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HERCULES Series
Industry's first 60A half brick DC/DC Converter 48V Input, 1.5V, 2.2V, 3.3V or 5.0V
The Hercules Series are the highest performance half brick DC/DC converters in the industry with:
Output Current up to 60 Amperes Parallel up to 5 units Pin Programmable Output Voltage 200 Watts @ 100 Baseplate 69 Watts/cu. inch 2.4" x 2.4" x 0.4" Accurate Current Share Synchronizable Fixed Frequency Operation Automatic OVP tracking to Voltage Trim Output OK signal UL and CSA approved Two Year Warranty
Control Functions
Remote Sense Output Enable
Protection Features
Over Temperature Protection Over Voltage Protection Over Current Protection
Typical Characteristics
Output Setpoint Accuracy: 1.25% Load & Line Regulation: 0.25% Noise & Ripple: 75 mVp-p Long Term Temperature Drift: 0.5% Output Trim
Hercules Series, Page 1
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Part No. 98-002 Rev. 1.1
Specifications
General Specifications
Operating Temperature Storage Temperature Relative Humidity Vibration Weight Material Flammability Safety MTBF MIL-HDBK-217 -20C to +100C baseplate -40C to +100C 10% to 95% RH, Non-condensing 10-500Hz 0.75g peak 130gm, maximum UL94V-2 500,000 hours2 UL 1950, CSA C22.2 No. 950 approved1
Notes: 1. Requires one fuse located in either the plus or minus side of the 48V supply; fuse rated for 7A max for all conditions. 2. 80% load; 70C baseplate.
Input Characteristics
Baseplate Temperatures from 0C to +100C.
Parameter Name Test Condition Var Symbol Requirement Min Max Unit
Input Voltage Input Low Line Power On V Input Low Line Power Off V No Load Input Power Input Capacitor (external to the converter) Input Current 1.5V 2.2V 3.3V 5.0V Inrush Transient Efficiency 1.5V 2.2V 3.3V 5.0V Reflected Input Ripple Maximum Losses at Local Sense 1.5V 2.2V 3.3V 5.0V
VI VIon VIoff PIL Module Power On Module Shutdown VI=VInom rated 80V min II II II II VI = 36V, IO = 60A, VO = 1.5V VI = 36V, IO = 60A, VO = 2.2V VI = 36V, IO = 50A, VO = 3.3V VI = 36V, IO = 40A, VO = 5.0V VI = 48V, IO = IO max rated VO = VO nom , IO = IO rated, VI=VInom
36 30 80 - 250 - - - -
-
72 35 90 2.5 - 4.0 5.2 5.6 6.3
1.0
V V %VIon W F A A A A A2s % % % % Ap-p W W W W
66 74 77 80
- - - - 2.5 44 44 42 42
VI = 48V, IO = Io max rated, CI = 250F Pd VI = 48V, VO = VOnom IO = IOmax rated, TCase= 70C
- - - - -
Hercules Series, Page 2
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Part No. 98-002 Rev. 1.1
Specifications
Output Characteristics
Over the complete baseplate temperatures and input voltage ranges.
Parameter Name Test Condition Var Symbol Requirement Min Typ Max Unit
Output Voltage (nominal)
Rated Output Current
1.5V 2.2V 3.3V 5.0V 1.5V 2.2V 3.3V 5.0V
VOnom VOnom VOnom VOnom IO IO IO IO
Initial Output Voltage Tolerance (with remote sense) Noise and Ripple Static Load and Line Regulation Long Term Temperature Drift Voltage Programming Slope
VO = VOnom VO = VOnom VO = VOnom VO = VOnom Vadj = open, TC = +25C VI = VInom, IO = IOrated/2 20MHzP-P bandwidth, VI=36-72V, IO = 0 amps to 100% VI=36-72V, IO = 0.2 amps to 100%
- - - - 0 0 0 0 -1.25
1.5 2.2 3.3 5.0 - - - - -
- Vnom - Vnom - Vnom - Vnom 60/40 A 60/40 A 50/40 A 40/30 A 1.25 %VOnom 75 mVP-P
- -0.5 - - - -
- _ 0.30 0.014 0.44 0.02 0.66 0.03 1.0 0.04
0.25 %VOnom 0.5 - - - - %V mV/mV mV/mV mV/mV mV/mV
1.5V 2.2V 3.3V 5.0V
VIN = 48V VO = VOnom IO = IOrated/2
Vadj = 0.5V to 1.5V
Vadj Initial Tolerance Resistance Programming Tolerance Total Remote Sense Compensation (round trip)
Vadj = 1.0V Radj = 500 Radj = 1500 1.5V 2.2V 3.3V 5V VI = VImin, IO = IOmax rated
-11.7 +8.3 - - 110
1.25 %VOnom -8.3 %VOnom +11.7 %VOnom 100 mV 500 127 30 mV %VO prog. s
Output Overvoltage Protection (Latching) Output Voltage Protection Response Time TOVP VO = VOnom, IO = IOrated
-
Note: Overvoltage Protection must function over full programming range. Also, reference for OVP Threshold must be a redundant or equivalent reference.
