MCOTS-C-270-05-FT Single Output Full-brick MILITARY COTS DC/DC CONVERTER 155-425V Continuous Input 155-475V Transient Input 5V Output 80A Output 90% @ 40A / 88% @ 80A Efficiency Operation: -55°C to +100°C The MilQor series of Mil-COTS DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectification technology to the Military/Aerospace industry. SynQor’s ruggedized encased packaging approach ensures survivability in demanding environments. Compatible with the industry standard format, these converters operate at a fixed frequency, and follow conservative component derating guidelines. They are designed and manufactured to comply with a wide range of military standards. A 80 @ T U M O D C 15 C/D OT 5- C S 42 C -C 5( ON 47 VE 27 5V RT 0 ) ER -0 IN 5 5V -F T- N -M -F Mil-COTS Safety Features • 4250V dc, 100 MΩ input-to-output isolation • (see Standards and Qualifications page) Designed and Manufactured in the USA Operational Features Mechanical Features • Industry standard full-brick pin-out configuration • Size: 4.686” x 2.486” x 0.512” 119.0 x 63.1 x 13.0 mm • Total weight: 9.9oz (280g) • Flanged baseplate version available Control Features • • • • • • MCOTS series converters (with an MCOTS filter) are designed to meet: Phone 1-888-567-9596 Input under-voltage lockout/over-voltage shutdown Output current limit and short circuit protection Input over-voltage protection Output over-voltage protection Thermal shutdown Screening/Qualification Specification Compliance Product # MCOTS-C-270-05-FT Protection Features • • • • • Fully Isolated On/Off control Remote sense for the output voltage Output voltage trim range of +10%, -20% Active current sharing (full feature option) Clock synchronization (full feature option) Start synchronization (full feature option) • MIL-HDBK-704 (A-F) • RTCA/DO-160E Section 16 • MIL-STD-1275 (B,D) • DEF-STAN 61-5 (Part 6)/(5 or 6) • MIL-STD-461 (C, D, E, F) • High efficiency, 88% at full rated load current • Operating input voltage range: 155-425 V • Fixed frequency switching provides predictable EMI • • • • • AS9100 and ISO 9001:2008 certified facility Qualified to MIL-STD-810 Available with S-Grade or M-Grade screening Pre-cap inspection per IPC-610, Class III Temperature cycling per MIL-STD-883, Method 1010, Condition B, 10 cycles • Burn-In at 100C baseplate temperature • Final visual inspection per MIL-STD-2008 • Full component traceability www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 1 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification BLOCK DIAGRAM REGULATION STAGE ISOLATION STAGE CURR ENT SENSE 5 POSITIVE INPUT 16-18 POSITIVE OUTPUT T1 T1 6 T2 T2 NEGATIVE INPUT ISOLATION BARRIER 13-15 GATE DR IVERS UVLO OVSD 3 ON/OFF + CURR ENT LIMIT GATE CONTROL 7 VAUX 10 OPTO-ISOLATION PRIMARY CONTROL 4 NEGATIVE OUTPUT TRIM SECOND ARY CONTROL ON /OFF - 11 + SENSE 12 1 − SENSE SyncIn (Full Feature Option) 8 DATA COUPLING 2 Start Sync (Full Feature Option) SyncOut (Full Feature Option) 9 I Share (Full Feature Option) TYPICAL CONNECTION DIAGRAM Vin(+) Vin External Input Filter Electrolytic Capacitor Vout(+) Vsense(+) ON/OFF Trim Vsense(_) Vin(_) Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Rtrim-up or Rtrim-down Cload Iload Vout(_) Doc.# 005-0006051 Rev. D 08/06/2014 Page 2 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification MCOTS-C-270-05-FT ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 270dc unless otherwise noted; full operating temperature range is -55 °C to +100 °C baseplate 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 Input to Base-Plate Output to Base-Plate Operating Temperature Storage Temperature Voltage at ON/OFF input pin INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Turn-On Threshold Input Under-Voltage Turn-Off Threshold Input Over-Voltage Turn-Off Threshold Input Over-Voltage Turn-On Threshold Recommended External Input Capacitance Input Filter Component Values (L\C) Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Terminal