Page 1
HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Features
• Low profile (-11mm) single board design
• 1500VDC input to output isolation meets
basic insulation
• High efficiency - to 92% at full load
• Start-up into high capacitive load
• Low conducted and radiated EMI
• Output overcurrent protection
• Output overvoltage protection
• Overtemperature protection
• Remote sense
• Set point accuracy ± 1%
• Remote on/off (primary referenced), positive
Applications
• Distributed power architectures
• Telecommunications equipment
• LAN/WAN applications
• Data processing applications
or negative logic
• Output voltage trim adjust, positive or
negative
• UL 1950 Recognized, CSA 22.2 No. 950-95
certified, TUV IEC950
Description
The new HLS30 series of high-density, single-output DC/DC converters, convert standard telecom and
datacom voltages into isolated low voltage outputs. High efficiencies and a patent-pending board design
create superior thermal transfer that enhances product reliability and eliminates the need for a heatsink.
Selection Chart
Model Input
voltage
VDC
HLS30ZG 36-75 4.8 5.0 30 100 91
HLS30ZE 36-75 3.3 3.3 30 75 89
HLS30ZD 36-75 2.5 2.5 30 50 88
This product is intended for integration into end-use equipment. All the required procedures for CE marking of end-use equipment
should be followed
.
Input
current,
max
ADC
Output
voltage
VDC
Output rated
current I
rated
ADC
Output
Ripple/Noise,
mV p-p
Typical
Efficiency
@ I
rated
%
Rev. 10/01
Page 1 of 8
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Absolute Maximum Ratings
Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely effect
long-term reliability and cause permanent damage to the converter.
Parameter Conditions/Description Min Max Units
Input voltage Continuous
Transient, 100mS
Operating Temperature At 100% load -40 100
Storage Temperature -40 125
ON/OFF Control Voltage Referenced to -Vin 50 VDC
75
100
VDC
VDC
°C
°C
Environmental and Mechanical Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise
noted.
Parameter Conditions/Description Min Nom Max Units
Shock Halfsine wave, 3 axes 50 g
Sinusoidal Vibration GR-63-Core, Section 5.A.2 1
Weight 1.6/46 Oz/g
Water Washing Standard process Yes
MTBF Per Bellcore TR-NWT-000332 1,780 kHrs
Isolation Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise
noted.
Parameter Conditions/Description Min Nom Max Units
Insulation Safety Rating Basic
Isolation Voltage 1500 VDC
Isolation Resistance 10 MOhm
Isolation Capacitance 1100 pF
Input Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise
noted.
Parameter Conditions/Description Min Nom Max Units
Input Voltage Continuous 36 48 75 VDC
Turn-On Input Voltage Ramping Up 33 VDC
Turn-Off Input Voltage Ramping Down 32 VDC
Turn-On Time To Output Regulation Band
100% Resistive Load
Input Reflected Ripple Current Full Load, 12uH source
inductance
Inrush Transient Vin=Vin.max 0.1 A2s
5mS
80 mA p-p
Rev. 10/01
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Output Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise
noted.
Parameter Conditions/Description Min Nom Max Units
Output Voltage Setpoint Accuracy Vin=Vin.nom, Full Load -1 1 %Vout
Output Current* 3 30 ADC
Line Regulation Vin.min to Vin.max, Iout.max 0.2 %Vout
Load Regulation Vin=Vnom, Iout.min to
Iout.max
Total output voltage regulation Over all input voltage, load,
and temperature conditions
Remote Sense Headroom 0.5 VDC
Dynamic Regulation
Peak Deviation
Settling Time
Admissible Load Capacitance Iout.max, Nom Vin 30,000
Output Current Limit Threshold** Vout≤0.97Vout.nom 110 140 %Iout
Switching Frequency 270 kHz
Overvoltage Protection,
Non Latching
Trim Range Iout.max, Vin=Vnom 90 110 %Vout
50-75% load step change
to 1% error band
Over all input voltage and
load conditions
-2 2 %Vout
120 140 %Vout
0.2 %Vout
8
150
%Vout
µS
µF
* At Iout<Iout.min, the output may contain low frequency component that exceeds ripple specifications.
** Overcurrent protection is non-latching with auto recovery.
Feature Specifications
All specifications apply over specified input voltage, output load and temperature range, unless otherwise
noted.
