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picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 1 of 15 ? PI3106-01-HVIZ cool-power ? series 18-36v input, 12v / 4.2a / 50w output very high density isolated dc-dc converter (334w/in 3 ) description the cool-power ? PI3106-01-HVIZ is a very high density isolated dc-dc c onverter implementing a high efficiency soft-switching power architecture. the PI3106-01-HVIZ operate s over an input range of 18v to 36vdc, delivering ~50w of output power (12vout @ 4.2a), yielding an unprecedented power density of 334w/in 3 . the PI3106-01-HVIZ is available in a space saving surface mountable 0.87? x 0.65? x 0.265? package, achieving ~50% space reduction versus conventional solutions. the switching frequency of 900khz allows for small input and output filter components which further reduces the total size and cost of the overall system solution. the output voltage is sensed and fed back to the internal controller using a proprietary isolated magnetic feedback scheme which allows for high bandwidth and good common mode noise immunity. the PI3106-01-HVIZ requires no external feedback compensation and offers a total solution with a minimum number of external components. a rich feature set is offered, including output voltage trim capability, output over-voltage protection, adjustable soft-start, over-current prot ection with auto-restart, over and under input voltage lockout and a temperature monitoring and protection function that provides an analog voltage proportional to the die temperature as shut down and alarm capabilities. PI3106-01-HVIZ 18v-36vin, 12vout, 4.2a very high density isolated dc-dc converter features ? efficiency up to 88.5% ? high switching frequency minimizes input filter requirements and reduces output capacitance ? proprietary ?double-clamped? zvs buck-boost topology ? proprietary isolated magnetic feedback ? small footprint (0.57 in 2 ) enables pcb area savings ? very low profile (0.26 in) ? industrial input voltage range (18-36vdc) ? on/off control, positive logic ? +10/-20% trim ? temperature monitor (tm) & over-temperature protection (otp) ? input uvlo & ovlo and output ovp ? over current protection with auto restart ? adjustable soft-start ? starts up into high capacitive loads ? 2250v input to output isolation applications ? industrial dc-dc power conversion package information ? surface mountable 0.87? x 0.65? x 0.265? package typical application schematic diagram figure 1 picor PI3106-01-HVIZ shown with system fuse, filter, decoupling and extended soft start PI3106-01-HVIZ
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 2 of 15 pin description and maximum ratings figure 2 picor PI3106-01-HVIZ pin out pin description pin name description +in primary side positive input voltage terminals. -in primary side negative input voltage terminals. enable converter enable option, functions as 5v re ference and on/off control pin. pull low for off. trim/ss external soft start pin and trim function. conn ect to sgnd or enable through resistor for trim up or trim down. tm temperature measurement output pin. sgnd signal ground, primary side referenced. +out isolated secondary dc output voltage positive terminals. -out isolated secondary dc output voltage negative terminals. absolute maximum ratings +in to -in max operating voltage -1.0 to 41vdc (operating) +in to -in max peak voltage 45vdc (non-operating, 100ms) enable to ?in -0.3 to 6.0vdc tm to ?in -0.3 to 6.0vdc trim/ss to ?in -0.3 to 6.0vdc +out to ?out -0.5 to 14.5.0vdc isolation voltage (+in/-in to +out/-out) 2250vdc isolation capacitance (+in/-in to +out/-out) 280 pf continuous output current 4.2a dc (tcase < 100c) peak output current 12a dc (11mm heatsink, 600lfm) operating junction temperature -40 to 125c storage temperature -50 to 125c case temperature during reflow 245c trim/ss +in sgnd tm enable -in +out -out PI3106-01-HVIZ
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 3 of 15 functional block diagram trim/ss +out sgnd -out -in +in enable tm lff - + rss css int vref 1.22v rfb1 cfb1 cfb2 - + error amp driver - + dc slow current limit driver synchronous rectifier - + dc output ovp - + dc input uvp input ovp - + dc over temp - + dc enb period ramp - + dc enable - + dc on-duty ramp - + zvs power train + - dc timing logic fb fb enb +5v ea fault - + dc 120us delay 120us delay fault latch and reset logic reset fault run bias start bias vcc temp sensor zvs power train zvs fb figure 3 PI3106-01-HVIZ functional block diagram