Ripple Current Recommended Input Fuse 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 Operating Output Current Range (Start up) Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection Auxiliary power Typ. Max. Units Notes & Conditions 600 425 475 V V V Continuous Continuous 1 s transient, square wave 4250 2300 2300 +100 +135 18 V dc V dc V dc °C °C V 425 154 145 503 460 7 V V V V V µF µF\µH\µF A mA mA V mA A 5.0 5.05 V ±0.1 ±0.1 ±0.3 ±0.3 75 5.125 % % mV V 400 80 80 80 112 20,000 mV mV A A A V A mA µF 10 10 6.9 10.0 mV µs % % V V -0.5 -55 -65 -2 155 146 135 496 446 270 150 140 500 453 7 0.272/56/1.2 30 10 0.2 316 4.95 -75 4.8 200 40 0 0.8 88 100 2.6 0.3 4 3.9 60 20 200 150 -20 5.6 7.0 6.3 8 Baseplate temperature 475V transient for 1 s Typical ESR 1Ω see Note 3 Internal values; see Figure E Vin min; trim up; in current limit See Figure 12 RMS,Full load Fast acting external fuse recommended Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 1 Full load Full load Subject to thermal derating See application notes Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 13&18; Figure C; see Note 2 Across Pins 13&18 Over full temp range Maximum current of 50mA, Referenced to Vout(–) Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 2: Trim-up range is limited below 10% at low line and full load.Applying more than 6.2V between trim pin and Vout(-) may damage the unit. Note 3: An input capacitor with series resistance is necessary to provide system stability. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 3 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification MCOTS-C-270-05-FT ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 270dc unless otherwise noted; full operating temperature range is -55 °C to +100 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. DYNAMIC CHARACTERISTICS Turn-On Transient Turn-On Time 90 Start-Up Inhibit Time 360 400 440 Output Voltage Overshoot 0 ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) 4250 Isolation Resistance 100 Isolation Capacitance (input to output) N/A TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature 125 Board Temperature 125 Transformer Temperature 125 Maximum Baseplate Temperature, Tb 100 FEATURE CHARACTERISTICS Switching Frequency 350 375 400 ON/OFF Control Off-State Voltage 2.4 18 On-State Voltage -1 0.8 ON/OFF Control Input Resistance 3 Over-Temperature Shutdown OTP Trip Point 125 Over-Temperature Shutdown Restart Hysteresis 10 EFFICIENCY 100% Load 88 50% Load 90 FULL FEATURE OPTION Clock Sync 350 375 400 Current Share 2.2 RELIABILITY CHARACTERISTICS Calculated MTBF per MIL-HDBK-217F 1.2 Calculated MTBF per MIL-HDBK-217F 0.120 Note 1: Higher values of isolation capacitance can be added external to the module. Note 2: Do not apply a clock signal lower than specified frequency. Units ms ms % V dc MΩ pF °C °C °C °C Notes & Conditions Full load, Vout=90% nom. See Figure F Maximum Output Capacitance See Absolute Maximum Ratings See Note 1 Package rated to 150 °C UL rated max operating temp 130 °C kHz V V Application notes Figures A & B kΩ °C °C Average PCB Temperature % % kHz V 106 Hrs. 106 Hrs. See Note 2 Full load Ground Benign, 70°C Tb Ground Mobile, 70°C Tb STANDARDS COMPLIANCE Parameter Notes & Conditions STANDARDS COMPLIANCE UL 60950-1/R2011-12 Reinforced Insulation CAN/CSA C22.2 No. 60950-1/A1:2011 EN 60950-1/A12:2011 CE Marked 2006/95/EC Low Voltage Directive 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. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 4 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification 92 92 91 90 90 Efficiency (%) Efficiency (%) 89 88 86 87 86 85 84 425 Vin 84 270 Vin 83 155 Vin 5 10 15 20 25 30 35 40 45 50 Load Current (A) 55 60 65 70 75 80 Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 425 Vin 270 Vin 155 Vin 82 -55ºC 82 25ºC 100ºC Case Temperature (ºC) Figure 2: Efficiency at nominal output voltage and 60% rated power vs. case temperature for minimum, nominal, and maximum input voltage. 