Technical Specification BQ4H480FTx64 230-400V 48V 64A 3040W 4250V Full-brick Input Output Current Power Isolation DC-DC Converter The BQ4H480FTx64 bus converter is a next-generation, board-mountable, isolated, fixed switching frequency DC-DC converter that uses synchronous rectification to achieve extremely high conversion efficiency. The series provides an isolated step down voltage from 385V to 48V intermediate bus with no regulation in a standard full-brick module. The BQ4H480FTx64 converter is ideal for creating the mid-bus voltage required to drive standard 48V DC-DC non-isolated converters. BQ4H48H TC64NRS Model Operational Features • • • • • Mechanical Features High efficiency, 97.2% at full rated load current Delivers 64A full power with minimal derating Operating input voltage range: 230-400V Fixed frequency switching provides predictable EMI No minimum load requirement • Industry standard full-brick size • Size: 2.486” x 4.686” (63.14x119.02mm), 0.512” (13mm) • Encased unit weight: 10.2 oz (289 g) Protection Features • Input under-voltage and over voltage lockout protects • Output current limit and short circuit protection (auto recovery) • Thermal shutdown Control Features • On/Off control referenced to input side • Inherent current share (by droop method) for high current and parallel applications. • Clock synchronization (primary referenced) Contents Page No. Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standards Compliance & Qualification Testing . . . . . . . . . . . . . . . . . . . . Technical Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Features 3 5 6 9 • UL 60950-1/R2011-12 (pending) • EN60950-1/A2:2013(pending) • CAN/CSA-C22.2 No. 60950-1/A1:2011(pending) Product # BQ4H480FTx64 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 1 Input: 230-400V Output: 48V Current: 64A Package: Full-brick 2.486 0.020 [63.14 0.50] SEATING PLANE HEIGHT 0.512 0.005 [ 13.00 0.12] 2.000 [50.80] PIN EXTENSION 0.136 [3.46] TOP VIEW 7 5 6 8 4 0.010 [0.25] 3 9 10 4.686 0.020 [119.02 0.50] 3.290 [83.57] 3.060 [77.72] 2.830 [71.88] 4.200 [106.68] 3.400 [86.36] 2.950 [74.93] 11 2.450 [62.23] 2.000 [50.80] 1.500 [38.10] 12 13 14 21 1 0.50 [12.7] 0.100 [2.54] 0.02 [0.5] 0.100 [2.54] 2.120 [53.85] PIN DESIGNATIONS NOTES 1) RECOMMENDED TORQUE PER SCREW IS 6in-lb (0.7Nm). 2) BASEPLATE FLATNESS TOLERANCE IS 0.010" (.25mm) TIR FOR SURFACE. 3) PINS 1-6 ARE 0.040" (1.02mm) DIA. WITH 0.080" (2.03mm) DIA. STANDOFF SHOULDERS 4) PINS 7-14 ARE 0.062" (1.57mm) DIA. WITH 0.100" (2.54mm) DIA. STANDOFF SHOULDERS 5) ALL PINS: MATERIAL: COPPER ALLOY FINISH: MATTE TIN OVER NICKEL PLATE 6) UNDIMENSIONED COMPONENTS ARE SHOWN FOR VISUAL REFERENCE ONLY 7) THREADED OR THROUGH-HOLE OPTIONS AVAILABLE. 8) WEIGHT: 10.2 oz (289 g) 9) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Product # BQ4H480FTx64 1.050 [26.67] 0.550 [13.97] Phone 1-888-567-9596 Pin Name 1 Vin(+) 2 Vin(+) 3 Sync In 4 ON/OFF 5 6 7 8 9 10 11 12 13 14 www.synqor.com Vin(-) Vin(-) Vout(-) Vout(+) Vout(-) Vout(+) Vout(-) Vout(+) Vout(-) Vout(+) Function Positive Input Voltage Positive Input Voltage Clock synchronization TTL input to turn converter on and off, referenced to Vin(-) with internal pull up Negative input voltage Negative input voltage Negative output voltage Positive output voltage Negative output voltage Positive output voltage Negative output voltage Positive output voltage Negative output voltage Positive output voltage Doc.