Hercules Series, Page 3
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Part No. 98-002 Rev. 1.1
Specifications
Output Characteristics (continued)
Over the complete baseplate temperatures and input voltage ranges.
Parameter Name Test Condition Var Symbol Min Requirement Typ Max Unit
Current Limit (nominal)
Short Circuit Current
Transient Response 1, 2
1.5V 2.2V 3.3V 5.0V 1.5V 2.2V 3.3V 5.0V 1.5V 2.2V 3.3V 5.0V
IOlim IOlim IOlim IOlim
VO = 90% VOnom, VI = 48V
VO = 0.2 to 0.4V, VI = 72V
Istep =15A, di/dt=10A/sec CO = 35-470f caps Istep =28A, di/dt=28A/sec CO = 35-470f caps Istep =12A, di/dt=10A/sec CO = 10-470f caps Istep =10A, di/dt=10A/sec CO = 5-470f caps ton IO = 5A, VI= VImin to VImax Cin = 250f, 80V Cout = 10,000f tantalum & 0.47f Ceramic VI= VImin to VImax IO= IOmin to IOmax Capacitors as in Turn On Time IO = 5A, VImin to VImax Cin = 250f, 80V Co = 330f tantalum & 0.47f Ceramic ESR@17,000f = 2m Vin = 48V, Vo = Vonom I = 10% Iop to Iop
61 61 46 37 - - - - - - - - - 10
- - - - - - - - - -
72 72 54 42 80/55 80/55 70/55 55/45 3 3 3 3 600 75
A A A A A A A A %VOnom %VOnom %VOnom %VOnom s ms
Settling Time to 1% Turn On Time (to 90% final value)
Rise Time (10% to 90%)
Trise
10
-
20
ms
Turn Off Time (to 10% initial value)
toff
-
-
2.0
ms
External Load Capacitance Current Sharing (Secondary Side) Synchronization Fanout Over Temperature Shutdown (Latching) Isolation Resistance (1500VDC) Input-Output
Ishare
1,500 -- 1 - 10
18,800 5 5 125
f %IOmax units C M
TBASEPLATE
-
Notes: 1. Transient response is for a positive or a negative current step within the range of 5% of Imax to Imax. 2. Transient response is measured with the specified number of 470F tantalum external load capacitors with a maximum ESR of 55m each.
Hercules Series, Page 4
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Part No. 98-002 Rev. 1.1
Specifications
Control Signal Characteristics
Parameter Name Test Condition Symbol Requirement Min Max Unit
Enable_L Function Control Voltage (Secondary Side) Enable Function Control Resistance (Secondary Side) OTW-L Overtemperature Warning
VENABLE
RENABLE
I SINK I LEAKAGE VL TOTW-L Time delay
MODOK_L
I LEAKAGE ISINK VL
Enable_L asserted Enable_L de-asserted Source Current (VENABLE = 0.8V) Enable_L asserted Enable_L de-asserted Source Current (RENABLE = 100) OTW_L asserted, VS = 5V, RL = 50 OTW_L de-asserted, VS = 15V OTW_L asserted, VS = 5V, RL =5K VI = 48V, VO = rated VO, IO= Rated IOmax, Fan-off early warning time before converter shuts down due to thermal overload MODOK_L de-asserted, VS = 15V MODOK_L asserted, VS = 5V, RL = 50 MODOK_L asserted, VS = 5V, RL = 5K
0 4.5 - - 200K - 8 - - 500
0.8 5.5 -1.0 100 - -1.0 20 10 0.2 -
V V mA mA mA A V ms
- 8 -
10 20 0.2
A mA V
Maximum Output Load Current (IOP) vs Number of Converters
No. of Converters 1.5V & 2.2V 3.3V 5.0V
1 2 3 4 5
60A 117A 174A 231A 288A
50A 87.75A 130.5A 173.25A 216A
40A 58.5A 87.0A 115.5A 144A
Thermal Characteristics (CA)
Air Velocity (m/s) Thermal Resistance (Baseplate to Ambient) C/W 0.9" Heatsink 1.4" Heatsink
0.5 1.0 1.5 2.0 2.5
3.0 1.9 1.6 1.4 1.3
2.1 1.3 1.1 1.0 0.9
Hercules Series, Page 5
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Part No. 98-002 Rev. 1.1
Application Notes
Signal Characteristics: Per table on page 5.