Parameter Conditions/Description Min Nom Max Units
Shutdown (ON/OFF)
Negative Logic
- Converter ON
- Source Current
- Converter OFF
-Open Circuit Voltage
Positive Logic
- Converter ON
- Open Circuit Voltage
- Converter OFF
- Source Current
Overtemperature
Protection
On/Off signal is low – converter is ON
ON/OFF pin is connected to -Vin
ON/OFF pin is floating
On/Off signal is low –converter is OFF
ON/OFF pin is floating
ON/OFF pin is connected to -Vin
Average PCB Temp. – Shut down
- Recover
-1.0
3.5
3.5
-1.0
0.85
2
3
90
1.8
50
50
1.8
0.46
VDC
mADC
VDC
VDC
VDC
VDC
VDC
mADC
°C
Rev. 10/01
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Characteristic curves
Fig. 1 HLS30ZG (5V) Efficiency vs. Output Load
Fig. 2 HLS30ZE (3.3V) Efficiency vs. Output
Load
Fig. 4 HLS30ZG (5V) Input Characteristic
Fig. 5 HLS30ZE (3.3V) Input Characteristic
Fig. 3 HLS30ZD (2.5V) Efficiency vs. Output
Load
Rev. 10/01
Fig. 6 HLS030ZD (2.5V) Input Characteristic
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Typical Application
Figure 7 below shows the recommended
connections for the HLS30 series converter.
Fig.7 Typical application of HLS30 series
The HLS30 series converters do not require any
external components for proper operation.
However, if the distribution of the input voltage to
the converter contains significant inductance, the
capacitor C1 may be required to enhance
performance of the converter. A minimum of a
47μF electrolytic capacitor with the ESR<0.7Ω is
recommended for the HLS30 series.
If magnitude of the inrush current needs to be
limited, see the “Inrush Current Control
Application Note” on Power-One website
www.power-one.com.
For output decoupling we recommend to use a
10μF tantalum and a 1μF ceramic capacitors
connected directly across the output pins of the
converter. Note, that the capacitors do not
substitute the filtering required by the load.
resistor between the ON/OFF pin and the +Vin
pin.
When the ON/OFF pin is used to achieve remote
control, the user must take care to insure that the
pin reference for the control is really the -Vin pin.
The control signal must not be referenced ahead
of EMI filtering or remotely from the unit. Optically
coupling the information and locating the optical
coupler directly at the module will solve any of
these problems.
Note:
If the ON/OFF pin is not used, it can be left
floating (positive logic), or connected to the -Vin
pin (negative logic).
Output Voltage Trim
The trim feature allows the user to adjust the
output voltage from the nominal value. This can
be used to compensate distribution drops,
perform margining in production, or accommodate
other requirements when output voltage needs to
be adjusted from the nominal. There are two trim
options available in the HLS30 series.
Standard Negative Trim (No suffix)
The negative trim method is the Power-One
standard. The HLS30 standard trim units trim up
with a resistor from the TRIM pin to the Sense pin
and trim down with a resistor from the TRIM Fig.8
HLS30 series negative trim schematic pin to the
+Sense pin as shown in Figure 8.
Shutdown Feature Description
The ON/OFF pin in the HLS30 series converters
functions as a normal soft shutdown. It is
referenced to the –Vin pin (see Figure 7). With
positive logic, when the ON/OFF pin is pulled low,
the output is turned off and the unit goes into a
very low input power mode. With negative logic,
when the ON/OFF pin is pulled low, the unit is
turned on.
An open collector switch is recommended to
control the voltage between the ON/OFF pin and
the -Vin pin of the converter. The ON/OFF pin is
pulled up internally, so no external voltage source
is required. The user should avoid connecting a
Rev. 10/01
Fig. 8 HLS30 series negative trim schematic
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
The general equation (1) for changing the output
voltage on the standard trim modules is invariant,
but the constants in the equation change due to
different internal design.
VBA
R
=
TRIM
where A and B are constants from the table
below, and ΔV is the absolute value of the desired
change in the output voltage in Volts.
Model
HLS30ZG 3.77 6.81 11.58 9.88
HLS30ZE 2.07 3.92 3.5 5.61
HLS30ZD 1.27 3.92 1.31 4.95
Optional Positive Trim (suffix –T)
The -T option units trim up with a resistor from the
TRIM pin to the +Sense pin and trim down with a
resistor from the TRIM pin to the –Sense pin as
shown in the Figure 9.
∆×−
,
V
∆
ABAB
KOhm (1)
Trim up Trim down
where ΔV% is the output voltage change
expressed in percents of the nominal output
voltage, Vout.
Notes:
1. When the output voltage is trimmed up, the
output power from the converter must not
exceed its maximum rating. This is
determined by measuring the output voltage
on the output pins, and multiplying it by the
output current.
