Technical S pecification PQ60120HZA50 35-75V 12V 50Amp 2250Vdc Half-brick Input Output Current Isolation DC/DC Conver ter Th e PQ6 0120 H ZA50 P owe r Qor ® Ze ta ha lf -br i ck con ve r te r is a next-generation, board-mountable, isolated, fixed s witch ing fre qu en cy DC/DC c onver ter . T he Zeta ser ies o ffer s ind u st r y lea d ing po wer de ns it y f or s ta n da r d iso la t ed DC /DC con v ert er s wit h b o th a wid e inp u t r an ge an d a ti ght l y r egu la t ed ou tp u t . Ta rget ed for u se in in te rmed ia t e bu s a r chi te ct ur es , t hi s mo du l e s up p lies a n i so la t ed st ep d own v ol tage fr om 3 5- 75 V t o 12 V a nd p ro v ides m or e a va il ab l e p owe r a n d h igh er efficien cy t h an mos t co mp et iti ve bu s con v er ter s. T hi s c on ver ter is av a ila b le in op en- fr ame an d ba s e plated versions. RoHS Compliant (see page 12 ). Operational Features • Ultra-high efficiency, 95% at full rated load current, 96.5% at half rated load current • Delivers up to 50A of output current (600W) with optional base-plate configuration • Wide input voltage range: 35V – 75V, with 100V 100ms input voltage transient capability • Fixed frequency switching provides predictable EMI performance • No minimum load requirement means no preload resistors required • Wide output voltage trim range (-50% to +5%), see trim section Mechanical Features • Industry standard half-brick pin-out configuration • Industry standard size: 2.3” x 2.4” (58.4 x 61.0mm) • Total height only 0.50” (12.7mm) for baseplated unit, open-frame only 0.420” (10.67mm) • Total weight: 4.3 oz. (123 grams) for baseplated unit, open-frame 2.6oz. (75 grams) • Flanged pins designed to permit surface mount soldering (avoiding wave solder) using FPiP technique Contr ol Features • On/Off control referenced to input side (positive and negative logic options are available) Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com PQ60120HZA50 Module Pr otection Features • Input under-voltage lockout disables converter at low input voltage conditions • Output current limit and short circuit protection protects converter and load from damage and consequent hazardous conditions • Active back bias limit provides smooth startup with external load induced pre-bias • Latching output over-voltage protection protects load from damaging voltages • Thermal shutdown protects converter from abnormal environmental conditions Safety Features • 2250V, 30 MW input-to-output isolation provides input/output ground separation • UL/cUL 60950-1 recognized (US & Canada), basic insulation rating • TUV certified to EN60950-1 • Meets 72/23/EEC and 93/68/EEC directives which facilitates CE Marking in user’s end product • Board and plastic components meet UL94V-0 flammability requirements Doc.# 005-2HZ612J Rev. A 8/20/07 Page 1 Input: Output: Current: Package: Technical Specification MECHANICAL DIAGRAM (open frame) 35-75 V 12 V 50 A (600W) Half-brick 2.40 (61.0) 1.40 (35.56) 1.000 (35.56) 0.700 (17.78) 0.400 (10.16) (58.4) (10.49 +0.43) Overall height 9 2.30 0.413 +0.017 8 7 6 Top View Side View 5 1.90 0.400 (48.3) (10.16) 0.044 +0.027 0.145 typ. (3.68) See Note 3 Load Board Flanged Pin See Note 10 (1.12 +0.68) Bottom side Clearance 1 2 3 4 0.50 0.400 (12.7) 0.19 1.000 (4.8) (10.16) (35.56) 1.40 (35.56) NOTES 1) Pins 1-4, 6-8 are 0.040” (1.02mm) diameter. with 0.080” (2.03mm) diameter standoff shoulders. 2) Pins 5 and 9 are 0.080” (2.03 mm) diameter with 0.125” (3.18mm) diameter standoff shoulders. 3) Other pin extension lengths available. Recommended pin length is 0.03” (0.76mm) greater than the PCB thickness. 4) All Pins: Material - Copper Alloy Finish - Matte Tin over Nickel plate 5) Undimensioned components are shown for visual reference only. 6) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 7) Weight: 2.6 oz. (75 g) typical 8) Workmanship: Meets or exceeds IPC-A-610C Class II 9) UL/TUV standards require a clearance greater than 0.04” (1.02mm) between input and output for Basic insulation. This issue should be considered if any copper traces are on the top side of the user’s board. Note that the ferrite cores are considered part of the input/primary circuit. 