Military Power 800W Output 25V ZG800-220S25-PEC
Key Features
Output power: 800W
Wide input range: 170-280Vdc
High conversion efficiency: 93%
Line regulation to ±0.5%
Load regulation to ±0.5%
Fixed operating frequency
Isolation voltage: 2000V
Load sharing to 20 units
Enable(ON/OFF)control
Output over-load protection
Hiccup mode short circuit protection
Over-temperature protection
Input under-voltage lock-out
Output voltage trim: ±5%
Product Overview
These DC-DC converter modules use advanced power processing, control and packaging technologies to provide the performance, flexibility, reliability and cost effectiveness of a mature power component. High frequency Active Clamp switching provides high power density with low noise and high efficiency.
Electric Characteristics
Electrical characteristics apply over the full operating range of input voltage, output load and base plate temperature, unless otherwise specified. All temperatures refer to the operating temperature at the center of the base plate. All data testing at Ta=25oC except especial definition.
1.1 Absolute Maximum Ratings
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Input Voltage |
|
|
300 |
Vdc |
Continuous, non-operating |
|
|
280 |
Vdc |
Continuous, operating |
|
|
300 |
Vdc |
Operating transient protection,<100mS |
Isolation voltage |
|
|
2000 |
|
Input to output |
Operating Temperature |
-55 |
|
100 |
℃ |
In view of PCB Temperature |
Storage Temperature |
-65 |
|
125 |
℃ |
|
Enable to Vin- Voltage |
-2.0 |
|
10 |
Vdc |
|
1.2 Input Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Input Voltage Range |
170 |
220 |
280 |
Vdc |
Continuous |
Under-Voltage Lockout |
|
165 |
169 |
Vdc |
Turn-on Threshold; min. load |
125 |
150 |
|
Vdc |
Turn-off Threshold; half load |
Maximum Input Current |
|
|
6 |
A |
Full Load;170Vdc Input |
Efficiency |
|
93 |
|
% |
Full Load; Rating Input voltage; Figures1-2 |
Disabled Input Current |
|
20 |
|
mA |
Enable pin low |
Recommend External Input Capacitance |
|
100 |
|
μF |
Typical ESR 0.1-0.2Ω |
1.3 Output Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Output Voltage Set Point |
24.75 |
25.00 |
25.25 |
Vdc |
Nominal input; Min. load |
Output Voltage Range |
24.5 |
25.00 |
25.5 |
Vdc |
|
Output Current Range |
0.5 |
|
32 |
A |
Subject to thermal derating; Figure 5-6 |
Line Regulation |
|
±0.02 |
±0.5 |
% |
Low line to high line; full load |
Load Regulation |
|
±0.02 |
±0.5 |
% |
Min. load to full load; nominal input |
Temperature Regulation |
|
±0.01 |
±0.02 |
%/℃ |
Over operating temperature range |
Current Limit |
35.2 |
41 |
45 |
A |
Output voltage 95% of nominal |
Short Circuit Current |
0.5 |
41 |
45 |
A |
Output voltage <800 mV |
Ripple (RMS) |
|
60 |
|
mV |
Nominal input; full load; 20 MHz bandwidth, Figure 11 |
Noise(Peak-to-Peak) |
|
250 |
|
mV |
Maximum Output Cap |
|
5000 |
|
μF |
Nominal input; full load |
Output Voltage Trim |
|
±5 |
|
% |
Nominal input; full load; 25°C |
1.4 Dynamic Response Characteristics
Parameter |
Typ |
Units |
Notes |
Change In Output Current |
1300 |
mV |
50% to 75% to 50% Iout max. Figure 9 |
Change In Output Current |
1500 |
mV |
50% to 75% to 50% Iout max. Figure 10 |
Settling Time |
400 |
μS |
To within 1% Vout nom. |
Turn-on Time |
20 |
μS |
Full load; Vout=90% nom. Figure 7 |
Shut-down Fall Time |
300 |
μS |
Full load; Vout=10% nom. Figure 8 |
Output Voltage Overshoot |
5 |
% |
|
1.5 Functional Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Switching Frequency |
180 |
200 |
220 |
KHz |
Regulation stage and Isolation stage |
Trim(Pin21) |
See part 7.4 Voltage Trim(Pin21) |
Output Voltage Trim |
|
|
5 |
% |
Trim up, Trim Pin to Vout(-). |
