC-DC Regulated Power Supply Module, 1 Output, 150W, Hybrid, 2.400 X 3.450 INCH, 0.500 INCH HEIGHT, 3/4 BRICK PACKAGE-14 |
| 文件： | 总27页 (文件大小：2635K) |
| 中文： | 中文翻译 | 下载： | 下载PDF数据表文档文件 |
Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Features
•
High density design in an industry standard
¾ brick size (2.4” x 3.45” x 0.5”)
Highly efficient topology with synchronous
rectifiers (η up to 92 %)
•
•
•
Unique mechanical and thermal design
Very high reliability achieved through
generous design safety margins
•
Tightly regulated output voltage, very low
output ripple, excellent dynamic performance
Monotonic start up
Provides basic insulation. I/O electric strength
test voltage 1500 V DC
Output voltage trim range ± 10 %
Remote sense, Primary remote ON/OFF
Overload, over temperature protection
Approvals cULus, TÜV, CE for LVD
•
•
•
•
•
•
Options / Accessories
Applications
•
Latest generation of broadband telecom
•
•
•
•
•
Negative ON/OFF logic
Long pins
and datacom equipment
•
•
•
High end computers
Wide trim range -30 %, +10 %
Horizontal heat sink
Vertical heat sink
Fibre optic network equipment
Gate array and RAM bank applications
Description
The TXS is a series of 75 to 120 A, open frame, highly efficient, board mountable DC-DC converters with a
unique patented thermal and mechanical design. These low voltage – high amperage converters supply the
next generation of microprocessors, gate arrays and integrated circuits with reliable power. The TXS series
features input under voltage lockout, overload and over temperature protection and fulfills all requirements
for a perfect fit into Distributed Power Architectures (DPAs).
Table of contents
Data section, tables
-
-
-
-
-
Output over voltage protection
Connection in parallel or in series
Output over current protection
Low input voltage
15
15
16
16
17
-
-
-
-
-
Selection chart, absolute max ratings
Approvals, safety, fusing
2
3
Electrical specification
3-5
5-6
6
EMC, reliability, environmental spec.
List of available application notes
Over temperature protection
Implementation
Characteristic curves
-
-
-
-
-
-
-
-
-
-
Safety considerations
EMC specification
18-19
20-22
22
-
-
-
-
-
Efficiency and power loss
Static and dynamic regulation
Turn on, turn off
7-8
9
Stability, input impedance
On board input and output filters
Thermal considerations
Reliability
10
11
12
22
Input and output ripple
23-25
25
Inrush current and MTBF figures
Description of functions
Layout considerations
Screw fixing
26
-
-
-
Trim function
13-14
14-15
15
26
Remote sense
Mechanical drawings
Ordering information
27
Loss and efficiency measurements
27
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Selection Chart
Model
Input voltage
range
Output
voltage
[V]
Output rated
current,
[A]
Rated power
[W]
Required airflow
[LFM] 1 / 2
[V]
TXS75ZY
TXS75ZA
TXS75ZB
TXS80ZC
TXS80ZD
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZC
TXS100ZD
TXS120ZY
TXS120ZA
TXS120ZB
1.2
1.5
1.8
2.0
2.5
1.2
1.5
1.8
2.0
2.5
1.2
1.5
1.8
90
110
160
75
80
112
135
160
200
120
150
180
200
250
144
180
216
210
250
300
250
36-75
290
100
120
350
380
500
400 3
450 3
500 3
1 LFM = Linear Feet per Minute (200 LFM ≈ 1 m/s)
2 Conditions: TA = 60 °C, TBase plate = 100 °C, Ui nom ±25 %, linear airflow, stand alone module.
Æ See pages 23 to 25 and calculation tool on TXS product CD ROM.
3 Preliminary data
Options / Accessories
Options / Accessories
Suffix
Remarks
see Control Specifications table 3
Negative Logic
N
Unit enabled when control signal is low
Long Pin, Lengths: 0.24’’ (6.1 mm)
P2
Standard pin length: 0.18” (4.6 mm)
Standard trim range: 90 to 110 % Uo nom
Wide Trim Range: 70 to 110 % Uo nom
R
(see pages 13/14)
Horizontal Heat sink
0.24" (6.1 mm)
1H
2H
3H
1V
2V
3V
(Includes thermal pad)
To extend operating thermal range
0.45" (11.4 mm)
0.95" (24.1 mm)
0.24" (6.1 mm
Fins on horizontal heat sinks run from the
input pins toward the output pins. Fins on
vertical heat sinks 90 ° to this.
Vertical Heat sink
(Includes thermal pad)
0.45" (11.4 mm)
0.95" (24.1 mm)
Absolute Maximum Ratings
Stress in excess of the absolute maximum ratings may cause performance degradation, adversely affect
long term reliability or cause permanent damage to the converter.
Parameter
Maximum Input voltage (Ui)
Conditions/Description
Min
Max
Units
V DC
V DC
°C
Continuous
36
75
Transient, 100 ms
Full load
Non operational
One minute max.
TTL compatible, referenced to Vi (-)
Adjusted by trim and/or sense
100
100
115
1500
5.5
Operating Base Plate Temperature (TBP
Storage Temperature (TS)
)
-40
-55
°C
I/O Electric Strength Test Voltage
V DC
V DC
% Uo nom
ON/OFF Control Voltage (USD
)
-1.0
Maximum Output Voltage (Uo)
120
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Safety Specification and Approvals
Approvals
Parameter
Conditions/Description
Value
EN 60950:2000, UL 60950
CSA 22.2 No. 60950-00
UL/TÜV Approvals
UL file No E132494
Safety
Parameter
Conditions/Description
I/Case, I/O
Value
Basic 1
Isolation
1
O/Case
Functional
I/Case, I/O
1500 V DC
500 V DC
typ. 50 MΩ
typ. 1.6 nF
Electric Strength Test Voltage 2
O/Case
Insulation Resistance
I/O Capacitance
EN 60950:2000/UL 60950
TA = 25 °C
TA = 25 °C
1
2
100 % factory test, one second
Fusing Considerations:
This power module is not internally fused. To meet safety requirements, an input line fuse should always be
used! Select a fuse according the specified input current in Table 1. The fuse rating should be selected in the
range [1.3·Ii max..10 A]. The UL file calls for a fuse rated F, 125 V DC, 10 A max. Refer to the fuse
manufacturer’s data for further information.
Electrical Specification
Unless otherwise stated the specification applies over the entire input voltage, output load and temperature
ranges. Sense lines are connected directly to the power pins. Trim pin is left open.
Table 1: Input Specification
Parameter
Conditions/Description
Min
36
Nom
48
Max
75
Units
Input Voltage
Ui
A
Max. Input Current
2.9
3.55
4.2
TXS75ZY
TXS75ZA
TXS75ZB
TXS80ZC
TXS80ZD
A
A
5.0
6.2
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZC
TXS100ZD
3.9
4.85
5.7
Ii max
Ui min, Io max, TBP = 100 °C
6.4
7.8
1
TXS120ZY
4.8
6.0
6.9
1
A
A
TXS120ZA
1
TXS120ZB
Inrush Current: All Types
Iinrush
Ui nom, Io max
0
(See figures 23/24)
Reflected Input Ripple Current
(See figure 21)
Stand-by Power
Ii R
Ui nom, Io max
10
mAp-p
W
Pi off
Shut down active
0.3
0.5
External Input Capacitance for
stable Operation [µF/Po]
(See page 22)
µF /
Ci
100
125 W
1 Preliminary data
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Table 2: Output Specification
Parameter
Conditions/Description
Min
Nom
Max
Units
Set Point
TXSxxxZY
TXSxxxZA
TXSxxxZB
TXSxxxZC
TXSxxxZD
1.194
1.492
1.791
1.990
2.487
1.2
1.5
1.8
2.0
2.5
1.206
1.508
1.809
2.010
2.513
Uo
Ui nom, 50% Io max
TA = 25 °C
,
V DC
Output Voltage Accuracy
± 0.5
% Uo
% Uo
Ui min to Ui max
,
Static Line Regulation
± 0.05
± 0.05
± 0.1
Io max, TA = 25 °C
(see figure 9)
Ui nom
,
Static Load Regulation
(see figure 10)
± 0.1
% Uo
0 to 100 % Io max, TA = 25 °C
Ui nom, Io max
Output Voltage Deviation over
± 0.3
± 1
% Uo
% Uo
Temperature Range
Uo Overall Tolerance
Output Voltage Ripple and Noise
(see figures 17/19)
RMS
Ui min to Ui max, Io min to Io max
TA = 25 °C
Ur
7
30
16
70
mV
mV
% Uo nom
20 MHz Bandwidth
Peak to Peak
Output Voltage Trim Range 1 / 3
UTR
Ui min to Ui max, Io min to Io max
± 10
2/ 3
Output Current
0
0
0
0
75
80
TXS75xx
TXS80xx
TXS100xx
TXS120xx
Io
Ui min to Ui max
A DC
100
120
Output Current Limit Threshold
Ilim
Hiccup, self recovery 4
110
130
% Io nom
Efficiency
88.0
87.5
89.0
88.5
90.0
89.5
91.0
90.5
91.0
90.5
TXS75ZY
TXS100ZY
TXS75ZA
TXS100ZA
TXS75ZB
Ui nom, Io max
%
η
TXS100ZB
TXS80ZC
TXS100ZC
TXS80ZD
TXS100ZD
(see figures 1-4)
Switching Frequency
Input and Output Ripple
Frequency
Fs
190
760
kHz
kHz
4·Fs
Dynamic Load Regulation
(see figures 11/12)
Peak Deviation
∆Io = 25 A, dIo/dt = 2 A/µs
TA = 25 °C
± 10
100
% Uo nom
µs
Settling Time
Start Up Time (over Ui or
ON/OFF) (see figures 14-16)
Admissible Load Capacitance
(see figures 15/16)
Ui nom, Io max
Ui nom, Io max
11
15
ms
Co
0
100
mF
1
3
2
Wide trim range optional
No minimum load required
Reduced output power of models ZB (1.8 V) and ZD (2.5 V) at minimum input voltage, highest base plate temperature
and increased Uo (via Trim or Sense). Explanation and limits see page 16.