10) The flanged pins are designed to permit surface mount soldering (avoiding the wave soldering process) through the use of the flanged pin-in-paste technique. Product # PQ60120HZA50 Phone 1-888-567-9596 PIN DESIGNATIONS Pin No. Name Function 1 Vin(+) Positive input voltage 2 ON/OFF TTL input to turn converter on and off, referenced to Vin(-), with internal pull up. 3 Reserved Not connected 4 Vin(-) Negative input voltage 5 Vout(-) Negative output voltage 6 SENSE(-) Return remote sense 7 TRIM Output voltage trim 8 SENSE(+) Positive remote sense 9 Vout(+) Positive output voltage Notes: 1. SENSE(–) should be connected to Vout(–) either remotely or at the converter. 2. Leave TRIM pin open for nominal output voltage. 3. SENSE(+) should be connected to Vout(+) either remotely or at the converter. www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 2 Input: Output: Current: Package: Technical Specification MECHANICAL DIAGRAM (base-plated) 35-75 V 12 V 50 A (600W) Half-brick 2.40 (61.0) 2.00 (50.8) 1.400 (35.56) 1.000 (25.40) 0.700 (17.78) 0.400 0.20 (10.16) (5.1) 9 Side View 8 7 6 5 0.495 +0.024 (12.57 +0.6) 2.30 Overall height (58.4) 0.20 (5.1) Top View 1.90 (48.3) 1.90 (48.3) 0.044 +0.027 (1.12 +0.68) 0.145 typ. Bottom side Clearance (3.68) See Note 6 Flanged Pin See Note 12 0.19 (4.8) Load Board 1 2 3 4 0.50 0.400 (10.16) 1.000 (25.40) (12.6) M3 Threaded Standoff 4 Places See Note 1 1.400 (35.56) NOTES 1) M3 screws used to bolt unit’s baseplate to other surfaces (such as heatsink) must not exceed 0.100” (2.54 mm) depth below the surface of the baseplate. 2) Applied torque per screw should not exceed 6in-lb. (0.7 Nm) 3) Baseplate flatness tolerance is 0.004” (.10mm) TIR for surface 4) Pins 1, 2, 4, 6-8, are 0.040” (1.02mm) diameter with 0.080” (2.03mm) diameter standoff shoulders 5) Pins 5, 9 are 0.080” (2.03mm) diameter shoulderless pins. 6) Other pin extension lengths available 7) All Pins: Material - Copper Alloy Finish - Matte Tin over Nickel plate 8) Undimensioned components are shown for visual reference only. 9) Weight: 4.3 oz. (123 g) typical 10) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 11) Workmanship: Meets or exceeds IPC-A-610C Class II 12) The flanged pins are designed to permit surface mount soldering (allowing to avoid the wave soldering process) through the use of the flanged pin-in-paste technique. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com PIN DESIGNATIONS Pin connections are identical to open frame version shown on page 2. Use “B” as 10th letter in part number for base-plated version (see ordering page). Doc.# 005-2HZ612J Rev. A 8/20/07 Page 3 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick PQ60120HZA50 ELECTRICAL CHARACTERISTICS TA=25°C, airflow rate=300 LFM, Vin=48Vdc unless otherwise noted; full operating temperature range is -40°C to +100°C ambient temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Operating Transient Protection Isolation Voltage (input to output) Operating Temperature Storage Temperature Voltage at ON/OFF input pin INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Reflected Ripple Current Input Terminal Ripple Current Recommended Input Fuse Input Filter Component Values (L\C) Recommended External Input Capacitance OUTPUT CHARACTERISTICS Output Voltage Set Point Output Voltage Regulation Over Line1 Over Load1 Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise2 Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage3 Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance DYNAMIC CHARACTERISTICS Output Voltage during Load Current Transient For a Step Change in Output C urrent (0.1A/µs) For a Step Change in Output Current (5A/µs) Settling Time Turn-On Transient Turn-On Time Output Voltage Overshoot EFFICIENCY 100% Load 50% Load TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance Isolation Capacitance4 Note Note Note Note 1: 2: 3: 4: Typ. -40 -55 -2 Max. Units 100 80 100 2250 100 125 18 V V V V °C °C V Continuous Continuous 100ms transient, square wave Basic insulation, Pollution Degree 2 100V transient for 100ms 35 48 75 V 31.5 29.0 1.5 33.0 30.5 2.5 34.5 32.0 3.5 20 200 40 V V V A mA mA V mA mA A µH\µF µF 125 20 1.0 5 220 20 30 0.75\11 220 11.72 12.00 +1.0\120 +1.0\120 +90 11.60 90 20 0 55 13 0 60 5.0 18 3 12.28 V +240 12.40 %\mV %\mV mV V 150 30 50 65 23 4 12 350 500 1 24 27 94.5 95.0 96.5 30 2 125 125 125 2250 30 1000 mV mV A A V A mA mF Notes & Conditions 100% Load, 