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picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 1 of 18 ? PI3101 cool-power tm series 36-75v input, 3.3v / 18a / 60w output very high density isolated dc-dc converter (400w/in 3 ) description the cool-power tm PI3101 is a very high density isolated dc-dc converter implementing a high efficiency soft-switching power architecture. the PI3101 operates over a wide range input of 36v to 75vdc, delivering ~60w of output power (3.3vout @ 18a), yielding an unprecedented power density of 400w/in 3 . the PI3101 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 PI3101 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. PI3101-00-hviz 36-75vin, 3.3vout, 18a very high density isolated dc-dc converter features ? efficiency up to 87% ? 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 (0.265 in) ? wide input voltage range operation (36-75vdc) ? on/off control, positive logic ? +10/-10% trim ? temperature monitor (tm) & over-temperature protection (otp) ? input uvlo & ovlo and output ovp ? over current protection with auto restart ? adjustable soft-start ? 2250v input to output isolation applications ? power over ethernet (poe) ? communications ? telecom systems ? network power package information ? surface mountable 0.87? x 0.65? x 0.265? package typical application schematic diagram figure 1 picor PI3101 shown with system fuse, filter, decoupling and extended soft start
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 2 of 18 pin description and maximum ratings figure 2 picor PI3101-00-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 75vdc (operating) +in to -in max peak voltage 100vdc (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 6.0vdc isolation voltage (+in/-in to +out/-out) 2250vdc isolation capacitance (+in/-in to +out/-out) 330pf continuous output current 18a dc (tcase < 100c) peak output current 34adc (11mm heatsink, 600lfm) operating junction temperature -40 to 125c storage temperature -40 to 125c case temperature during reflow 245c trim/ss +in sgnd tm enable -in +out -out
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 3 of 18 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 - + dc fast current limit 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 PI3101 functional block diagram
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 4 of 18 electrical specifications unless otherwise specified: 36v < v in < 75v, 0a < i out < 18a, -40 ? c < t case < 100 ? c (1) parameter symbol min typ max units conditions input specifications input voltage range v in 36 48 75 vdc input dv/dt (1) v indvdt 1.0 v/s v in = 75v input under-voltage turn-on v uvon 32.5 34 35 vdc i o = 1.8a input under-voltage turn-off v uvoff 30.5 32 33 vdc i o = 1.8a input under-voltage hysteresis v uvh 2 vdc i o = 1.8a input over-voltage turn-on v ovon 75.7 78 81 vdc i o = 1.8a input over-voltage turn-off v ovoff 77.7 80 82.3 vdc i o = 1.8a input over-voltage hysteresis v ovh 2 i o = 1.8a input quiescent current i q 2.5 madc v in = 48v, enable = 0v input idling power p idle 4.0 w v in = 48v, i out = 0a input standby power p sby 0.225 w v in = 48v, enable = 0v input current full load i in 1.4 adc t case = 100 ? c i out = 18a ? fl = 86.5% typical v in =48v input reflected ripple current i inrr 10 mapp l in = 2h c in = 47f 100v electrolytic + 2x1f 100v x7r ceramic recommended ext input capacitance c in 49 f c in = 47f 100v electrolytic + 2x1f 100v x7r ceramic c in = cbulk + chf output specifications output voltage set point v out 3.3 vdc i out = 9a total output a ccuracy v oa -3 +3 % line regulation v rli 0.25 % v in = 36v-75v, i out = 18a load regulation v rlo 1.5 % v in = 48v, i out = 0-18a output voltage trim range v oadj -10% 10% % output current range i out 18 adc over current protection i ocp 18.8 26 33 adc efficiency ? full load ? fl 84.5 86.5 % t case = 100 ? c, v in =48v efficiency ? half load ? hl 84.5 % t case = 100 ? c, v in =48v output ovp set point v ovp 4.1 vdc output ripple voltage v orpp 75 mvpp c out = 12x10f 10v x7r dc- 20mhz using PI3101-eval1 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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 5 of 18 electrical specifications (continued) unless otherwise specified: 36v < v in < 75v, 0a < i out < 18a, -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 10 mf v in = 75v, 18a resistive load c ss = 1f load transient deviation v odv 90 110 mv i out = 25% step 0.1a/s c out = 12x10f 10v x7r load transient recovery time t ovr 120 s i out = 25% step 0.1a/s c out = 12x10f 10v x7r v out - 1% maximum output power p out 60 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 100 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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 6 of 18 electrical specifications (continued) unless otherwise specified: 36v < v in < 75v, 0a < i out < 18a, -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 = 48v, full 18a 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 3 10 a fast acting littlefuse nano2 series fuse mechanical specifications parameter symbol min typ max units conditions mechanical parameters PI3101 package weight m pkg 7.2 g no heat sink 2.2 cm no heat sink PI3101 package length l pkg 0.87 ins no heat sink 1.65 cm no heat sink PI3101 package width w pkg 0.65 ins no heat sink 0.673 cm no heat sink PI3101 package height h pkg 0.265 ins 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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 7 of 18 functional description : input power pins in(+) and in(-): the input power pins on the PI3101 are connected to the input power source which can range from 36v to 75v dc. under surge conditions, the PI3101 can withstand up to 100v dc for 