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Datasheet: F3D480T20A (Vicor Corporation)

VI Chip PFM Power Factor Module

 

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Vicor Corporation
Vicor Corporation
Tel: 800-735-6200
Power Factor Module
Rev. 1.0
Page 1 of 14
vicorpower.com
F3D480T20A
PRELIMINARY
+Out
IN
+IN
TM
F3D480T20A
8395846576834856
C
S
NRTL
US
U.S. & FOREIGN PATS. AND PATS. PENDING. MADE IN U.S.A.
PFM
TM
DC+
PR
SC
SG
Out
BV
RSV
PC
Pb
Input: rectified 120/240 Vac sinusoidal
Output: 48 Vdc programmable
Output power: Up to 200 W
4,242 Vdc reinforced insulation
90% efficiency
375 W/in
3
power density
Low profile: 0.25"
Surface mount J Lead package
Meets EN 61000-3-2 harmonic current limits
F3D480T20A
VI Chip PFM
Power Factor Module
Output Power
Designator
(P
OUT
x 0.1)
A = Analog
Control
F
3
D
480 T
20
A
Power Factor
Module
Input Designator
3 = 115/230 Vac
Product Grade Temperatures (C)
Grade
Storage
Operating
T
-40 to150
-40 to125
M
-65 to150
-55 to125
Package
D = Double VIC w/ J leads
Output Voltage
Designator
(V
OUT
x10)
Part Numbering
Product Description
The PFM (Power Factor Module) is a VI Chip
power component that converts a rectified
120/240 Vac line to an isolated, regulated DC
voltage programmable from 26 V to 48 V.
Rated at 200 W, the PFM meets EN61000-3-2
harmonic current limits and is available in a double
VIC package measuring only 1.69" (43,0) x
1.26" (32,0) x 0.25" (6,2). The PFM power density
is 375 W/in
3
.
The PFM is the front-end VI Chip for AC-DC
power systems. It requires only a rectifier, input
filter and an output capacitor to provide
a high density, power factor corrected, 200 W
power supply. The high operating frequency and
soft switching allow miniaturization of power train
components and make EMI filter components
smaller than those required by lower frequency,
hard switching converters. Output energy storage
is accomplished at SELV levels providing packaging
and interconnect flexibility not available with
conventional AC Front Ends.
PFMs may be paralleled with power sharing for
added power or redundancy in single or three
phase systems. The output voltage can be
programmed to meet the requirements of system
loads and/or additional downstream conversion
devices such as Vicor's Pre Regulator Modules (PRMs)
and Voltage Transformation Modules (VTMs).
Actual Size
Absolute Maximum Ratings
Parameter
Min
Max
Unit
Notes
Input voltage (+IN to -IN)
Operating
90
264
Vrms
Rectified AC sinusoidal
Non-operating
0
450
Vdc
100 ms
Input voltage slew rate
25
V/s
PC to -IN
-0.3
7
Vdc
BV to -IN
-0.3
50
Vdc
PR to -OUT
-0.3
7
Vdc
SC -0.3
1.5
Vdc
Output voltage (+OUT to -OUT)
-0.5
55
Vdc
Output current
6
A
Dielectric withstand (input to output)
4,242
Vdc
Reinforced insulation
1 Min
Temperature
Operating junction
-55
125
C
M-Grade
Storage
-65
150
C
M-Grade
Case peak temperature during reflow
225
C
MSL 3
Case peak temperature during reflow
245
C
MSL 6
L
N
Input Filter / Rectifier
PFM
Load
48 Vdc
200 W
PFM
Vicor Corporation
Tel: 800-735-6200
Power Factor Module
Rev. 1.0
Page 2 of 14
vicorpower.com
F3D480T20A
PRELIMINARY
Parameter
Min
Typ
Max
Unit
Note
Source voltage low range
90
132
Vrms
The PFM is not designed to support output load
Source voltage high range
180
264
Vrms
when the input is 132 to 175 Vrms
Source frequency range
47
63
Hz
Rectified AC Input Source
The PFM operates from a full bridge rectified AC line with the following characteristics:
Parameter
Min
Typ
Max
Unit
Note
Set point
47.5
48.0
48.5
Vdc
Output may be trimmed down from factory set point
Output voltage trim range
26
48
48.0
Vdc
via external trim resistor. See page 4, SC pin
Output current
0
4.1
A
Vout
= 48 Vdc
Output power
0
200
W
Vout
= 48 Vdc see Fig. 22 for heat sink information
OVP set point
56
58
Vdc
Line regulation
0.3
1
%
Load regulation
0.5
1
%
Efficiency
88
90
%
120 Vrms 75% load
No load power dissipation
0.75
W
Meets Energy Star no load limit
Current share accuracy
5
10
%
Switching frequency ripple
240
300
mV pk-pk
~1.2 MHz with 10 F ceramic bypass capacitance
Line frequency ripple
350
750
mV rms
With 10,000 F output capacitor
1.12 2.0
V
pk-pk
Start up time
From application of power
2.0
2.5
5.0
S
No overshoot
Dynamic response
Voltage deviation
6
%
Of Vout
Recovery time
500
mS
Output capacitance
1,500
2,200
10,000
F
Required for PFC. Output ripple is a function of output
Hold-up capacitance
1,500
2,200
10,000
F
and hold-up capacitance. See Fig.8 for hold-up time.
