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MILDeratingBrochure

By Yvonne Richardson,2014-08-25 18:40
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MILDeratingBrochure

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     24 V and 300 V DC-DC Converter Modules

     Module Construction & Component Derating

     This document provides a detailed view of the construction for Maxi, Mini and Micro DC-DC converters as well as the component design derating guidelines.

     Qualification Testing

     Acceleration To determine the ability of parts to withstand constant acceleration, as an indicator of the mechanical strength limits. Standard: MIL-STD-810F, Method 513.5, Procedure II Environment: Acceleration step from 2 ?C 7 g, 6 direction Altitude To observe low air pressure effects on either operational or non-operational design parameters.

     Standard: MIL-STD-810F, Method 500.4, Procedure I & II Environment: 40,000 ft. and 70,000 ft. operational

     Explosive Atmosphere To determine the ability of equipment to operate in the presence of an explosive atmosphere. Standard: MIL-STD-810F, Method 511.4, Procedure I, operational Environment: Fuel-air explosive atmospheres HALT Demonstrates product design margin and robustness.

     Standard: Vicor internal reference EIAJESD22-A110-B Environment: Operational limits verified / destruct limits determined

     High Temperature Operational Life An operational test used to detect thermally activated failure mechanisms.

     Standard: Vicor internal reference EIAJESD22-A110-B Environment: Nominal line, 75% Load, temperature within 5?ãC max operational

     Humidity A humidity test simulates the moisture-laden air found in tropical regions. Standard: MIL-STD-810F, Method 507.4 Environment: 240 hours, 95% RH Mechanical Shock To determine the ability to withstand mechanical shocks from suddenly applied forces or an abrupt change in motion produced by handling, transportation or field operation. Standard: MIL-STD-810F, Method 516.5, Procedure I Environment: Functional shock, 40 g Standard: MIL-S-901D, lightweight hammer shock Environment: 3 impacts/axis, 1, 3, 5 ft. Standard: MIL-STD-202F, Method 213B Environment: 60 g, 9 ms half sine; 75 g, 11 ms saw tooth shock. Random Mechanical Vibration To evaluate the construction, materials and mounting of the device for ruggedness. Standard: MIL-STD-810F, Method 514.5, Procedure I, Category 14 Environment: Sine and random vibration for helicopter AH-6J main rotor with overall level of 5.6 g for 4 hours per axis Standard: MIL-STD-810F, Method 514.5C, general minimum integrity Environment: 7.7 g for 1 hour per axis. Resistance

    to Solvents To verify that component markings will not become illegible and that electrical and mechanical integrity will not be disturbed when exposed to solvents. Standard: MIL-STD-202G, Method 215K Environment: Ambient temperature, ambient humidity Temperature Humidity Bias An operational test that evaluates the reliability of the device package in humid environments. Standard: JESD22-A101-B Environment: 85?ãC, 85% RH, high line input voltage Thermal Shock To determine the resistance of the part to sudden changes in temperature.

     Standard: MIL-STD-202G, Method 107G, Condition B1 and MIL-HDBK-344A Environment: -65?ãC to 125?ãC, 1,000 cycles

     Temperature Cycle Conducted to determine the ability of devices to withstand mechanical stresses induced by alternating high and low temperature extremes. Standard: JESD22-A104-B Environment: -40?ãC to 125?ãC, 1,000 cycles

     Characterization Process

     Electro Static Discharge Classifies the device according to its susceptibility to damage or degradation by exposure to electrostatic discharge. Standard: MIL-STD-883C, Method 3015 Environment: Ambient temperature, ambient humidity Fungus To determine if a material(s) will support the growth of specific fungi.

     Standard: MIL-STD-810F, Method 508.5 Environment: Severe climate conditions

     Salt Fog To determine the resistance of the equipment to the effects of a salt atmosphere, primarily corrosion. Standard: MIL-STD-810F, Method 509.4 Environment: Salt fog harsh environment Solderability To evaluate the solderability of terminations that are normally joined by a soldering operation. Standard: MIL-STD-202G, Method 208H Environment: Continuous solder coating for a minimum of 95% surface area Terminal Strength Determines the resistance to external force on the terminals.

     Standard: MIL-STD-202G, Method 211A, Test Condition A Environment: Ambient temperature, ambient humidity

     AMCOM Testing Developed in partnership with the U.S. Army Aviation and Missile Command to demonstrate the ability to withstand sequential harsh environments, which simulate storage, field use and a 10 year service life in a ground mobile environment. Standard: US Army Aviation and Missile Command Environment: High temp / high humidity, temp cycle, power cycle

     Module Size/Power Chart

     Maxi

     Output Voltage 2V 3.3 V 5V 12 V 15 V 24 V 28 V 36 V 48 V 24 Vin max. Output Power N/A 264 W 400 W 400 W 400 W 400 W 400 W 400 W 400 W 300 Vin max. Output Power 160 W 264 W 400 W 500 W 500 W 500 W 500 W 500 W 500 W

     Mini

     24 Vin max. Output Power N/A 150 W 200 W 200 W 200 W 200 W 200 W 200 W 200 W 300 Vin max. Output Power 100 W 150 W 200 W 250 W 250 W 250 W 250 W 250 W 250 W

     Micro

     24 Vin max. Output Power N/A 75 W 100 W 100 W 100 W 100 W 100 W 100 W 100 W 300 Vin max. Output Power 50 W 75 W 100 W 150 W 150 W 150 W 150 W 150 W 150 W

     Consult factory for other input / output / power modules.

