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al80a ampss ? astec modular power supply system 120-240w output power dc-dc converter module technical reference manual series highlights ? high efficiency - up to 86% ? 85c baseplate/case operating temperature ? low output ripple and noise ? high reliability - over 1 million hours mtbf ? wide input voltage range ? design to meet telecom specifications enhanced series
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 2 contents introduction....................................................................................................... 4 special features .............................................................................................. 4 ordering information ........................................................................................ 5 safety ............................................................................................................... 5 electrical specifications .....................................................6 absolute maximum ratings C all models ......................................................... 6 pin connections - all models ............................................................................ 7 insulation - all models....................................................................................... 8 electrical specifications for 48v input models (al80a-048l-xxxfyy) .............. 9 electrical specifications for 300v input models (al80a-300l-xxxfyy) .......... 11 functional description .....................................................13 enable control (enable) .............................................................................. 13 remote sense (+sense, -sense) .............................................................. 13 output voltage adjustment (v adj) ............................................................... 13 current limit adjustment (c lim adj) ........................................................... 14 current sharing (c share) .......................................................................... 14 current monitoring (c mon) .......................................................................... 15 clock signals (clk in, clk out) ................................................................. 15 temperature monitoring (temp mon) ........................................................... 15 design considerations .....................................................16 input bulk capacitors ..................................................................................... 17 remote loads ................................................................................................ 17 input fusing ................................................................................................... 17 parallel connection considerations ............................................................... 17 input undervoltage protection ........................................................................ 17 overtemperature protection ........................................................................... 17 break regulation ............................................................................................ 17 thermal data ................................................................................................. 17 mtbf ............................................................................................................. 17 output ripple and noise ................................................................................ 17 conducted emi............................................................................................... 18
rev. 03 mar 99 ampss ? reference manual electrical specifications 3 application examples .......................................................19 mechanical information ....................................................20 dimensions .................................................................................................... 20 recommended pcb layout ........................................................................... 21 heatsink mounting information ....................................................................... 22
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 4 al80a enhanced series dc-dc converters introduction the al80a is an isolated, single output dc to dc converter module, providing up to 240w output. the al80a features full safety isolated low voltage secondary side control and a baseplate/ case operating temperature of up to 85c. special features ? high efficiency - up to 86% ? 500 khz fixed frequency switching ? 85c baseplate operating temperature (no derating) ? low output ripple and noise ? excellent transient response ? safety isolated low voltage control ? high reliability - over 1 million hours mtbf ? wide input voltage range ? parallelable with accurate current sharing ? current and temperature monitoring outputs ? regulation to zero load current sensing and control pwm control and gating osc +in -in c share enable clk in clk out temp mon v adj - sense + sense - out + out 21 24 26 29 1 12 31 32 3 11 6 5 2 internal temperature sensor id resistor 4 c mon 10 primary side secondary side c lim adj 8 output detection over- voltage protection voltage sensing and control 300vmodules only mosfet switcher pg/id 7 aux ampss tm power module clk in 6 clk out 5 c share 4 c mon 3 temp mon 2 +sense 1 7 pg/id 8 c lim adj 9 rsv 10 v adj 11 enable 12 -sense + output - + input - 31 32 21 22 23 24 26 27 28 29
rev. 03 mar 99 ampss ? reference manual electrical specifications 5 ordering information please contact astec for information on other output voltages, power ranges and configurations. safety ul: ul1950 csa: csa c22.2 no.950 vde: vde 0805 iec950 en60950 ce: ce mark please contact astec for information on specific module approvals. note: ensure all modules are used according to the installation instructions provided with each module. model number in pu t volta g e output volta g e output c u rren t output power al80a-300l-020f60 300v 2.0v 60a 120w AL80A-300L-033F50 300v 3.3v 50a 165w al80a-300l-050f40 300v 5v 40a 200w al80a-300l-120f18 300v 12v 18a 216w al80a-300l-150f16 300v 15v 16a 240w al80a-300l-063f34 300v 6.35v 34a 215w al80a-048l-050f40 48v 5v 40a 200w all modules are designed to meet the following specifications ets300-132-2 ets300-386-1 (1) en55022-a (1) en55022-b (1) en41003 iec6100-44 (1) iec6100-45 (1) iec950 vde0871-a (1) vde0878-a (1) btnr2511(5) (1) (1) require additional external circuitry for full compliance. please refer to application section of this manual or contact technical support office for further information.