35 Vin, trimmed up 5% 0.25V/µs input transient RMS thru 4.7µH inductor RMS Fast blow external fuse recommended Internal values; see Figure F (Lin\C2) Typical ESR 0.1-0.2W Over sample, line, load, temperature & life 20MHz bandwidth Full Load Full Load Subject to thermal derating Output Voltage 10% Low Negative current drawn from output source Negative current drawn from output source 12Vout at 50A Resistive Load mV mV ms 50% to 75% to 50% Iout max, 470 µF load cap “ To within 1% Vout nom ms % Full load, ON/OFF to Vout=90% nom. % % Figures 1 & 2 Figures 1 & 2 °C °C °C Package rated to 150°C UL rated max operating temp 130°C See Figures 3 - 6 for derating curves V MW pF Line and load regulation is limited by duty cycle quantization and does not indicate a shift in the internal voltage reference. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]). If the output voltage falls below the Output DC Current Limit Shutdown Voltage for more than 50ms, then the unit will enter into hiccup mode, with a 500ms off-time. Higher values of isolation capacitance can be added external to the module. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 4 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick ELECTRICAL CHARACTERISTICS (Continued) Parameter P FEATURE CHARACTERISTICS Switching Frequency Regulation Stage Switching Frequency Isolation Stage ON/OFF Control (Option P) Off-State Voltage On-State Voltage ON/OFF Control (Option N) Off-State Voltage On-State Voltage ON/OFF Control (Either Option) ON/OFF Control Hysteresis Pull-Up Voltage Pull Up Resistance Output Voltage Trim Range Output Over-Voltage Protection Over-Temperature Shutdown Over-Temperature Shutdown Restart Hysteresis RELIABILITY CHARACTERISTICS Calculated MTBF (Telcordia) Calculated MTBF (MIL-217) Field Demonstrated MTBF Min. Typ. Max. Units 247.50 123.75 250.00 125.00 252.50 126.25 kHz kHz -2.0 4.0 1.0 18 V V 4.0 -2 18 1.0 V V Notes & Conditions Over sample, temp & life Over sample, temp & life Figures A & B 4.75 -50 113 1.5 5.00 10 118 120 10 5.25 +5 123 2.1 1.9 V V kW % % °C °C 106 Hrs. 106 Hrs. 106 Hrs. Measured across Pins 8 & 4; see trim section Over full temp range; % of nominal Vout Average PCB Temperature TR-NWT-000332; 80% load,300LFM, 40oC Ta MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta See website for details STANDARDS COMPLIANCE Parameter P Notes STANDARDS COMPLIANCE UL/cUL 60950-1 EN60950-1 72/23/EEC 93/68/EEC Needle Flame Test (IEC 695-2-2) IEC 61000-4-2 GR-1089-CORE Telcordia (Bellcore) GR-513 File # E194341, Basic insulation & pollution degree 2 Certified by TUV Test on entire assembly; board & plastic components UL94V-0 compliant ESD test, 8kV - NP, 15kV air - NP (Normal Performance) Section 7 - electrical safety, Section 9 - bonding/grounding • 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. QUALIFICATION TESTING Parameter P QUALIFICATION TESTING Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability # Units 32 5 5 10 5 5 5 15 pins Test Conditions 95% rated Vin and load, units at derating point, 1000 hours 10-55Hz sweep, 0.060” total excursion,1 min./sweep, 120 sweeps for 3 axes 100g minimum, 2 drops in x and y axis, 1 drop in 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, 85% RH, 1000 hours, 2 minutes on and 6 hours off MIL-STD-883, method 2003 • Extensive characterization testing of all SynQor products and manufacturing processes is performed to ensure that we supply robust, reliable product. Contact the factory for official product family qualification documents. OPTIONS PATENTS SynQor provides various options for Pin Length and Feature Set for this family of Power Interface Modules. Please consult the last page for information on available options. SynQor is protected under various patents. Please consult the last page for further information. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 5 Input: Output: Current: Package: Technical Specification 50 98 45 96 40 Power Dissipation (W) 100 Efficiency (%) 94 92 90 88 86 35Vin 48Vin 75Vin 84 82 35-75 V 12 V 50 A (600W) Half-brick 35 30 25 20 15 35Vin 48Vin 75Vin 10 5 0 80 0 10 20 30 40 0 50 Load Current (A) 10 20 30 40 50 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: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 50 45 40 Iout (A) 35 30 25 20 15 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 10 200 LFM (1.0 m/s) 5 100 LFM (0.5 m/s) 0 25 40 55 70 85 Ambient Air Temperature (oC) Figure 3: Maximum output power derating curves vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM with air flowing across the converter from pin 4 to pin 1 (nominal input voltage). Figure 4: Thermal plot of converter at 36 A load current (432 W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter sideways from pin 4 to pin 1 (nominal input voltage). 