2. In order to avoid creating apparent load
regulation degradation, it is important that the
trim resistors are connected directly to the
remote sense pins, and not to the load or to
traces going to the load.
3. The HLS30 series converters will trim down
further than the 10% limit. In general, this is
permissible. The user must confirm that the
results are acceptable in his application.
Safety Considerations
Fig.9 HLS30 series positive trim schematic
The equations below determine the trim resistor
value required to achieve a ΔV change in the
output voltage.
R
R
=
UP
DOWN
%)100(
VVout
∆+×
−
%225.1
V
∆×
100
=
V
∆
%
−
2
, kOhm
∆
%2100
V
∆×+
%
V
,kOhm
The HLS30 series converters feature 1500 Volt
DC isolation from input to output. The input to
output DC resistance is greater than 10MOhm.
These converters are provided with Basic
insulation between input and output circuits
according to all IEC60950 based standards.
Nevertheless, if the system using the converter
needs to receive safety agency approval, certain
rules must be followed in the design of the
system. In particular, all of the creepage and
clearance requirements of the end-use safety
requirements must be observed. These
documents include UL60950, CSA60950-00 and
EN60950, although other additional requirements
may be needed for user’s specific applications.
The HLS30 series converters have no internal
fuse. An external fuse must be provided to
protect the system from catastrophic failure, as
illustrated in Figure 7. The fuse with a rating not
greater than 10A is recommended. The user can
select a lower rating fuse based upon the highest
inrush transient at the maximum input voltage
and the maximum input current of the converter at
the minimum input voltage. Both input traces and
the chassis ground trace (if applicable) must be
capable of conducting a current of 1.5 times the
Rev. 10/01
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
value of the fuse without opening. The fuse must
not be placed in the grounded input line, if any.
In order for the output of the HLS30 series
converter to be considered as SELV (Safety Extra
Low Voltage) or TNV-1, according to all IEC60950
based standards, one of the following
requirements must be met in the system design:
• If the voltage source feeding the module is
SELV or TNV-2, the output of the converter
may be grounded or ungrounded.
• If the voltage source feeding the module is
ELV, the output of the converter may be
considered SELV only if the output is
grounded per the requirements of the
standard.
• If the voltage source feeding the module is a
Hazardous Voltage Secondary Circuit, the
voltage source feeding the module must be
provided with at least Basic insulation
between the source to the converter and any
hazardous voltages. The entire system,
including the HLS30 converter, must pass a
dielectric withstand test for Reinforced
insulation. Design of this type of systems
requires expert engineering and
understanding of the overall safety
requirements and should be performed by
qualified personnel.
air, while up to 28A reliably with 200LFM forced
air.
Fig.10 HLS30ZG (5V) derating curves
Thermal Considerations
The HLS30 series converters are designed for
natural or forced convection cooling. The
maximum allowable output power of the
converters is determined by meeting the derating
criteria of all electronic components used in the
power supplies. An example of the derating
criteria for the semiconductor junction
temperature is not to exceed 120C to provide
reliable long-term operation of the converters.
Note: Please contact Power-One for more
derating criteria for other components.
The graphs in Figures 10-12 show the maximum
output current of the HLS30 series converters at
different ambient temperatures under both natural
and forced (longitudinal airflow direction, from pin
1 to pin 4) convection. As an example, from
Figure 10, the HLS30ZG operating at 55C can
deliver up to 25.5A reliably with 100LFM forced
Rev. 10/01
Fig.11 HLS30ZE (3.3V) derating curves
Fig.12 HLS30ZD (2.5V) derating curves
.
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HLS30 Series – 30A Half-Brick DC/DC Converter
48V Input Data Sheet
5.0V, 3.3V, 2.5V Output
Mechanical Drawing
PIN FUNCTION
1-Vin
2No Pin
3On/Off
4+Vin
5 -Vout
6-Sense
7Trim
8+Sense
9 +Vout
Tolerances: .xx + .020 (.5)
.xxx + .010 (.25)
Pin Diameter + 0.002 (.05)
Ordering Information
Options Suffixes to add to part number
Positive- no suffix requiredRemote ON/OFF
Negative- Add “N” suffix
Negative- no suffix requiredTrim
Positive - Add “T” suffix
Pin Length
0.18”- no suffix required
0.11”- Add “8” suffix
0.15”- Add “9” suffix
Notes
1. Consult factory for the complete list of available options.
2. Power-One products are not authorized for use as critical components in life support systems, equipment used in hazardous
environments, or nuclear control systems without the express written consent of the President of Power-One, Inc.
3. Specifications are subject to change without notice.
Rev. 10/01
Page 8 of 8
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