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 6 general 300v i nput 48vinput continuous input voltage 400v 72v input surge voltage (1 sec) 425v 75v isolation, input to output* 2700vdc 2100vdc isolation input to baseplate* 2700vdc 2100vdc isolation, output to baseplate* 500vdc 500vdc operating temperature (baseplate) -20 to 85c storage temperature -40 to 105c operating relative humidity (non-condensing) 10% to 95% storage relative humidity (non-condensing) 95% max altitude (operating) < 3000m altitude (storage) < 9000m lead temperature (soldering 5 seconds) 235c electrical specifications absolute maximum ratings C all models exceeding the specified absolute maximum ratings may severely damage the module. these ratings are intended as guidelines for absolute worst case operating conditions and are not to be interpreted as recom- mended operating condition notes: * for 300v input : all isolation barriers on 300v input modules have been designed and tested to meet 4242vdc as required by iec950 for reinforced insulation. the complete module should not be subjected to a 3000vac input-to-output test because this can result in input-baseplate-output breakdown. ampss dc-dc modules are class i equipment. power supply systems using ampss modules must also be class i equipment. each ampss dc-dc module is fully tested in factory according to the stand- ards. therefore power supply systems need only be subjected to hi-pot test for basic insulation which is 1500vac (ac) input to ground. specifications electrical characteristics are guaranteed over the full baseplate/case temperature range (-20 to 85c) and for the full range of input voltage (v i ) and for the full load range (0 to i o rated). except where indicated , +sense and -sense are connected to the output terminals at the point of measurement, enable is connected to -sense. all other pins are left floating. definitions v i , v o and i o are actual operating conditions, v inom , v onom and i orated are nominal ratings. secondary control pins +sense v o - 0.5 to v o + 0.5 vdc -sense -0.5 to 0.5 vdc temp mon -0.5 to 7 vdc c mon -0.5 to 7 vdc c share -0.5 to 7 vdc clk out -50 to 50 vdc clk in -50 to 50 vdc c lim adj -0.5 to 7 vdc v adj -0.5 to 7 vdc pg/id 0.5 to v o + 0.5vdc enable -0.5 to 20 vdc note : v o = module output voltage all voltage are with respect to negative output
rev. 03 mar 99 ampss ? reference manual electrical specifications 7 pin connections - all models control pins pin no pin nam e type description recomm ended connections 1 +s ense input u sed for re m o te sen se fu nction to com pe nsa te for load bus resistance if rem ote se nsing is n ot req uired connect to +outp ut pins 21-24 of th e m od ule 2temp monoutput p rovides a voltage signal proportional to the internal absolute temperature of the m odule a nalog signal output. leave unconnected if not used 3c monoutput p rovides a current signal proportional to the current being supplied by the m odule a nalog signal output. leave unconnected if not used 4 c share input/output a llo w s m o d u le s c o n n e c te d in pa rallel to a ccu ra tely sh are current connect to c s ha re pins of other m odules. leave unconnected if not used 5 clk out output p rovides a 1m hz clock output for synchronization with other m odules capacitor coupled output. leave unconnected if not used 6 clk in input a ccepts a 1mhz clock input for synchronization with other m odules capacitor coupled input. leave unconnected if not used 7 p g /id o utp ut high level output (v pg/ id = v o ) indicates m odule converter is running. can also be used to ide ntify th e nominal output voltage of the m odule by measuring resistance between p g/id and +se ns e id re sistan ce = [v o (nom) ]1 k w . leave unconnected if not used 8 c lim a dj input used to adjust the current lim it s e t p o in t leave unconnected if not used 9 rsv - reserved leave unconnected 10 v adj input used to adjust module output voltage leave unconnected if not used 11 e na ble input e nables or disables the ou tpu t o f th e m od ule m ust be connected to -s ense pin or drive n to <0 .8v w .r.t. -s e n s e to enable the output of the module 12 -sense in put/ reference u sed for re m