Short circuit protection
5.5
6.0
A
Current limited
Output
Electrical characteristics
(Conditions: 25C case, 75% rated load and specified input voltage range unless otherwise specified.)
Parameter
Min
Typ
Max
Unit
Note
Undervoltage shut down
82
85
Vrms
Source voltage
Overvoltage shut down
265
275
Vrms
Source voltage
Power factor
0.94
47 63 Hz
Inrush current
5
A pk
Input
(Operating from AC input source)
Vicor Corporation
Tel: 800-735-6200
Power Factor Module
Rev. 1.0
Page 3 of 14
vicorpower.com
F3D480T20A
PRELIMINARY
Electrical (cont.)
(conditions: 25C case, 75% rated load and specified input voltage range)
Control Pins
(See page 4 for pin description)
Pin
Min
Typ
Max
Unit
Note
BV (Bias Voltage)
-0.5
48
V
Referenced to -IN
PC (Primary Control)
DC voltage
4.8
5.0
5.2
Vdc
Referenced to -IN
Module disable threshold
2.3
2.4
Vdc
Module enable threshold
2.5
2.6
Vdc
Disable hysteresis
100
mV
Current limit
2.0
2.7
3.5
mA
PC pulled low
Analog control
PR (Parallel Port)
Voltage
0.6
7.5
V
Referenced to SG, see PR pin pg.4
Source current
1
mA
External capacitance
100
pF
SC (Secondary Control)
Voltage
1.23
1.24
1.25
Vdc
Referenced to SG
Internal capacitance
1.0
nF
External capacitance
0.7
F
Electromagnetic Compatibility
(configured as illustrated in Fig. 18 )
Harmonic currents
EN 61000-3-2, Amendment 14
See Fig. 11
Line disturbance / immunity
EN 61000-4-11
Interruptions and brownouts
Transient / surge immunity
EN 61000-4-5
2 kV 50 s line or neutral to earth
1 kV 50 s line to neutral
Conducted emissions
EN 55022, Level B
With filter ( see Fig. 18 )
Flicker / inrush
EN 61000-3-3
Parameter
Min
Typ
Max
Unit
Note
Over temperature shut down
125
130
135
C
Junction temperature
Junction-to-case thermal impedance
0.6
C/W
Case-to-ambient thermal impedance
2.3
C/W
46 mm x 46 mm x11mm heatsink #31474
with 300 LFM
Dielectric withstand
4,242
Vdc
Input to output
Insulation resistance
10
M ohms
Input to output
Capacitance
110
pF
Input to output
Leakage current
30
A
Line fuse Rating
250
Vac
Always ascertain and observe applicable safety,
4
A
regulatory and agency specifications
Mechanical
Weight
1.0 / 30
oz / g
Length
1.69 / 43
in / mm
Width
1.26 / 32
in / mm
Height
0.25 / 6.2
in / mm
Reflow parameters
Contact Vicor for information regarding soldering of
the PFM to printed circuit boards.
Resistance to cleaning
IEC 68-2-45 XA
Water
+55 5C
Solvents
Method 1
Isopropyl alcohol
+35 5C
Agency approvals (pending)
cTVus
UL/CSA 60950, EN 60950
CE
Low voltage directive
General
Vicor Corporation
Tel: 800-735-6200
Power Factor Module
Rev. 1.0
Page 4 of 14
vicorpower.com
F3D480T20A
PRELIMINARY
Primary side
+IN / -IN DC voltage
The PFM operates from a full wave rectified AC voltage within the
limits shown on page 2. PFMs have internal over / undervoltage
lockout functions that prevent operation outside of the specified rms
input range. PFMs will turn on when the input voltage rises above its
undervoltage lockout. If the input voltage exceeds the overvoltage
lockout, PFMs will shut down until the overvoltage fault clears.
