AFL5000D Series Dual Output, Hybrid High Reliability DC/DC Conver

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AFL5000D Series Dual Output, Hybrid High Reliability DC/DC Conver

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AFL5000D Series
Dual Output, Hybrid High Reliability DC/DC Converters
DESCRIPTION Series DC/DC converters feature high power density with derating over full military temperature range. This series offered part complete family converters providing single dual output voltages operating from nominal +28, +50, +120 +270 volt inputs with output power ranging from watts. applications requiring higher output power, individual converters operated parallel. internal current sharing circuits assure accurate current distribution among paralleled converters. This series incorporates Lambda Advanced Analog's proprietary magnetic pulse feedback technology providing optimum dynamic line load regulation response. This feedback system samples output voltage pulse width modulator fixed clock frequency, nominally KHz. Multiple converters synchronized system clock range synchronization output converter. Undervoltage lockout, primary secondary referenced inhibit, soft-start load fault protection provided models. These converters hermetically packaged enclosure variations, utilizing copper core pins minimize resistive losses. Three lead styles available, each fabricated with Lambda Advanced Analog's rugged ceramic lead-to-package seal assuring long term hermeticity most harsh environments. Manufactured facility fully qualified MIL-PRF38534, these converters available four screening grades satisfy wide range requirements. grade fully compliant requirements MIL-PRF-38534 class grade fully processed screened class requirement, necessarily meet other MIL-PRF-38534 requirements, e.g., element evaluation Periodic Inspections (PI) required. Both grades tested meet complete group test specification over full military temperature range without output power deration. grades with more limited screening also available less demanding applications. Variations electrical, mechanical FEATURES screening accommodated. Contact Lambda Advanced Analog with specific requirements. Volt Input Range Volt Outputs Available High Power Density Watt Output Power Parallel Operation with Power Sharing Profile (0.380") Seam Welded Package Ceramic Feedthru Copper Core Pins High Efficiency Full Military Temperature Range Continuous Short Circuit Overload Protection Output Voltage Trim Primary Secondary Referenced Inhibit Functions Line Rejection 50KHz External Synchronization Port Fault Tolerant Design Single Output Versions Available Standard Military Drawings Available
SPECIFICATIONS
ABSOLUTE MAXIMUM RATINGS
Input Voltage Soldering Temperature Case Temperature -0.5V 100V 300°C seconds Operating -55°C +125°C Storage -65°C +135°C -55°C TCASE +125°C, unless otherwise specified.
Group Subgroups Note Volts, 100% Load AFL5005D AFL5012D AFL5015D AFL5005D AFL5012D AFL5015D OUTPUT CURRENT AFL5005D AFL5012D AFL5015D OUTPUT POWER AFL5005D AFL5012D AFL5015D MAXIMUM CAPACITIVE LOAD OUTPUT VOLTAGE TEMPERATURE COEFFICIENT OUTPUT VOLTAGE REGULATION Line Load Cross AFL5005D AFL5012D AFL5015D Each Output Note Volts, 100% Load Notes -0.015 Note Load, Load, 100% Load Volts. Volts. Note Positive Output Negative Output Positive Output Negative Output Positive Output Negative Output -1.0 -8.0 -1.0 -5.0 -1.0 -5.0 -0.5 -1.0 Positive Output Negative Output Positive Output Negative Output Positive Output Negative Output Positive Output Negative Output Positive Output Negative Output Positive Output Negative Output Volts Notes Either Output Either Output Either Output Total Both Outputs. Notes 6,11 10,000 4.95 -5.05 11.88 -12.12 14.85 -15.15 4.90 -5.10 11.76 -12.24 14.70 -15.30 5.00 -5.00 12.00 -12.00 15.00 -15.00 Test Conditions