60 40 35 Power Dissipation (W) 50 Power Dissipation (W) 88 40 30 20 425 Vin 10 30 25 20 15 10 425 Vin 270 Vin 5 270 Vin 155 Vin 155 Vin 0 -55ºC 0 0 10 20 30 40 50 Load Current (A) 60 70 80 Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at TCASE=25°C. 25ºC 100ºC Case Temperature (ºC) Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. case temperature for minimum, nominal, and maximum input voltage. 90 6.0 80 5.0 70 Output Voltage (V) Iout (A) 60 50 40 30 4.0 3.0 2.0 425 Vin 20 270Vin 1.0 10 155 Vin 0 70 80 90 100 110 0.0 0 Base Plate Temperature (°C) Figure 5: Maximum output current vs. base plate temperature (nominal input voltage). Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 20 40 60 Load Current (A) 80 100 Figure 6: Output voltage vs. load current showing typical current limit curves. See Current Limit section in the Application Notes. www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 5 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Figure 7: Startup waveform with 1% load. Input voltage pre-applied, Ch 1 : Vout, Ch2 : ON/OFF Pin . Figure 8: Turn-on transient at full resistive load and zero output capacitance initiated by Vin. ON/OFF Pin previously low. Ch 1: Vout (2V/div). Ch 2: Vin (100V/div). Figure 9: Input terminal current ripple, iC, at full rated output current and nominal input voltage (200 mA/div). Bandwidth: 25MHz. See Figure 17. Figure 10: Output voltage ripple, Vout, at nominal input voltage and rated load current (100 mV/div). Load capacitance: 1μF ceramic capacitor and 10μF tantalum capacitor. Bandwidth: 25 MHz. See Figure 17. Figure 11: Output voltage response to step-change in load current (50%-75%50% of Iout(max); dI/dt = 0.1 A/μs). Load cap: 1 μF ceramic and 15 μF tantalum capacitors. Ch 1: Vout (1V/div), Ch 2: Iout (20A/div). Figure 12: Output voltage response to step-change in input voltage (250V/ms). Load cap: 100 μF electrolytic output capacitance. Ch 1: Vin (100V/div), Ch 2: Vout (1V/div). Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 6 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification -20 0.1 Forward Transmission (dB) Output Impedance (ohms) -30 0.01 0.001 270Vin 425Vin 0.0001 100 1,000 10,000 -50 -60 -70 -80 425Vin 155Vin -100 100,000 10 Hz 100 1,000 10,000 100,000 Hz Figure 13: Magnitude of incremental output impedance (Zout = vout/iout) for minimum, nominal, and maximum input voltage at full rated power. Figure 14: Magnitude of incremental forward transmission (FT = vout/vin) for minimum, nominal, and maximum input voltage at full rated power. 1000 Input Impedance (Ohms) -10 Reverse Transmission (dB) 270Vin -90 155Vin 10 -40 -20 -30 -40 270Vin 100 10 270Vin 425Vin 425Vin 155Vin 155Vin 1 -50 10 100 1,000 10,000 Hz 10 100,000 1,000 10,000 100,000 Hz Figure 15: Magnitude of incremental reverse transmission (RT = iin/iout) for minimum, nominal, and maximum input voltage at full rated power. Figure 16: Magnitude of incremental input impedance (Zin = vin/iin) for minimum, nominal, and maximum input voltage at full rated power. 1 µF ceramic capacitor 4.7 µH source impedance i VSOURCE 100 C 100 µF, 0.2Ω ESR electrolytic capacitor DC/DC Converter VOUT 10 µF, 100mΩ ESR tantalum capacitor Figure 17: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 9) and Output Voltage Ripple (Figure 10). Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 Figure 18: Load current (50A/div) as a function of time (5ms/div and 100ms/div) when the converter attempts to turn on into a 10 mΩ short circuit. www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 7 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification CONTROL FEATURES BASIC OPERATION AND FEATURES This Mil-COTS converter series uses a two-stage power conversion topology. The first stage is a buck-converter that 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-up or step-down to achieve the output voltage required. Both