50 45 40 Iout (A) 35 30 25 20 15 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 10 200 LFM (1.0 m/s) 5 100 LFM (0.5 m/s) 0 25 40 55 70 85 Ambient Air Temperature (oC) Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM with air flowing lengthwise from input to output (nominal input voltage). Product # PQ60120HZA50 Phone 1-888-567-9596 Figure 6: Thermal plot of converter at 36 A load current (432 W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from input to output (nominal input voltage). www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 6 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick Figure 7: Turn-on transient at full load (resistive load) (10 ms/div). Ch 1: Vout (5 V/div) Ch 2: ON/OFF input (5 V/div) Figure 8: Turn-on transient at zero load (10 ms/div). Ch 1: Vout (5 V/div) Ch 2: ON/OFF input (5 V/div) Figure 9: Output voltage response to step-change in load current (50%-75%-50% of Iout(max); dI/dt = 0.1 A/µ s; 1 ms/div). Load cap: 1 uF ceramic and 470 µ F, 15 mW ESR electrolitic capacitors. Top trace: Vout (500 mV/div). Bottom trace: Iout (10 A/div). Figure 10: Output voltage response to step-change in load current (50%-75%50% of Iout(max): dI/dt = 5 A/µ s; 1 ms/div). Load cap: 470 µ F, 15 mW ESR electrolitic capacitor. Top trace: Vout (500 mV/div). Bottom trace: Iout (10 A/div). Figure 13 4.7 µH source impedance Figure 12 Figure 14 iS VSOURCE iC 220 µF, 0.2W ESR electrolytic capacitor DC/DC Converter VOUT 1 µF 15 µF, ceramic 100mW ESR capacitor tantalum capacitor Figure 11: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 12), Input Reflected Ripple Current (Figure 13) and Output Voltage Ripple (Figure 14). Product # PQ60120HZA50 Phone 1-888-567-9596 Figure 12: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 4.7 µ H source impedance and 220 µ F electrolytic capacitor (1 A/div; 2 µ s/div). See Figure 11. www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 7 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick Figure 13: Input reflected ripple current, is, through a 4.7 µ H source inductor, using a 220 µ F input capacitor, at nominal input voltage and rated load current (10 mA/div; 2 µ s/div). See Figure 11. Figure 14: Output voltage ripple at nominal input voltage and rated load current (50 mV/div; 2 µ s/div). Load capacitance: 1 µ F ceramic capacitor and 15 µ F tantalum capacitor. Bandwidth: 20 MHz. See Figure 11. Figure 15: Output voltage response to step-change in input voltage (35 V to 75 V in 300 µ s; 1 ms/div). Load cap: 470 µ F, 15 mW ESR electrolitic capacitor. Top trace: Vout (500 mV/div). Bottom trace: Vin (10 V/div), at zero load current. Figure 16: Load current (10 A/div; 10 ms/div) as a function of time when the converter attempts to turn on into a 1 mW short circuit. 16 14 Output Voltage (V) 12 10 8 6 4 36Vin 48Vin 75Vin 2 0 -25 -15 -5 5 15 25 35 45 55 65 Load Current (A) Figure 17: Output voltage vs. load current showing typical current limit curves and OVP shutdown point. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 8 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick BASIC OPERATION AND FEATURES CONTROL FEATURES The PowerQor Zeta series converter uses a two-stage power conversion topology. The first stage keeps the output voltage constant over variations in line, load, and temperature. The second stage uses a transformer to provide the functions of input/output isolation and voltage step-down to achieve the low output voltage required. REMOTE ON/OFF (Pin 2): The ON/OFF input, Pin 2, permits the user to control when the converter is on or off. This input is referenced to the return terminal of the input bus, Vin(-). The converter is available with either positive or negative logic used for the ON/OFF input. Both the first stage and the second stage switch at a fixed frequency for predictable