AFL50xxD
Static Characteristics
Parameter INPUT VOLTAGE OUTPUT VOLTAGE
Unit
5.05 -4.95 12.12 -11.88 15.15 -14.85 5.10 -4.90 12.24 -11.76 15.30 -14.70 12.8
+0.015 +0.5 +1.0
%/°C
+1.0 +8.0 +1.0 +5.0 +1.0 +5.0
Static Characteristics
Parameter OUTPUT RIPPLE VOLTAGE
(Continued)
Group Subgroups
Test Conditions Volts, 100% Load, 10MHz
Unit
AFL5005D AFL5012D AFL5015D
mVpp mVpp mVpp
INPUT CURRENT Load Inhibit Inhibit INPUT RIPPLE CURRENT AFL5005D AFL5012D AFL5015D CURRENT LIMIT POINT Expressed Percentage Full Rated Load
Volts IOUT Shorted Shorted Volts, 100% Load
VOUT VNOM Current split equally positive negative outputs. Note Volts
mApp mApp mApp
LOAD FAULT POWER DISSIPATION Overload Short Circuit EFFICIENCY AFL5005D AFL5012D AFL5015D ENABLE INPUTS (Inhibit Function) Converter Sink Current Converter Sink Current SWITCHING FREQUENCY SYNCHRONIZATION INPUT Frequency Range Pulse Amplitude, Pulse Amplitude, Pulse Rise Time Pulse Duty Cycle ISOLATION DEVICE WEIGHT MTBF
Volts, 100% Load Logical Note Logical High Note Note -0.5 -0.5 Note Note
nSec KHrs
Input Output Case (except Test 500VDC Slight Variations with Case Style MIL-HDBK-217F, 40°C
Dynamic Characteristics
Parameter LOAD TRANSIENT RESPONSE AFL5005D Positive Output Amplitude Recovery Amplitude Recovery AFL5005D Amplitude Negative Output Recovery Amplitude Recovery AFL5012D Positive Output Amplitude Recovery Amplitude Recovery AFL5012D Amplitude Negative Output Recovery Amplitude Recovery AFL5015D Positive Output Amplitude Recovery Amplitude Recovery AFL5015D Amplitude Negative Output Recovery Amplitude Recovery LINE TRANSIENT RESPONSE Amplitude Recovery TURN-ON CHARACTERISTICS Overshoot Delay LOAD FAULT RECOVERY LINE REJECTION
-55°C TCASE +125°C, Volts unless otherwise specified.
Group Subgroups Note Load Step 100% Load Step Load Step 100% Load Step Load Step 100% Load Step Load Step 100% Load Step Load Step 100% Load Step Load Step 100% Load Step Note Step Volts Note Enable (Pins high open) Same Turn Characteristics. MIL-STD-461D, CS101, 30Hz 50KHz Note mSec -500 µSec -450 -450 µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec µSec
Test Conditions
Unit
-450 -450
-750 -750
-750 -750
-750 -750
-750 -750
Notes Specifications: Parameters 100% tested guaranteed limits specified table. Recovery time measured from initiation transient where VOUT returned within VOUT load. Line transient transition time µSec. Turn-on delay measured with input voltage rise time between volts millisecond. Current limit point that condition excess load causing output voltage drop nominal. Parameter verified part another test. electrical tests performed with remote sense leads connected output leads load. Load transient transition time µSec. Enable inputs internally pulled high. Nominal open circuit voltage 4.0VDC. Load current split equally between +Vout -Vout. Output load must distributed that minimum total output power being provided outputs. Cross regulation measured with load tested output while changing load other output from 80%.
AFL5000D Case Outlines
Case Case
Variation Case
3.000
0.128
2.760 0.050 0.250 0.250
0.050
0.25
1.260 1.500
1.000
0.200 Non-cum 0.040
1.000
2.500
0.220
0.040 0.220 2.800
2.975 0.238
0.525 0.42 0.380 0.380
Case
Case
Variation Case
1.150
0.300 0.140 0.050 0.050
0.250
0.250
1.500 1.750 2.00
1.000
0.200 Non-cum 0.040
1.000
0.040 0.220 0.36 2.800
1.750 2.500 2.975 0.238
0.375
0.220
0.525
0.380
0.380
Tolerances, unless otherwise specified:
.XXX
±0.010 ±0.005
AFL5000D Designation
Designation
Positive Input Input Return Case Enable Sync Output Sync Input Positive Output Output Return Negative Output Output Voltage Trim Share Enable
Available Screening Levels Process Variations 5000D Series.