Timing diagram hiccup mode: see figure 37.
4
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Table 3: Control Specification
Parameter
Conditions/Description
Ui nom
Referenced to
Vi (-) (pin 1)
Min
Nom
Max
Units
Shut Down Control 1 (ON/OFF, Pin 3)
Unit disabled if shut down low
Unit operating if active high or open
-1
1.5
1.5
5.5
V
Inverse Shut Down1 / 3 (ON/OFF, Pin 3)
Unit operating if shut down low
Ui nom
referenced to
Vi (-) (pin 1)
-1
1.5
1.5
5.5
V
Unit disabled if active high or open
Standard shut down, USD = 0
Inverted shut down, USD = 0
0.02
0.12
mA
mA
Shut Down Sink Current (ISD
)
Referenced to
Trim Input 2
(Trim, Pin 7)
0
Uo
sense (-) (pin 8)
V
Trim Input Impedance
20
kΩ
1
2
3
Shut down control signal = TTL compatible, see page 14
Control function and block diagram for Uo adjustment over a trim voltage UTR or a trim resistor RTR see pages 13/14.
Inverse shut down = option N.
Table 4: Protection Specification
Parameter
Conditions/Description
Min
Nom
Max
Units
V
Input Under Voltage Lockout
Turn on
34
32
36
Turn off
Hiccup (self recovery)
31
110
Overload Protection
Output OVP
130
% Io max
Continuous limitation,
no switch off
1
Models ZA, ZB, ZY
125
115
% Uo set
Models ZC, ZD
Automatic recovery
(Thermistor)
Measurement point on PCB
Over Temperature Shut Down
120
5
°C
K
Over Temperature Hysteresis
1
Uo set: Output voltage adjusted over trim or sense.
EMC and Reliability Specification
Table 5: EMC
Parameter
Electrostatic Discharge
Air
Conditions/Description
Value
Performance
IEC/EN 61000-4-2, level 4
15 kV
15 kV
3 V/m
Ui nom, Io max
criterion A 1
criterion A 1
Contact
Electromagnetic Field
Fast Transients/Burst
To Input
To Output
Electromagnetic Emission
IEC/EN 61000-4-3, level 2
IEC/EN 61000-4-4, level 4
8 kV/2.5 kHz
2 kV/5 kHz
B
Ui max, Io max
criterion A 1
CISPR 22/EN 55022, conducted 2
pass
3
1
2
3
See page 22
Radiated emissions depend heavily on the implementation.
With external filter, see pages 20/21
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Table 6: Reliability
Parameter
Conditions/Description
Value
Calculated MTBF 1
Ground benign, full load
TBP = 80 °C
44.6 years / 390 kh
31.7 years / 277 kh
21.8 years / 191 kh
Acc. MIL-HDBK 217F Notice 2
(See pages 12/25)
TBP = 90 °C
TBP = 100 °C
Burn In
Manufacturing Facilities
Full load
24 h
ISO 9001 certified
1
Further information on MTBF: See reliability report on TXS product CD ROM
Environmental and Mechanical Specification
Parameter
Conditions/Description
Min
Nom
Max
Units
Damp Heat
IEC/EN 60068-2-3, 93 %, 40 °C
56
Days
1
Shock
IEC 60068-2-27
6 ms, 3 shocks in each direction,
100
gn
Unit operating
1
Sinusoidal Vibration
IEC 60068-2-6,
0.7
10
mm
gn
10…60/60…2000 Hz
Unit operating
1
Random Vibration
IEC/EN 60068-2-64,
2
20…500 Hz,
0.07
40
gn /Hz
Unit operating
Bump
IEC/EN 60068-2-29,
6 ms, 1000 shocks in each direction,
Unit operating
gn
Water Cleaning
Standard cleaning and drying process 2
1
2
Unit secured with the four case mounting screws on the PCB during the tests. The test BPC had a size of
176x137x3.3 mm
Cleaning with Vigon A200. For parameters and alternative cleaning procedures consult factory.
Inadequate cleaning and drying procedures can adversely affect the reliability of the module.
Application Notes
Application notes and full measurement reports are included on the TXS Product CD ROM, which is
available on request. Ask your local representative.
Title
Thematic
Reliability Report TXS Series
Reliability prediction background. Calculation for TXS-series
Reliability and Derating of DC-DC Bricks with
Comparison of different design concepts and its effects on brick
Optimised Mechanical Construction
temperature and reliability
Thermal Performance of TXS
TXS Layout Considerations
Thermal basics, design rules for system integration
How to implement a 100 A module on a PCB
Second source issues. Comparison to two paralleled 60A bricks
Second Source Solutions for TXS
TXS EMI and EMC Report
Next generation of TXS modules
TXS Stability Prediction
TXS Thermal Dimensioning (Calculator)
EMC basics, EMC performance of TXS series
Preliminary data: Product optimisation, Outlook
Interactive tool to predict dynamic step response
Interactive tool to find the required airflow, the maximum allowed
output current, the base plate temperature and the resulting MTBF
TXS Design verification Reports
TXS Design Maturity Test
Extended Design Integrity Test
Thermal measurement results
TXS Product Presentation
Measurement data over temperature for different TXS types
Accelerated ageing tests measurement report
Stress tests measurement report
Database (thermal pictures)
Power point document
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Characteristic Curves
The following figures show typical characteristics for the TXS bricks at TA = 25 °C / 400 LFM.
Efficiency:
TXS Efficienca
92
91.5
91
92
91.5
91
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
90.5
90
90.5
90
89.5
89
89.5
89
88.5
88
88.5
88
87.5
87
87.5
87
86.5
86
86.5
86
0
20
40
60
80
100
0
20
40
60
80
100
Output Current [A]
Output Current [A]
Figure 1
Figure 2
TXS Efficienca
TXS Efficienca
92
91.5
91
90
89.5
89
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
90.5
90
88.5
88
89.5
89
87.5
87
88.5
88
86.5
86
87.5
87
85.5
85
86.5
84.5
86
0
84
0
20
40
60
80
100
20
40
60
80
100
Output Current [A]
Output Current [A]
Figure 3
Figure 4
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Power loss figures:
TXS loss at Ui = 36V
TXS loss at Ui = 48V
30
25
20
15
10
5
30
25
20
15
10
5
TXS100ZY
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
TXS100ZA
TXS100ZB
TXS100ZD
0
0
0
20
40
60
80
100
0
20
40
60
80
100
Output Current [A]
Output Current [A]
Figure 5
Figure 6
TXS loss at Ui = 60V
TXS loss at Ui = 75V
30
25
20
15
10
5
35
30
25
20
15
10
5
TXS100ZY
TXS100ZY
TXS100ZA
TXS100ZB
TXS100ZD
TXS100ZA
TXS100ZB
TXS100ZD
0
0
0
0
20
40
60
80
100
20
40
60
80
100
Output Current [A]
Output Current [A]
Figure 8
Figure 7
the dissipation of the converters is increased
because of the positive temperature coefficient
of copper and MOS FETs. The loss at a specific
base plate temperature can be estimated using
table 7 on page 15.