o te sen se fu nction to com pe nsa te for load bus resistance if rem ote se nsing is n ot req uired connect to -outp ut pins 26-29 of th e m od ule input pins pin no pin name type description recommended connections 31 +input input power input - positive a 220f electrolytic capacitor connected between the +input and - input p ins is recommended 32 -input input power input - negative (return) see + input for recommendations output pins pin no pin name type description recommended connections 21-24 +output output power output - positive ensure good electrical connection and sufficient co pp er on pcb la y outs 26-29 -output output power output - negative see +output for recommendations ampss tm power module clk in 6 clk out 5 c share 4 c mon 3 temp mon 2 +sense 1 7 pg/id 8 c lim adj 9 rsv 10 v adj 11 enable 12 -sense + output - + input - 31 32 21 22 23 24 26 27 28 29
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 8 control signals parameter conditions parameter min typ max units temp mon - temperature v t mon sensitivity 9.8 10.0 10.2 mv/c monitor signal source impedence 1k w c mon - current monitor i o = i orated i c m on 0.9 1.0 1.1 ma signal measured range 20 100 %i orated c share - current share c share pins of modules in c share accuracy 3% 10 %i o ave function parallel connected max no. of units 10 clk out - clock output v clk ou t 3.3 5.1 vp-p clk in open clock freq. 0.98 1.00 1.02 mhz max fan out 2 clk in - clock input v clk in 3.5 5.5 vp-p clock freq 0.9 1.0 1.1 mhz pg/id power good / converter running : v pg/ id 100 %v o identification function i o 3 5%i orated for models with i orated i o > 1a for models with i orated <20a converter not running 300vin v pg/ id 0.2 v converter running 48vin v pg/ id 1.0 v 2.0v output resistance, pg/id 1.96 2.0 2.04 k w 2.2v output to +output 2.16 2.20 2.24 k w 3.3 v output 3.23 3.30 3.36 k w 5v output 5.00 5.10 5.20 k w 6.35v output 6.08 6.20 6.32 k w 12v output 11.76 12.00 12.20 k w 15v output 14.70 15.00 15.30 k w c lim adj - current limit short c lim adjust to -sense c lim set point 20 %i omax adjustment connect a 1k w 1% from c lim to c lim set point 80 %i omax -sense pin v adj - voltage adjust adjust using external resistor v o 90 110 %v onom enable - module enable module enabled v en able 00.8v module disabled v en able 210v v en able = 0.8v enable current source 100 150 a insulation - all models insulation parameter conditions min typ max units input-output insulation resistance 500vdc 10 m w input-baseplate insulation resistance 500vdc 10 m w output-baseplate insulation resistance 500vdc 10 m w
rev. 03 mar 99 ampss ? reference manual electrical specifications 9 transient characteristics parameter conditions min typ max units turn-on time v i = 0 to v in om 110msec transient response step-load excursion (25% to 75% load change @ al80a-048l-050f40 150 250 mv 0.1a/s, recovery to 1% v o ) step-load response al80a-048l-050f40 250 s input characteristics parameter conditions min typ max units input voltage 36 48 72 v input surge voltage (1 second) 75 v input low line power on voltage module power on 30 35 v input low line power off voltage module shutdown 80 90 %v io n no load input power v i = v inom 10 w input capacitance 5f input current low line, nom v o , max i o al80a-048l-050f40 7.5 a electrical specifications for 48v input models (al80a-048l-xxxfyy)
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 10 electrical specifications for 48v input models (cont'd) output characteristics parameter conditions min typ max units nominal (factory set) output voltage al80a-048l-050f40 5.0 v output voltage set point accuracy t c = +25c, v i = v inom , i o = i orated -1 1 %v onom remote sense com p ensation v i = v imin 0.5 v output voltage adjust 90 110 %v onom nominal (factory set) output al80a-048l-050f40 120 125 130 %v onom overvoltage protection trip point line regulation v imin to v imax 0.2 %v onom load regulation 0 to i omax 0.2 %v onom noise and ripple 20mhz bandwidth al80a-048l-050f40 100 150 mv output current al80a-048l-050f40 0 40 a output current limit v o dropped to 90% of v onom 105 110 115 %i omax short circuit current 160 %i omax temperature coefficient per c baseplate temperature 0.02 %v o /c overtemperature shutdown 87 95 110 c efficiency v o = v onom , v i = v inom , i o = i orated al80a-048l-050f40 79 81 %