# 005-0006678 Rev. 3 03/05/15 Page 2 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Specification BQ4H480FTx64 Electrical Characteristics Ta = 25 °C, airflow rate = 300 LFM, Vin = 385V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C base plate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Isolation Voltage Input to Output Input to Base-plate Output to Base-Plate Operating Temperature Storage Temperature Voltage at ON/OFF input pin INPUT CHARACTERISTICS Operating Input Voltage Range Product # BQ4H480FTx64 -0.5 Max. Units Notes & Conditions 500 450 V V -40 4250 2300 2300 100 Vdc Vdc Vdc °C -45 -2 125 18 °C V 400 450 V V 10.5 V V V V V V A mA mA mA mA A µF 230 155 Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Input Over-Voltage Shutdown Turn-On Voltage Threshold Turn-Off Voltage Threshold Maximum Input Current No-Load Input Current Disabled Input Current Input Reflected-Ripple Current Input Terminal-Ripple Current Recommended Input Fuse (see Note 1) Recommended External Input Capacitance Input Filter Component Values (L\C) OUTPUT CHARACTERISTICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Disabled Maximum Output Capacitance EFFICIENCY 100% Load 50% Load Typ. 385 385 154 150 4.0 410 420 50 5.0 15 150 30 12.5 47 6.8\0.33 µH\µF 48 V 44.3\21.5 TBD TBD %\V %\mV %\mV V 27.5 Phone 1-888-567-9596 50.0 250 90 0 500 64 mV mV A 3,000 A V mA µF 80 30 0.7 97.2 97.5 www.synqor.com Continuous Transient, 100 ms Continuous Transient, 100 ms Vin = 230 V RMS through 5µH inductor RMS, full load Fast blow external fuse recommended Typical ESR 0.1-0.2 Ω Internal values; see Figure E Vin = 385 V, Io = 0 A Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 2 Full load Full load Subject to thermal derating; Vin = 385 V Vin = 385 V Vin = 385 V Negative current drawn from output 48 Vout at 32 A Resistive Load % % Doc.# 005-0006678 Rev. 3 03/05/15 Page 3 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Specification BQ4H480FTx64 Electrical Characteristics (continued) Ta = 25 °C, airflow rate = 300 LFM, Vin = 385V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C base plate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. DYNAMIC CHARACTERISTICS Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Turn-On Transient Turn-On Time (with 3mF output capacitance) Start-Up Inhibit Time Output Voltage Overshoot ISOLATION CHARACTERISTICS Typ. Max. Units Notes & Conditions 350 150 mV µs 50% to 75% to 50% Iout max To within 1% Vout nom 40 200 0 ms ms % Half load (resistive), Vout=90% nom. -40 °C to +125 °C; Figure F 8 mF load capacitance Isolation Voltage (dielectric strength) 4250 V See Absolute Maximum Ratings Isolation Resistance 100 MΩ Isolation Capacitance (input to output) N/A pF Note 3 Semiconductor Junction Temperature 125 °C Package rated to 150 °C Board Temperature 125 °C UL rated max operating temp 130 °C Transformer Core Temperature 125 °C Maximum Base-Plate Temperature, Tb 100 °C FEATURE CHARACTERISTICS Switching Frequency 150 175 200 kHz Clock Synchronization 400 500 kHz ON/OFF Control Application notes Figures A & B On-State Voltage -1 0.4 V Off-State Voltage 2 18 V Pull-Up Voltage 5 V Pull-Up Resistance 124 kΩ Over-Temperature Shutdown OTP Trip Point 140 150 °C Average PCB Temperature Over-Temperature Shutdown Restart Hysteresis 10 °C RELIABILITY CHARACTERISTICS Calculated MTBF (Telcordia) TR-NWT-000332 TBD 106 Hrs. 80% load, 200LFM, 40 °C Ta Calculated MTBF (MIL-217) MIL-HDBK-217F TBD 106 Hrs. 80% load, 200LFM, 40 °C Ta Field Demonstrated MTBF 106 Hrs. See our website for details Note 1: UL’s product certification tests were carried out using 12.5A fast blow fuse. Fuse interruption characteristics have to be taken into account while designing input traces. User should ensure that Input trace is capable of withstanding fault currents. Note 2: For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 3: Isolation capacitance can be added external to the module (recommended). Product # BQ4H480FTx64 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 4 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Specification Standards