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AC100 SERIES
Rev C December 2007
ISOLATED AC-DC Converter AC100 SERIES APPLICATION NOTE Rev C
Page 1
AC100 SERIES
Rev C December 2007
Content
1. INTRODUCTION 2. AC100 CONVERTER FEATURES 3. GENERAL DESCRIPTION ABSOLUTE MAXIMUM RATINGS 5. MAIN FEATURES AND FUNCTIONS 5.1 Operating Temperature Range 5.2 Output Voltage Adjustment 5.3 Over Current Protection 5.4 Over Voltage Protection 5.5 V-Sense 6. SAFETY 7. APPLICATIONS 7.1 Power De-Rating Curves 7.2 Efficiency vs. Load Curves 7.3 Test Set-Up 7.4 Output Ripple and Noise Measurement 7.5 Output Capacitance 7.6 EMI 8. MECHANICAL OUTLINE DIAGRAMS 8.1 AC100 Mechanical Outline Diagrams 9.INSTALLATION INSTRUCTION 10. PART NIMBER 3 3 3 4 6 6 6 6 6 6 6 6 7 9 11 11 11 11 12 12 12 14
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AC100 SERIES
Rev C December 2007 1. Introduction
This application note describes the features and functions of Intronics power's AC100 series of open frame, Isolated AC-DC Converters. These are highly efficient, reliable and compact, high power density, single output AC/DC converters. Ultra-high efficiency operation is achieved through the use of synchronous rectification and drive control techniques. The modules are fully protected against short circuit and over-voltage conditions. Intronics power's world class automated manufacturing methods, together with an extensive testing and qualification program; ensure that all AC100 series converters are extremely reliable. A block diagram of the AC100 series converter is shown in Figure 1. Extremely high efficiency power conversion is achieved through the use of synchronous rectification and drive techniques. Essentially, the * * * * * Universal Input Range Regulated Outputs Continuous Short Circuit Protection 3" X 5" size Open-Frame Type
3. General Description
2. AC100 Converter Features
* * * * 100W Isolated Output High Efficiency Up to 85% Fixed Switching Frequency Power factor correction Up to 0.9
powerful AC100 series topology is based on an isolated synchronous forward converter. The control loop is optimized for unconditional stability, fast transient response and a very tight line and load regulation. The output voltage can be adjusted from +5% to -5%, using a variable resistor.
AC Input
Input Filter
Bridge Rectifier
MOSFET Switch
Transformer
MOSFET Rectifier
Output Filter
Vout
PFC Controller
PFC Choke & MOSFET Switch
PWM Controller
Optocoupler Isolation
Refernce &Error AMP
Figure 1. Electrical Block Diagram
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AC100 SERIES
Rev C December 2007
4. Technical Specifications
(All specifications are typical at nominal input, full load at 25 unless otherwise noted.) PARAMETER ABSOLUTE MAXIMUM RATINGS
Input Voltage Continuous Operating Temperature Storage Temperature Input/Output Isolation Voltage INPUT CHARACTERISTICS Operating Voltage Range Input Frequency Range Maximum Input Current Power factor correction 1 minute
NOTES and CONDITIONS
Device
Min.
Typical Max.
Units
90 0 -20 4242
264 +40 +85
Vdc Vdc
100 47 100% Load, Vin=90Vac 100% Load, Vin=Nominal Vin AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 1.5 0.9 7.0 6.0 5.0 5.0 5.0 5.0 4.0
240 63
Vac Hz A
No-Load Input Power
Vin=264Vac
W
Leakage Current Inrush Current OUTPUT CHARACTERISTIC
Vin=240Vac, cold
start at 250C.