rev. 03 mar 99 ampss ? reference manual electrical specifications 11 electrical specifications for 300v input models (al80a-300l-xxxfyy) transient characteristics parameter conditions min typ max units t u rn -o n tim e v i = 0 to v in o m 110msec transient response step-load excursion al80a-300l-020f60 100 200 mv (25% to 75% load change @ AL80A-300L-033F50 100 200 mv 0.1a/s, recovery to 1% v o ) al80a-300l-050f40 100 200 mv al80a-300l-063f34 190 317 mv al80a-300l-120f18 360 600 mv al80a-300l-150f16 450 750 mv step-load response all modules 250 s except AL80A-300L-033F50 600 s al80a-300l-020f60 600 s input characteristics parameter conditions min typ max units input voltage all models 180 300 400 v except al80a-300l-063f34 205 400 v AL80A-300L-033F50 230 400 v al80a-300l-020f60 230 400 v input surge voltage (1 second) 425 v input low line power on voltage module power on 154 175 v input low line power off voltage module shutdown 80 90 %v ion no load input power v i = v inom 5w input capacitance 0.5 f input current low line, nom v o , max i o al80a-300l-020f60 0.85 a AL80A-300L-033F50 1.00 a al80a-300l-050f40 1.50 a al80a-300l-063f34 1.60 a al80a-300l-120f18 1.60 a al80a-300l-150f16 1.75 a
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 12 output characteristics parameter conditions min typ max units nominal (factory set) output voltage al80a-300l-020f60 2.0 v AL80A-300L-033F50 3.3 v al80a-300l-050f40 5.0 v al80a-300l-063f34 6.35 v al80a-300l-120f18 12.0 v al80a-300l-150f16 15.0 v output voltage set point accuracy t c = +25c, v i = v inom , i o = i orated -1 1 % v onom remote sense com p ensation v i = v im in 0.5 v output voltage adjust 90 110 %v onom nominal (factory set) output all models 120 125 130 %v onom overvoltage protection trip point except : al80a-300l-020f60 140 150 160 %v onom AL80A-300L-033F50 130 138 145 %v onom al80a-300l-063f34 120 127 134 %v onom line regulation v im in to v im a x all modules 0.2 %v o except al80a-300l-020f60 10 mv AL80A-300L-033F50 10 mv load regulation 0 to i omax all modules 0.4 %v o except al80a-300l-020f60 15 mv AL80A-300L-033F50 15 mv noise and ripple 20mhz bandwidth al80a-300l-020f60 100 150 mv AL80A-300L-033F50 100 150 mv al80a-300l-050f40 100 150 mv al80a-300l-063f34 127 190 mv al80a-300l-120f18 240 360 mv al80a-300l-150f16 300 450 mv output current al80a-300l-020f60 0 60 a AL80A-300L-033F50 0 50 a al80a-300l-050f40 0 40 a al80a-300l-063f34 0 34 a al80a-300l-120f18 0 18 a al80a-300l-150f16 0 16 a output current limit v o dropped to 90% of v onom 105 110 115 %i omax short circuit current 150 %i omax temperature coefficient per c baseplate temperature 0.02 %v o /c overtemperature shutdown all models 87 95 110 c efficiency v o = v onom , v i = v inom , i o = i orated al80a-300l-020f60 67 69 % AL80A-300L-033F50 77 79 % al80a-300l-050f40 81 83 % al80a-300l-063f34 80 82 % al80a-300l-120f18 84 86 % al80a-300l-150f16 84 86 % electrical specifications for 300v input models (cont'd)
rev. 03 mar 99 ampss ? reference manual electrical specifications 13 functional description this section explains how to implement the functions found on the al80a enhanced series. enable control (enable) the enable pin is a ttl compatible input used to turn the output of the module on or off. the module output is enabled when the enable pin is con- nected to -sense or driven to a logic low of <0.8v (but not negative) with respect to -sense. the output is disabled when the enable pin is open or driven to a logic high >2v with respect to -sense. all monitoring and housekeeping functions (including clock signals) continue to operate nor- mally. output voltage adjustment (v adj) the output voltage of the module may be accurately adjusted by up to 10% of the nominal factory set output. adjustment can be made using a 1k ohm trimming potentiometer connected as indicated above. remote sense (+sense, -sense) connect the +sense and -sense pins of the al80a directly to the load to allow the module to compensate for the voltage drop across the conduc- tors carrying the load current. if remote sensing