Compliance & Qualification Testing Parameter Notes & Conditions STANDARDS COMPLIANCE Pending UL 60950-1/R2011-12 (pending) Basic insulation EN60950-1/A2:2013(pending) CAN/CSA-C22.2 No. 60950-1/ A1:2011(pending) Note: An external input fuse must always be used to meet these safety requirements. Contact SynQor for official safety certificates on new releases or download from the SynQor website. Parameter QUALIFICATION TESTING Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability Product # BQ4H480FTx64 # Units 32 5 5 10 5 5 5 15 pins Phone 1-888-567-9596 Test Conditions Pending 95% rated Vin and load, units at derating point, 1000 hours 10-55 Hz sweep, 0.060" total excursion, 1 min./sweep, 120 sweeps for 3 axis 100g minimum, 2 drops in x, y and z axis -40 °C to 100 °C, unit temp. ramp 15 °C/min., 500 cycles Toperating = min to max, Vin = min to max, full load, 100 cycles Tmin-10 °C to Tmax+10 °C, 5 °C steps, Vin = min to max, 0-105% load 85 °C, 95% RH, 1000 hours, continuous Vin applied except 5 min/day MIL-STD-883, method 2003 www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 5 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Figures 100 230 Vin 385 Vin 99 Efficiency (%) 400 Vin 98 97 96 95 10 15 20 25 30 35 40 45 50 55 60 65 Load Current (A) Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 2: Efficiency at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (nominal input voltage). 90 230 Vin 80 Power Dissipation (W) 385 Vin 70 400 Vin 60 50 40 30 20 10 10 15 20 25 30 35 40 45 50 55 60 65 Load Current (A) Figure 3: Power dissipation vs. load current for minimum, nominal, and maximum input voltage at TCASE=25°C. Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (nominal input voltage). Data Pending Data Pending Semiconductor junction temperature is within 1°C of surface temperature Figure 5: Maximum output current vs. base plate temperature. Product # BQ4H480FTx64 Phone 1-888-567-9596 Figure 6: Maximum output power vs. base plate temperature. www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 6 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Figures 50 Data Pending Output Voltage (V) 45 230Vin 40 385Vin 400Vin 35 30 25 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Load Current (A) Figure 7: Output voltage vs. load current for different input voltages showing typical current limit curves. Figure 8: Output voltage vs. load current, regulation curves for minimum, nominal, and maximum input voltage at TCASE=25°C. Figure 9: Turn-on transient at half load (resistive load) (10 ms/div). Load cap: 1µF ceramic capacitor no capacitor bank. Input voltage pre-applied. Ch 1: Vout (10V/div). Ch 2: ON/OFF input (2 V/div). Figure 10: Turn-on transient at half load (resistive load) (10 ms/div). Load cap: 1µF ceramic capacitor and 3mF elctrolytic capacitor bank. Input voltage preapplied. Ch 1: Vout (10V/div). Ch 2: ON/OFF input (2 V/div). Figure 11: Output voltage response to step-change in load current (50%-75%50% of Iout(max); dI/dt = 0.1A/µs). Load cap: 15µF tantalum cap and 1µF ceramic cap. Ch 1: Vout (500mV/div), Ch 2: Iout (50A/div). Figure 12: Output voltage response to step-change in load current (50%-75%50% of Iout(max): dI/dt = 1A/µs). Load cap: 15µF, 30 m© ESR tantalum cap and 1µF ceramic cap. Ch 1: Vout (500mV/div), Ch 2: Iout (50A/div). Product # BQ4H480FTx64 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 7 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Technical Figures Input Reflected Ripple Current Output Voltage Ripple Input Terminal Ripple Current source impedance iS iC DC-DC Converter VOUT VSOURCE electrolytic capacitor electrolytic capacitor ceramic capacitor Figure 13: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 14), Input Reflected Current (Figure 