MIL-STD-883 Method Suffix
-20°C +85°C
Requirement
Temperature Range Element Evaluation Internal Visual Temperature Cycle Constant Acceleration Burn-in Final Electrical (Group Seal, Fine Gross External Visual
Suffix
-55°C +125°C
Suffix
-55°C +125°C
Suffix
-55°C +125°C MIL-PRF-38534
2017 1010 2001 1015 MIL-PRF-38534 1014 2009
Cond 500g
Cond Cond 160hrs 125°C -55, +25, +125°C Cond
Cond Cond 160hrs 125°C -55, +25, +125°C Cond
96hrs 125°C 25°C
96hrs 125°C 25°C Cond
Commercial Standards
Part Numbering
Model Input Voltage
120=120 270=
Screening Case Style
Output Voltage
Outputs
Single Dual
AFL5000D Circuit Description
Figure Dual Output Block Diagram
INPUT INPUT FILTER OUTPUT FILTER PRIMARY BIAS SUPPLY OUTPUT
ENABLE
CURRENT SENSE
OUTPUT RETURN
OUTPUT FILTER SYNC OUTPUT SHARE CONTROL SYNC INPUT
OUTPUT
ERROR
AMPLIFIER
SHARE ENABLE TRIM
CASE
INPUT RETURN
Circuit Operation Application Information series converters employ forward switched mode converter topology. (refer Figure Operation device initiated when voltage whose magnitude within specified input limits applied between pins pins enabled logical open) primary bias supply will begin generating regulated housekeeping voltage bringing circuitry primary side converter life. power MOSFETs used chop input voltage into high frequency square wave, apply this chopped voltage power transformer. this switching initiated, voltage impressed second winding power transformer which then rectified applied primary bias supply. When this occurs, input voltage excluded from bias voltage generator primary bias voltage becomes internally generated. switched voltage impressed secondary output transformer windings rectified filtered provide positive negative converter output voltages. error amplifier secondary side compares positive output voltage precision reference generates error signal proportional difference. This error signal magnetically coupled through feedback transformer into control section converter varying pulse width square wave signal driving MOSFETs, narrowing pulse width output voltage high widening low. These pulse width variations provide necessary corrections maintain magnitude output voltage within its' specified limits. Because primary secondary sides coupled magnetic elements, full isolation from input output achieved.
Although incorporating several sophisticated useful ancillary features, basic operation AFL5000D series initiated simply applying input voltage pins connecting appropriate loads between pins course, operation converter with high power density should attempted before secure attachment appropriate heat dissipator. (See Thermal Considerations, page Inhibiting Converter Output alternative application removal voltage input, user control converter output providing compatible, positive logic signals either enable pins (pin 12). distinction between these signal ports that enable (pin referenced input return (pin while enable (pin referenced output return (pin Thus, user access inhibit function either side isolation barrier. Each port internally pulled "high" that when used, open connection both enable pins permits normal converter operation. When their desired, logical "low" either port will shut converter down. Figure Enable Input Equivalent Circuit
+5.6V 100K 1N4148 Disable 290K 2N3904 150K
Internally, these ports differ slightly their operation. use, Enable completely shuts down circuits converter, while Enable shuts down secondary side while altering controller duty cycle near zero. Externally, either port transparent user save minor differences idle current. (See specification table). Synchronization Multiple Converters When operating multiple converters, system requirements often dictate operation converters common frequency. accommodate this requirement, series converters provide both synchronization input synchronization output. sync input port permits synchronization converter compatible external frequency source operating between KHz. This input signal should referenced input return have duty cycle. Compatibility
requires transition times less than maximum level +0.8 volts minimum high level +2.0 volts. sync output another converter which been designated master oscillator provides convenient frequency source this mode operation. When external synchronization indicated, sync should left unconnected thereby permitting converter operate its' internally frequency. sync output signal continuous pulse train KHz, with duty cycle ±5%. This signal referenced input return been tailored compatible with sync input port. Transition times less than level output impedance less than ohms. This signal active when input voltage within specified operating range converter inhibited. sync output adequate drive reserve synchronize least five additional converters. typical connection illustrated Figure III.
Figure III. Preferred Connection Parallel Operation
Power Input
Case Enable Sync Sync
Enable Share
Trim Output Return Output
Optional Synchronization Connection
Share
Case Enable Sync Sync
Enable Share
Trim Output Return Output
Negative Load Positive Load
Case Enable Sync Sync
Enable Share
Trim Output Return Output
(Other Converters)
Parallel Operation Current Stress Sharing Figure III. illustrates preferred connection scheme operation converters with outputs operating parallel. this connection permits equal current sharing among members whose load current exceeds capacity individual AFL. important feature series operating parallel mode that addition sharing current, stress induced temperature will also shared. Thus member paralleled operating higher case temperature, current provides load
will reduced compensation temperature induced stress that device.
