Advancing the Power Curve® MIL-STD Compliant High Efficiency Field Proven Military “Off-The-Shelf” Power Converters & Filters Made in USA Products for the Military and Aerospace Industry Isolated Converters “Off-the-shelf” DC-DC Converters for Cost Sensitive Military/Avionics Applications The MilQor® series of Mil-COTS Isolated DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectifier technology to the Military/Avionics industry. These “off-the-shelf” converters are compatible with the industry standard format, operate at a fixed frequency, and follow conservative component derating guidelines. MilQor® products are designed and manufactured to comply with a wide range of military standards. MCOTS Product Features Protection High efficiency, up to 95% at full rated load current Fixed frequency switching provides predictable EMI No minimum load requirement Rugged design for harsh environments Full Feature option on some models Flanged baseplate available Industry standard pin-out configurations and standard footprints. Compliance Features MilCOTS converters with MilCOTS filters are designed to meet: MIL-HDBK-704-8 (A through F) RTCA/DO-160 Section 16, 17, 18 MIL-STD-1275 (B, D) MIL-STD-461 (C, D, E, F) DEF-STAN 61-5 (part 6)/(5, 6) Family Product Cont. Input Voltage Output Voltage Input under-voltage lockout Output current limit and short circuit protection Active back bias limit Output over-voltage protection Thermal shutdown (not on DM Package Size) Control On/Off control referenced to input side (ON/OFF control islolated in Full Bricks) Remote sense for the output voltage Digital Output Current Sharing (HZ only) Output voltage trim range of: +10% to -20% (Half-Brick Zeta) +10% to -50% (Quarter-Brick Exa) +10% to -50% (Sixteenth Brick) +10% to -10% Package Size/ (Performance Level) Heatsink Option Screening Level Options 1R2:1.2V 12:12V FZ: Full Brick (Zeta) 1R5:1.5V 15:15V FP: Full Brick (Peta) N:Encased, 1R8:1.8V 24:24V FT: Full Brick (Tera) Baseplate 2R5:2.5V 28:28V HZ:Half Brick (Zeta) D:Encased, 3R3:3.3V 36:36V HP: Half Brick (Peta) Non-Threaded S:S-Grade [ ]:Standard MCOTS 05:5V 40:40V HT:Half Brick (Tera) Baseplate M:M-Grade F: Full Feature 07:7V 48:48V QE: Quarter Brick (Exa) F:Encased, 7R5:7.5V 50:50V QT: Quarter Brick (Tera) Flanged 08:8V 135:135V SM: Sixteenth Brick (Mega) Baseplate 10:10V 270:270V DM: Demi Brick (Mega) Part Numbering Example: MCOTS-C-28-05-HP-N-M For valid part numbers, refer to the website or contact your local sales representative. 28:16-40V 28E:16-70V 28V:9-40V 28VE:9-70V C: Converter 48:34-75V 150:90-210V 270:155-425V 270H:240-425V 270N:240-280V * Not all features apply, see individual product data sheet for product specifics. FILTERS DC Filter Modules SynQor provides EMI filters for the MIL-COTS DC-DC converters. All EMI filters provide high levels of differential‑mode and common-mode attenuation and include stabilizing bulk capacitors and damping resistors. MCOTS DC Filter Features Low DC resistance Differential-mode attenuation Common-mode attenuation Bulk capacitance provides input system stabilization for downstream power converters DC Filter Model Number HALF BRICK MCOTS-F-28-T-HT MCOTS-F-270-P-HT QUARTER BRICK MCOTS-F-28-P-QT MCOTS-F-48-P-QT MCOTS-F-270-P-QT DEMI BRICK MCOTS-F-28-P-DM MCOTS-F-28E-P-DM Input Voltage Output Current No electrolytic capacitors (all ceramic design) High-voltage isolation between common-mode pins and input / output Wide temperature range operation Designed to meet MIL-STD-461 Isolation Voltage