     Part Numbering

     V

     24

     Input Voltage

     A

     Package A = Maxi B = Mini C = Micro

     12

     Output Voltage

     M

     Product Grade E = ?C10 to +100?ãC C = ?C20 to +100?ãC T = ?C 40 to +100?ãC H = ?C40 to +100?ãC M = ?C55 to +100?ãC

     400

     Output Power

     B

     L

     Pin Style Blank = Short solder L = Long solder *S = Short ModuMate *N = Long ModuMate Baseplate Blank = Slotted 2 = Threaded 3 = Thru hole

     Maxi converter example:

     V24A12M400BL

     24 Vin, Maxi, 12 VOUT @ 400 W, long solder pins, slotted baseplate

     Mini converter example:

     V300B28H250BL2

     300 Vin, Mini, 28 VOUT @ 250 W, long solder pins, threaded baseplate

     Micro converter example:

     V24C5M100BL3

     24 Vin, Micro, 5 VOUT @ 100 W, long solder pins, thru-hole baseplate

     *Compatible with the InMate and SurfMate socketing systems.

     MAXI

     4

     2

     5 6

     10

     8 9

     7

     12 11

     1

     2.2" 55,9 mm

     4.6" 116,8 mm

     3

     0.5" 12,7 mm

     1

     MINI

     2

     MICRO

     2

     4

     4

     6 5 8 6 9 7

     10 11 12 11

     5

     10

     9 8

     7

     12

     1 1

     1.45" 36,8 mm

     2.28" 57,9 mm

     3 3

     2.28" 57,9 mm

     1

     1

     Component

     The photos to the left illustrate typical Maxi, Mini and Micro DC-DC converters and the captions below provide information as to materials and operating parameters. Temperatures and voltages shown are for nominal input voltages under full load conditions at 100?ãC baseplate; maximum device ratings are shown in parenthesis.

     24 V Inpu

     24 VOUT Maxi V24A24M400BL 5 VOUT Mini V24B5H200BL

     1

     Baseplate

     Provides mounting, mechanical rigidity and heat spreading.

     Aluminum 6063T-5 Quantity: 6 121?ãC (150?ãC) 37 V (60 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum Quantity: 4 (forward) + 8 (shunt) Forward: 117?ãC (150?ãC) 87 V (200 V) Shunt: 105?ãC (150?ãC) 87 V (200 V) ?Èj = 10?ãC/W 110?ãC (180?ãC) core

     Aluminum 6063T-5 Quantity: 3 126?ãC (150?ãC) 35 V (60 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum

     2

     Mosfet MLP

     Main switch and common drain for low conducted and radiated noise Functions as an EMI shield to reduce conducted and radiated noise, supplies electrical isolation for the pins and provides mechanical protection for the module.

     3

     Insert Molded Terminal Block and Shield

     4

     Rectifier MLP

     A dual diode rectifier

     Quantity: 4 (forward) + 4 (shun Forward: 121?ãC (150?ãC) 21 V (45 V) Shunt:115?ãC (150?ãC) 21 V (45 V) ?Èj = 10?ãC/W 116?ãC (180?ãC) core

     5

     Main Transformer

     Provides voltage transformation and primary to secondary isolation.

     6

     Input Capacitor

     Reduces reflected ripple and conducted noise in conjunction with the input inductor. Reduces reflected ripple and conducted noise in conjunction with the input capacitors.

     Quantity: 18 24 V (50 V) Quantity: 4 101?ãC (180?ãC) core Quantity: 4 102?ãC (180?ãC) core Quantity: 16 24 V (50 V) Quantity: 9 87 V (250 V)

     Quantity: 6 24 V (50 V) Quantity: 1 104?ãC (180?ãC) core Quantity: 2 117?ãC (180?ãC) core Quantity: 4 5 V (10 V) Quantity: 5 21 V (50 V)

     7

     Input Inductor

     8

     Output Inductor

     Reduces output ripple in conjunction with the output capacitors. Reduces output ripple in conjunction with the output inductor. Quasi-resonant tank for zero-current- switching converter

     9

     Output Capacitor

     10

     Resonant Capacitor

     11

     Brain (primary)

     Contains primary control device (ASIC).

     102?ãC (135?ãC)

     108?ãC (135?ãC)

     12

     Brain (secondary)

     Contains secondary control device (ASIC).

