Irf AFL27003R3S Service Manual

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PD - 94462E

AFL27003R3S

HIGH RELIABILITY
HYBRID DC/DC CONVERTER

Description

The AFL Series of DC/DC converters feature high power
density with no derating over the full military temperature
range. This series is offered as part of a complete family
of converters providing single and dual output voltages
and operating from nominal +28 or +270 volt inputs with
output power ranging from 80 to 120 watts. For
applications requiring higher output power, multiple
converters can be operated in parallel. The internal
current sharing circuits assure equal current distribution
among the paralleled converters. This series
incorporates International Rectifier’s proprietary
magnetic pulse feedback technology providing optimum
dynamic line and load regulation response. This
feedback system samples the output voltage at the pulse
width modulator fixed clock frequency, nominally 550
KHz. Multiple converters can be synchronized to a system
clock in the 500 KHz to 700 KHz range or to the
synchronization output of one converter. Undervoltage
lockout, primary and secondary referenced inhibit, soft­start and load fault protection are provided on all models.

These converters are hermetically packaged in two
enclosure variations, utilizing copper core pins to
minimize resistive DC losses. Three lead styles are
available, each fabricated with International Rectifier’s
rugged ceramic lead-to-package seal assuring long
term hermeticity in the most harsh environments.

Manufactured in a facility fully qualified to MIL-PRF­38534, these converters are available in four screening
grades to satisfy a wide range of requirements. The CH
grade is fully compliant to the requirements of MIL-PRF­38534 for class H. The HB grade is fully processed and
screened to the class H requirement, but does not have
material element evaluated to the class H requirement.
Both grades are tested to meet the complete group “A”
test specification over the full military temperature range
without output power deration. Two grades with more
limited screening are also available for use in less

270V Input, 3.3V Output

AFL

Features

n 160 To 400 Volt Input Range
n 3.3 Volt Output
n High Power Density - 46 W / in
n 66 Watt Output Power
n Parallel Operation with Stress and Current

Sharing

n Low Profile (0.380") Seam Welded Package
n Ceramic Feedthru Copper Core Pins
n High Efficiency - to 74%
n Full Military Temperature Range
n Continuous Short Circuit and Overload

Protection

n Remote Sensing Terminals
n Primary and Secondary Referenced

Inhibit Functions

n Line Rejection > 60 dB - DC to 50KHz
n External Synchronization Port
n Fault Tolerant Design
n Dual Output Versions Available
n Standard Military Drawings Available

demanding applications. Variations in electrical,
mechanical and screening can be accommodated.
Contact IR Santa Clara for special requirements.