Maximum (to commonDC Resistance @ Differential-Mode Attenuation mode) 100°C Common-Mode Attenuation Continuous Surge (<100ms) ±40V ±500V +100V, -50V ±630V 30A 9A 2250V 2500V 40mΩ 106mΩ >80dB @ 250kHz >70dB @ 250kHz >36dB @ 250kHz >50dB @ 250kHz ±40V ±80V ±500V ±50V ±100V ±630V 30A 20A 4.0A 2250V 2250V 2500V 20mΩ 32mΩ 180mΩ >80dB @ 250kHz >80dB @ 250kHz >80dB @ 500kHz >36dB @ 250kHz >36dB @ 250kHz >50dB @ 500kHz ±40V ±70V ±50V ±100V 10A 10A 1000V 1000V 60mΩ 60mΩ >80dB @ 500kHz >80dB @ 500kHz >60dB @ 500kHz >60dB @ 500kHz AC Line Filter Modules SynQor provides AC Line filters for the MIL-COTS series of PFC modules and DC-DC converters. SynQor’s high‑performance filters are designed to comply with industry EMI standards. MCOTS AC Filter Features 1kW@115Vrms (Single Phase) - Half-Brick 2kW@115Vrms (L-N) (Three Phase) All ceramic capacitor design High voltage isolation between baseplate and input/output Internally damped Low power dissipation Complies with industry EMI standards when used with SynQor MPFC and DC-DC converter modules Model Number Input Phase MACF-U-230-ET MACF-060-230-HT MACF-400-230-HT MACF-115-3PH-UNV-HT Single Phase Single Phase Single Phase Three Phase Input Frequency 50/60Hz & 400Hz 50/60Hz 400Hz 45-800Hz Input Voltage 85-264Vrms 85-264Vrms 85-264Vrms 85-140Vrms (L-N) Output Current 4.5Arms 9Arms 9Arms 8Arms Output Power 500W@115Vrms/1kW@230Vrms 1kW@115Vrms/2kW@230Vrms 1kW@115Vrms/2kW@230Vrms >2kW@115Vrms (L-N) Power Factor Correction Military Grade Power Factor Correction Module The MPFCQor Power Factor Correction module is an essential building block of an AC-DC power supply. Used in conjunction with a hold-up capacitor, SynQor’s high efficiency MCOTS DC-DC converters and SynQor’s MCOTS AC line filter, the MPFCQor will draw a nearly perfect sinusoidal current (PF>0.99) from a single phase AC input. The MPFCQor module can be paralleled to achieve higher power. The module is supplied completely encased to provide protection from the harsh environments seen in many military and extreme environments. Operational Features Protection/Control Features Universal input voltage range: 85-264Vrms Narrow input voltage range: 85-180Vrms Universal input frequency range: 47 - 63Hz / 360 - 800Hz Up to 700W output power (Half-Brick) Up to 350W output power (Quarter-Brick) ≥0.99 Power Factor High efficiency: Up to 95% (115Vrms) Internal inrush current limit Auxiliary 10V bias supply 100°C max baseplate temperature at full power Can be paralleled with current sharing (Half‑Brick Only) Compatible with SynQor’s MCOTS DC-DC Converters & SynQor’s AC line filters PFC Enable Load Enable (also: Power Out Good signal) AC Power Good Signal (Half‑Brick Only) Clock synchronization (Half‑Brick Only) Output current monitor/current sharing (Half‑Brick Only) Input current limit and auto-recovery short circuit protection Auto-recovery input under/over-voltage protection Auto-recovery output over-voltage protection Auto-recovery thermal shutdown Mil-COTS Power Factor Correction Module Family Vin Range Output Voltage MPFC U:85-264V 115:85-180V 270:270Vdc 390:390Vdc Package Size HP:Half-brick Peta QP:Quarter-brick Peta Thermal Design N: Encased, Threaded Baseplate D:Encased, Non-threaded Baseplate F:Encased, Flanged Baseplate Part Numbering Example: MPFC-U-390-HP-N-M For valid part numbers, refer to the website or contact your local sales representative. Screening Level S :S-Grade M:M-Grade 3-Phase Power Factor Correction Military Grade 3-Phase Power Factor Correction Module The MPFCQor