Output power:
Input power:
Efficiency:
Po = Uo · Io
Pi = Ui · Ii
η = Po / Pi
Dissipation:
P= Pi - P= P· (1 / η
The report “Next generation TXS modules”
shows preliminary data of power loss and
efficiency. Depending on the type, the no load
and at full load loss can be reduced by up to 7W.
Efficiency and power loss of high output current
converters are difficult to measure. See figure 36
Figures 1-8 are typical curves, measured at ambient
temperature. At elevated base plate temperatures
.
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Line and Load Regulation:
1.4
1.2
1
1.2
1
0.8
0.6
0.4
0.2
0
Vi = 37 V
Vi = 51 V
Vi = 75 V
Io = 0 A
0.8
0.6
0.4
0.2
0
Io = 45 A
Io = 90 A
-40
-25
0
25
50
75
90
-40
-25
0
25
50
75
90
Temperature [°C]
Temperature [°C]
Figure 10: Load Regulation TXS100ZD
Io = 0…90 A, TA = -40…+90 °C
TBP = 100°C
Figure 9:
Line Regulation TXS100ZD
Ui = 37…75 V, TA = -40…+90 °C
TBP = 100°C
For correct measurement results, the sense pins should be connected directly to the power pins.
Dynamic Response:
Negative Load Step: dIo = 25 A
Positive Load Step: dIo = 25 A
Ch1: V(Uo), 50 mV/div. Ch3: Io, 20 A/div.
time 40 µs/div.
Ch1: V(Uo), 50 mV/div. Ch3: Io, 20 A/div.
time 40 µs/div.
Figure 12: TXS100ZD Load Step 100 A to 75 A
@ TA = 25 °C, Ui = Ui nom
Figure 11:
TXS100ZD Load Step 75 A to 100 A
@ TA = 25 °C, Ui = Ui nom
The apparent overshoot in the output voltage load step recovery is due to an overshoot in the current drawn
by the electronic load. The dynamic performance of the converter at different dIo/dt and different capacitive
loads can be estimated with an interactive tool on the TXS CD ROM.
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Remote Turn off
Remote Turn on
Ch1: V(Uo), 0.5 V/div. Ch2: V(USD), 2 V/div.
time: 200 µs/div.
Ch1: V(Uo), 0.5 V/div. Ch2: V(USD), 2 V/div.
time: 4 ms/div.
Figure 14: TXS100ZD remote turn on
Figure 13: TXS100ZD remote turn off
@100 A, TA = 25 °C, Ui = Ui nom
@100 A, TA = 25 °C, Ui = Ui nom
Switching on Ui with Co = 34 mF
Remote Turn on with Co = 34 mF
Ch1: V(Uo), 0.5 V/div. Ch2: V(USD), 2 V/div.
Ch1: V(Ui), 10V/div.
Ch2: V(Uo), 0.5V/div.
time: 4 ms/div.
time: 2 ms/div.
Figure 15: TXS100ZD remote turn-on:
@100 A resistive and 34 mF 1
capacitive load, @ TA = 25 °C
Ui = Ui nom, td = 11 ms
Figure 16: TXS 100ZB Ui switch-on: 0 to 75V
@100 A resistive and 34 mF 1
capacitive load, @TA = 25 °C
td = 12 ms
The turn on and off curves are typical, but they look almost identical at all input voltages [36...75 V],
temperatures [-40...+100 °C] and for all models [1.2...2.5 V]. The same curves apply whether the module is
switched using the remote signal or the input voltage.
Figures 15 and 16 show that TXS modules are capable of monotonic start up into loads with very high or
very low impedance without stability problems.
1
The ESR of the 34 x 1 mF Tantalum capacitors is < 0.3 mΩ in total.
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Output Ripple
Cin = 220 uF/100 V
ESR < 0.1 Ohm, 100 kHz
Electronic load
Vi(+)
Vi(-)
Vo(+)
Vo(-)
DC Supply or
+
Battery
1 uF X7R // 22 uF
Tantal 10 V / B
TXS module
Rshunt = 1 mOhm
Scope
Primary wiring inductance
approximately 2 uH
@20 MHz BWL
3 cm
coaxial cable
time: 1 us/div.
Figure 18: Output Ripple Test Set Up
Figure 17: Output Ripple TXS100ZD
@ Io = 100 A, Ui nom, TA = 25 °C
mVpp
mVpp
mVpp
@ - 40 °C
@ + 25 °C
@ + 100 °C
Figure 19: Output Ripple of TXS100ZD over Line, Load [0..90A] and Temperature
Reflected Input Ripple
Current probe
Electronic
Load
Lin 12 uH
I i AC + I i DC
I
i R
D U T
T X S 1 0 0 Z D
Cin 100 uF
(0.1 Ohm)
Figure 20: Input Current Reflected Ripple Test Set Up
35
30
25
Figure 22:
AC-part of the converter input current Ii
.
20
15
10
5
Iin pp
[mA]
AC
measured on a TXS100ZD at TA = 25 °C,
Ui = 75 V. Upper curve: full load; lower curve:
no load. 0.2 A/div. time = 2 µs/div.
0
36
40
44
Figure 21:
48
52
Uin [V]
56
60
64
Reflected input current IiR pp:
Measured on a TXS100ZD at full load
and ambient temperature.
68
72
76
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Inrush Current
MTBF Figures
1000
ON/OFF Signal
Uo @ Ui=75 V
Uo @ Ui=36 V
100
Ii with 200 mA/div
10
1
GB
GF
20
30
40
50
60
70
80
90
100
Ch 1: Iin @ 75 V, 0.2 A/div., Ch R1: Iin @ 36 V, 0.2 A/div.
Base-Plate Temperature [°C]
Ch 2: ON/OFF signal,
Ch 3: Uo @ Ui= 75 V, 1 V/div.
Ch R3: Uo @ Ui = 36 V, 1 V/div.
time: 2 ms/div.
Figure 26: Calculated MTBF Values for Ground
Benign and Ground Fixed at Different
Base Plate Temperatures
Figure 23: No Load Inrush Current
TXS100ZD-NP2, Inhibit Switch On
Ui = 36 V and 75 V
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
ON/OFF Signal
Uo @ Ui=75 V
Uo @ Ui=36 V
after 10 years
after 8 years
after 6 years
after 4 years
Ii @36Vwith 2 A/div
Ii @75Vwith 2 A/div
20
30
40
50
60
70
80
90
100
Base-Plate temperature TBP [°C]
Ch 1: Iin @ 75 V, 2 A/div., Ch R1: Iin @ 36 V, 2 A/div.
Ch 2: ON/OFF signal, Ch 3: Uo @ Ui = 75 V, 1 V/div.
Figure 27:
Probability of Survival at Ground
Ch R3: Uo @ Ui =36 V, 1 V/div.
time: 2 ms/div.
Benign (TBP)
Figure 24: Full Load Inrush Current
TXS100ZD-NP2, inhibit switch on
Ui = 36 V and 75 V
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
Cin = 220 uF/100 V
after 10 years
ESR < 0.1 Ohm, 100 kHz
Resistive load
after 8 years
after 6 years
after 4 years
Vo(+)
Vo(-)
Vi(+)
Vi(-)
DC Supply
I(lim) = 16 A
+
Uo(t)
Ii(t)
TXS module
Rshunt = 10 mOhm
20
30
40
50
60
70
80
90
100
Base-Plate temperature TBP [°C]
Primary wiring inductance
approximately 6 uH
Digital Scope
20 MHz BWL
Current Probe
Figure 28: Probability of Survival at Ground
Figure 25: Inrush Current Measurement Set Up
Fixed (TBP)
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Trim function controlled by an adjust resistor
Output Voltage Trimming
116%
114%
112%
110%
108%
106%
104%
102%
100%
98%
Radj connectet to Uo -
Radj connected to Uo+
The Trim feature allows the user to adjust the
output voltage in the range 90 …110 % Uo nom
.
The output voltage can either be adjusted using an
external resistor or with an external voltage source.
The adjust resistor should be connected close to
the unit. The voltage source should be connected
to sense (-).
96%
94%
92%
90%
Adjustment of Uo with an external resistor
The trimming resistor needed to reach Uo Set can be
calculated using equations 1 and 2:
88%
0.1
1
10
100
1000
Adjustment Resistor Value [kOhm]
Figure 31: Trim with an external adjust resistor
Increasing the output voltage:
To increase the output voltage a resistor should be
connected between pins 4 and 7 as indicated in
the figure below.