Input Signals:
Enable_L: This input signal is used to enable the output of the converter when activated (active Low). The signal is referenced to the output side (-Sense). Enable_L does not require an external pull-up resistor. If an external pull-up is used it should be tied to +5V. To minimize start-up problems it is recommended that Enable_L be driven from an open-drain configured FET. Voltage Adjust: The output voltage of the converter shall be adjustable as specified in the table on page 3. The voltage adjust pin sources 1 mA current. The adjustment shall be done using an external voltage source or a resistor connected between the Voltage Adjust pin and the - Sense pin. See below for output voltage adjustment application information. Current Share: When two or more converters are connected in parallel, their current share pins must be connected together to allow proper load sharing. Sync: When two or more converters from the same manufacturer are connected in parallel, their sync pins may be connected together to synchronize their operating frequencies. When two or more converters from different manufacturers are connected in parallel their sync pins must NOT be connected together. Output Signals: MODOK_L: MODOK_L shall be asserted to indicate that the output voltage is in regulation. When two or more converters are operating in parallel a failed converter may or may not de-assert its MODOK_L signal. OTW_L: OTW_L shall be asserted to indicate that the converter temperature is too high and that the converter is about to shut down. OTW_L will be asserted a minimum of 500 msec before the converter shuts down due to an overtemperature condition. The output of this signal is the open drain of a FET. The output is current limited to 8-15 mA and may be used to drive an external LED directly. Output Voltage Adjustment: Voltage Programming: A voltage may be applied between the Voltage Adjust pin (pin 5) and the - Sense pin (pin 1) to adjust the output voltage up or down from the nominal output voltage by a maximum of 10%.
The trim voltage for the GPH1V5-40 and GPH1V5-60 is:
(VO - 1.5) VTRIM = ------------ + 1.0V 0.30
For the GPH2V2-40 and GPH2V2-60 the output voltage may be trimmed to +15% , - 10%. The trim voltage for these two units is:
VTRIM (VO - 2.2) = ------------ + 1.0V 0.44
The trim voltage for the GPH3V3-40 and GPH3V3-60 is:
(VO - 3.3) VTRIM = ------------ + 1.0V 0.66
The trim voltage for the GPH5V0-30 and GPH5V0-40 is:
(VO - 5.0) VTRIM = ------------ + 1.0V 1.0
Resistor Programming: A resistor may be connected between the Voltage Adjust pin (pin 5) and the - SENSE pin (pin 1) to adjust the output voltage up or down from the nominal output voltage by a maximum of +/- 10 %. The GPH2V2-40, -60 may be adjusted +15 %, -10 %. The value of the trim resistor is for a single converter or for multiple paralleled converters with separate trim resistors on each of their Voltage Adjust pins. Although not recommended, the Voltage Adjust pins for N paralleled converters may be tied together. In this case the value of the trim resistor will be RTRIM/N. For the GPH1V5-40 and GPH1V5-60, the trim resistor value in Kohms for these two units is:
(VO - 1.5) RTRIM = ------------ + 1.0K 0.30
The resistor value in Kohms for the GPH2V2-40 and GPH2V2-60 is:
(VO - 2.2) RTRIM = ------------ + 1.0K 0.44
The resistor value in Kohms for the GPH3V3-40 and GPH3V3-60 is:
(VO - 3.3) RTRIM = ------------ + 1.0K 0.66
Hercules Series, Page 6
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Part No. 98-002 Rev. 1.1
Application Notes
The resistor value in Kohms for the GPH5V0-30 and GPH5V0-40 is:
RTRIM (VO - 5.0) = ------------ + 1.0K 1.0
48V RTN 4 80 UH 3 48V 2 L1 1 C1 270F 63V + C2 1F 100V In (-) In (+)
Thermal Considerations:
Thermal considerations are an important factor in the reliable operation of the converter. The maximum operating baseplate temperature is 100C. The maximum recommended operating baseplate temperature is 90C. The baseplate temperature is a function of the losses within the converter, the converter ambient temperature, and airflow across the heat sink. The reference baseplate temperature is measured at the center coordinates of the baseplate. The baseplate temperature can be approximated by the following equation:
1- TBASEPLATE = POUTPUT*----------*RBASEPLATE-AMBIENT + TAMBIENT
In (+) In (-)
+ Input - P Enable
DC/DC Converter
+
Output
RLOAD
C3 1F 100V
C4 1F 100V
Case
-
L1 Common Mode Inductor C1 270F, 63V Aluminum Electrolytic Capacitor C2-C4 1F, 100V Ceramic capacitor
Where: TBASEPLATE is the temperature of the baseplate. TAMBIENT is the local ambient temperature around the converter is the efficiency of the converter (see table on page 2) RBASEPLATE-AMBIENT is the thermal resistance from the baseplate to the ambient environment. This is a function of the heat sink and air velocity. See table on page 5 for thermal resistance characteristics. Recommended Input Filter, Fuse and Case Connections: A fuse is required in series with the plus or minus side of the 48V input to meet safety requirements. The following input filter circuit is recommended for all applications. The fuse should be inserted between the capacitors and the plus or minus input of the converter. The case should be connected to the output return.