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 4 of 15 electrical specifications unless otherwise specified: 18v < v in < 36v, 0a < i out < 4.2a, -40 ? c < t case < 100 ? c (1) parameter symbol min typ max units conditions input specifications input voltage range v in 18 24 36 vdc input dv/dt (1) v indvdt 1.0 v/s v in = 36v input under-voltage turn-on v uvon 17 vdc i o = 4.2a input under-voltage turn-off v uvoff 16 vdc i o = 4.2a input under-voltage hysteresis v uvh 1 vdc i o = 4.2a input over-voltage turn-on v ovon 40 vdc i o = 4.2a input over-voltage turn-off v ovoff 41 vdc i o = 4.2a input over-voltage hysteresis v ovh 1 i o = 4.2a input quiescent current i q 2 madc v in = 24v, enable = 0v input idling power p idle 3.8 w v in = 24v, i out = 0a input standby power p sby 0.225 w v in = 24v, enable = 0v input current full load i in 2.38 adc t case = 100 ? c i out = 4.2a ? fl = 88.2 % typical v in =24v input reflected ripple current i inrr 13 mapp l in = 0.47h c in = 100f 63v electrolytic + 2x4.7f 50v x7r ceramic recommended ext input capacitance c in 109.4 f c in = 100f 50v electrolytic + 2x4.7f 50v x7r ceramic c in = cbulk + chf output specifications output voltage set point v out 12.0 vdc i out = 2.1 a total output a ccuracy v oa -3 +3 % line regulation v rli 0.25 % v in = 18v-36v, i out = 4.2a load regulation v rlo 1.5 % v in = 24v, i out = 0-4.2a output voltage trim range v oadj -20% 10% % output current range i out 4.2 adc over current protection i ocp 7.7 12 adc v in = 52v efficiency ? full load ? fl 88.2 % t case = 100 ? c, v in =24v efficiency ? half load ? hl 84.6 % t case = 100 ? c, v in =24v output ovp set point v ovp 14.5 vdc output ripple voltage v orpp 120 mvpp c out = 6x2.2f 16v x7r dc- 20mhz switching frequency f sw 900 khz output turn-on delay time t ondly 80 ms v in = v uvon to enable = 5v
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 5 of 15 electrical specifications (continued) unless otherwise specified: 18v < v in < 36v, 0a < i out < 4.2a, -40 ? c < t case < 100 ? c (1) parameter symbol min typ max units conditions output specifications (continued) output turn-off delay time t offdly 10 s v in = v uvoff to enable < 1.8v soft-start ramp time t ss 380 s enable = 5v to 90% vout c ss = 0 maximum load capacitance c out 10000 f c ss = 0, c out = al electrolytic load transient deviation v odv 360 mv i out = 50% step 0.1a/s c out = 6x2.2f 16v x7r load transient recovery time t ovr 100 s i out = 50% step 0.1a/s c out = 6x2.2f 16v x7r v out - 1% maximum output power p out 50 w auxiliary control pins enable dc voltage reference output v ero 4.65 4.9 5.15 vdc output current limit (2) i ecl -3.3 -2.6 -1.9 madc enable = 3.3v start up current limit (2) i esl -120 -90 -60 a enable = 1v module enable voltage v eme 1.95 2.5 3.05 vdc module disable voltage v emd 1.8 2.35 2.9 vdc disable hysteresis v edh 150 mv enable delay time t ee 10 s disable delay time t ed 10 s maximum capacitance c ec 1500 pf maximum external toggle rate f ext 1 hz trim/ss trim voltage reference v ref 1.22 vdc internal capacitance c refi 10 nf external capacitance c ref 1 f internal resistance r refi 10 k ? tm (temperature monitor) temperature coefficient tm tc 10 mv/k temperature full range accuracy tm acc -5 5 k drive capability i tm -100 a tm output setting v tm 3.00 v ambient temperature = 300k
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 6 of 15 electrical specifications (continued) unless otherwise specified: 18v < v in < 36v, 0a < i out < 4.2a, -40 ? c < t case < 100 ? c (1) parameter symbol min typ max units conditions thermal specification junction temperature shutdown t max 130 135 140 c v in = 36v, full 4.2a load junction-to-case thermal impedance r ? j-c 3 c/w case-to-ambient thermal impedance r ? c-a 15 c/w mounted on 4.2 in 2 1oz. cu 6 layer pcb 25c regulatory specification iec 60950-1:2005 (2 nd edition), en 60950-1:2006 iec 61000-4-2 ul 60950-1:2007 can/csa c22.2 no. 60950-1-07 recommended input fuse rating i fuse 4 10 a fast acting littlefuse nano2 series fuse mechanical specifications parameter symbol min typ max units conditions mechanical parameters PI3106-01-HVIZ package weight m pkg 7.2 g no heat sink 2.2 cm no heat sink PI3106-01-HVIZ package length l pkg 0.87 in no heat sink 1.65 cm no heat sink PI3106-01-HVIZ package width w pkg 0.65 in no heat sink 0.673 cm no heat sink PI3106-01-HVIZ package height h pkg 0.265 in no heat sink note (1) : these parameters are not production tested but are guaranteed by design, characterization and correlation with statistical process control. unless otherwise specified, ate tests are completed at room temperature. note (2): current flow sourced by a pin has a negative sign.