Adjustment of Uo with an external voltage
The required adjust voltage can be determined
using equation 3.
Vi (+)
Vo (+)
Sense (+)
2
6
4
Vi (+)
2
3
Vo (+)
6
4
R Load
Sense (+)
3
R TR
ON/OFF
- Up
Trim
7
R Load
7
ON/OFF
Trim
Sense (-)
Vo (-)
+
8
5
U TR
1
Vi
(-)
Sense (-)
Vo (-)
8
5
1
Vi (-)
Figure 29: Trim up
Figure 32: Trim up and down with an external
voltage source referenced to sense (-)
RTR - up [k] = 2.4k · Uo/(Uo - Uo nom) – 17.6k
1)
UTR [V] = (Uo – 0.88 · Uo nom)/0.24
3)
Decreasing the output voltage:
To decrease the output voltage a resistor should
be connected between pins 7 and 8 as indicated in
the figure below.
By connecting pin 7 to Vo (+), the output voltage is
set to 112 %. By connecting pin 7 to Vo (-), the
output voltage is set to 88 %.
Trim function controlled by an adjust voltage
Vi (+)
2
Vo (+)
Sense (+)
6
4
112%
R Load
108%
104%
100%
96%
3
7
ON/OFF
Trim
R TR
- Down
Sense (-)
Vo (-)
8
5
1
Vi (-)
Figure 30: Trim down
92%
RTR - down [k] = 2.4k · Uo/(Uo nom - Uo) – 17.6k
2)
88%
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
Uadj / Uo(nom)
Figure 33: Trim with an external adjust voltage
Example: RTR to trim up Uo to 106% is needed
Example: UTR to trim Uo of the TXS100ZB to 90 %
RTR-up [k] = 2.4k · Uo/(Uo - Uo nom) – 17.6k
RTR-up [k] = 2.4k · 1.06/(1.06 – 1) – 17.6k
RTR-up [k] = 24.8k
TXS100ZB Uo nom = 1.8 V
Uo = 0.9 · 1.8 V = 1.62 V
UTR = (1.62 – 1.584) / 0.24 = 0.15V
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Limits:
The shut down function is TTL compatible. USD
The combined Uo set by trim and sense should not
exceed 120 % Uo nom. The minimum Uo set by trim
should not be set below 88 % Uo nom. For increased
trim range use the option wide trim (option R).
should be kept below 5.5 V. Alternatively an open
collector switch or equivalent can be used. The
remote control pin is pulled up internally, so that no
external voltage source is required. A bipolar
transistor, a FET or an opto coupler output can be
used as a switch.
Note:
When the output voltage is trimmed upwards, the
output power Po from the converter should not
exceed its maximum rating Po. (The voltage
directly at the output pins multiplied by the output
current).
The user should take care that the shut down
control signal is referenced directly to Vi(-) close to
the converter pins.
2
Vi (+)
Vo (+)
6
4
Open collector
switch
Sense (+)
Input Filter
3
7
ON/OFF
Trim
Wide Trim Range
USD
The wide trim range option (option R) will allow an
Sense (-)
Vo (-)
8
5
extended adjustment range of 70…110 % Uo nom
,
1
Vi (-)
Option R covers two neighbouring output voltages.
If trimmed down, the converters perform identically
to the standard types, if trimmed up, the converters
have slightly increased loss compared to the
standard types.
Figure 34:
Shut down
Shut down is active after a delay of approximately
300 µs and has a soft restart after typically
6-10 ms. (see figures 13/16).
The adjustment functions differently for the wide
The turn on over the shut down function does not
create any inrush current and has a monotonic
form without overshoot. (see figures 22/23).
trim range as for the standard trim:
Adjustment of Vo with an external voltage
UTR [V] = (Uo – 0.7 · Uo nom)/0.42
If the shut down control pin is not used, it can be
left open. With option N the shut down pin must be
hard wired to the Vi(-) pin.
Adjustment of Vo with an external resistor
Uo increasing: (RTR connected to Vo (+))
Remote Sense
RTR - up [k] = 2.4k · Uo/(Uo - Uo nom) – 14k
Remote sense compensates for distribution losses
by regulating the voltage at the remote sense
connections.
Uo Decreasing: (RTR connected to Vo (-))
RTR - down [k] = 6k · Uo/(Uo nom - Uo) – 14k
When the trim pin is left open, the converter
regulates to Uo nom. The input impedance of the trim
pin is equal to the standard trim 20 kΩ. When
trimming with an external voltage source
Uo Set is Uo nom at UTR = Uo nom/1.4 .
Vi (+)
Vo (+)
2
6
4
Sense (+)
R Load
3
ON/OFF
7
Trim
10R
8
5
Sense (-)
Vo (-)
1 Vi (-)
Shut Down Feature
Figure 35:
Remote Sense
The shut down (ON/OFF control, pin 3) is available
with positive logic or with negative logic as an
option. Shut down is referenced to Vi (-).
The sense pins are internally connected to the
power pins over 10 Ω resistor, to prevent an
uncontrolled output voltage in case of interrupted
sense wires.
Positive logic:
Unit off, when pin 3 pulled to Vi (-) or USD <1.5 V
Unit working, when pin 3 open or USD >1.5 V
To minimize noise pick up, appropriate layout
techniques should be used. The sense wires
should not be wired in loops, but close together. If
possible sense should be placed on top of a layer
Negative logic: (Option -N)
Unit off, when pin 3 open or USD >1.5 V
Unit on, when pin3 pulled down to Vi (-)
or USD <1.5 V
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Open sense wires result in measurement errors. A
with the negative return Vo (-). More layout
low drop precision shunt, rated for 100A should be
information can be found on the TXS CD ROM.
used to measure the output current.
The following points should be observed, when
To remember: At 100 A, a 1 mΩ resistor in trace
or over a bad contact in the measurement set up
can produce as much as 100 mV of voltage drop
or a measuring error of 100 mV · 100 A = 10 W !
The loss and efficiency measurements in the
graphs were done in a test system at room
temperature. To calculate the approximate
dissipation at elevated base plate temperatures,
the correction factors of the following table can be
used:
sense wires are used:
•
•
The output voltage of the TXS modules should
not be increased above +20 % of Uo nom. This
limit includes any increase due to remote
sense and an output voltage set-point
adjustment over the trim function.
The output power of the TXS module is
defined as the output voltages at the power
pins multiplied by the load current. When the
output voltage is increased to compensate
voltage drops, the output power from the
converter is increased as well. The power
should not exceed its maximum rating.
Io / TBP
110 100
90
80
70
60
46
100A
80A
60A
1.18 1.12 1.08 1.05 1.03 1.02
1.11 1.09 1.07 1.05 1.03 1.01
1.07 1.06 1.04 1.03 1.02 1.01
1
1
1
•
If not used, the remote sense pins have to be
connected as short as possible to Vo (+) and
Vo (-) respectively. If not connected, the
output voltage shows an increased line and
load regulation.
Table 7:
Correction factor
k
for different
output currents at elevated base
plate temperatures TBP.
Dissipation at TA: PLoss= Pi - Po = Po · (1/η - 1)
Dissipation at TBP: PLoss(TBP) = PLoss(Graph) · k
•
•
The sense wires are loaded with a small signal
current. Do not place resistors or filters into
the sense wires.
The PCB layout of the power tracks to the load
should result in a low wiring inductance.
Otherwise the dynamic performance even with
sense wires is degraded.
The dissipation at elevated base plate
temperatures is needed to determine the cooling
requirements ( page 23: Thermal considerations).
Æ
Output Over Voltage Protection
•
Do not use filter capacitors between sense
and power pins. They could possibly influence
the stability of the module.
The units have a built in over voltage protection,
which prevent an uncontrolled increase of the
output voltage in case of catastrophic failures of
the converter. The over voltage protection consist
of a second control loop, which is independent of
the main regulating circuit.
Power loss and Efficiency
The protection is set to 125 % Uo set (Models ZY,
ZA, ZB, ZC) and 115 % Uo set (Model ZD).
The measurement of loss and efficiency at very
high output current converters is quite difficult. To
avoid measurement errors, a Kelvin connection
directly at the module terminals should be used.
sense should be wired directly to the power pins.
The over voltage protection is not switching, but
regulating, so that the converter can’t be
accidentally turned of by noise or EMI. Output
voltage adjustment over sense or trim can’t trigger
the over voltage protection, because the protection
Ii
Io
Vi (+)
2
3
Vo (+)
6
4
level is tracking with Uo set
.
Sense (+)
R Load
+
7
ON/OFF
Trim
Ui
Operation in Parallel
Uo
USH = RSHi * Ii
Paralleling of two converters is not possible.