5 |
|
|
% |
Trim down, Trim Pin to Vout(+). |
Enable(ON/OFF)Control(Pin11) |
See part 7.1 |
Enable Voltage Enable Source Current |
|
2 |
|
Vdc |
Enable pin floating |
|
1 |
|
mA |
|
Enable (ON - OFF Control) Positive Logic |
2.5 |
|
10 |
Vdc |
ON-Control, Logic high or floating |
-0.5 |
|
0.2 |
Vdc |
OFF-Control, Logic low |
Over-Load Protection |
110 |
120 |
140 |
% |
Current-Mode, Pulse by Pulse Current Limit Threshold,(%Rated Load) |
Short-Circuit Protection |
|
|
20 |
mΩ |
Type: Hiccup Mode, Non-Latching, Auto-Recovery,Threshold,Short-Circuit Resistance |
Over-Temperature Protection |
|
115 |
|
℃ |
Type: Non-Latching, Auto-Recovery;Threshold, PCB Temperature |
|
15 |
|
℃ |
Hysteresis |
1.6 Isolation Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Isolation Voltage |
|
|
2000 |
Vdc |
Input to Output |
|
|
2000 |
Vdc |
In to base |
|
|
500 |
Vdc |
Out to base |
Isolation Resistance |
100 |
|
|
MΩ |
At 500VDC to test it when atmospheric pressure and R.H. is 90% |
Isolation Capacitance |
|
1000 |
|
pF |
|
2. General Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Weight |
|
11.3(320) |
|
Oz (g) |
Encapsulated |
MTBF (calculated) |
0.1 |
|
|
MHrs |
TR-NWT-000332; 80% load,300LFM, 40℃ Ta |
3. Environmental Characteristics
Parameter |
Min |
Typ |
Max |
Units |
Notes |
Operating Temperature |
-55 |
|
100 |
℃ |
Extended, base PCB temperature |
Storage Temperature |
-65 |
|
115 |
℃ |
Ambient |
Temperature Coefficient |
|
|
±0.02 |
%/℃ |
|
Humidity |
20 |
|
95 |
%R.H. |
Relative Humidity, Non - Condensing |
4. Standards Compliance
UL/cUL60950
EN60950
GB4943
IEC 61000-4-2
Needle Flame Test (IEC 695-2-2)
5. Qualification Specification
Parameter |
Notes |
Vibration |
10-55Hz sweep, 1 min./sweep, 120 sweeps for 3 axis |
Mechanical Shock |
100g min, 2 drops in x and y axis, 1 drop in z axis |
Cold(in operation) |
IEC60068-2-1 Ad |
Damp Heat |
IEC60068-2-67 Cy |
Temperature Cycling |
-40°C to 100°C, ramp 15°C/min., 500 cycles |
Power/Thermal Cycling |
Vin = min to max, full load, 100 cycles |
Design Marginality |
Tmin-10°C to Tmax+10°C, 5°C steps, Vin = min to max, 0-105% load |
Life Test |
95% rated Vin and load, units at derating point, 1000 hours |
Solderability |
IEC60068-2-20 |
6. Typical Wave And Curves
Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C.
Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C.
Figure 3: Output voltage vs.output current.( nominal input voltage).
Figure 4: .Max output current vs. input voltage.
Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 0 LFM through 800 LFM with air flowing from pin 1 to pin 4 (nominal input voltage).
Figure 6: Thermal plot of converter at full load current (800W) with 25°C air flowing at the rate of 800 LFM. Air is flowing across the converter from pin 1 to pin 4 (nominal input voltage).
Figure 7: Turn-on transient at full load (resistive load) (20 ms/div).Input voltage pre-applied. Ch 1: Vout (10V/div).Ch 2: ON/OFF input(1V/div)
Figure 8: Shut-down fall time at full load (400 µs/div). Ch 1: Vout (10V/div).Ch 2: ON/OFF input (1V/div).
Figure 9: Output voltage response to step-change in load current (50%-75%-50% of Iout(max); dI/dt = 0.1A/μs). Load cap: 10μF, 100 mΩ ESR tantalum capacitor and 1μF ceramic capacitor. Ch 1: Vout (1V/div).
Figure 10: Output voltage response to step-change in load current (50%-75%-50% of Iout(max): dI/dt = 2.5A/μs). Load cap:10μF, 30 mΩ ESR tantalum capacitor and 1μF ceramic cap. Ch 1: Vout (1V/div).
Figure 11: Output voltage ripple at nominal input voltage and rated load current (100mV/div). Load capacitance: 1μF ceramic capacitor and 10μF tantalum capacitor. Bandwidth: 20 MHz.