BV - bias voltage
A 47 F 50 V electrolytic capacitor must be connected between this
port and IN to provide energy storage for the primary bias circuit.
RSV reserved
PC primary control
The PFM voltage output is enabled when the PC pin is open circuit
(floating). To disable the PFM output voltage, the PC pin is pulled to
IN. Open collector optocouplers, transistors, or relays can be used to
control the PC pin. When using multiple PFMs in a high power array,
the PC ports should be tied together to synchronize their turn on.
Secondary side
DC+
A hold-up capacitor should be connected between this port and SG
to provide output hold-up in the event of an input power failure.
For 10 ms hold-up at full load, a 2,200 F 50 V electrolytic capacitor
is recommended. DC+ should not be back driven.
PR parallel port (analog control models only)
The PR port signal, which is proportional to the PFM output power,
supports current sharing among PFMs. To enable current sharing, PR
ports should be interconnected. No bypass capacitance should be used
when interconnecting PR ports and steps should be taken to minimize
stray capacitance and noise coupling into this line (e.g, by minimizing
the width of PR port interconnect traces that lay over, or in proximity
to, signal grounds or power / ground planes). The PR port is referenced
to SG.
Pin/Control Functions
BOTTOM VIEW
+OUT
-OUT
+IN
B V
RSV
PC
-IN
Power Factor Module (PFM)
DC+
PR
SC
SG
SC secondary control (analog control models only)
The output voltage may be programmed, margined or trimmed down
by connecting a voltage source or resistor between the SC port and SG
port. The slew rate of the output voltage may be reduced by controlling
the rate-of-rise for the voltage at the SC port ( e.g. to limit inrush into a
capacitive load).
The following expression should be used to calculate the required set
point resistor value. No resistor is required if the user desires a nominal
48 V output.
R = ( Vo / (48 - Vo) ) 30.1 k
Where: R = the set point resistor
Vo = the desired output voltage set point
Example:
Vo R
42 V 211 k
36 V 90.3 k
SG signal return (analog control models only)
This port should be used as reference for the SC, PR, and DC+ ports.
Care must be taken to insure there are no low impedance paths
between -OUT and SG. Such a path could allow current to bypass the
internal current sense resistor.
+ OUT / -OUT voltage output
These ports provide the isolated DC output voltage. The OUT pin is
separated from the SG (Signal Return) pin by the internal current
sensing resistor.
Safety consideration
Care must be exercised to insure appropriate spacing, clearance and
creepage distances are maintained between line side terminals and
secondary SELV terminals.
P
1 nF
ref
1.25 V
1.25 V
Full Scale
SC
SG
30.1 k
Figure 2--Functional block diagram
Figure 1-- PFM pin out
Table 1
Vicor Corporation
Tel: 800-735-6200
Power Factor Module
Rev. 1.0
Page 5 of 14
vicorpower.com
F3D480T20A
PRELIMINARY
The PFM power-processing module consists of two major functional
blocks: an Adaptive Voltage Transformation Module (VTM) that
interfaces directly to the rectified line followed by a microprocessor
controlled Post Regulator Module (PRM). In contrast to offline power
factor correction topologies, input current shaping and energy storage
are accomplished on the secondary side of the isolation boundary.
Adaptive VTM
The Adaptive VTM acts as a nearly ideal DC-to-DC transformer. It
accepts the rectified AC input from the power source, configures its
step down ratio, or K factor, based on the magnitude of the input
voltage, and produces an isolated DC output that instantaneously
tracks the input. The Adaptive VTM configures itself by paralleling
input cells in low voltage input mode or by series configuration of
input cells in high voltage input mode. Operating over the worldwide
AC mains, the Adaptive VTM reduces the voltage variation applied to
the PRM stage from 3 to1 to 1.5 to1. This reduction in voltage range
allows greater performance and economy than would be possible
without Adaptive Transformation, which is enabled by Vicor's
proprietary class of Cascaded Topologies.
The PFM uses a Sine Amplitude Converter (SAC) Cascaded Topology
providing zero-voltage/zero-current switching through a low Q
resonant circuit to eliminate switching losses. The SAC can be
operated efficiently at high frequencies, typically in the 3 MHz range.
The high operating frequency allows miniaturization of power train
components with a commensurate increase in converter power
density. High operating frequency and soft switching makes EMI
filtering components smaller than those required by lower frequency,
hard switching converters.
Figure 3-- 120 Vac input configuration
Figure 4-- 240 Vac input configuration
+IN
IN
Control
To PRM
+IN
IN
To PRM
Control
PFM Theory of Operation
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