EMI performance. Rectification of the transformer’s output is accomplished with synchronous rectifiers. These devices, which are MOSFETs with a very low on-state resistance, dissipate significantly less energy than Schottky diodes, enabling the PowerQor converter to achieve high efficiency. Dissipation throughout the converter is so low that it does not require a heatsink for operation. Since a heatsink is not required, the PowerQor converter does not need a metal baseplate or potting material to help conduct the dissipated energy to the heatsink. As an open frame module, the PowerQor converter can be built more simply and reliably using high yield surface mount techniques on a PCB substrate. The PowerQor series of half-brick, quarter-brick and eighth-brick converters uses the industry standard footprint and pin-out configuration. ON/OFF ON/OFF Vin(_) Remote Enable Circuit ON/OFF Vin(_) Vin(_) Negative Logic (Permanently Enabled) ON/OFF Positive Logic (Permanently Enabled) 5V In the positive logic version, the ON/OFF input is active high (meaning that a high voltage turns the converter on). In the negative logic version, the ON/OFF signal is active low (meaning that a low voltage turns the converter on). Figure A details five possible circuits for driving the ON/OFF pin. REMOTE SENSE(+) (Pins 7 and 5): The SENSE(+) inputs correct for voltage drops along the conductors that connect the converter’s output pins to the load. Pin 7 should be connected to Vout(+) and Pin 5 should be connected to Vout(-) at the point on the board where regulation is desired. If these connections are not made, the converter will deliver an output voltage that is slightly higher than its specified value. Note: The output over-voltage protection circuit senses the voltage across the sense leads (pins 7 and 5) to determine when it should trigger, not the voltage across the converter’s output pins (pins 8 and 4). OUTPUT VOLTAGE TRIM (Pin 6): The TRIM input permits the user to adjust the output voltage across the sense leads up or down according to the trim range specifications. SynQor uses industry standard trim equations. To decrease the output voltage, the user should connect a resistor between Pin 6 (TRIM) and Pin 5 (SENSE(–) input). For a desired decrease of the nominal output voltage, the value of the resistor should be: Rtrim-down = ON/OFF CMOS (100% )_2 D kW where Vin(_) Open Collector Enable Circuit Vin(_) Direct Logic Drive D% = Vnominal – Vdesired Vnominal x 100% Figure A: Various circuits for driving the ON/OFF pin. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 9 Input: Output: Current: Package: Technical Specification To increase the output voltage, the user should connect a resistor between Pin 6 (TRIM) and Pin 7 (SENSE(+) input). For a desired increase of the nominal output voltage, the value of the resistor should be Rtrim-up = –2 xV ( Vnominal ) 1.225 DES + VNOM Figure B graphs the relationship between the trim resistor value, Rtrim-up and Rtrim-down, showing the total range the output voltage can be trimmed up or down. 5 10 15 20 25 30 35 40 45 50 10,000.0 Trim Resistance (kOhms) 1,000.0 100.0 10.0 PROTECTION FEATURES Input Under-Voltage Lockout: The converter is designed to turn off when the input voltage is too low, helping to avoid an input system instability problem, which is described in more detail in the application note titled "Input System Instability" on the SynQor website. The lockout circuitry is a comparator with DC hysteresis. When the input voltage is rising, it must exceed the typical "Turn-On Voltage Threshold" value* before the converter will turn on. Once the converter is on, the input voltage must fall below the typical Turn-Off Voltage Threshold value before the converter will turn off. Output Current Limit: If the output current exceeds the "Output DC Current Limit Inception" point*, then a fast linear current limit controller will reduce the output voltage to maintain a constant output current. If as a result, the output voltage falls below the "Output DC Current Limit Shutdown Voltage"* for more than 50ms, then the unit will enter into hiccup mode, with a 500ms off-time. The unit will then automatically attempt to restart. 