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 7 of 15 functional description : input power pins in(+) and in(-): the input power pins on the PI3106-01-HVIZ are connected to the input power source which can range from 18v to 36v dc. under surge conditions, the PI3106-01-HVIZ can withstand up to 45v dc for 100 ms without incurring damage. the user should take care to avoid driving the input rails above the specified ratings. since the PI3106-01-HVIZ is designed with high reliability in mind, the input pins are continuously monitored. if the applied voltage exceeds the input over-volt age trip point (typically 41v) the conversion process shall be terminated immediately. the converter initiates soft-start automatically within 80ms after the input voltage is reduced back to the appropriate value. the input pins do not have reverse polarity protection. if the pi3106 is operated in an environment where reverse polarity is a concern, the user should consider using a polarity protection device such as a suitably rated diode. to avoid the high loss es of using a diode, the user should consider the much higher efficiency picor family of intelligent cool-oring ? solutions that can be used in reverse polarity applications. information is available at picorpower.com . the PI3106-01-HVIZ will draw nearly zero current until the input voltage reaches the internal start up threshold. if the enable pin is not pulled low by external circuitry, the output voltage will begin rising to its final value of 12v about 80ms after the input uv lockout releases. this will occur automatically even if the enable pin is floating. to help keep the source impedance low, the input to the PI3106-01-HVIZ should be bypassed with (2) 4.7uf 50v ceramic capacitors of x7r dielectric in parallel with a low q 100uf 50v electrolytic capacitor. to reduce emi and reflected ripple current, a series inductor of 0.2 to 0.47uh can be added. the input traces to the module should be low impedance configured in such a manner as to keep stray inductance minimized. enable pin: the enable pin serves as a multi-function pin for the PI3106-01-HVIZ. during normal operation, it outputs the on-board 4.9v regulator which can be used for trimming the module up. the enable pin can also be used as a remote enable pin either from the secondary via an optocoupler and some external isolated bias supply or from the primary side through a small signal transistor, fet or any device that sinks 3.3ma, minimum. if the enable pin is lower than 2.35v typical, the converter will be held off or shut down if already operating. a third feature is offered in that during a fault condition such as output ovp, input uv or ov, or output current limit, the enable pin is pulled low in ternally. this can be used as a signal to the user that a fault has occurred. whenever the enable pin is pulled low, the trim/ss pin follows, resetting the internal and external soft-start circuitry. all faults will pull enable low including over temperature. if increased turn on delay is desired, the enable pin can be bypassed with a small capacitor up to a maximum of 1500pf. trim/ss pin: the trim/ss pin serves as another multi-purpose pin. first, it is used as the reference for the internal error amplifier. connecting a resistor from trim/ss to sgnd allows the reference to be margined down by as much as -20%. connecting a resistor from trim/ss to enable will allow the reference and output voltage to be margined up by 10%. if the user wishes a longer start up time, a small ceramic capacitor can be added to trim/ss to increase it. it is critical to connect any device between trim/ss and sgnd and not -in, otherwise high frequency noise will be introduced to the reference and possibly cause erratic operation. tm pin: the tm pin serves as an output indicator of the internal package temperature which is within approximately +/- 5 ? k of the hottest junction temperature. because of this, it is a good indicator of a thermal overload condition. the output is a scaled, buffered analog voltage which indicates the internal temperature in degrees kelvin. upon a thermal overload, the tm pin is pulled low, indicating a thermal fault has occurred. upon restart of the converter, the tm pin reverts back to a buffered monitor. the thermal sh utdown function of the PI3106-01-HVIZ is a fault feature which interrupts power processing if a certain maximum temperature is exceeded. tm can be monitored by an external microcontroller or circuit configured as an adaptive fan speed controller so that air flow in the system can be conveniently regulated. sgnd pin: the PI3106-01-HVIZ sgnd pin is the ?quiet? control circuitry return. it is basically an extension of the internal signal ground. to avoid contamination and potential ground loops, this ground should not be connected to -in since it is already star connected inside the package. connect signal logic to sgnd, not -in.