100ms without incurring damage. the user should take care to avoid driving the input rails above the specified ratings. since the PI3101 is designed with high reliability in mind, the input pins are continuously monitored. if the applied voltage exceeds the input over-voltage trip point (typically 80v) 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 PI3101 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 losses of using a diode, the user should consider the much higher efficiency picor family of intelligent cool-oring tm solutions that can be used in reverse polarity applications. information is available at picorpower.com . the PI3101 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 3.3v 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 PI3101 should be bypassed with (2) 1uf 100v ceramic capacitors of x7r dielectric in parallel with a low q 47uf 100v electrolytic capacitor. to reduce emi and reflected ripple current, a series inductor of 2 to 4.7uh 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 PI3101. 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 10%. 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 PI3101 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 PI3101 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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 8 of 18 output power pins +out and -out: the output power terminals out(+) and out(-) deliver the 18a maximum output current from the PI3101 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 PI3101 does not require 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 PI3101 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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 9 of 18 typical performance characteristics: figure 4 conversion efficiency (tcase = 100 ? c) figure 5 power dissipation vs i o (tcase = 100 ? c) figure 6 power dissipation vs temp (no heat sink) figure 7 p out vs temp (no heat sink)
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 10 of 18 typical performance characteristics: figure 8 p out vs temp vs flow (6.3mm heat sink) figure 9 p out vs temp vs flow (11mm heat sink) figure 10 r ? c-a (no heat sink longitudinal flow) figure 11 r ? c-a ( heat sinks longitudinal flow) figure 12 thermal image v in = 48v i o = 18a flow = 600lfm longitudinal no heat sink temp = 25 c
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 11 of 18 typical performance characteristics: figure 13 r ? c-a (no heat sink transverse flow) figure 14 r ? c-a (heat sinks transverse flow) figure 15 thermal image v in = 48v i o = 18a flow = 600lfm x-flow no heat sink temp = 25 c figure 16 output ripple (v in = 48v i o = 18a c out = 12x10f x7r ceramic) figure 17 transient response 0.1a/s (v in = 48v i out = 4.5-9a c out = 12x10f x7r ceramic) figure 18 transient response 0.1a/s (v in = 48v i out = 9-4.5a c out = 12x10f x7r ceramic) 27.6c 106.3c 40 60 80 100
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 12 of 18 typical performance characteristics: figure 19 transient response 0.1a/s (v in = 48v i out = 9-13.5a c out = 12x10f x7r ceramic) figure 20 transient response 0.1a/s (v in = 48v i out = 9-13.5a c out = 12x10f x7r ceramic) figure 21 output ovp forced via trim pin (v in = 48v i out = 9a c out = 12x10f x7r ceramic) figure 22 start up v in vs v out (v in = 36v i out = 9a c out = 12x10f x7r ceramic) figure 23 start up v in vs v out (v in = 48v i out = 18a c out = 12x10f x7r ceramic) figure 24 start up v in vs v out (v in = 75v i out = 9a c out = 12x10f x7r ceramic)
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 13 of 18 typical performance characteristics: figure 25 start up v in vs v out (v in = 75v i out = 18a c out = 12x10f x7r ceramic) figure 26 start up enable vs v out (v in = 36v i out = 18a c out = 12x10f x7r ceramic) figure 27 shut down enable vs v out (v in = 36v i out = 18a c out = 12x10f x7r ceramic) figure 28 shut down v in vs v out (v in = 48v i out = 18a c out = 12x10f x7r ceramic) figure 29 start up enable vs v out trim down 10% (v in = 36v i out = 18a c out = 12x10f x7r ceramic) figure 30 start up enable vs v out trim up 10% (v in = 36v i out = 18a c out = 12x10f x7r ceramic)
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 14 of 18 typical performance characteristics: figure 31 start up enable vs v out (v in = 36v i out = 18a resistive c out = 4mf c ss = 0.1f) figure 32 start up enable vs v out (v in = 75v i out = 18a resistive c out = 4mf c ss = 0.1f) figure 33 start up enable vs i out short circuit (v in = 48v shorting bar across +out to -out) figure 34 forced over temperature (v in = 75v t case = 135c i out = 27a)
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 15 of 18 package outline & recommended pcb land pattern figure 35
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 16 of 18 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 36 picor PI3101 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 PI3101-00-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 PI3101-00-hviz rev 1.1, april 29 th , 2010 page 17 of 18 ordering information and available options: available options ? PI3101-eval1 evaluation board : if you wish to evaluate the electrical and thermal pe rformance of the PI3101, pico r can make available the PI3101-eval1 evaluation board. it comes with a fully popul ated high density isolat ed dc-dc power supply and a comprehensive user manual. for details contact pico r applications engineering or visit our website at www.picorpower.com. figure 37 picor PI3101-eval1 evaluation board (actual size)
picor corporation ? picorpower.com PI3101-00-hviz rev 1.1, april 29 th , 2010 page 18 of 18 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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