Power Factor Correction module is an essential building block of an AC-DC power supply. Used in conjunction with SynQor’s MCOTS AC line filter and a limited amount of stabilizing capacitance, the 3-Phase MPFCQor will draw a nearly perfect sinusoidal current from each phase of a 3-Phase AC input. The module is supplied completely encased to provide protection from the harsh environments seen in many military and extreme environments. Operational Features Protection/Control Features Full-brick form factor industry standard 1.5kW continuous (2.0kW surge) Semi-regulated output: 270Vdc Compatible with Military Standard 60Hz, 400Hz and var. freq. systems Meets military standards for harmonic content Minimal Inrush current Additional Half-brick input filter available to meet full EMI 100°C max baseplate temperature at full power Compatible with SynQor MCOTS - 270 Converters Enables systems with repetitive load transients to pass MIL-STD-461 CE101 with superior load current rejection PFC Enable and Battle Short inputs All control pins referenced to separate ground with functional isolation AC and DC Power Good outputs Clock synchronization output 3.3V standby power output Input current limit and auto-recovery short circuit protection Auto-recovery input under/over-voltage protection Auto-recovery output over-voltage protection Auto-recovery thermal shutdown Mil-COTS Power Factor Correction Module Family Vin Range Input Phases Vout Package Size Thermal Design Screening Level N: Encased, Threaded Baseplate S:S-Grade MPFC 115: 85-140V 3PH: Three-Phase 270: 270Vdc FP: Full-brick Peta D:Encased, Non-Threaded Baseplate M:M-Grade F:Encased, Flanged Baseplate Part Numbering Example: MPFC-115-3PH-270-FP-N-M For valid part numbers, refer to the website or contact your local sales representative. High Voltage Non-Isolated Military-Grade High Voltage, Non-Isolated DC-DC Converters The high input voltage non-isolated DC-DC converters offer unique solutions for converting high-powered, variable voltages to a wide range of output voltages. The converter is a non‑isolated buck-boost regulator, which employs synchronous rectification to achieve extremely high conversion efficiency. These products are suitable for use in IBA, or to provide a regulated output voltage from a variable voltage source such as a battery. They can be configured to ‘buck’ the input voltage down or ‘boost’ the input voltage up using a single external resistor. Battery Charging Features High-Voltage Non-Isolated (Key feature of Trimmable Current Limit) Provides the power conversion platform for battery charging Output current limit is externally controlled for constant-current charging Current can be set with an external resistor or an active circuit Current analog signal provided for instrumentation and control functions Ideal diode output stage with zero back-drive currents prevents discharge of battery when not charging Output voltage set-point is independently controlled through trim pin Unit will smoothly transition between current and voltage modes as charging cycle needs change Model Number Brick Size Half-brick MCOTS-N-28V-60-HG MCOTS-N-28V-60-QT Quarter-brick MCOTS-N-28VE-90-HG Half-brick MCOTS-N-28VE-90-QT Quarter-brick Family MCOTS Product Vin Range Input Voltage 9-60V 9-60V 9-90V 9-90V Vout Output Voltage 0-60V 0-60V 0-90V 0-90V Package Size Current 40A 25A 26A 18A Max Output Power 2000W 1500W 2000W 1500W Thermal Design High Efficiency 96% Efficiency 96% Efficiency 96% Efficiency 97% Efficiency Screening