Rail transportation isolated DC-DC Converters Railway Power Supply Rail transportation isolated DC-DC converters DC-DC Converter Key Performance Highlights SynQor’s RailQor line of DC-DC converters is designed to provide isolated DC power in the transportation industry for such electronics as LED displays, audio amplifiers, safety monitors, lighting, and communications systems under the European Standard EN 50155. These converters use SynQor’s synchronous rectifier based technology to achieve extremely efficient industry leading performance. Due to the difficult environmental conditions the transportation market poses on power supplies, SynQor has designed the RailQor line for optimal performance in the most demanding applications. RailQor Input/Output Ratings Family Output Voltage 5V 12V 2:1 Input Ratio RQ1B Max. Iout / Power Out Max. Iout / Power Out 24V Package Size / Power Level 48V 110V (66V - 160V) Continuous Input Range, 170V Transient 10A / 50W 25A / 125W 48A / 240W 4.1A / 50W 12A / 144W 21A / 252W 10A / 50W 25A / 125W 46A / 230W 4.1A / 50W 12A / 144W 21A / 252W 2:1 Input Ratio RQ72 15V 3.3A / 50W 10A / 150W 17A / 255W 2A / 48W 6A / 144W 10A / 240W Quarter-brick Mega 3A / 150W Quarter-brick Tera 5.3A / 255W Half-brick Peta 72V (42V - 110V) Continuous Input Range 3.3A / 50W 10A / 150W 17A / 255W 2A / 48W 6A / 144W 10A / 240W Quarter-brick Mega 3A / 150W Quarter-brick Tera 5.3A / 255W Half-brick Peta 12:1 Input Ratio 68V (12V - 154V) Continuous Input Range, 170V Transient RQ68 5.3A / 26.5W 2.3A / 27.6W 1.8A / 27W 1.1A / 26.4W Quarter-brick Mega Max. Iout / Power Out 10.6A / 53W 4.4A / 53W 3.5A / 52.5W 2.2A / 53W Half-brick Giga 4:1 Input Ratio RQ18 Max. Iout / Power Out Family RQ24 18V (9V - 36V) Continuous Input Range, 40V Transient 10A / 50W 20A / 100W 36A / 180W 4.1A / 50W 8.3A / 96W 15A / 180W 3.3A / 50W 6.6A / 100W 12A / 180W Output Voltage 2A / 48W 4.1A / 98W 7.5A / 180W 2A / 100W 3.7A / 178W Quarter-brick Mega Quarter-brick Tera Half-Brick Peta Package Size / Power Level 40V 2:1 Input Ratio 24V (18V - 36V) Continuous Input Range, 50V Transient Max. Iout / Power Out 12.5A / 500W Half-brick Zeta Unique characteristics of the RailQor line include the following: •• Full load efficiencies up to 93% •• Input voltage ranges fully cover the requirements of EN 50155 •• Full power operation at baseplate temperature range from -40°C to 100°C. •• Encased module provides protection from harsh environments available with optional flanged style baseplate. Quarter-brick 25W-50W Mega Series •• Low power dissipation at very light loads, resulting in efficiencies exceeding 88% at as little as 10W output. •• No derating in environments with zero airflow and ambient temperatures up to 85°C with no heatsink. EN 50155 Requirements and RailQor Features EN50155 Requirements Nominal Continuous Input RailQor Capabilities Transient Input Family Continuous Input Transient Input 24V 17V– 30V 14V– 34V RQ18 9V– 36V 9V – 40V(100ms) 72V 50V– 90V 43V– 101V RQ72 42V– 110V 42V– 110V 110V 77V– 137V 66V– 160V RQ1B 66V– 160V 66V – 170V(100ms) 24V – 110V 17V– 137V 14V– 160V RQ68 12V– 154V 12V – 170V(100ms) Product Features The RailQor converter series is composed of next-generation, board-mountable, isolated, fixed switching frequency DC‑DC converters that use synchronous rectification to achieve extremely high power conversion efficiency, even at low output power levels. The Quarter-brick 25W-50W Mega Series power dissipation is so low that no heatsink is necessary to operate at 85°C in an enclosed environment without airflow. Each module is supplied completely encased to provide protection from the harsh environments seen in many industrial and transportation applications. OPERATIONAL GENERAL SPECIFICATIONS •• High efficiency at full load up to 93% •• Quarter-brick 25-50W Mega Series has no derating in environments with zero airflow and ambient temperatures up to 85°C with no heatsink. •• Input voltage ranges: 9-36V, 42V-110V, 12-154V & 66V-160V •• Input voltage ranges fully cover the requirements of EN 50155 •• Full power operation at baseplate temperature range from -40°C to 100°C. •• Output power up to 500W •• Fixed frequency switching, low output noise •• No minimum load requirement •• Encased module to provide protection from harsh environments and available with optional flanged style baseplate. •• Operating Temperature -40ºC to +100ºC •• Output Voltage Set Point ±1.0% •• Output Voltage Ripple <1% of Vout (typ.) •• Switching Frequency 240 - 350kHz •• Transient Response <7% of Vout (typ.) •• Output Voltage Trim Range+10% to -20% •• Isolation Voltage Up to 3000Vdc •• EN50155 Compliance •• RIA 12 Compliance with external circuit MECHANICAL •• Industry standard pin-out configuration •• Flanged baseplate available •• Industry standard footprint: Half-brick: 2.4" x 2.5" Quarter-brick: 1.5" x 2.4" PROTECTION/CONTROL •• Input under-voltage lockout •• Output current limit and short circuit protection •• Active back bias limit prevents damage to converter •• Output over-voltage protection •• Thermal shutdown SAFETY RQ1B, RQ72 & RQ68 •• Reinforced Insulation •• Up to 3000V, 100MΩ input-to-output isolation •• CAN/CSA C22.2 NO. 60950-1/A1:2011 •• UL 60950-1/R:2011-12 •• EN 60950-1/A2:2013 •• CE marked RQ18 •• Basic Insulation •• 2250V, 30MΩ input-to-output isolation •• CAN/CSA C22.2 NO. 60950-1/A1:2011 •• UL 60950-1/R:2011-12 •• EN 60950-1/A12:2011 100 50 95 90 Efficiency (%) Pout (W) 40 30 20 10 0 42.00 72.00 Input Voltage (V) 110.00 Typical RailQor quarter-brick 50W encased converter (no heatsink) maximum output power derating over input voltage at 85°C and natural convection airflow. 