is not required (for example if the load is close to the module) the sense pins should be connected directly to the modules output pins to ensure accurate regulation. note: if the sense leads fail open circuit, the module will revert to local sense at the output pins. incorrect connection of sense leads may damage the module -sense + sense 1 12 +o/p -o/p r pot =1k r ext modelno value of rext al80a- 048l -022f60 0 w al80a-xxxl-033f50 0 w al80a-xxxl-050f40 0 w al80a- 300l-063f34 130 w al80a-xxxl-120f18 1.1k w al80a-xxxl-150f16 1.5k w 0 20406080100 80 100 120 %r pot v out (%ofv o ) voltage adjust characteristic v adj +sense -sense +o/p -o/p 7 6 1 12 +o/p -o/p 7 6 1 12 +sense -sense load +sense -sense +o/p -o/p 7 6 1 12 0.5v max voltage at load module output voltage load current volts
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 14 current limit adjustment (c lim adj) a constant current limiting circuit protects the module under overload or short circuit conditions. with the c lim pin left unconnected the current limit is factory set to 110% of the module's rated output, but may be adjusted across the range 20% to 100% using a resistor connected between c lim and -sense as shown. power good/identification (pg/id) this pin provides an indication that the module's converters are working, and can also be used to identify the factory set output voltage of the module. the pg/id pin goes high to the level of the output voltage (v o ) to indicate that the module is operating and delivering power. the output goes low if the converters stop operating due to a fault such as an overtemperature or overvoltage condition. the pg/ id pin will also go low if the module is disabled via the enable pin. the resistance between the pg/id pin and the +sense of the module can be used to determine the output voltage of the module. with no power applied the output voltages and resistances are as shown in the table below: current sharing (c share) to ensure that all modules in a parallel system accurately share current, the c share pins on each module should be connected together. the voltage on the c share pins represents the average load current per module. each module compares this average with its own current and adjusts its output voltage to correct the error. in this way the module maintains accurate current sharing even under variable or light load conditions. note: the -sense and +sense pins of each module must also be connected to a common load point to ensure accurate current sharing. output voltage (v) resistance (k w ) 2.0 2.0 2.2 2.2 6.3 6.2 3.3 3.3 55.1 12 12 15 15 1 12 pg 1.0v vo converter not running converter running +v o -v o output to load 7 6 v 48v (nom) models 300v (nom) models 0.2v vo converter not running converter running +sense -sense +o/p -o/p 7 6 1 12 rext 0.0 1.0 2.0 3.0 4.0 0 20 40 60 80 100 % of c limit adj r ext (k ohm) c lim adj current limit adjust characteristic +sense -sense +o/p -o/p 7 6 1 12 +sense -sense +o/p -o/p 7 6 1 12 to c share of next module from c share of previous module
rev. 03 mar 99 ampss ? reference manual electrical specifications 15 clock signals (clk in, clk out) the module's internal clock is accurate and stable over its full operating range and synchronization is not normally required, but it can reduce noise in paralleled systems. clock signals can be wired in series (the clk out pin of one module to the clk in pin of the next etc) in which case all the modules will be synchronized with the first module in the chain. alternatively, an external clock signal of 5vpk-pk at 1mhz10% can be connected to the clk in pins of all the modules. if the clock input to any module fails, the module will automatically switch back to its internal clock and will continue to operate normally. the clk in and clk out signals are ac coupled, so any module can clock another module regardless of polarity. current monitoring (c mon) the c mon pin provides an indication of the amount of current supplied by the module. the output of the c mon pin is a current source proportional to the output current of the module, where 0.2 to 1ma = 20 to 100% i o rated . the c mon output can be paralleled with c mon outputs from other modules