rev. aug 20, 2004 page 1 of 10 www.power-one.com hl s serie s d c - dc converte r d a ta shee t 48vdc input, 30 & 40 amp half-bricks applications ? distributed power architectures ? telecommunications equipment ? lan/wan ? data processing features ? low profile, (-11mm) single-board design ? input-to-output isolation: 1500vdc, basic insulation ? high efficiency - to 91% at full load ? start-up into high capacitive load ? low conducted and radiated emi ? output overcurrent protection ? output overvoltage protection ? overtemperature protection ? remote sense ? set point accuracy 1% ? remote on/off (primary referenced), positive or negative logic ? output voltage trim adjust, positive or negative ? ul1950 recognized, csa 22.2 no. 950-95 certified, tuv iec950 description the hls series of high density, single-output dc-dc converters, convert standard telecom and datacom voltages into isolated low-voltage outputs. high efficiencies and a unique copper-core printed circuit board design create superior thermal characteristics that enhance product reliability and eliminate the need for a heat sink. model selection model input voltage vdc input current, max adc output voltage vdc output rated current i rated adc output ripple/noise, mv p-p typical efficiency @ i rated % hls30zg 36-75 4.8 5.0 30 100 91 hls30ze 36-75 3.3 3.3 30 100 89 hls30zd 36-75 2.5 2.5 30 100 88 hls40zb 36-75 3.0 1.8 40 100 88 hls40za 36-75 2.5 1.5 40 100 87 this product is intended for integration into end-use equipment. all the required procedures for ce marking of end-use equipme nt should be followed.
rev. aug 20, 2004 page 2 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s absolute maximum ratings stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect long- term reliability, and cause permanent damage to the converter. parameter conditions/description min max units input voltage continuous transient, 100ms 75 100 vdc vdc operating temperature ambient -40 100 c storage temperature -40 125 c on/off control voltage referenced to -vin 50 vdc environmental, mechanical & reliability specifications all specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. parameter conditions/description min nom max units maximum pcb operating temp. 100 c operating humidity relative humidity, non-condensing 95 % storage humidity relative humidity, non-condensing 95 % shock halfsine wave, 6ms, 3 axes 50 g sinusoidal vibration gr-63-core, section 5.4.2 1 weight 1.4/40 oz/g water washing standard process yes mtbf (hls30) per bellcore tr-nwt-000332 1,780 khrs (hls40) per bellcore tr-nwt-000332 1,500 khrs isolation specifications all specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. parameter conditions/description min nom max units insulation safety rating basic isolation voltage input/output 1500 vdc isolation resistance input/output 10 m ? isolation capacitance input/output 1800 pf
rev. aug 20, 2004 page 3 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s input specifications all specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. parameter conditions/description min nom max units input voltage continuous 36 48 75 vdc turn-on input voltage ramping up 32 - 35 vdc turn-off input voltage ramping down 31 - 33 vdc turn-on time to output regulation band 100% resistive load 5 10 ms input reflected ripple current full load, 12h source inductance 80 ma p-p inrush transient vin=vin.max 0.1 a 2 s output specifications all specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. parameter conditions/description min nom max units output voltage setpoint accuracy vin=vin.nom, full load -1 1 %vout output current * hls30 3 30 adc hls40 4 40 adc line regulation vin.min to vin.max, iout.max hls30 0.25 %vout hls40 0.5 %vout load regulation vin=vnom, iout.min to iout.max hls30 0.2 %vout hls40 0.5 %vout output temperature regulation (tboad temp) =-40 c to +100 c) - 0.03 %/ c remote sense headroom note: *** 10 %vout dynamic regulation peak deviation settling time 50-75% load step change to 1% error band 8 500 %vout s admissible load capacitance iout.max, nom vin 30,000 f output current limit threshold ** vout 0.97vout.nom 110 140 %iout switching frequency hls30zd 210 khz hls30zg & hls30ze 300 khz hls40za & hls40zb 250 khz overvoltage protection, non latching (hiccup type) over all input voltage and load conditions 115 