USH = RSHo * Io
Sense (-)
Vo (-)
8
5
1
Vi (-)
Operation in Series
TXS units can be connected in series. Consult the
Figure 36:
Efficiency Measurement Set Up
factory for additional information if
connection of modules is planned.
a
serial
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Output Over Current Protection
Energy of the overload current
7000
6000
5000
4000
3000
2000
1000
0
When the converter output is overloaded or
shorted, the module will go into hiccup mode. In
the hiccup mode, the brick is switched off
completely and restarted after
a
period of
approximately 550 ms. If the overload- or short
circuit is still present then, the converter will hiccup
until the overload is removed.
In order to be capable of starting large capacitive
loads, the converter provides a minimum on time
of approximately 30 ms.
100
102
104
106
108
110
112
114
Output current TXS100 [A]
Iopeak
2, proportional to the
Io(t) Hiccup mode
delta Io =
Iopeak - Io Lim
Figure 39: Function of Io
thermal energyramts the overload location
Iolim
Iolim
110
Low Input Voltage
Input under voltage lookout
Up to 800 ms
time
The unit is equipped with an input under voltage
lockout circuit, which ensures a defined start up
sequence.
off time = constant
550 ms typ
R Load
on - pulse duration
see graph
ton min 30 ms
0.8
Nominal load
Turn-On
Turn-Off
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
Overload
time
Short circuit
Figure 37:
Hiccup Timing at Overload
With increasing overload, the peak output current
is slightly increased (delta Io typically up to 13 A).
At the same time the on pulse duration is reduced,
so that the total energy in an overload condition is
limited.
29
30
31
32
33
34
35
36
Vi [V]
Typical "on-pulse" duration in overload
Figure 40: TXS under voltage on / off hysteresis at
light load
14
12
10
8
Reduced output power of models ZB, ZD
The models ZB (1.8 V) and ZD (2.5 V) have a
reduced output power at minimum input voltage
when operated at highest base plate temperature
6
4
2
and increased Uo
(over Trim or Sense). The
Set
reduction is due to a duty cycle limitation of the
controller.
0
0
200
400
600
800
1000
Puls duration [ms]
The rated output power of these two types [180 W
resp. 250 W] is available under the following
conditions:
Figure 38: Characteristic of over current protection
The off period allows hot tracks and loads to cool
Ui min >37 V: for TBP = 100 °C and Uo = Uo nom
down. The heating energy at the location of the
Ui min >40 V: for TBP = 100 °C and Uo = 112 % Uo nom
2
short circuit and in the PCB is proportional to Irms
.
·
2
2
At low input voltage, the ZB and ZD models will
switch off and soft restart periodically. The
operation is very similar to an under voltage
lockout or over current protection.
The following graph shows, that Irms = Io
ton/T is reduced at high overload, which repduulscees
the danger of overheating and further damage to
the system.
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
components, because they are bridging the safety
Over Temperature Protection
barrier between primary and secondary. Safety
agencies don’t allow operation of the opto-couplers
over the rated temperature, which is in almost
every case 100 °C.
These units feature
a
non latching over
temperature protection circuit to prevent thermal
damage in case of failures of the cooling system.
A
second function of the over temperature
Competition single board converters might be
specified for 120 °C or even 130 °C PCB operating
temperatures, but can‘t be operated at this point
because of the on board opto-couplers. Safety
agencies will insist on a temperature reduction of
up to 30 K.
protection, is to prevent long term operation at
elevated temperatures due to poor thermal system
design. Long time thermal overload reduces the
reliability of the converters.
A PTC measures the surface temperature of the
PCB near the main transformers. The temperature
protection switches the converter off completely at
approximately 120 °C. After cooling down by 5 to
10 Kelvin, the converter is restarted.
Thermal time constant
TXS modules have a large thermal time constant
of approximately 7 K/Min. A large time constant
increases the converter ruggedness. It allows short
term operation at overload without triggering the
temperature protection. In case of changing loads,
←
PTC
the converter operates at
a lower average
temperature which improves the expected lifetime.
Finally a large time constant gives additional
operating time after a break down of the cooling
system.
←
OPTO-COUPLER
Figure 41: TXS100-ZY at 300 LFM, Ui = 48 V,
Io = 100 A, TA = 27.9 °C, TBP = 59.7 °C,
TPCBmax = 74.1 °C, dT = 14.4 K
Hot Spots
TXS modules have large component and material
safety margins. The temperature protection is not
set close to destructive limits. Laboratory tests with
disabled protection at an on board temperature of
170 °C (24 h, full load) showed no performance or
material degradation after cooling down.
The thermal picture of a TXS-
module, underlayed with layout
data shows clearly that hot spots
are successfully avoided. The
temperature distribution in the
Survival under such extreme operating conditions
is only possible, when a converter has a uniform
temperature distribution without any hot spots. Hot
spots are peak temperatures considerably above
the neighbouring components. Hot spots can be
seen quite often in converters without base plate
and are the result of a poor thermal design.
middle
section
with
the
synchronous rectifiers is flat. The
temperature rise above the base
plate is only 14.4 K.
The red area is the only warm
section on a TXS. All other power
Converters with hot spots need a large derating or
they will suffer a large reduction to the expected
life time.
components are located on the
bottom of the board where they are in direct
thermal contact with the base plate. A thermally
conductive potting material keeps the temperature
rise above the base plate to below 2 K.
Opto Couplers
On TXS modules, thermally sensitive components
such as the opto-couplers are placed on a much
cooler, separate hybrid circuit. opto-couplers see a
highly accelerated aging at operating temperatures
above 100 °C. Additionally they are safety critical
Detailed information on the mechanical concept of
the converter, the thermal system design rules and
measurement results are available on the TXS
product CD ROM (available reports see page 6).
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Definitions
Safety Considerations
The following section should help to classify the
supplying circuit of the converter. For the precise
identification of the voltage types in a system, the
relevant safety standard should be used.
Primary circuit = Circuit connected to the AC mains
which makes it hazardous per definition.
TXS modules have been designed for building into
system applications in pollution degree
2
environments 1.
The converters provide basic insulation1 from
input to output and from input to the metallic base
plate. The insulation supports 1500 V DC electric
strength test voltage and has an insulation
resistance >50 MΩ.
Secondary circuit = Circuit which is isolated from a
primary circuit. A battery without connection to a
primary circuit is considered to be a secondary
circuit.
The converters provide functional insulation1
between output and base plate. The insulation
supports 500 V DC electric strength test voltage.
The base plate is normally floating. For safety
reasons the base plate may only be connected to
the secondary or safety ground.
SELV, ELV and TNV are secondary circuits.
SELV: Safety Extra Low Voltage
ELV:
TNV:
Extra Low Voltage
Telecommunication Network Voltage
If the system using the converter requires safety
agency approval, certain rules should be followed
in the design of the system. In particular, all
creepage and clearance distance requirements of
the appropriate standard should be observed. This
document refers to UL 60950, EN 60950:2000 and
CSA 60950-00 only. Specific applications may
have additional requirements.
SELV = User accessible secondary circuit with
U <60 V DC and no transients. An SELV circuit
remains safe even after single faults.
ELV = Basic insulated circuit with the same limits
as a SELV circuit but without protection to 60 V in
case of a single fault.
TNV = Double or reinforced insulated secondary
circuit, isolated from earth and connected to a
telecommunication network or a circuit meeting the
TNV specifications.
• The converter has no internal fuse. An external
fuse should be provided to protect the system. For
UL purpose the fuse needs to be UL-listed. A fuse
rating not greater than 10 A is recommended. The
user can select a lower rating fuse based upon the
inrush transient of the input filter and the maximum
input current of the converter (see page 2). Both
input tracks and the chassis ground track (if
applicable) should be capable of conducting a
current of 1.5 times the value of the fuse without
failure. The fuse should be placed in the non-
grounded input line.
• The maximum specified input voltage is 100 V
DC for 100 ms. Exceeding of this voltage limit may
destroy the input stage of the converter but it will
not damage the insulation 2.
• If an input supply other than SELV is used, the
components on the primary of the converter may
need to be considered as hazardous. The report:
“TXS layout considerations” on the TXS CD ROM
provides recommendations for the PCB layout
beneath the converter.
Table 8: Normal condition:
With
Without Transients
Transients 1
TNV-1
ELV
SELV
<60 V DC or 42.4 V AC peak
TNV-3
TNV-2
<120 V DC or 70.7 V AC peak 2
Table 9: Maximum voltage after a single fault:
With
Without Transients
Transients 1
TNV-1
<120 V continuous 3
ELV
SELV
<60 V, 120 V
for 0.2 s max
Possibly
hazardous
TNV-3
TNV-2
<120 V continuous 3
1
2
Up to 1.5 kV transients possible.