to indicate the total current supplied in a paralleled system. temperature monitoring (temp mon) the temp mon pin provides an indication of the module's internal temperature.the voltage at the temp mon pin is proportional to the temperature of the module interior at 10mv per c, where: module temperature (c) = (v temp mon x 100) - 273 the temperature monitor signal can be used by thermal management systems (e.g. to control a variable speed fan). it can also be used for overtemperature warning circuits and for thermal design verification of prototype power supplies and heatsinks. +sense -sense +o/p -o/p 7 6 1 12 i o 50% 100% 0 v 0.00ma 0.25ma 0.50ma 0.75ma 1.00ma i cmon 6k ohm max 0-1ma +sense -sense +o/p -o/p 7 6 1 12 +sense -sense +o/p -o/p 7 6 1 12 clk out clk in to clk in of next module clk out from clk out of previous module clk in 100?c 50 ?c 0 ?c +sense -sense +o/p -o/p 7 6 1 12 module internal temperature v 2.73v 3.23v 3.73v v temp mon 2.98v 3.48v -20 ?c 2.53v
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 16 design considerations input bulk capacitors electrolytic bulk reservoir capacitors placed close to the module input pins are recommended to ensure the module is fed with a low source impedance. for the al80a enhanced series module typical values are 220f/100v for 48v modules and 220f/450v for 300v modules. remote loads if the sensed load is some distance from the module, the module's output voltage may rise sufficiently to trigger the ovp protection circuit during a step load change due to bus inductance. fitting a decoupling capacitor at the load can reduce this effect. it should be noted that a distributed power solution, using ampss tm modules placed close to their loads, will optimize transient response. parallel connection considerations a master-slave configuration is not required for ampss tm modules. al80a modules may be con- nected in parallel using a simple, single wire connec- tion. current sharing in multi-module paralleled systems, all modules will share current to within 3% (typical) of the average load current per module when the c share pins of each module are connected together. the +sense and -sense pins of each module should be connected to common points as close as possible to the load. synchronization modules are synchronized by connecting the clk out pin of one module to the clk in pin of the next. consecutively connected modules operate out of phase with each other, resulting in ripple cancellation at the inputs and outputs of paralleled modules. if the clock input to a module fails, it will automatically revert to its internal clock and continue to operate normally. input fuse rating 300v 10a / 250v 48v 10a / 250v input fusing ampss modules do not have an in-line fuse fitted internally. in order to comply with csa, vde and ul safety regulations it is recommended that a fuse of the following rating be fitted at the module's input. + +i/p -i/p 220 f v i +sense -sense +o/p -o/p load 7 6 1 12 load +sense -sense c share 7 1 12 +sense -sense c share 1 12 clk out 6 clk in +o/p -o/p 7 6 +o/p -o/p
rev. 03 mar 99 ampss ? reference manual electrical specifications 17 input undervoltage protection an input undervoltage protection circuit protects the module under low input voltage conditions. hyster- esis is built into the al80a enhanced series module to allow for high levels of ripple on the input supply voltage without causing the module to cycle on and off. typically 300v modules will turn on when the input exceeds 160v and turn off below 140v. 48v modules will turn on above 33v and turn off below 28v (see electrical specifications for exact figures). overtemperature protection if the module's internal temperature exceeds 87c, the module will latch off. to reset the module the input supply must be cycled off and then on again, or toggle enable off/on allowing a period of time for the module to cool down. overtemperature shutdown can also be programmed to occur at lower temperatures by using the temp mon output to control the enable pin. break regulation al80a enhanced series modules are designed to deliver full rated output current at up to 0.5v above v o nom at the minimum specified input voltage. thermal