7. Function Specifications
7.1 Enable (ON/OFF) Control (Pin 11)
The Enable pin allows the power module to be switched on and off electronically. The Enable (ON/OFF) function is useful for conserving battery power, for pulsed power application or for power up sequencing. The Enable pin is referenced to the -Vin. It is pulled up internally, so no external voltage source is required. An open collector (or open drain) switch is recommended for the control of the Enable pin. When using the Enable pin, make sure that the reference is really the -Vin pin, not ahead of EMI filtering or remotely from the unit. Optically coupling the control signal and locating the opto coupler directly at the module will avoid any of these problems. If the Enable pin is not used, it can be left floating (positive logic) or connected to the -Vin pin (negative logic).Figure A details five possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry.
Figure A: Various circuits for driving the ON/OFF pin.
Figure B: Internal ON/OFF pin circuitry.
7.2 Sync-In (Pin 12)
The operating frequency is set to 200KHz and can be synchronized by an external clock connected between the Sync-In pin and ground (-)Vin. The clock frequency must be within the range of 180KHz to 280KHz, and the clock must be able to pull the Sync-In pin down greater than 400ns but less than 800ns. The Sync-In pin can be left floating if not used.
7.3 Remote Sensing (Pins 20 and 22)
Remote sensing allows the converter to sense the output voltage directly at the point of load and thus automatically compensates the load conductor distribution & contact losses (Figure C). There is one sense lead for each output terminal, designated +Sense and -Sense. These leads carry very low current compared with the load leads. Internally a resistor is connected between sense terminal and power output terminal. If the remote sense is not used, the sense leads needs to be shorted to their respective output leads(Figure D).
Figure C: Remote Sense Connection
Care has to be taken when making output connections. If the output terminals should disconnect before the sense lines, the full load current will flow down the sense lines and damage the internal sensing resistors. Be sure to always power down the converter before making any output connections. The maximum compensation voltage for line drop is up to 0.5V.
Figure D: Remote Sense is not Used.
7.4 Voltage Trim (Pin 21)
Output voltage can be adjusted up or down with an external resistor. There are positive trim logic and negative trim logic available. For positive logic, the output voltage will increase when an external trimming resistor is connected between the Trim and +Vout/+Sense pin. The output voltage will decrease when an external trimming resistor is connected between Trim and -Vout/-Sense pin. A multi-turn 20KΩ trim pot can also be used to adjust the output voltage up or down(Figure E & F).
Trim-Up |
Trim Pin to -Sense |
Trim-Down |
Trim Pin to +Sense |
Figure E:Positive Trim Logic
Figure F: Trim Pot Connection
7.5 Sync-Out (Pin 15)
This pin contains a clock signal referenced to the Sense(-) pin. The frequency of this signal will be twice of either the module's internal clock frequency or the frequency established by an external clock applied to the Sync-In pin. The Sync-Out pin can be left floating if not used.
7.6 Temp Monitor (Pin 14)
The converter internal (printed circuit board) temperature can be measured from this pin. The temperature slope is -10.9mV/°C, ±0.2% typ and the tempera-ture range is -50°C (2.6V) to +125°C (0.71V).
7.7 Current Monitor (Pin 19)
Output current can be measured from this pin. The current range is min. load (1.0V) to full load (5.0V). The Current Monitor pin is referenced to the Sense(-) and can be left floating if not used.
7.8 Vaux Voltage (Pin 13)
The nominal auxiliary output voltage is 10V. Maximum allowed load is 20mA.The auxiliary output source is not short circuit protected. If it is overloaded, the main converter will be switched off.
7.9 Phase-Shift (Pin 9)
Groups of DC-DC converters can be programmed to operate in different phases to reduce the input reflected ripple current and to reduce the load transient response time as well. The desired phase can be program by connecting a resistor from Phase Shift pin to vin(-). Some programming resistances are not standard values, provision for trimming is recommended.
Figure G: Phase Shift application circuit
Phase Shift Resistor Selection Table |
Phase |
0° |
90° |
120° |
180° |
240° |
270° |
360° |
Resistor |
Open |
Jumper |
4.34K |
17.1K |
43.9K |
76.7K |
Open |
*Please make provision pads for resistor trimming on you PCB to accommodate any non-standard resistance value.