Level N: Encased, Threaded Baseplate S:S-Grade N:Non-isolated 28V:9-60V 60:0-60V QT: Quarter-brick Tera D:Encased, Non-threaded Baseplate M:M-Grade Converter 28VE:9-90V 90:0-90V HG:Half-brick Giga F:Encased, Flanged Baseplate Part Numbering Example: MCOTS-N-28VE-90-HG-N-M For valid part numbers, refer to the website or contact your local sales representative. Bus Converters Rugged, High Efficiency Next Generation DC-DC Bus Converters These military-grade bus converters are the next-generation, board-mountable, isolated, fixed switching frequency DC‑DC converters that use synchronous rectification to achieve extremely high conversion efficiency. The power dissipated by the converter is so low that a heatsink is not required, which saves cost, weight, height, and application effort. MCOTS-Bus converters are ideal for creating the mid‑bus voltage required to drive point‑of‑load (non-isolated) converters in IBA. Model Number MCOTS-B-270-31 MCOTS-B-600-31 Family Package Size Half-Brick Half-Brick Product MCOTS B:Bus Converter Input Voltage 230-400V 440-700V Vin Range Vout Input Transient 155-450V 400-750V Output Voltage 29.7V 30.3V Package Size 270: 230-400V 31: 31V HT: Half-brick Tera 600: 440-700V Output Output Current Max Power 32.5A 1000W 32.5A 1000W Thermal Design Efficiency 95% 95% Screening Level :Encased, Threaded Baseplate N S:S-Grade D:Encased, Non-Threaded Baseplate M:M-Grade F:Encased, Flanged Baseplate Part Numbering Example: MCOTS-B-600-31-HT-N-M For valid part numbers, refer to the website or contact your local sales representative. Mil-COTS Listed by Package Size & Output Voltage Single Output MCOTS-28 Demi 16-40Vin Cont. 50Vin 1s Trans. Absolute Max Vin = 60V MCOTS-28 Vout Dual Output Vout 3.3V 5.0V 12V 15V 28V Demi Brick 15A 50W 10A 50W 4.0A 48W 3.3A 50W 1.8A 50W 1.2V 1.5V 1.8V 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V ±5.0V ±12V 10A 4A 3.3A 50W Total 48W Total 50W Total 28V 40V 48V Full Zeta 16-40Vin Cont. 50Vin 1s Trans. Absolute Max Vin = 60V 1/2 Zeta 60A 108W 1/2 Peta 50A 165W 1/4 Exa 40A 40A 40A 40A 30A 48W 60W 72W 100W 99W 25A 25A 25A 20A 15A 1/16 Mega 30W 38W 45W 50W 50W 1/4 Tera MCOTS-28E 16-70Vin Cont. 100Vin 1s Trans. Absolute Max Vin = 100V MCOTS-28V Vout 1.5V 1.8V MCOTS-28VE Vout 40V 48V 50V 10A 8A 400W 400W 4.5A 3.7A 180W 178W 2.5A 120W 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 50A 21A 17A 10A 9A 250W 252W 255W 240W 252W 50A 36A 24A 15A 12A 7.5A 6.5A 165W 180W 180W 180W 180W 180W 182W 25A 17A 12A 7A 5.5A 3.5A 2.8A 83W 85W 84W 84W 83W 84W 78W 30V 40V 48V 50V 6A 5A 240W 250W 4.5A 3.7A 180W 178W 1.8A 86W 2.5V 3.3V 5V 7V 7.5V 12V 15V 24V 28V 50A 21A 17A 10A 9A 250W 252W 255W 240W 252W 45A 32A 22A 13A 11A 6.7A 5.8A 149W 160W 165W 156W 165W 161W 162W 25A 17A 12A 7A 5.5A 3.5A 2.8A 83W 85W 84W 84W 83W 84W 78W 30V 40V 48V 50V 6A 5A 240W 250W 4A 3.4A 160W 163W 1.8A 86W 1.8V 2.5V 1/2 Zeta 55A 99W 35A 63W 1/2 Peta 1/4 Tera Vout 1.2V 1/2 Zeta 34-75Vin Cont. 100Vin 1s Trans. Absolute Max Vin = 100V 1.8V 60A 72W 40A 1/4 Tera 48W 25A 1/16 Mega 30W 1/2 Peta MCOTS-150 90-210Vin Cont. 250Vin 1s Trans. Absolute Max Vin = 250V MCOTS-270 Vout 1.5V 5V 7V 12V 15V 60A 50A 40A 300W 600W 600W 60A 60A 60A 60A 46A 35A 21A 17A 90W 108W 150W 198W 230W 245W 252W 255W 40A 40A 40A 30A 25A 20A 12A 10A 60W 72W 100W 99W 125W 140W 144W 150W 25A 25A 20A 15A 10A 7A 4A 3A 38W 45W 50W 50W 50W 49W 48W 45W 3.3V 3.3V Full Tera 155-425Vin Cont. 475Vin 1s Trans. Absolute Max Vin = 600V 1/2 Tera 1/4 Tera MCOTS-270H 240-425Vin Cont. 475Vin 1s Trans. Absolute Max