15) and Output Voltage Ripple (Figure 16). Figure 14: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 5µH source impedance and 47µF electrolytic capacitor (100 mA/div). See Figure 13. Figure 15: Input reflected ripple current, is, through a 5 µH source inductor, using a 47µF electrolytic input capacitor (10mA/div). See Figure 13. Figure 16: Output voltage ripple at nominal input voltage and rated load current (100 mV/div). Load capacitance: 1µF ceramic capacitor and 330µF elctrolytic capacitor. Bandwidth: 20 MHz. See Figure 13. Figure 17: Rise of output voltage after the removal of a short circuit across the output terminals. Rshort = 5mΩ. Ch1: (20V/div). Ch2: Iout (50A/div). Bandwidth: 20MHz. Product # BQ4H480FTx64 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 8 Input: 230-400V Output: 48V Current: 64A Package: Full-brick Ordering Information Part Numbering System Ordering Information The part numbering system for SynQor’s dc-dc converters follows the format shown in the example below. The tables below show the valid model numbers and ordering options for converters in this product family. When ordering SynQor converters, please ensure that you use the complete 15 character part number consisting of the 12 character base part number and the additional characters for options. Add “-G” to the model number for 6/6 RoHS compliance. BQ 4 H 4 8 F T C 6 4 N R S - G 6/6 RoHS Options (see Ordering Information) Model Number Input Voltage BQ4H480FTx64xyz-G 230-400V Output Voltage 48V Max Output Current 64A Output Current Thermal Design Performance Level Package Size The following options must be included in place of the w x y z spaces in the model numbers listed above. Output Voltage Input Voltage Product Family Thermal Design C - Encased The first 12 characters comprise the base part number and the last 3 characters indicate available options. The “-G” suffix indicates 6/6 RoHS compliance. Options Description: w x y z Enable Logic Pin Style N - Negative R - 0.180" Feature Set S - Standard Application Notes A variety of application notes and technical white papers can be downloaded in pdf format from our website. RoHS Compliance: The EU led RoHS (Restriction of Hazardous Substances) Directive bans the use of Lead, Cadmium, Hexavalent Chromium, Mercury, Polybrominated Biphenyls (PBB), and Polybrominated Diphenyl Ether (PBDE) in Electrical and Electronic Equipment. This SynQor product is 6/6 RoHS compliant. For more information please refer to SynQor’s RoHS addendum available at our RoHS Compliance / Lead Free Initiative web page or e-mail us at [email protected]. Not all combinations make valid part numbers, please contact SynQor for availability. PATENTS SynQor holds the following U.S. patents, one or more of which apply to each product listed in this document. Additional patent applications may be pending or filed in the future. Contact SynQor for further information and to order: Phone: Toll Free: Fax: E-mail: Web: Address: Product # BQ4H480FTx64 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 USA Phone 1-888-567-9596 5,999,417 6,222,742 6,545,890 6,594,159 6,731,520 6,894,468 6,896,526 6,927,987 7,050,309 7,072,190 7,085,146 7,119,524 7,269,034 7,272,021 7,272,023 7,558,083 7,564,702 7,765,687 7,787,261 8,023,290 8,149,597 8,493,751 8,644,027 Warranty SynQor offers a three (3) year limited warranty. Complete warranty information is listed on our website or is available upon request from SynQor. Information furnished by SynQor is believed to be accurate and reliable. However, no responsibility is assumed by SynQor for its use, nor for any infringements of patents or other rights of third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of SynQor. www.synqor.com Doc.# 005-0006678 Rev. 3 03/05/15 Page 9