data natural convection thermal impedance of the al80a package without a heatsink is approximately 4c/w. a standard horizontal fin heatsink available from astec (part number apa501-80-002) with 11mm fins and 8mm pitch, will reduce module thermal imped- ance to 1c /w with a forced air flow of 250lpm when mounted with a thermal pad (astec p/n apa502-80-001) between heatsink and module. output ripple and noise al80a enhanced series modules are designed to generate very low ripple and noise. when mounted on logic boards, for example, sufficient decoupling is normally provided by the components used to decouple the logic ics, and no additional decoupling is required. mtbf predicted mtbf for the al80a enhanced series is greater than 1,000,000 hours at maximum rated output and 50c baseplate temperature. calculated mtbf by mil-hdbk-217e under ground benign conditions is 200,000 hours. 0 0.2 0.4 0.6 0.8 1 1.2 0 200 400 600 800 1000 vair (l f m) thermal resistance baseplate to ambient (c/w) f orced convection for ap a501-80-002 at 200w output 90% 100% 110% 36 40 72 %v onom +0.5v v i (48v input modules) 90% 100% 110% va vb 400 %v onom +0.5v v i ( 300v in p ut modules ) (typical) (typical) foral80-300-0009, va=205,vb=225 al80-300-0002/0008 va=230,vb=250 others va=180,vb=200
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 18 conducted emi although ampss tm modules contain both common mode and differential mode input emi filtering, power supply systems using these modules will require additional emi filtering to enable the system to meet relevant emi standards. al80a modules have an effective input to ground (baseplate) capacitance of 450pf. this should be accounted for when calculating the maximum emi y capacitance to meet ground leakage current specifi- cations. 9 8 12 5 +i/p -i/p + - protective earth baseplate
rev. 03 mar 99 ampss ? reference manual electrical specifications 19 application examples ac input design parallel connection design +sense -sense +o/p -o/p +i/p -i/p 7 6 1 12 5v@40a c lim adj v adj enable l n e 220vac + protective earth load +sense -sense +o/p -o/p +i/p -i/p 7 6 1 12 + clk out +sense -sense +o/p -o/p +i/p -i/p 7 6 1 12 clk in c share c share + vdc in + - al80 al80
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 20 mechanical information dimensions the dimensions are given in mm (inches). note that the baseplate must be connected to protective earth before power is supplied to the module. baseplate ( connect to protective earth) 2 input pins ? 1.52(0.060) 0.05(0.002) 12controlpins ? 0.64,2.54grid 0.05 ( ? 0.025,0.1grid 0.002) 8 output pins ? 1.52(0.060) 0.05(0.002) 116.8(4.60) 61.0(2.40) 29 12 1 28 27 26 24 23 22 21 6 7 32 31 12.7 (0.50) 106.68(4.200) 50.80(2.000) 22.86(0.900) 3.81(0.150) typ 7.62 (0.300) 15.24 (0.600) 7.5(0.30) typ 5.1(0.20) typ 4.1(0.16) typ notes: 1. all dimensions in mm and (inches) 2. baseplate must be connected to protective earth 3. general tolerance: .x 0.5(0.02) .xx 0.25(0.010) 4. surface flatness: concave 0.12mm max convex 0.38mm max ? 3.81(0.150) r3.8(0.15) typ
rev. 03 mar 99 ampss ? reference manual electrical specifications 21 recommended pcb layout the al80a enhanced series module may be mounted to a board either by soldering or by using spring sockets. materials : control pins are tin plated phospher-bronze. input and output pins are tin plated copper. 21 12 1 29 6 7 32 31 50.80(2.000) 22.86(0.900) 106.68(4.200) 15.24 (0.600) 3.81(0.150) typ 7.62 (0.300) 2.54 (0.100) c a b 2.54grid 0.05 (0.10grid 0.002) hole size for pcb direct soldering hole size for spring socket mounting* hole size for m3.5 machine screw *spring sockets are available from astec in packs of 20 control pin sockets and 15 power pin sockets, p art no. apa504-00-001. sockets are not suitable for out p ut current g reater than10a p er p in. a ? 2.00+0.15/-0 ( ? 0.079+0.006/-0) ? 4.5+0.08/-0 ( ? 0.177+0.0031/-0) for m3.5 b ? 2.00+0.15/-0 ( ? 0.079+0.006/-0) ? 2.670.05 ( ? 0.105 0.002) c ? 1.00+0.15/-0 ( ? 0.039+0.006/-0) ? 1.37 0.05 ( ? 0.054 0.002) recommended hole size table:- view from pcb component side notes: 1. pcb component side view is shown. 2. all dimensions in mm and (inches). 3. general tolerance: .xx0.1(0.006).