When operating shared mode, important that symmetry connection maintained assurance optimum load sharing performance. Thus, converter outputs should connected load with equal lengths wire same gauge should connected common physical point, preferably load along with converter return leads. converters paralleled must have their share pins connected together. This arrangement diagrammatically illustrated Figure III. showing output return pins connected star point which located close possible load. consequence topology utilized current sharing circuit, share utilized other functions. applications requiring only single converter, voltage appearing share used "total current monitor". share open circuit voltage nominally +1.00v load increases linearly with increasing total output current +2.20v full load. Note that current refer here total device output current, that positive negative output currents. Thermal Considerations Because incorporation many innovative technological concepts, series converters capable providing very high output power from package very small volume. These magnitudes power density only obtained combining high circuit efficiency with effective methods heat removal from junctions. This requirement been effectively addressed inside device; when operating maximum loads, significant amount heat will generated this heat must conducted away from case. maintain case temperature below specified maximum 125°C, this heat must transferred conduction appropriate heat dissipater held intimate contact with converter base-plate. Since effectiveness this heat transfer dependent intimacy baseplate-heatsink interface, strongly recommended that high thermal conductivity heat transferring medium inserted between baseplate heatsink. material most frequently utilized factory during testing burn-in processes sold under trade name Sil-Pad® 4001. This
1Sil-Pad registered Trade Mark Bergquist, Minneapolis,
particular product insulator electrically conductive versions also available. these materials assures maximum surface contact with heat dissipater thereby compensating minor surface variations. While other available types heat conductive materials thermal compounds provide similar effectiveness, these alternatives often less convenient frequently messy use. conservative estimating total heat sink surface area (AHEAT SINK) required maximum case temperature rise above ambient temperature given following expression: HEAT SINK 0.85
-1.43
where case temperature rise above ambient, device dissipation watts Pout example, assume that desired operate AFL5015D while maintaining case temperature +85°C area where ambient temperature held constant +25°C; then 60°C. worst case full load efficiency this device 100W; thus power dissipation full load given 0.205) 20.5W required heat sink area HEAT SINK 0.85 20.5
-1.43
56.3
Thus, total heat sink surface area (including fins, any) this example, would limit case rise 60°C above ambient. flat aluminum plate, 0.25" thick approximate dimension side) would suffice this application still environment. Note that meet criteria this example, both sides plate require unrestricted exposure +25°C ambient air.
Input Filter AFL5000D series converters incorporate single stage input filter whose elements dominate input load impedance characteristic during turn-on sequence. input circuit shown Figure Figure Input Filter Circuit
2.1uH
Table Output Voltage Trim Values Limits
AFL5005D Vout 0.94uF 4.583 Radj 12.5K 33.3K 200K 190K 2.5K AFL5012D Vout 12.5 12.4 12.3 12.2 12.1 12.0 11.7 11.3 10.8 10.6 10.417 Radj 47.5K 127K 285K 760K 975K 288K 72.9K 29.9K AFL5015D Vout 15.5 15.4 15.3 15.2 15.1 15.0 14.6 14.0 13.5 13.0 12.917 Radj 62.5K 167K 375K 1.0M 1.2M 325K 117K 12.5K
Undervoltage Lockout minimum voltage required input converter initiate operation. This voltage volts. preclude possibility noise other variations input falsely initiating halting converter operation, hysteresis approximately volts incorporated this circuit. Thus input voltage droops volts, converter will shut down remain inoperative until input voltage returns volts. Output Voltage Adjust trim (10), magnitude output voltages adjusted over limited range either positive negative direction. Connecting resistor between trim either output return positive output will raise lower magnitude output voltage. span output voltage magnitude restricted limits shown Table Figure Connection VOUT Adjustment
Enable Share
Note that nominal magnitude output voltage resides middle table corresponding resistor value magnitude above nominal, adjust resistor connected output return. magnitude below nominal, adjust resistor connected positive output. (Refer Figure output voltage settings that within limits, between those presented Table suggested that resistor values determined empirically selection variable resistor. value thus determined then replaced with good quality fixed resistor permanent installation. When trim feature elected, user should aware that temperature performance converter output voltage will affected temperature performance resistor selected adjustment element therefore, user advised employ resistors with very small temperature coefficient resistance.
AFL50xxD
Sense Sense Return Vout Loads
Connect Radj increase, decrease.
©Lambda Advanced Analog
information this data sheet been carefully checked believed accurate; however responsibility assumed possible errors. These specifications subject change without notice.
980820
MIL-PRF-38534 Qualified 9001 Registered
2270 Martin Avenue Santa Clara 95050-2781 (408) 988-4930 (408) 988-2702

AFL5000D Series Dual Output, Hybrid High Reliability DC/DC Conver

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