3.5 80
mA A
Output Voltage Set Point
Vin=Nominal Vin , Io=Io.max, Tc=25
AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480
4.95 8.91 11.88 14.85 17.82 23.76 47.52
5.0 9.0 12.0 15.0 18.0 24.0 48.0 20.0 11.2 8.4 6.7 5.6 4.2 2.1 20
5.05 9.09 12.12 15.15 18.18 24.24 48.48
Vdc
Operating Output Current Range
A
Holdup Time Output Voltage Regulation Load Regulation Line Regulation Output Voltage Ripple and Noise
Vin=115Vac 10% load to Full load Vin=high line to low line 20MHz bandwidth Full load, 0.1uF ceramic and 220uF E.L capacitor AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480
mS 1.0 0.5 % %
100 90 120 150 180 240 480
mV
Peak-to-Peak Full load, 0.1uF ceramic and 10uF E.L capacitor
mV
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AC100 SERIES
Rev C December 2007
PARAMETER
Output Current-Limit Output Votage-Limit Turn-On Transient Start-Up Time, From Input
NOTES and CONDITIONS
Output Voltage =90% Nominal Output Voltage
Device
Min. 110 110
Typical Max. 130 150 130 150 5 20000 12000 8400 6700 5600 4200 2100 82 85 85 85 85 85 85 4242 2121 707
Units % % s
Vin=90Vac AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 AC100S050 AC100S090 AC100S120 AC100S150 AC100S180 AC100S240 AC100S480 1 minute 1 minute 1 minute 100 67 Pout=max rated power -5
Maximum Output Capacitance
Vin=Nominal Vin at Full load
uF
EFFICIENCY
100% Load
%
ISOLATION CHARACTERISTICS Input to Output Input to Earth Output to Earth Isolation Resistance FEATURE CHARACTERISTICS Switching Frequency Output Voltage Adjustment GENERAL SPECIFICATIONS MTBF Weight
Vdc Vdc Vdc M KHz %
+5
Io=100%of Io.max;Ta=25 per MIL-HDBK-217F
TBD 0.385
M hours Kg
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AC100 SERIES
Rev C December 2007
5. Main Features and Functions
5.1 Operating Temperature Range
Intronics power's AC100 series converters highly efficient converter design has resulted in its ability to operate ambient temperature environment (0 to 40). Due consideration must be given to the derating curves when ascertaining maximum power that can be drawn from the converter. The maximum power drawn is influenced by a number of factors, such as: * * * Input voltage range. Output load current. These can be effective heat sinks for the converter.
5.4 Over Voltage Protection
All different voltage models have a full continuous over voltage protection. The power module will supply up to 150% of rated voltage. In the event of an over voltage converter will go into a hiccup mode protection.
5.5 V-Sense
V-sense measures the use as outputting the voltage. The maximum length of the sense lines is 1200mm. The min gauge wire that can be used 26AWG. If does not use and needn't need to join .
5.2 Output Voltage Adjustment
The output voltage on all models is in the range from +5% to -5% but can't exceed the watt value of the products .
6. Safety
CB Approval TUV Approval UL Approval
5.3 Over Current Protection
All different voltage models have a full continuous short-circuit protection. The unit will auto recover once the short circuit is removed. To provide protection in a fault condition, the unit is equipped with internal over-current protection. The unit operates normally once the fault condition is removed. The power module will supply up to 150% of rated current. In the event of an over current converter will go into a hiccup mode protection.
7. Applications
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AC100 SERIES
Rev C December 2007
7.1 Power De-Rating Curves
g 100% O u t p u t lo a d 75% 50% 25% 0% 0 10 20 30 40 50 60 70 Ambient temperature(oC)
100% O u tp u t lo a d 75% 50% 25% 0% 0 10 20 30 40
o
50
60
70
Ambient temperature( C)
Figure 6a. Typical Power De-rating for AC100S050
Figure 6b.Typical Power De-rating for AC100S090
100% O u tp u t lo a d 75% 50% 25% 0% 0 10 20 30 40
o
100% O u tp u t lo a d 70 75% 50% 25% 0% 50 60 0 10 20 30 40
o
50
60
70
Ambient temperature( C)
Ambient temperature( C)
Figure 6c.Typical Power De-rating for AC100S120
Figure 6d.Typical Power De-rating for AC100S150
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AC100 SERIES
Rev C December 2007
100% O u tp u t lo a d 75% 50% 25% 0% 0 10 20 30 40
o
100% O u tp u t lo a d 75% 50% 25% 0% 50 60 70 0 10 20 30 40
o
50
60
70
Ambient temperature( C)
Ambient temperature( C)
Figure 6g.Typical Power De-rating for AC100S180
Figure 6h.Typical Power De-rating for AC100S240
g 100% O u t p u t lo a d 75% 50% 25% 0% 0 10 20 30 40 50 60 70 Ambient temperature(oC)
Figure 6i.Typical Power De-rating for AC100S480
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AC100 SERIES
Rev C December 2007
7.2 Efficiency vs. Load Curves
AC100S050
90.0 80.0