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09/01/04

AFL27003R3S

Specifications

ABSOLUTE MAXI MUM RATI NGS

Input Voltage -0.5V to 500V

Soldering Temperature 300°C for 10 seconds

Case Temperature Operating -55°C to +125°C

Electrical Performance Characteristics -55°C < T

Parameter

INPUT VOLTAGE Note 6 160 270 400 V

OUTPUT VOLTAGE

OUTPUT CURRENT

OUTPUT POWER

MAXIMUM CAPACITIVE LOAD

OUTPUT VOLTAGE
TEMPERATURE COEFFICIENT

OUTPUT VOLTAGE REGULATION

Line

Load

OUTPUT RIPPLE VOLTAGE

INPUT CURRENT

No Load

Inhibit 1
Inhibit 2

INPUT RIPPLE CURRENT

CURRENT LIMIT POINT

Expressed as a
Percentage
of Full Rated Load

LOAD FAULT POWER
DISSIPATION

Overload or Short Circuit

EFFICIENCY

SWITCHING FREQUENCY

ISOLATION

MTBF

For Notes to Specifications, refer to page 3

Storage -65°C to +135°C

< +125°C, 160V< V

CASE

Group A

Subgroups

VIN = 270 Volts, 100% Load

1

2, 3

VIN = 160, 270, 400 Volts, Note 6

Note 6 66 W

4 Note 1 10,000

VIN = 270 Volts, 100% Load - Note 1, 6

1, 2, 3

1, 2, 3

1, 2, 3

2, 3
1, 2, 3
1, 2, 3

1, 2, 3

1, 2, 3

1, 2, 3

1, 2, 3 500 550 600 KHz

No Load, 50% Load, 100% Load
VIN = 160, 270, 400 Volts

VIN = 160, 270, 400 Volts, 100% Load,
BW = 10MHz

VIN = 270 Volts

1

I

= 0

OUT

Pin 4 Shorted to Pin 2
Pin 12 Shorted to Pin 8

VIN = 270 Volts, 100% Load

B.W. = 10MHz

V

= 90% V

OUT

1
2
3

V

= 270 Volts

IN

VIN = 270 Volts, 100% Load

1 Input to Output or Any Pin to Case

(except Pin 3). Test @ 500VDC

MIL-HDBK-217F, AIF @ TC = 40°C

Test Conditions

Note 5

NOM

< 400V unless otherwise specified.

IN

Min Nom Max Unit

3.27

3.23

-0.015 +0.015 %/°C

-10.0

-35.0

115
105
125

72

100

300 KHrs

3.30

20 A

74

3.33

3.37

+10.0

+35.0

30 mVpp

15.0

17.0

3.00

5.00

60 mApp

125
115
140

30

V

V

µfd

mV

mV

mA
mA
mA
mA

%
%
%

W

%

MΩ

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Elecrical Performance Characteristics (Continued)

AFL27003R3S

Parameter

ENABLE INPUTS

Sink Current
Converter On
Sink Current

SYNCHRONIZATION INPUT

Pulse Amplitude, Hi
Pulse Amplitude, Lo
Pulse Rise Time
Pulse Duty Cycle

LOAD TRANSIENT RESPONSE

Amplitude

Recovery

Amplitude
Recovery

LINE TRANSIENT RESPONSE

Amplitude
Recovery

TURN-ON CHARACTERISTICS

Overshoot
Delay

LOAD FAULT RECOVERY

LINE REJECTION

Notes to Specifications:

(Inhibit Function)

Converter Off

Frequency Range

Group A

Subgroups

1, 2, 3

1, 2, 3

1, 2, 3

1, 2, 3

1, 2, 3

4, 5, 6

4, 5, 6

4, 5, 6

4, 5, 6

4, 5, 6

4, 5, 6

Logical Low, Pin 4 or Pin 12
Note 1
Logical High, Pin 4 and Pin 12 - Note 9
Note 1

Note 1
Note 1

Note 2, 8

Load Step 50% ⇔ 100%

Load Step 10% ⇔ 50%

Note 1, 2, 3

VIN Step = 160 ⇔ 400 Volts

VIN = 160, 270, 400 Volts. Note 4

Enable 1, 2 on. (Pins 4, 12 high or open)

Same as Turn On Characteristics.

MIL-STD-461, CS101, 30Hz to 50KHz

Note 1

Test Conditions

Min Nom Max Unit

-0.5

2.0

75

500

2.0

-0.5

20

-450

-450

-500

50

60 70 dB

1. Parameters not 100% tested but are guaranteed to the limits specified in the table.

2. Recovery time is measured from the initiation of the transient to where V

has returned to within ±1% of V

OUT

at 50% load.

3. Line transient transition time ≥ 100 µSec.

4. Turn-on delay is measured with an input voltage rise time of between 100 and 500 volts per millisecond.

5. Current limit point is that condition of excess load causing output voltage to drop to 90% of nominal.

6. Parameter verified as part of another test.

7. All electrical tests are performed with the remote sense leads connected to the output leads at the load.

8. Load transient transition time ≥ 10 µSec.

9. Enable inputs internally pulled high. Nominal open circuit voltage ≈ 4.0VDC.

0.8

100

50

100

700

10

0.8

100

80

450
200

450
400

500
500

250
120

V

µ

A

V

µA

KHz

V
V

nSec

%

mV

µSec

mV

µ

Sec

mV

µSec

mV

mSec

OUT

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