     102?ãC (135?ãC)

     108?ãC (135?ãC)

     Encapsulant

     Two component silicone elastomer

     Thermal connectivity: 32 W/m Temperature rating guide: 200?ã

     MTBF

     MIL-HDBK-217F: G.B. @ 25?ãC Baseplate MTBF in 1000 hours PRISM ties together several tools into a comprehensive system reliability prediction methodology that accounts for the myriad of factors that can influence reliability.

     1963

     3677

     PRISM

     0.077008

     0.050843

     ut

     15 VOUT Micro V24C15M100BL 24 VOUT Maxi V300A24H500BL

     300 V Input

     5 VOUT Mini V300B5M200BL 15 VOUT Micro V300C15H150BL

     Aluminum 6063T-5 Quantity: 2 111?ãC (150?ãC) 33 V (60 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum Quantity: 2 (forward) + 2 (shunt) Forward: 104?ãC (150?ãC) 57 V (100 V) Shunt: 104?ãC (150?ãC) 57 V (100 V) ?Èj = 10?ãC/W 107?ãC (180?ãC) core

     Aluminum 6063T-5 Quantity: 6 119?ãC (150?ãC) 484 V (550 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum Quantity: 8 (forward) + 8 (shunt) Forward: 106?ãC (150?ãC) 135 V (200 V) Shunt: 110?ãC (150?ãC) 135 V (200 V) ?Èj = 10?ãC/W 119?ãC (180?ãC) core

     Aluminum 6063T-5 Quantity: 3 120?ãC (150?ãC) 404 V (650 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum Quantity: 4 (forward) + 4 (shunt) Forward: 116?ãC (150?ãC) 24 V (30 V) Shunt: 115?ãC (150?ãC) 24 V (30 V) ?Èj = 10?ãC/W 119?ãC (180?ãC) core

     Aluminum 6063T-5 Quantity: 2 129?ãC (150?ãC) 406 V (650 V) ?Èj = 10?ãC/W DuPont Zenite/ Clad Aluminum Quantity: 2 (forward) + 2 (shunt) Forward: 112?ãC (150?ãC) 71 V (100 V) Shunt: 112?ãC (150?ãC) 71 V (100 V) ?Èj = 10?ãC/W 127?ãC (180?ãC) core

     nt)

     Quantity: 3 24 V (50 V) Quantity: 1 101?ãC (180?ãC) core Quantity: 1 103?ãC (180?ãC) core Quantity: 2 15 V (25 V) Quantity: 4 57 V (100 V)

     Quantity: 18 300 V (600 V) Quantity: 4 103?ãC (180?ãC) core Quantity: 4 110?ãC (180?ãC) core Quantity: 16 24 V (50 V) Quantity: 10 135 V (250 V)

     Quantity: 6 300 V (600 V) Quantity: 2 107?ãC (180?ãC) core Quantity: 2 125?ãC (180?ãC) core Quantity: 4 5 V (10 V) Quantity: 7 24 V (50 V)

     Quantity: 3 300 V (600 V) Quantity: 1 113?ãC (180?ãC) core Quantity: 1 112?ãC (180?ãC) core Quantity: 2 15 V (25 V) Quantity: 4 71 V (100 V)

     102?ãC (135?ãC)

     109?ãC (135?ãC)

     118?ãC (135?ãC)

     114?ãC (135?ãC)

     102?ãC (135?ãC)

     109?ãC (135?ãC)

     118?ãC (135?ãC)

     114?ãC (135?ãC)

     mk ?ãC

     Thermal connectivity: 32 W/mk Temperature rating guide: 200?ãC

     4299

     2482

     4230

     5077

     0.036276

     0.080457

     0.044114

     0.062450

     Maximum device ratings in parenthesis.

     USA

     vicorpower.com

     Vicor Corporation 25 Frontage Road Andover, MA 01810-5413 Tel: 978-470-2900 Fax: 978-475-6715 Vicor Corporation Lombard, IL 60148 Tel: 630-769-8780 Fax: 630-769-8782 Vicor, Westcor Division Sunnyvale, CA Tel: 408-522-5280 Fax: 408-774-5555 Picor Corporation Slatersville, RI Tel: 401-235-1100 Fax: 401-235-1117 picorpower.com

     Europe

     vicoreurope.com

     Vicor France Tel: +33 1 34 52 18 30 Fax: +33 1 34 52 28 30 Vicor Germany Tel: +49 89 962 439 0 Fax: +49 89 962 439 39 Vicor Italy Tel: +39 02 22 47 23 26 Fax: +39 02 22 47 31 66 Vicor UK Tel: +44 1276 678222 Fax: +44 1276 681269

     Asia

     vicor-asia.com

     Vicor Hong Kong Tel: +852-2956-1782 Fax: +852-2956-0782

     Japan

     vicr.co.jp

     Vicor Japan Co., Ltd. Tel: +81-3-5487-5407 Fax: +81-3-5487-3885

     P/N 33395 Rev 1.0

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