For DC voltages with overlaid AC voltages the limit:
U
AC/70.7 V + UDC/120 V < 1 applies.
1
Exception: According deviation 2 in UL60950, the limit
80 V DC instead of 120 V DC applies in a DC-power
system for TNV2.
According to UL 60950, EN 60950:2000, CSA 60950-00
2 The creepage and clearance distance and the insulation
thickness were dimensioned for 200 V DC. The
converters have been approved for basic insulation. It is
in the responsibility of the customer to use the converter
in applications, where supplementary insulation is
required.
3
In the event of a single fault, the voltage can
rise to 1500 V for 1 ms, then fall down to 400 V within
14 ms and stay at 400 V DC over 185 ms. Limiting
curve, see figure in IEC 60950:2000.
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
User accessible output
- A protective device limiting Uo to 60 V DC
max. should be connected between the
output lines of the TXS. (Clamp, Suppressor
Diode, …)
If a circuit connected to the converter output is
operator accessible, the output should be SELV.
The following table shows some possible
installation configurations. However it is the sole
responsibility of the installer/system designer to
assure the compliance with the relevant and
applicable safety regulations.
- The output should be earthed.
- The earth connections and the protective
device should be adequately dimensioned to
allow the fuse to reliably interrupt.
- The power system consisting of the TXS
modules and the primary supply (see figure
42) should successfully pass the SELV
reliability tests.
The output is considered SELV, according to EN
60950:2000, UL 60950, CSA 60950-00, if one of the
following requirements is met in the system design:
Output circuit
Power Bus Voltage
(Input of TXS module)
note A/B
3: All of the following points should be fulfilled:
- The power bus and the output circuit needs
to be floating:
Earthed
Unearthed
SELV
SELV
- To achieve an ELV power bus voltage, the
front end needs at least basic insulation.
- The supply of the front end, which feeds the
power bus should have a nominal voltage
below 150 V AC or 200 V DC. A transient
protection to 1500 V peak is required.
- A protection diode is required on the input of
the module.
Earthed/Unearthed SELV
Earthed/Unearthed ELV
note 1
note 2/6
note 4, 5
note 3
Unearthed
Unearthed
Unearthed
TNV-1
TNV-2
TNV-3
note 5
note 4, 5
not
Earthed
allowed
hazardous secondary
note 2
4: To achieve a TNV power bus voltage, the
power bus should be isolated from any other
hazardous voltage including the AC mains by
reinforced insulation. In addition, it needs to
be reliably isolated from earth.
Unearthed
note 7
hazardous secondary
Table 10: Installation configurations to achieve
an SELV output with TXS modules.
5
An impulse or high voltage test is required.
TXS modules were already tested for this
requirement. If hand held equipment is directly
connected to the output circuit, the test should
be repeated together with this equipment (see
safety standard).
Intermediate power
Mains
Output circuit
~
SELV
AC-DC
frond end
or
Input
Fuse
TXS
Module
Battery *
-
6: The conditions for an ELV power bus need to
be fulfilled. To achieve an ELV power bus
voltage, the front end needs at least basic
insulation.
~
Earth connection
Suppressor Diode
* Battery insulated
from primary circuits
and
Earth connection
7: This configuration is only possible if the
manufacturing at Power-One follows a special
inspection program. Consult factory if
required. It is much easier, if the unearthed
hazardous voltage can be characterized as
TNV-2 circuit. (Æ note 5 applies).
Figure 42: Supply system with TXS. All possible
additional elements are shown. See notes
1 to 7 if they are required or not.
Notes
A: An input fuse should be provided in the un-
earthed input path (fuses see pages 3/18).
B: The power bus voltage should be limited or
regulated to maximum 75 V DC in order of not
to damage the TXS modules.
ELV or TNV outputs
If the output of a TXS needs only to be an ELV or
TNV circuit, less stringent requirements apply.
The power module has an ELV output if the input
is ELV or hazardous with a nominal voltage below
200 V DC. The power module has a TNV output if
the input is TNV. No additional requirements apply.
For other combinations, consult the safety standards.
1: No additional requirements
2: All of the following points should be fulfilled:
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
EMC Specification
limits, level B is fulfilled in all cases.
The TXS generates EMI noise at the switching
frequency and all it’s harmonics.
One stage input filter
Only a small external filter with few components is
required, to reduce the conducted noise below the
limits of EN 55022 Class B.
There are two types of EMI: conducted and
radiated emissions. Conducted emissions are
currents generated by the converter, propagating
mainly over the input and output wires. Radiated
emission consists on electrical and magnetic fields.
F
L1
Io
Ii
Vi (+)
2
Vo (+)
Sense (+)
6
4
R Load
Uo
Ui
+
3
7
ON/OFF
Trim
Conducted Noise
C2
C4
C1
Sense (-)
Vo (-)
Conducted or low frequency noise is measured
between the input lines and protective earth
between 150 kHz and 30 MHz with a measure-
ment receiver. Radiated high frequency noise is
measured as a field between 30 MHz and 1 GHz
with an antenna or with an absorber clamp on the
input/output wires
8
5
1
Vi (-)
C1, C2: 100 uF/100 V
C3, C3: 2.2 nF
L1: 1 mH, Ferrite
C3
Y
Figure 44: TXS with a one stage input filter.
C1, C2
= 100 uF/100 V (Rubycon YXA), C3,
C4 = 2.2 n/250 V (Wima MP3-Y). L1 = 1 mH; Ferrite
Measurement set up
µi = 10’000, 16 turns (B64290L658 T38 Epcos)
A TXS100ZB was selected as a representative unit
for all the EMI measurements. Other models use
similar layouts, have the same mechanical
construction and have similar internal voltages.
The unit was operated at full load with
approximately 200 LFM airflow. Additional input
filters were placed as close as possible to the pins.
The output of the converter was wired over 15 inch
(38 cm) cables to a resistive load.
The conducted noise was measured with a 50 Ω
LISN (Line Impedance Stabilization Network
according to EN 55022 and CISPR 22 and an
EMC measurement receiver (PMM 8000).
Figure 45: TXS100ZB-N with one stage input filter
according to Figure 44.
Peak measurement in the Vi (-) line.
No external filter
The TXS generates predominantly common mode
Two stage input filter
The following circuit combines two common mode
filter stages.
noise.
80 dBuV
Quasi Peak limit EN55011/22
70 dBuV
60 dBuV
50 dBuV
40 dBuV
C3
F
Ii
L2
L1
Io
Vi (+)
2
3
Vo (+)
6
4
Sense (+)
R Load
Uo
Ui
+
7
ON/OFF
Trim
30 dBuV
20 dBuV
C2
C1
Sense (-)
Vo (-)
8
5
1
Vi (-)
Measured noise
Peak
10 dBuV
C1, C2: 100 uF/100 V
Average limit
C3, C3: 2.2 nF
Y
C4
0 dBuV
L1: 1 mH, Ferrite
L2: 7.5uH, MPP
10 MHz
30 MHz
1 MHz
150 kHz
Figure 46: TXS100ZB-N with a two stage input filter:
Figure 43: TXS100ZB-N at Ui
and full load
nom
without an input filter and unearthed
C1, C2 = 100 uF/100 V (Rubycon YXA), C3, C4 =
output. Peak measurement Vi (-) line.
Only peak measurements were made. If the peak
values are below the average and the quasi peak
2.2 n/250 V (Wima MP3-Y). L1 = 1 mH; Ferrite
µ =10’000, 16 turns
(B64290L658 T38 Epcos),
I
L2 = 7.5 uH, 125 u MPP Powder core (Magnetics
55050-A2)
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Figure 49: TXS100ZB-N with a one stage input
Figure 47: TXS100ZB-N with a two stage input
filter and an earthed output over an
inductor in the ground line according
to Figure 48
filter according to Figure 32.
Peak measurement in the Vi (-) line.
A two stage input filter can be used, if a better high
frequency damping is required.
Peak measurement in the Vi (-) line.
Two stage input filter and grounded output
Grounded output or grounded case
For safety reasons or to reduce possible EMI
coupling to the secondary, the output circuit may
need to be connected to protective earth.
Grounding the output or the case has a negative
influence on the EMI performance. To overcome
this problem, a two stage input filter is proposed
(see figures 50/51).
Alternatively, if the ground connection is needed
for safety reasons only, an inductor in the ground
line can be used (Figures 48/49). This solution
allows a safe connection and minimises high
frequency emission.