Vin = 600V 3.3V 5V 6V 12V 24V 25A 600W 10.5A 252W 6A 144W 28V 30V 40V 48V 50V 21.5A 15A 12A 602W 600W 600W 9A 6.3A 5.2A 252W 252W 250W 5A 5A 3A 3A 140W 150W 120W 144W 15V 24V 30A 150W 1/4 Tera Vout 3A 2.5A 120W 120W 30V 60A 108W 35A 63W 1.5V 6A 300W 5V 7.5V 9.6V 12V 15V 24V 28V 60A 42A 33A 26A 16A 14A 300W 403W 396W 390W 384W 392W 50A 36A 24A 15A 12A 7.5A 6.5A 165W 180W 180W 180W 180W 180W 182W 30A 24A 10A 8A 4.3A 99W 120W 120W 120W 120W 1/2 Zeta 1/4 Tera 12.5A 500W 5A 4A 200W 192W 3.3V 1/4 Tera Vout 18A 504W 7A 196W 10.7A 300W 4A 112W 50V 135V 270V 3.7A 999W 10A 3.7A 500W 500W 2.5V 60A 108W 1/2 Peta 1/2 Peta MCOTS-48 1.8V 1/2 Zeta 9-40Vin Cont. 55Vin 1s Trans. Absolute Max Vin = 60V 9-70Vin Cont. 100Vin 1s Trans. Absolute Max Vin = 100V 1.5V 60A 42A 34A 21A 300W 504W 510W 504W 40A 27A 16A 13A 8.33A 200W 202W 192W 195W 192W 40A 25A 20A 200W 300W 300W 24A 17A 10A 8A 5A 120W 119W 120W 120W 120W 10A 7A 4A 50W 49W 48W ±15V 60A 198W 30A 99W 5V 80A 400W 50A 250W 30A 150W 6V 25A 150W Vout 5V 28V 36V Full Peta 100A 500W 28.6A 801W 22.2A 799W 12V 50A 600W 25A 300W 13A 156W 15V 40A 600W 20A 300W 10A 150W MCOTS-270N 240-280Vin Cont. 200-350Vin 1s Trans. Absolute Max Vin = 600V 24V 25A 600W 12.5A 300W 6.25A 150W 28V 48V 5.35A 150W 3.1A 149W 28V 21.4A 599W 10.7A 300W 5.35A 150W 48V 12.5A 600W 6.3A 302W 3.1A 149W Vout 8V 10V 28V 1/2 Tera 50A 400W 40A 400W 14.5A 406W Product Screening & Qualification Product Screening Screening Baseplate Operating Temperature Storage Temperature Pre-Cap Inspection Temperature Cycling Burn-In Final Electrical Test Final Visual Inspection Process Description IPC-610 Class III Method 1010, Condition B, 10 Cycles 100°C Baseplate 100% MIL-STD-2008 S-Grade -55°C to +100°C -65°C to +135°C • 12 hours 25°C • M-Grade -55°C to +100°C -65°C to +135°C • • 96 hours -55°C, +25°C, +100°C • Product Qualification Qualification Details Temperature Cycling Visual, mechanical and electrical test before, during and after 1000 hour burn-in @ full load Visual, mechanical and electrical test before, during and after shock and vibration tests +85°C, 95%RH, 1000 hours, 2 minutes on 6 hours off 500 cycles of -55°C to +100°C (30 minute dwell at each temperature) Solderability 15 pins Life Testing ShockVibration Humidity DMT Altitude -65°C to +110°C across full line, and load specifications in 5°C steps 70,000 feet (21 km) # Tested (# Failed) 15 (0) 5 (0) 8 (0) 10 (0) 15 (0) 7 (0) 2 (0) Consistent with MIL-STD-883F Method Consistent with MIL-STD-883F Method 5005 Method 1005.8 — — MIL-STD 202, Methods 201A and 213B Method 1004.7 — Method 1010.8 Condition A Method 2003 — — — — — Advancing the Power Curve® Located in Boxborough, MA USA, SynQor is a leading supplier of power conversion solutions to the military, avionics, transportation, medical, industrial, telecommunications and computing markets. SynQor’s innovative products are designed to exceed the demanding performance, quality, and reliability requirements of today’s power electronic engineers who develop leading-edge infrastructure hardware. SynQor provides all the power conversion modules needed to build a power system, and it also provides complete power systems. SynQor’s capabilities include both standard and custom solutions, and it delivers them with industry leading service and support. SynQor’s total commitment to quality, customer satisfaction and continuous improvement drives our business processes. 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] Rev. B 006-0005601 - 07/16/2015 www.SynQor.com Made in USA