7.10 Load-Sharing (LS Pin 17)
Two or more modules can be operated in parallel for either redundant operation or additional power requirements. Connecting Load-Sharing pins together will force load (current) sharing between the connected modules. The Load-Sharing pin can be left floating if not used. The load sharing accuracy is load dependant and the correlation is listed below:
±8.0% @ 20% load
±2.5% @ 40% load
±1.5% @ 70% load
±1.0% @ 90% load
Figure H: Load sharing application circuit
7.11 Protection Features
·Input Under-Voltage Lockout: The converter is designed to turn off when the input voltage is too low, helping avoid an input system instability problem, The lockout circuitry is a comparator with DC hysteresis. When the input voltage is rising, it must exceed the typical Turn-on Voltage Threshold value(listed on the specification page) before the converter will turn on. Once the converter is on, the input voltage must fall below the typical Turn-off Voltage Threshold value before the converter will turn off. ·Output Current Limit: The maximum current limit remains constant as the output voltage drops. However, once the impedance of the short across the output is small enough to make the output voltage drop below the specified Output DC Current-Limit Shutdown Voltage, the converter into hiccup mode indefinite short circuit protection state until the short circuit condition is removed. This prevents excessive heating of the converter or the load board.
·Over-Temperature Shutdown: A temperature sensor on the converter senses the average temperature of the module. The thermal shutdown circuit is designed to turn the converter off when the temperature at the sensed location reaches the Over-Temperature Shutdown value. It will allow the converter to turn on again when the temperature of the sensed location falls by the amount of the Over-Temperature Shutdown Restart Hysteresis value.
8. Typical Application And Design Consideration
8.1 Typical Application Circuit
Figure I: Typical application circuit (negative logic unit, permanently enabled).
9. Test Method
9.1 Output Ripple & Noise Test
The output ripple is composed of fundamental frequency ripple and high frequency switching noise spikes. The fundamental switching frequency ripple (or basic ripple) is in the 100KHz to 1MHz range; the high frequency switching noise spike (or switching noise) is in the 10 MHz to 50MHz range. The switching noise is normally specified with 20 MHz bandwidth to include all significant harmonics for the noise spikes.
The easiest way to measure the output ripple and noise is to use an oscilloscope probe tip and ground ring pressed directly against the power converter output pins, as shown below. This makes the shortest possible connection across the output terminals. The oscilloscope probe ground clip should never be used in the ripple and noise measurement. The ground clip will not only act as an antenna and pickup the radiated high frequency energy, but it will introduce the common-mode noise to the measurement as well.
The standard test setup for ripple & noise measurements is shown in Figure J. A probe socket (Tektronix, P.N. 131.0258-00) is used for the measurements to eliminate noise pickup associated with long ground clip of scope probes.
Figure J: Ripple & Noise Standard Testing Means.
10. Physical Information
10.1 Mechanical Outline
Notes: 1. Pins 1-8 are 0.6” (1.52mm) dia. without shoulders.
2. Pins 9-22 are 0.025”(0.64mm) Square.
3. Pin 9 to 14 referenced to Vin(-). Pin 15 to 22 referenced to Sense(-).
4. Tolerances: x.xx ±0.02 in. (x.x ±0.5mm), x.xxx ±0.010 in. (x.xx ±0.25mm).
10.2 Pin Designations
Pin No. |
Name |
Function |
1 |
Vin(+) |
Positive input voltag |
2 |
Vin(+) |
Positive input voltag |
3 |
Vin(-) |
Negative input voltage |
4 |
Vin(-) |
Negative input voltage |
5 |
Vout(-) |
Negative output voltage |
6 |
Vout(-) |
Negative output voltage |
7 |
Vout(+) |
Positive output volt |
8 |
Vout(+) |
Positive output volt |
9 |
Phase Shift |
To reduce the input reflected ripple current and to reduce the load transient response time |
10 |
TSB |
Thermal Shut-Down Bus |
11 |
Enable |
TTL input to turn converter ON and OFF, referenced to Vin(-), with internal pull up. |
12 |
Sync-In |
The operating frequency is set to 200KHz and can be synchronized by an external clock connected between the Sync-In pin and ground (-)Vin. |
13 |
Vaux |
Auxiliary output voltage |
14 |
Temp. Monitor |
The converter internal (printed circuit board) temperature can be measured from this pin. |
15 |
Sync-Out |
This pin contains a clock signal referenced to the Sense(-) pin. |
16 |
ORing FET Drive |
The FET Drive pin provides a DC voltage of about 10V above the main output |
17 |
Load Sharing |
Two or more modules can be operated in parallel for either redundant operation or additional power requirements. |
18 |
Power Good |
The Power Good pin indicates the operating state of the module |
19 |
Current Monitor |
Output current can be measured from this pin. |
20 |
Sense(-) |
Negative remote sense. SENSE(-) may be connected to Vout(-) or left open. |
21 |
Trim |
Output voltage trim. Leave TRIM pin open for nominal output voltage. |
22 |
Sense(+) |
Positive remote sense. SENSE(+) may be connected to Vout(+) or left open. |