140 %vout trim range iout.max, vin=vnom 90 110 %vout * at iout rev. aug 20, 2004 page 4 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s feature specifications all specifications apply over specified input voltage, output load, and temperature range, unless otherwise noted. parameter conditions/description min nom max units on/off (on/off signal is low ? converter is on) converter on sink current -1.0 1.8 1 vdc madc negative logic (-n suffix) on/off (pin #3) (primary side ref. to -vin) converter off open circuit voltage 3.5 2 50 vdc vdc (on/off signal is low ? converter is off) converter on open circuit voltage 3.5 3 50 vdc vdc positive logic (-p suffix) on/off (pin #3) (primary side ref. to -vin) converter off sink current -1.0 1.8 1 vdc madc over temperature protection type non-latching, auto-recovery threshold 100 120 c auto recovery average pcb temperature 90 c
rev. aug 20, 2004 page 5 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s characteristic curves: figure 1 . hls30zg (5v) efficiency vs. output load figure 2 . hls30ze (3.3v) efficiency vs. output load figure 3 . hls30zd (2.5v) efficiency vs. output load figure 4 . hls40za (1.5v) efficiency vs. output load 55 60 65 70 75 80 85 90 95 4 8 12 16 20 24 28 32 36 40 output current, a efficiency, % 36v 48v 75v figure 5 . hls40zb (1.8v) efficiency vs. output load 55 60 65 70 75 80 85 90 95 4 8 12 16 20 24 28 32 36 40 output current, a efficiency, % 36v 48v 75v
rev. aug 20, 2004 page 6 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s typical application figure 6 shows the recommended connections for the hls series converter. figure 6 . typical applicati on of hls series the hls series converters do not require any external components for proper operation. however, if the distribution of the input voltage to the converter contains significant inductance, the capacitor c1 may be required to enhance performance of the converter. a minimum of a 47 f electrolytic capacitor with the esr<0.7 ? is recommended for the hls series. refer to the ?inrush current control application note? on www.power-one.com for suggestions on how to limit the magnitude of the inrush current. for output decoupling we recommend using one 10 f tantalum and one 1 f ceramic capacitors connected directly across the output pins of the converter. note, that the capacitors do not substitute the filtering required by the load. shutdown feature description the on/off pin in the hls series converters functions as a normal soft shutdown. it is referenced to the ?vin pin (see figure 6). with positive logic , when the on/off pin is pulled low, the output is turned off and the unit goes into a very low input power mode. with negative logic , when the on/off pin is pulled low, the unit is turned on. an open collector switch is recommended to control the voltage between the on/off pin and the -vin pin of the converter. the on/off pin is pulled up internally, so no external voltage source is required. the user should avoid connecting a resistor between the on/off pin and the +vin pin. when the on/off pin is used to achieve remote control, the user must take care to insure that the pin reference for the control is really the -vin pin. the control signal must not be referenced ahead of emi filtering or remotely from the unit. optically coupling the information and locating the optical coupler directly at the module will solve any of these problems. note : if the on/off pin is not used, it can be left floating (positive logic), or connected to the -vin pin (negative logic). output voltage trim the trim feature allows the user to adjust the output voltage from the nominal value. this can be used to compensate distribution drops, perform margining in production, or accommodate other requirements when output voltage needs to be adjusted from the nominal. there are two trim options available in the hls series. negative-trim (no p/n suffix) all hls negative-trim models trim up with a resistor connected from the trim pin to the (-) sense pin and trim down with a resistor from the trim pin to the (+) sense pin as shown in figure 7. figure 7 . hls series negative trim schematic