al80a e n h ance d s er i es rev. 03 mar 99 ampss ? reference manual 22 heatsink mounting information heatsinks for ampss tm modules are available in a variety of sizes and fin orientation. mounting kits and thermal pads are also available. the table below shows the options available for al80a enhanced series. a heatsink mounting kit provides the most conven- ient way to mount the heatsink to the module and then mount the assembly onto a circuit board ampss tm modules may be retained by their input and output pins only, or may be fixed to the board using bolts screwed into the tapped studs which are provided as part of the mounting kit. in both cases the studs provide clearance between the module and the circuit board to facilitate pcb cleaning operations. note: baseplate and heatsink must be connected to protective earth description model number dimensions free air thermal inches mm resistance heatsink, "80" size, vertical fin. apa501-80-001 4.53x2.32x0.6 115x59x15 2.7c/w heatsink, "80" size, horizontal fin apa501-80-002 4.53x2.32x0.6 115x59x15 2.4c/w heatsink, "80" size, vertical fin. apa501-80-003 4.53x2.32x0.9 115x59x22.5 2.2c/w heatsink, "80" size, horizontal fin apa501-80-004 4.53x2.32x0.9 115x59x22.5 2.0c/w heatsink, "80" size, vertical fin. apa501-80-005 4.53x2.32x1.5 115x59x37 2.0c/w heatsink, "80" size, horizontal fin apa501-80-006 4.53x2.32x1.5 115x59x37 1.7c/w heatsink, "80" size, low profile apa501-80-007 4.55x3.50x0.5 115.6x89x12 2.2c/w thermal pad, "80" size apa502-80-001 mounting kit, tapped studs apa503-00-001 mounting kit, solder studs apa503-00-002 mounting kit, tapped studs apa503-00-007 for low profile heatsink mounting kit, solder studs apa503-00-008 for low profile heatsink spring sockets (20 cont. 15pwr) apa504-00-001 1 2 to provide optimal thermal contact between heatsink and module, it is recommended that the mating surface of the heatsink should have a surface flatness of no greater than 0.1mm. the use of a thermal pad or thermal grease is also recommended.
rev. 03 mar 99 ampss ? reference manual electrical specifications 23 the recommended torque of using ampss mounting kit for module/heatsink is: it is assumed that all four mounting screws are being torqued to a common surface. other thermal management schemes are at customer discretion as long as the maximum thermal rating of the specific module is not exceeded. heatsink torquing sequence 1 2 4 3 screw size torque m3 4-6kg-cm (3.5-5.2 lb-in) m3.5 6-8kg-cm (5.2-6.9 lb-in)
europe astec europe ltd. astec house, unit 9 waterfront business park, merry hill, dudley west midlands, dy5 1lx u.k. tel : 01384-842211 fax : 01384-843355 north america astec america, inc,. 5810 van allen way, carlsbad ca 92008, usa. tel : 760-930-4600 fax : 760-930-0698 for further information contact : asia astec agencies limited 6th floor, cdw building, 382-392 castle peak road, tsuen wan, n.t. hong kong tel : 852 2437-9662 fax : 852 2402-4426 apa701-al80 rev. 03 mar 99

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