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 8 of 15 output power pins +out and -out: the output power terminals out(+) and out(-) deliver the 4.2a maximum output current from the PI3106-01-HVIZ through the j-lead output pins. this configuration allows for a low impedance output and should be connected to multi-layer pcb parallel planes for best performance. due to the high switching frequency, output ripple and noise can be easily attenuated by adding just a few high quality x7r ceramic capacitors while retaining adequate transient response for most applications. the PI3106-01-HVIZ does not requi re any feedback loop compensation nor does it require any opto-isolation. all isolation is contained within the package. this greatly simplifies the us e of the converter and eliminates all outside influences of noise on the quality of the output voltage regulation and feedback loop. it is important for the user to minimize resistive connections from the load to the converter output and to keep stray inductance to a minimum for best regulation and transient response. the very small size footprint and height of the PI3106-01-HVIZ allows the converter to be placed in the optimum location to allow for tight connections to the point of load. for those applications absolutely requiring very tight regulation, contact picor engineering at picorpower.com for a remote sense application circuit which can be used.
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 9 of 15 typical performance characteristics: 10 20 30 40 50 60 70 80 90 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 load current (amps) % efficiency 16v@100c 24v@100c 36v@100c 50v@100c 16v@-55c 24v@-55c 36v@-55c 50v@-55c figure 4 conversion efficiency 11.64 11.74 11.84 11.94 12.04 12.14 12.24 12.34 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 load current (amps) output voltage (volts) 16v@100c 24v@100c 36v@100c 50v@100c 16v@-55c 24v@-55c 36v@-55c 50v@-55c figure 5 line and load regulation 0 1 2 3 4 5 6 7 8 9 10 11 12 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 load current (amps) power dissipation (watts) 16v@100c 24v@100c 36v@100c 50v@100c 16v@-55c 24v@-55c 36v@-55c 50v@-55c figure 6 power dissipation vs load figure 7 maximum power dissipation no heatsink 0 5 10 15 20 25 30 35 40 45 50 55 60 65 0 1 2 3 4 5 6 7 8 9 10 0lfm 200lfm 400lfm 600lfm 800lfm 1000lfm ambient temperature degrees c maximum dissipated power watts
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 10 of 15 typical performance characteristics: figure 8 max power dissipation (6.3mm heat sink) figure 9 max power dissipation (11mm heat sink) figure 10 start up c ref =22nf (v in = 16v i o = 4.2a cc c out = 6x2.2f x7r ceramic) figure 11 start up c ref =22nf (v in = 24v i out = 4.2a cc c out = 6x2.2f x7r ceramic) figure 12 start up c ref =22nf (v in = 36v i out = 4.2a cc c out = 6x2.2f x7r ceramic) 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 1 2 3 4 5 6 7 8 9 10 0lfm 200lfm 400lfm 600lfm 800lfm 1000lfm ambient temperature degrees c maximum dissipated power watts 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 0 1 2 3 4 5 6 7 8 9 10 0lfm 200lfm 400lfm 600lfm 800lfm 1000lfm ambient temperature degrees c maximum dissipated power watts
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 11 of 15 typical performance characteristics: figure 13 transient response 0.1a/s (v in = 24v i out = 2.1-4.2a c out = 6x2.2f x7r ceramic) figure 14 output ripple (v in = 24v i out = 4.2a c out = 6x2.2f x7r ceramic)
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 12 of 15 package outline & recommended pcb land pattern figure 15
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 13 of 15 ordering information and available options: available options ? heat sinks : at present, picor offers four different heat sink op tions to accommodate the cust omers space and cooling needs. heat sinks are available in two sizes, one with 6.3mm fi ns and the other with 11mm fins. each of those heat sinks can be ordered with a specific air flow direction in mind, both x-flow and longitudinal are supported. figure 16 picor PI3106-01-HVIZ heat sink options: ? * assorted spring loaded push pins (not provided) are available to accommodate various pcb thicknesses. please visit www.vicorpower.com for ordering information and details. part number package PI3106-01-HVIZ 0.87?(w) x 0.65?(l) x 0.265?(h) 32784 transverse fins heatsink 11 mm * 32786 transverse fins heatsink 6.3mm * 32783 longitudinal fins heatsink 11 mm * 32785 longitudinal fins heatsink 6.3 mm *