rev. aug 20, 2004 page 7 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s the general equation (1) for changing the output voltage on the standard trim modules is invariant, but the constants in the equation change due to different internal design. k ? (1) where a and b are constants from the table below, and ? v is the absolute value of the desired change in the output voltage in volts. trim up trim down model a b a b hls30zg 3.77 6.81 11.58 9.88 hls30ze 2.07 3.92 3.5 5.61 hls30zd 1.27 3.92 1.31 4.95 hls40za see below n/a see below n/a hls40zb see below n/a see below n/a negative-trim, hls40 models (no p/n suffix) if an external resistor is placed between the trim pin and (+) sense pin, the output voltage decreases. the equation determines the required external resistor value to obtain an output voltage change of ? % ? . vo*(100- ? %)-122.5 r trim-dn = r1*(---------------------------) - r2 k ? vo* ? % if an external resistor is used between trim pin and (?) sense pin, the output voltage increases. the equation determines the required external resistor value to obtain an output voltage change of ? % ? . 122.5*r1 r trim-up = (------------- - r2) k ? vo* ? % where r1 and r2 are constants from the table below model r1 (k ? ) r2 (k ? ) hls30zg 3.077 6.81 hls30ze 1.690 3.92 hls30zd 1.039 3.92 hls40za 0. 223 0.15 hls40zb 0.475 1 ? note : ? % - percentage output voltage trim down or up. optional positive trim all models (?t, p/n suffix) the -t option units trim up with a resistor from the trim pin to the (+) sense pin and trim down with a resistor from the trim pin to the (?) sense pin as shown in the figure 8. figure 8 . hls series positive trim schematic the equations below determine the trim resistor value required to achieve a ? v change in the output voltage. % % 2 100 % 225 . 1 %) 100 ( v v v v vout r up ? ? + ? ? ? + = ,k ? 2 % 100 ? ? = v r down , k ? where ? v% is the output voltage change expressed in percents of the nominal output voltage, vout. notes : 1. when the output voltage is trimmed up, the output power from the converter must not exceed its maximum rating. this is determined by measuring the output voltage on the output pins, and multiplying it by the output current. 2. in order to avoid creating apparent load regulation degradation, it is important that the trim resistors are connected directly to the remote sense pins, and not to the load or to traces going to the load. 3. the hls series converters will trim down further than the 10% limit. in general, this is permissible. the user must confirm that the results are acceptable in his application. , v v b a r trim ? ? ? =
rev. aug 20, 2004 page 8 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s safety considerations the hls series converters feature 1500 volt dc isolation from input to output. the input to output dc resistance is greater than 10m ? . these converters are provided with basic insulation between input and output circuits according to all iec60950 based standards. nevertheless, if the system using the converter needs to receive safety agency approval, certain rules must be followed in the design of the system. in particular, all of the creepage and clearance requirements of the end-use safety requirements must be observed. these documents include ul60950, csa60950-00 and en60950, although other additional requirements may be needed for user?s specific applications. the hls series converters have no internal fuse. an external fuse must be provided to protect the system from catastrophic failure, as illustrated in figure 6. the fuse with a rating not greater than 10a is recommended. the user can select a lower rating fuse based upon the highest inrush transient at the maximum input voltage and the maximum input current of the converter at the minimum input voltage. both input traces and the chassis ground trace (if applicable) must be capable of conducting a current of 1.5 times the value of the fuse without opening. the fuse must not be placed in the grounded input line, if any. in order for the output of the hls series converter to be considered as selv (safety extra low voltage) or tnv-1, according to all iec60950 based standards, one of the following requirements must be met in the system design: ? if the voltage source feeding the module is selv or tnv-2, the output of the converter may be grounded or ungrounded. ? if the voltage source feeding the module is elv, the output of the converter may be considered selv only if the output is grounded per the requirements of the