C3
Ii
L2
L1
Io
Vi (+)
2
3
Vo (+)
6
4
Sense (+)
R Load
Uo
Ui
+
7
ON/OFF
Trim
C2
C1
Sense (-)
Vo (-)
8
5
1
Vi (-)
C1, C2: 100 uF/100 V
C3, C3: 2.2 nF Y
C4
L1: 1 mH, Ferrite
L2: 13mH, Amorph
Figure 50: TXS100ZB-N with a two stage input
filter and ground output.
C1, C2 = 100 uF/100 V (Rubycon YXA), C3, C4 =
According UL 60950, the ground inductor should
be capable to conduct 1.5 times the value of the
input fuse without failure. The overall impedance of
the connection should be below 0.1 Ω.
2.2 nF/250 V (Wima MP3-Y). L1 = 1 mH; Ferrite
µ = 10’000, 16 turns (B64290L658 T38 Epcos),
I
L2 = 13 mH, 15 turns, amorphous core (Magnetec
M128-01)
One stage input filter and ground Inductor
F
L1
Io
Ii
Vi (+)
2
Vo (+)
Sense (+)
6
4
R Load
Uo
Ui
+
3
7
ON/OFF
Trim
C2
C4
C1
Sense (-)
Vo (-)
8
5
1
Vi (-)
C1, C2: 100 uF/100 V
C3, C3: 2.2 nF
L1: 1 mH, Ferrite
C3
L2
Y
Figure 48: TXS100ZB-N with a one stage input
filter according figure 44 and an
inductor in the ground line to the
output.
Figure 51: TXS100ZB-N with a two stage input
filter and an earthed output. Peak
measurement in the Vi (-) line
L2 = 9.6 mH, µ = 50’000, (VAC W620)
I
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Radiated Noise
On Board Input and Output Filters
The radiated noise from the converter is extremely
difficult to predict since it depends largely upon the
TXS converters use a topology that achieves input-
and output ripple frequencies four times higher
than the switching frequency. This results in
excellent ripple and noise values and low external
filter requirements.
motherboard
layout
and
the
switching
characteristic of the loads.
The report: “TXS layout considerations” on the
TXS product CD ROM provides recommendations
for reducing the radiated noise through shielding
and optimal layout.
The on board output filter is a parallel connection
of very low impedance Tantalum capacitors
connected in parallel with an overall capacitance of
3.3 mF. Total ESR < 4.5 mΩ (@100 kHz/25 °C).
Input Impedance
The high efficient on-board input filter consists of
several ceramic capacitors, a damping network
All switching power supplies exhibit negative input
impedance. A power source with inductive output
impedance and/or the wiring inductance from the
supply to the converter can affect the stability of
the modules.
and
a
filter inductor. Two EMC capacitors
(Cy1+Cy2) in a series connection with 2.2 nF
each, are connected between primary and
secondary.
A good general stability rule is, that the magnitude
of the source impedance should be lower than the
magnitude of the input impedance of the module at
Lin
1
6
TXS
power s tage
all frequencies up to the switching frequency. The
minimum input impedance of
a
module is
C2
C 3
C 1
calculated as 20 log(Ui min / Ii max).
2
5
Example: At Ui min = 36 V and Ii max = 7.8 A (see
Table 1 on page 3), a TXS100ZD needs an AC-
impedance |Zline| < 13.2 dBΩ at full load.
A possibility to reduce the input impedance is to
connect a low ESR input filter capacitor between
the input lines (at least 100 uF per 125 W output
power is recommended). With such a blocking
capacitor, a performance within the specifications
can be achieved with almost all supply conditions.
C y 1 + Cy 2
Figure 52: On board input and output filters.
C1 = 1 uF, C2 = 6 · (1 uF), C3 = 3 mF
Cy = 1.1 nF, Lin = 0.9 uH for TXS
models ZC and ZD, 1.1 uH for models
ZY, ZA and ZB
Electromagnetic Susceptibility
To consider:
The converter does not react to EMI pulses.
However the Y capacitors and the interwinding
capacitance of the multilayer board can couple
some common mode noise to the secondary.
Earthing or decoupling the output with large Y
capacitors needs a two stage EMC filter or a
ground line inductor to meet the EMC conducted
noise level B (see EMC specifications).
- The stabilising input capacitor and the capacitors
of the input filters generate an inrush current.
- The blocking capacitor should be able to handle
the input ripple current of the module, which is
much larger than the reflected input ripple (see
measurement set up: figures 20/22).
- The capacitors may resonate with the inductance
of the input filter and the wiring. If this happens,
the resonance will require damping.
-
-
-
The EMI measurements have been done with
a one stage input filter according to Figure 44.
ESD pulses were directly discharged into the
TXS pins.
Burst pulses were applied in front of the input
filter.
Performance criterion A denotes normal operation,
no deviation from specification. Performance
criterion B denotes temporary deviation from
specification.
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Base Plate to Motherboard RthBP-PCB
Thermal Considerations
TXS converters provide an efficient way to
transport heat to the motherboard over the pins
and the case. Since the efficiency of this method
varies from design to design, it can’t be predicted.
(See report: “TXS layout considerations”)
TXS converters achieve one of the highest current
and power densities on the market. This would be
useless, if in practise the available current should
be reduced a lot because of cooling problems.
But TXS converters achieve also the highest full
load efficiency on the market and use a unique
thermal design which makes them to real high
density, high current converters.
Base Plate to Ambient RthBP-A
TXS modules are designed for forced convection
cooling. To estimate the thermal resistance at
different airflows the following graph can be used:
Maximum Base Plate Temperature
To ensure reliable long term operation, and to
comply with safety agency requirements, the base
plate temperature (TBP) should always be kept
below 100 °C. The maximum base plate
temperature is defined by two conditions:
Thermal Resistance v's Air-Flow Rate
3.00
2.50
2.00
1.50
1.00
0.50
0.00
•
Maximum multilayer temperature ≤ 120 °C.
(UL 130 °C print material is used: Power-One
designs use normally 10 K safety margin).
Maximum opto-coupler temperature ≤ 100 °C.
(Device limits, otherwise accelerated aging)
•
If the base plate temperature stays below 100 °C,
both of the above limits are kept under all
operating and cooling conditions.
50
100
150
200
250
300
350
400
450
500
550
Air-Flow Rate (LFM)
The maximum base plate temperature is limited by
the temperature protection, but should be verified
after system integration. TBP can be measured on
the temperature measuring point on the base
plate. See mechanical drawing for location.
Without Heat Sink
13mm (0.51'') Heat Sink (CUT)
11.4mm (0.45'') Heat Sink
6.1mm (0.24'') Heat Sink
24.1mm (0.95'') Heat Sink
Figure 53: Thermal resistances at laminar airflow
TXS modules are designed to work without
additional heat sink. But it is possible to attach an
external heat sink to the base plate.
Thermal Resistance
Heat sinks can efficiently help to increase the
thermal safety margin or to increase the available
power if the available airflow in a system is not
sufficient.
To operate the converters below the maximum
base plate temperature, sufficient cooling should
be provided. The modules can be cooled by
conduction, convection and radiation to the
surrounding environment.
Calculation of the Required Airflow
The path for the heat transport can be described
The thermal resistance RthBP-A allows determining
the required airflow or heat sink, for a given
ambient temperature and operating condition.
with
a thermal resistance. A low thermal
resistance allows a lot of heat or loss to flow from a
hot component x to the surrounding y.
1
2
The operating conditions define the loss of the
converter: Loss figures for different output
voltages, input voltage ranges, and output
currents can be found on page 8. They should
be corrected with the factors of Table 7 for the
targeted base plate temperature.
Rthxy = (Tx - Ty) / PLoss [K/W]
The thermal resistance between x and y is defined
as temperature difference between the two parts,
divided through the amount of loss flowing from the
hot to the cool part (see report “Thermal
performace of TXS” on the TXS product CD ROM
for further information).
TXS provide two main ways for heat transport:
Heat can be transported to the motherboard and to
ambient.
The required thermal resistance for a given
environment (TBP, TA) and loss can be
calculated using the formula from above:
RthBP-A = (TBP -TA) / PLoss. To remember: The
base plate temperature should not be
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
80
selected above 100 °C. It can be convenient
to use a base plate temperature below 100 °C
in order to optimise the expected lifetime.
TXS100ZY
TXS100ZA
TXS100ZB TXS100ZD
70
60
50
40
30
20
36..60V
36..75V
3
The value of RthBP-A allows to determine the
required airflow or heat sink using Figure 53.