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 14 of 15 ordering information and available options: available options ? pi3106-01-eval1 evaluation board : if you wish to evaluate the electrical and thermal perf ormance of the PI3106-01-HVIZ, picor can make available the pi3106-01-eval1 evaluation board. it comes with a fully populated high density isolated dc-dc power supply and a comprehensive user manual. for details cont act picor applications engineering or visit our website at www.picorpower.com. figure 17 picor pi3106-01-eval1 evaluation board
picor corporation ? picorpower.com preliminary PI3106-01-HVIZ rev 1.3, jan 17 th , 2012 page 15 of 15 warranty vicor products are guaranteed for two years from date of shipment against defects in material or workmanship when in normal use and service. this warranty does no t extend to products subjected to misuse, accident, or improper application or maintenance. vicor shall not be liable for collateral or consequential damage. this warranty is extended to the original purchaser only. except for the foregoing express warranty, vicor makes no warranty, express or limited, including, but not limited to, the wa rranty of merchantability or fitness for a particular purpose. vicor will repair or replace defective products in accor dance with its own best judgment. for service under this warranty, the buyer must contact vicor to obtain a re turn material authorization (rma) number and shipping instructions. products returned without prior authorizati on will be returned to the buyer. the buyer will pay all charges incurred in returning the product to the factory. vicor will pay all reshipment charges if the product was defective within the terms of this warranty. information published by vicor has been carefully ch ecked and is believed to be accurate; however, no responsibility is assumed for inaccura cies. vicor reserves the right to make changes to any products without further notice to improve reliability, function, or design. vicor does not assume any liability arising out of the application or use of any product or ci rcuit; neither does it convey any licens e under its patent rights nor the rights of others. vicor general policy does not recommend the use of its components in life support applications wherein a failure or malfunction may directly threaten life or in jury. per vicor terms and conditions of sale, the user of vicor components in life support applications assumes a ll risks of such use and indemnifies vicor against all damages. vicor?s comprehensive line of power solu tions includes high density ac-dc and dc-dc modules and accessory components, fully configurable ac-dc and dc-dc power supplies, and complete custom power systems. information furnished by vicor is believed to be accurate and reliable. however, no responsibility is assumed by vicor for its use. vicor components are not designed to be used in applications, such as life support systems, wherein a failure or malfunction could result in inju ry or death. all sales are subject to vicor?s terms and conditions of sale, which are available upon request. specifications are subject to change without notice. intellectual property notice vicor and its subsidiaries own intellectual property (including u.s. and foreign patents and pending patent applications) related to the products described in this data sheet. interested parties should contact vicor?s intellectual property department. the products described in this data sheet are prot ected by the following u.s. patents numbers: 6,788,033; 7,154,250; 7,561,446; 7, 361,844; d496,906; d506,438; 6,940,01 3; 7,038,917; 6,969,909; 7,166,898; 6,421,262; 7,368,957; re 40,072 vicor corporation picor corporation 25 frontage road 51 industrial drive andover, ma 01810 north smithfield, ri 02896 usa usa customer service: custserv@vicorpower.com technical support: apps@vicorpower.com tel: 800-735-6200 fax: 978-475-6715

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