1.0 0.1 0.0 % Increase in Vout few hundred hours, but not for an indefinite period or the product lifetime. The OVP trip point is set above this level, so it will not shut down from output overvoltage protection when trimmed up between 5% and 10%. Continuous operation of this converter while trimmed up more than 5% could affect long term reliability. Total DC Variation of Vout: For the converter to meet its full specifications, the maximum variation of the DC value of Vout, due to both trimming and remote load voltage drops, should not be greater than that specified for the output voltage trim range. kW VDES – VNOM 0 35-75 V 12 V 50 A (600W) Half-brick % Decrease in Vout Figure B: Trim Graph for 12Vout module Note: The TRIM feature does not affect the voltage at which the output over-voltage protection circuit is triggered. Trimming the output voltage too high may cause the over-voltage protection circuit to engage, particularly during transients. It is not necessary for the user to add capacitance at the Trim pin. The node is internally filtered to eliminate noise. Limited 10% up-trim: This converter is capable of operating for an indefinite period of time with the output trimmed up to 5% above the nominal 12V output level*. It may also be trimmed down by as much as 50% (to 6.0V) indefinitely. This converter is also capable of being trimmed up by as much as 10% (up to 13.2V) for shorter periods of time that are not a significant fraction of the product lifetime. For example, in a test situation, or for output voltage margining where it would remain trimmed up between 5% and 10% of the nominal voltage for a Back-Drive Current Limit: If there is negative output current of a magnitude larger than the "Back-Drive Current Limit while Enabled" specification*, then a fast back-drive limit controller will increase the output voltage to maintain a constant output current. If this results in the output voltage exceeding the "Output OverVoltage Protection" threshold*, then the unit will shut down. The full I-V output characteristics can be seen in Figure 17. Output Over-Voltage Limit: If the voltage directly across the output pins exceeds the "Output Over-Voltage Protection" threshold*, the converter will immediately stop switching. This shutdown is latching; unlike other shutdown types, the converter will not restart unless the input power is cycled or the ON/OFF input is toggled. Over-Temperature Shutdown: A temperature sensor on the converter senses the average temperature of the module. The thermal shutdown circuit is designed to turn the converter off when the * See Electrical Characteristics page. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 10 Input: Output: Current: Package: Technical Specification temperature at the sensed location reaches the "Over-Temperature Shutdown" value*. It will allow the converter to turn on again when the temperature of the sensed location falls by the amount of the "Over-Temperature Shutdown Restart Hysteresis" value*. APPLICATION CONSIDERATIONS Limited Output Voltage Resolution: The internal voltage control feedback loop has limited resolution. Therefore, the output voltage will exhibit discrete steps as the loop responds to changes in line, load, trim, or remote sense. For instance, on close examination, the startup ramp has a "stair-step" shape. Likewise, a load transient response will be composed of multiple discrete steps. The size of each step is well determined, and is shown in Figure C. A close-up picture of a single step is shown in Figure D. Stepping will not occur under steady state conditions. 35-75 V 12 V 50 A (600W) Half-brick this external feedback has taken control, the actual output voltage can still differ from the external reference voltage by as much as the step size. If the external feedback loop integrates this error voltage, it will cause a limit cycle oscillation. For this reason, external feedback using the sense and trim pins is not recommended. Input System Instability: This condition can occur because any DC/DC converter appears incrementally as a negative resistance load. A detailed application note titled “Input System Instability” is available on the SynQor website which provides an understanding of why this instability arises, and shows the preferred solution for correcting it. Current share and active trim not recommended: It is important to note that external feedback control using the sense or trim pins will cause sustained stepping. External current share or active trim circuits contain a separate reference voltage. After 140 Vout Step Size (mV) 120 100 80 60 40 = 12.0 Vout = 10.0 Vout 20 £ 8.75 Vout 0 35 40 45 50 55 60 65 70 75 Vin (V) Figure C: Output voltage resolution. Figure D: Smallest possible Vout step at 48Vin and 12Vout. * See Electrical Characteristics page. Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 11 Input: Output: Current: Package: Technical Specification Application Circuits: Figure E below provides a typical circuit diagram which details the input filtering and voltage trimming. Input Filtering and External Input Capacitance: Figure F below shows the internal input filter components. This filter dramatically reduces input terminal ripple current, which otherwise could exceed the rating of an external electrolytic input capacitor. The recommended external input capacitance is specified in the Input Characteristics section on the Electrical Specifications page. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. 35-75 V 12 V 50 A (600W) Half-brick 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 available as 5/6 RoHS compliant (product with lead) or 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]. Output Filtering and External Output Capacitance: Figure F below shows the internal output filter components. This filter dramatically reduces output voltage ripple. However, some minimum external output capacitance is required, as specified in the Output Characteristics section on the Electrical Specifications page. No damage will occur without this capacitor connected, but peak output voltage ripple will be much higher. Vout(+) Vin(+) Electrolytic Capacitor External Input Filter Vin 220µF ESR @ 0.2W Vsense(+) Trim ON/OFF Vsense(_) Vin(_) Rtrim-up or Rtrim-down Cload Iload Vout(_) Figure E: Typical application circuit (negative logic unit, permanently enabled). Lin Vin(+) Vout(+) C1 C2 Regulation Stage Current Sense Vin(_) Isolation Stage Vout(_) Figure F: Internal Input and Output Filter Diagram (component values listed on specifications page). Product # PQ60120HZA50 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HZ612J Rev. A 8/20/07 Page 12 Input: Output: Current: Package: Technical Specification 35-75 V 12 V 50 A (600W) Half-brick PART NUMBERING SYSTEM ORDERING INFORMATION The part numbering system for SynQor’s PowerQor 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 3 characters for options. A “-G” suffix indicates the product is 6/6 RoHS compliant. PQ 60 120 H Z A 50 N N S - G 6/6 RoHS Options (see Ordering Information) Output Current Thermal Design Model Number Input Voltage PQ60120HZw 50xyz PQ55530HZw 12xyz 35 - 75 V 38 - 55 V (see Ordering Info) Performance Level Output Max Output Voltage Current 12.0 V 50 A 53.0 V 11.5 A Package Size The following option choices must be included in place of the x y z spaces in the model numbers listed above. Output Voltage Input Voltage Product Family Options Description: w x y z The first 12 characters comprise the base part number and the last 3 characters indicate available options. Although there are no default values for enable logic and pin length, the most common options are negative logic and 0.145” pins. These part numbers are more likely to be readily available in stock for evaluation and prototype quantities. A “-G” suffix indicates 6/6 RoHS compliance. Application Notes Thermal Design Enable Logic A - Open Frame B - Baseplate P - Positive N - Negative Pin Length K - 0.110" N - 0.145" R - 0.180" Y - 0.250" Feature Set S - Standard Many operational functions of this converter are programmable. Contact the factory regarding customization. PATENTS (additional patent applications may be filed) A variety of application notes and technical white papers can be downloaded in pdf format from our website. SynQor holds the following patents, one or more of which might apply to this product: 5,999,417 6,594,159 6,927,987 6,222,742 6,731,520 7,050,309 6,545,890 6,894,468 7,072,190 6,577,109 6,896,526 7,085,146 Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: Product # PQ60120HZA50 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 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.# 005-2HZ612J Rev. A 8/20/07 Page 13