Paralleling Converters: Two to five converters can be paralleled as long as the following conditions are met. When all of the converters are from the same manufacturer the current share pins must be connected together and the sync pins may be connected together if desired. When converters from different manufacturers are paralleled, the current share pins must be connected together and the sync pins must NOT be connected together. The maximum output current for paralleled configurations is shown in the table on page 5. When a converter fails in a parallel configuration it may or may not deassert its MODOK_L signal. It should also be noted that current for the control circuit in the converter flows through the - SENSE lead. For this reason it is important to keep the impedance between the - SENSE pins on the converters in a parallel configuration low. The best approach is to connect the - SENSE pins together with as large of an etch as possible (250 milliohms maximum recommended) and then run a single set of sense leads to the remote sense point at the load.
Hercules Series, Page 7
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Part No. 98-002 Rev. 1.1
PACKAGE DETAIL
Pin Assignments
Indicates Pin 1 2.400 Max Notes: 1. General Tolerance: .XX = 0.02 .XXX = 0.005 2. Tolerance for 0.040 and 0.080 pins to be 0.002 3. Use 4-40 screws to mount heatsink 4. Bottom surface must be insulated (primary and/or secondary etch may run underneath case)
Power Pins Designation
2.400 Max
+Vout -Vout Case N/C -Vin +Vin
Pin Config. .080 round .080 round .040 round .040 round .040 round .040 round
Signal Pins (25 mils sq.) Pin Designation
Heatsink Profile
0.555 Max 0.175 0.240
Converter Recessed M3 Insert, 0.5 inches long (optionsl) 4plcs 0.200 Ref 0.350
1 2 3 4 5 6 7 8
-Sense SYNC MODOK_L OTW_L Voltage Adjust Enable_L Current Share + Sense
1.900
1.250 1.450 0.925 1.750 2.000 Case N/C -VIN +VIN 0.300
-VOUT -VOUT -VOUT J1
4 5 1 8
0.175 0.700 1.150 1.325 0.100
1.500
Galaxy Power Inc. warrants to the original purchaser that the products conform to this data sheet and are free from material and workmanship defects for a period of two (2) years from the date of manufacture, if this product is used within specified conditions. Galaxy Power Inc. reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such products or information. For additional details on this limited warranty consult the factory.
+VOUT +VOUT +VOUT
Bottom View (facing pins)
ORDERING INFORMATION
Model Number Output Voltage Max Current Efficiency (Typ) Model Number Output Voltage Max Current Efficiency (Typ)
GPH5V0-40 GPH5V0-30 GPH3V3-50 GPH3V3-40
5.0V 5.0V 3.3V 3.3V
40 A 30 A 50 A 40 A
85% 86% 81% 82%
GPH2V2-60 GPH2V2-40 GPH1V5-60 GPH1V5-40
2.2V 2.2V 1.5V 1.5V
60 A 40 A 60 A 40 A
74% 75% 67% 68%
* Heatsinks required: available on request. See table on page 5.
155 Flanders Road Westborough, MA 01581 508-870-9775 Fax: 508-870-9796 e-mail: galaxy@galaxypwr.com website: http://www.galaxypwr.com
(c) Copyright 2000 Galaxy Power. Specifications subject to change without notice.
Hercules Series, Page 8
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Part No. 98-002 Rev. 1.1

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