85 80 75 70 42Vin 65 110Vin 60 72Vin 0.0 0.5 1.0 Load Current (A) 1.5 2.0 Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C of a typical RailQor quarter-brick 50W converter. Applications Video Surveillance Systems Cabin Electrical Equipment Entertainment Systems Door Control LED Information Displays Wireless & Radio Communications Internal & External Lighting Access & Ticketing Machines Braking Control Motor Drive Controllers Embedded Computer Systems Technical Support SynQor understands the need for rapid development of new projects in the transportation industry and provides excellent support for new designs incorporating the RailQor product lines. Concerns regarding EN 50155 compliance, transient and surge suppression to meet RIA 12, design for optimal thermal performance and other techniques are described in our RailQor datasheets and in technical papers available at www.synqor.com. RailQor DC-DC Converter Part Numbering Guide Family RQ Output Voltage Cont. Vin 18: 9- 36V 24:18 - 36V 68: 12 -154V 72: 42 -110V 1B: 66 -160V Package Size Performance Series G: Giga 050:5V Mega 120:12V Q:Quarter-brick M: P: Peta 150:15V H:Half-brick T: Tera 240:24V Z: Zeta 480:48V Thermal Design Max. Iout 48:48A 46:46A 36:36A 25:25A 21:21A C:Encased 15:15A D:Encased 12:12A Non-Threaded 10:10A Baseplate 08:8A V: Flanged 07:7A Baseplate 06:6A 05:5A 04:4A 02:2A 01:1A Enable Logic Pin Length N: Negative R: 0.180" Features S: Standard Refer to the website, contact your local sales representative or distributor for valid part numbers. Specifications change without notice. Example: RQ72120QMC04NRS-G Application Notes •• “RailQor EN 50155 / RIA-12 Compliance & Evaluation Board Application Note” – Addresses the input voltage requirements of the European Railway Standards EN50155 and RIA-12 and how to meet them using SynQor’s RailQor DC-DC converters. The RailQor converters are designed to meet or exceed EN50155 input static and transient DC voltage requirements. Since some equipment is being designed to also comply with RIA-12 surges and transients, those requirements are discussed as well, along with the supplemental circuitry needed to meet those requirements. •• “EMI Characteristics” – An overview of EMI with suggestions for external filtering solutions and suggested layout and grounding practices. •• “Input System Instability” – Describes the phenomena of input instability in DC-DC converters and the preferred solution for correcting it. Datasheet Application Information •• How to lay out a board for optimal thermal performance with RailQor product •• Circuits for driving the enable pin •• How to trim the converter to compensate for resistive drops between supply and load RailQor Qualification Testing Testing Type Vibration Life Test Cold Dry Heat Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Damp Heat, Cyclic Solderability Units 5 30 5 5 5 5 5 5 5 15 Test Conditions EN 61373:1999 Category I, Class B, Body mounted 95% rated Vin and load, units at derating point, 1000 hours EN 60068-2-1:2007 EN 60068-2-2:2007 EN 61373:1999 Category I, Class B, Body mounted -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 EN 60068-2-3:2005 Pins MIL-STD-883, method 2003 Note: Governing Standard BS EN 50155:2007 Railway applications - Electronic equipment used on rolling stock Advancing The Power Curve® Headquartered in Boxborough, Massachusetts, at the location of its manufacturing operations with additional design center facility in Dallas, Texas and sales/marketing offices throughout the World, SynQor quickly became the technology, quality and service leader for high efficiency DC-DC converters. SynQor is a privately owned U.S. ISO 9001:2008 company. SynQor converters feature a patented two-stage power topology that greatly improves efficiency and optimizes the power dissipated by the converter. SynQor’s rugged DC-DC converters, AC-DC converters, filters and power supply systems are designed for a wide range of industrial and military applications including those required to withstand harsh environments: railway and transportation systems, industrial motion control, information displays, factory automation, critical military and power generation systems. SynQor Headquarters 155 Swanson Road Boxborough, MA 01719-1316 Phone: 978-849-0600 Fax: 978-849-0602 Toll Free (USA): 888-567-9596 E-mail: [email protected] www.SynQor.com Made in USA Visit our website for more information 005-0006150 Rev D 09/22/14