AC100S090
95.0 90.0 85.0 Efficiency (% 80.0 75.0 70.0 65.0 60.0 55.0 115VAC 230VAC 1 2 3 4 5 6 7 8 9 10 11 11.2 50.0 Output Current (A)
Efficiency (%
70.0 60.0 50.0 40.0 30.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
115VAC 230VAC
Output Current (A)
Figure 7a. AC100S050
Figure 7b. AC100S090
AC100S120
95.0 90.0 85.0
AC100S150
95.0 90.0 85.0 80.0 75.0 70.0 65.0 60.0 55.0
8.5
80.0 75.0 70.0 65.0 60.0 55.0 50.0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
115VAC 230VAC
Output Current (A)
Efficiency (%)
Efficiency (%
115VAC 230VAC
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7
50.0
Output Current (A)
Figure 7c. AC100S120
Figure 7d. AC100S150
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AC100 SERIES
Rev C December 2007
AC100S180
95.0
AC100S240
95.0 90.0 85.0
90.0 85.0
Efficiency (%
Efficiency (% 115VAC 230VAC
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 5.6
80.0 75.0 70.0 65.0 60.0 55.0 50.0
80.0 75.0 70.0 65.0 60.0 55.0 50.0 0.5 1 1.5 2 2.5 3 3.5 4 4.2
115VAC 230VAC
Output Current (A)
Output Current (A)
Figure 7g. AC100S180
Figure 7h. AC100S240
AC100S480
95.0 90.0 85.0
Efficiency (%
80.0 75.0 70.0 65.0 60.0 55.0 50.0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.1
115VAC 230VAC
Output Current (A)
Figure 7i. AC100S480
Page 10
AC100 SERIES
Rev C December 2007
7.3 Test Set-Up
The basic test set-up to measure parameters such as efficiency and load regulation is shown in Figure 8. When testing the Intronics power's AC100 series under any transient conditions please ensure that the transient response of the source is sufficient to power the equipment under test. We can calculate the * * Efficiency Load regulation and line regulation.
7.4 Output Ripple and Noise Measurement
The test set-up for noise and ripple measurements is shown in Figure 10. Measured method : Add a terminal wire is 50mmMIN that the output end needs to connect the sub length of line of one end . 1. Add a 0.1 uF ceramic capacitor and a 220 uF electrolytic capacitor to output at 20 MHz Band Width for AC100S050 , AC100S090 and AC100S120. 2. Add a 0.1 uF ceramic capacitor and a 10 uF electrolytic capacitor to output at 20 MHz Band Width for AC100S150 , AC100S180 , AC100S240 and AC100S480.
Terminal wire
The value of efficiency is defined as:
=
Where:
Vo x Io x 100% Pin
Vo is output voltage, Io is output current, Pin is input power,
AC Suppl
L
+Vo +
Loa
Oscillosco
0.1uF
N
-Vo
10uF/100V or220uF/35V
The value of load regulation is defined as:
Load .reg =
Where:
VFL - VNL x100% VNL
AC100
Figure 10. Output Voltage Ripple and Noise Measurement Set-Up VFL is the output voltage at full load VNL is the output voltage at 10% load
7.5 Output Capacitance
Intronics power' AC100 series converters provide unconditional stability with or without external capacitors. Intronics power' converters are designed to work with load capacitance up-to 1000uF per amp.
The value of line regulation is defined as:
Line.reg =
VHL - VLL x100% VLL
Where: VHL is the output voltage of maximum input voltage at full load. VLL is the output voltage of minimum input voltage at full load.
7.6 EMI Conductive EMI meets CISPR/FCC Class B
L AC Pin Supply N
+Vo V -Vo
A Load
Figure 8. AC100 Series Test Setup
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AC100 SERIES
Rev C December 2007 8. Mechanical Outline Diagrams
8.1 AC100 Mechanical Outline Diagrams
Dimensions are in millimeters Tolerance: x.x 0.5mm, unless otherwise noted AnnotationsAll models height does not exceed 34mmMAX .
for AC100S050
Figure 11. AC100 Mechanical Outline Diagram
9. Installation Instruction
Please use the mounting hold as: AC100S series : 4 holds of 3.17
And insert the spacer (Max 6) of height over 8mm to lift the unit .The vibration spec. is the value take when the unit is raised by 8mm spacers.
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AC100 SERIES
Rev C December 2007
Please reserve 4mm space from the surfaces and the sides of PCB, especially from the solder surface, 8mm space is necessary. If the space is not enough, the specification of insulation and withstand will not be satisfied.
FG should be connected to the earth terminal of the apparatus. If not, the conducted noise and output noise will increase.
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AC100 SERIES
Rev C December 2007 10. Part Number
AC - XXX S XXX
AC SERIES
100 Supply Max. Power
S Single Output 050Output Voltage 5.0 VDC 090Output Voltage 9.0 VDC 120Output Voltage 12 VDC 150Output Voltage 15 VDC 180Output Voltage 18 VDC 240Output Voltage 24 VDC 480Output Voltage 48 VDC
INTRONICS POWER INCORPORATED.
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