Derating
A “Derating” is the reduction of the available output
power at high ambient temperature. A derating
keeps the maximum temperatures of the unit
below safety critical limits.
airflow [LFM]
Figure 54: Maximum ambient temperature for
different TXS models at different
airflows at 100 A output current and
TBP=100 °C.
To decide how much the converter can be loaded,
some system parameters need to be known:
•
•
•
Maximum ambient temperature and minimum
airflow at the converter
90
TXS100ZY
TXS100ZA
TXS100ZB TXS100ZD
Height / space restrictions for an additional
heat sink
80
70
60
50
40
30
36..60V
36..75V
Layout situation (maximum current density,
neighboring heat sources, shadowing effects,
cooling to the board...)
•
Supply voltage and maximum output current
(average and peak)
•
•
Least favorable input voltage
Reliability target
airflow [LFM]
TXS derating curves were defined for converters
without heat sinks operating at constant base plate
temperatures of 100 °C !
Figure 55: Maximum ambient temperature for
different TXS models at different
airflows at 80 A output current and
TBP = 100 °C
Derating Curves
The derating curves allow a first rough estimation if
How to calculate the derating in situations where a
converter should operate at a lower base plate
temperature or when additional heat sinks can be
used?
a
design work. More detailed curves and
explanations can be found in the report “thermal
performance of TXS units” on the product CD
ROM. A second report “Next generation TXS
modules” shows preliminary data of optimised TXS
modules.
1 The thermal resistance for a given airflow and
heat sink can be found in figure 53
The derating data in the figures 54 and 55 shows
two bars for each airflow value. The first bar can
be used for 48 V battery types, where the input
voltage stays within 36 V to 60 V. The second bar
should be used for 60 V battery types, where the
continuous input voltage can be as high as 75 V.
2 The basic formula of the thermal resistance
RthBP-A = (TBP -TA) / PLoss allows to determine
the loss at this cooling condition: PLoss = (TBP
-
TA) / RthBP-A
3 Normalise the loss figure to the operating
ambient temperature using the correction factor
of table 7. Ploss 25°C = Ploss TBP / K
4 With the loss value at 25°C it is possible to
determine the maximum output current of the
converter using the loss figures on page 8.
At 75 V, TXS converters have increased loss
compared to the 36 V to 60 V input range. Thus
the maximum allowed ambient temperature for the
full input range is reduced.
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
The converter itself does not set the derating as for
Alternatively to this standardised calculation
methods, some companies use models based on
experience, returns and field data. This makes it
very difficult to compare reliability data from
different manufacturers. Especially if models from
the MIL-HDBK are used for components with good
reliability data only, and “in house” models for all
the others.
example the output current limit. It is the
responsibility of the end user to decide how much
current/power can be drawn in his design or how
much airflow is required, in order to ensure reliable
operation in the field.
Calculator
Instead of using the graphs, the required airflow or
the allowed output current can be calculated with a
automated, easy to use tool on the TXS Product
CD ROM. The tool uses interpolation between
values and also gives a prediction of the expected
life time for the chosen operating condition. 120A
units are not jet included.
MIL HDBK 217F Notice 2
There is an ongoing discussion about the best
suited method for reliability prediction.
The MIL-HDBK is the most elaborate, well
documented and most widely used tool for
predicting the component reliability. MIL models
are better suited to describing the component
loading in high density converters, than other
models. Belcore models for example were
developed for predicting the reliability of standard
telecom equipment, working at much lower
operating temperatures.
The problem with the MIL HDBK is, that the
models are often based on old data, neglecting
component improvements achieved in the market.
This leads to pessimistic results. Bad prediction
results, related design restrictions and resulting
higher product costs were the main reasons why
the US government recently cancelled the use of
the MIL-HDBK 217 in army specifications.
Important Reminder
Calculations and graphs only give a rough
guide to the required cooling. The specific card
and rack design can vary a lot, which makes it
almost impossible to predict the exact
temperatures of a Brick.
It is good practice to verify the thermal
performance in worst case operating conditions
with all obstructions in place at highest ambient
temperature before the card design is finished.
Reliability
For power supplies however there is no real
alternative for predicting reliability in sight.
Because it is easy to use and has models for all
components included, the MIL-HDBK-217 is still
the best method to get a quantitative measure of
the reliability.
The reliability of TXS converters was verified using
the MIL-HDBK and the Physics of failure approach.
Reliability Prediction
Reliability prediction is a calculation method, based
on the analysis of component failure rates of a
product or a system, with the target to predict the
rate at which the product will fail. It also pinpoints
areas for potential reliability improvements.
Physics of failure (PoF)
Because of the limitations of reliability prediction,
PoF is used as a second tool for a qualitative
measure of the reliability.
A reliability prediction gives not an exact value
for an individual module, but a statistical
estimate for an equipment population in the
field.
The basis of the analysis is a general reliability
prediction model, which describes how the
components react to electrical, thermal and
mechanical stress.
The Physics of failure approach defines a set of
specific screening and stress tests to detect
possible failure mechanism, to analyse the stress
response of the modules and verify their safety
margins.
The TXS CD ROM contains the results from a
“Design Maturity” and a “Design Integrity” test as a
part of the PoF analysis.
There are several calculation models available:
•
•
•
•
MIL-HDBK 217-F Notice 2
Belcore TR-332
PRISM
Background information about reliability prediction
and detection methods, the assumptions for the
calculation with the MIL HDBK and detailed results
can be found in the “reliability report for TXS DC-
DC Converters” on the TXS product CD ROM.
CNET RDF
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Layout Considerations
The layout for a TXS module has to be done
carefully to minimise EMI effects and to avoid
current crowding on the motherboard.
The application note “TXS layout considerations”
on the TXS product CD ROM gives some general
rules how to achieve a good layout. It explains how
to work with 100A currents, how EMI is avoided,
how signal wires should be routed and how the
module should be positioned. It gives safety advice
and describes the advantages of Bus Bars.
Screw fixing
To relieve the solder connections from mechanical
stress, it is recommended that the modules be
screwed to the motherboard. This is especially
important, if an external heatsink is used.
P1 standard Heat Sink
M3
Screw
Thermal
interface material
Alu base-plate
of TXS
0.5’ =12.7mm
Telecom
motherboard
d Print +/- Tol
Spring washer
Figure 56: Screw fixing of the TXS converter
Care should be taken when selecting the screw
lengths to mount the TXS on the motherboard and
the heatsink on the TXS. The available thread
length in the TXS case and the tolerances of the
screws and the board should be considered.
The minimum insertion depth of the screw in the
material should be 4.5 mm. It is recommend to use
spring washers to compensate for changes in the
motherboard thickness due to ageing and
temperature variations.
REV. FEB 18, 2003
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Product Specification
TXS Series: 75…120 A DC-DC Converters
36 to 75 V DC Input, 1.2, 1.5, 1.8, 2.0 and 2.5 V Output, 90 W to 250 W
Mechanical Drawings
Print mountable industry standard ¾ brick (2.4 x 3.45 x 0.5 inch3)
Converter weight: 150 g; Aluminium case (base plate) with metal mounting posts.
Measurement point for
case temperature Tc
Thermal Impedance
Pin
1
2
3
4
5
6
7
Function
Vi-
∅ inch (mm)
(Base plate to ambient)
0.08 ± 0.002
(2.03 ± 0.05)
Vi+
100 LFM
2.75 K/W
2.16 K/W
1.74 K/W
1.38 K/W
ON/OFF
Sense+
Vo-
Vo+
Trim
200 LFM
300 LFM
400 LFM
0.04 ± 0.002
(1.02 ± 0.05)
4x 0.085 ± 0.002
(4x 2.16 ± 0.05)
Note: Thermal impedance data is dependent on
many environmental factors. The exact thermal
performance should be validated for each specific
0.04 ± 0.002
(1.02 ± 0.05)
application. The figure is for
a stand-alone
8
Sense -
module. The thermal impedance was measured
with laminar airflow at 500 m over sea level.
Ordering Information
Available types, options and accessories: see tables on page 2. The sequence of options in the part number
should be set according to their position in the option table, eg: - NP2R1H
TXS [output current] Z [Code Output voltage] — [Code Option(s)]
Example:
TXS100ZB-NP2R1H
TXS with 1.8 V/100 A output, inverted logic shut down, long pins, wide trim and a 0.24” horizontal heat sink.
Notes
1. Power-One products are not authorized for use as critical components in life support systems, equipment used in hazardous
environments, or nuclear control systems without the express written consent of the President of Power-One, Inc.
2. Specifications are subject to change without notice.
REV. FEB 18, 2003
27 of 27
www.power-one.com
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