standard. ? if the voltage source feeding the module is a hazardous voltage secondary circuit, the voltage source feeding the module must be provided with at least basic insulation between the source to the converter and any hazardous voltages. the entire system, including the hls converter, must pass a dielectric withstand test for reinforced insulation. design of this type of system requires expert engineering and understanding of the overall safety requirements and should be performed by qualified personnel. thermal considerations the hls series converters are designed for natural or forced convection cooling. the maximum allowable output power of the converters is determined by meeting the derating criteria of all electronic components used in the power supplies. an example of the derating criteria for the semiconductor junction temperature is not to exceed 120 c to provide reliable, long-term operation of the converters. the graphs in figures 10-14 show the maximum output current of the hls series converters at different ambient temperatures under both natural and forced (longitudinal airflow direction, from pin 1 to pin 4) convection. this is further illustrated in fig. 9 as arrow ?a?. as an example, from figure 10, the hls30zg operating at 55 c can deliver up to 22a reliably with 100lfm forced air, while up to 25a reliably with 200lfm forced air. figure 9 . hls forced airflow directions (a, b, c) airflow directions ?a? and ?c? should be considered equivalent in terms of the cooling effectiveness each provides. direction ?b? can offer a marginal (< 3.5%) power capability improvement over that offered by ?a? or ?c?. this characteristic is demonstrated in fig. 15. note : figure 15 was established with vin=48vdc, and figures 10-14 at vin=52vdc. the resulting small difference in converter efficiency introduces an error term that prevents accurate correlation directly between figures 10 and 15.) pin side down a b c
rev. aug 20, 2004 page 9 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s thermal derating curve vin = 54v, orientation : vin- to vin + 0 5 10 15 20 25 30 35 25 40 55 70 85 ambient temperature (deg c) load current (a) nc (25 - 35 lfm) 100 lfm 200 lfm 300 lfm 400 lfm hls30zg figure 10 . hls30zg (5v) derating curves thermal derating curve vin = 54v, orientation : vin- to vin + 0 5 10 15 20 25 30 35 25 40 55 70 85 ambient temperature (deg c) load current (a) nc (25 - 35 lfm) 100 lfm 200 lfm 300 lfm 400 lfm hls30ze figure 11 . hls30ze (3.3v) derating curves thermal derating curve vin = 54v, orientation : vin- to vin + 0 5 10 15 20 25 30 35 40 45 25 40 55 70 85 ambient temperature (deg c) load current (a) nc (25 - 35 lfm) 100 lfm 200 lfm 300 lfm 400 lfm hls40za figure 12. hls40za (1.5v) derating curves thermal derating curve vin = 54v, orientation : vin- to vin + 0 5 10 15 20 25 30 35 25 40 55 70 85 ambient temperature (deg c) load current (a) nc (25 - 35 lfm) 100 lfm 200 lfm 300 lfm 400 lfm hls30zd figure 13. hls40zb (1.8v) derating curves thermal derating curve vin = 54v, orientation : vin- to vin + 0 5 10 15 20 25 30 35 40 45 25 40 55 70 85 ambient temperature (deg c) load current (a) nc (25 - 35 lfm) 100 lfm 200 lfm 300 lfm 400 lfm hls40zb figure 14. hls30zd (2.5v) derating curves thermal derating curve 0 5 10 15 20 25 30 25 40 55 70 85 ambient temperature (deg c) load current (a) 100 lfm(vin to vo) 100 lfm(vo to vin) hls30zg-nt ? =1a ? =.65a figure 15. hls30zd (2.5v) derating
rev. aug 20, 2004 page 10 of 10 www.power-one.com hls series d c - dc converter data shee t 48vdc in p ut, 30 & 4 0 am p hal f - bric k s mechanical drawing ordering information options suffixes to add to part number positive- no suffix required remote on/off negative- add ?n? suffix negative- no suffix required trim positive - add ?t? suffix 0.18?- no suffix required 0.11?- add ?8? suffix pin length 0.145?- add ?7? suffix notes: 1. consult factory for the complete list of available options. nuclear and medical applications - 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 respective divi sional president of power-one, inc. technical revisions - the appearance of products, including safety agency certifications pictured on labels, may change dependi ng on the date manufactured. specifications are subject to change without notice.
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