the first stage and the second stage switch at a fixed frequency for predictable EMI performance.The switching frequency of second stage is half of the swithcing frequency of first stage and locked in phase. Rectification of the transformer’s output is accomplished with synchronous rectifiers. These devices, which are MOSFETs with a very low on-state resistance, dissipate far less energy than Schottky diodes. This is the primary reason that the converter has such high efficiency, even at very low output voltages and very high output currents. These converters are offered totally encased to withstand harsh environments and thermally demanding applications. Dissipation throughout the converter is so low that it does not require a heatsink for operation in many applications; however, adding a heatsink provides improved thermal derating performance in extreme situations. This series of converters uses the industry standard footprint and pin-out configuration. On when switch is open 5V VIN (+) +ON/OFF -ON/OFF 5V Pins 11 and 12 must be connected for proper regulation of the output voltage. If these connections are not made, the converter will deliver an output voltage that is slightly higher than its set value. The voltage at the output terminals of the module will be trimmed up by the control circuit to compensate for voltage drops between the output pins of the module and the remote sense point. Note that the over-voltage protection (OVP) circuit senses the voltage at the output pins of the module. It is possible to inadvertently trip the OVP protection circuit if the voltage drop between the output pins and the sense point becomes too large. Hence, the remote sensing feature should be used only to compensate for small values of voltage drops to avoid triggering OVP due to a line or load transient. VOUT (+) SENSE (+) Opto U1 SENSE (-) 3.01k V OUT (-) VIN (-) On when switch is closed ON/OFF(+) and ON/OFF(-) (Pin 3 and 4) - Remote ON/OFF: The ON/OFF inputs, Pins 3 and 4, permit the user to turn the converter on or off. These two inputs are fully isolated from both the input and the output side of the power converter, allowing the user the option to manage the converter from the input or the output end. The user’s on/off control signal is applied between the ON/OFF(+) pin and the ON/OFF(-) pins. Figure A details two possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry. REMOTE SENSE(+) and SENSE(-) (Pins 11 and 12): The SENSE inputs correct for voltage drops along the conductors that connect the converter’s output pins to the load.Pin 11 should be connected to Vout(+) and Pin 12 should be connected to Vout(-) at the point on the board where regulation is desired. A remote connection at the load can adjust for a voltage drop only as large as that specified in this datasheet, that is [Vout(+) - Vout(-)] – [Vsense(+) - Vsense(-)] ≤ Sense Range % x Vout Pin 3 R1 C1 D1 100p VIN (+) +ON/OFF VOUT (+) SENSE (+) -ON/OFF SENSE (-) Pin 4 Figure B: Internal ON/OFF pin circuitry V OUT (-) VIN (-) Figure A: Example of two configurations for the enable signal Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 8 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification To decrease the output voltage, the user should connect a resistor between Pin 10 (TRIM) and Pin 12 [SENSE(-)]. For a desired decrease of the nominal output voltage, the value of the resistor should be: Rtrim-down = ( 90.9 Δ% ) 10,000 Trim Resistance (kOhms) OUTPUT VOLTAGE TRIM (Pin 10): The TRIM input permits the user to adjust the output voltage across the sense leads up or down according to the trim range specifications. 1,000 100 10 - 0.909 (kΩ) where 1 0 Δ% = | Vnominal – Vdesired Vnominal ( 1.0VOUT x (100+Δ%) 1.225Δ% - | x 100% 90.9 Δ% - 0.909 4 6 8 10 % increase Vout 12 14 16 18 20 % decrease Vout Figure C: Trim graph for trim-up, trim down. To increase the output voltage, the user should connect a resistor between Pin 10 (TRIM) and Pin 11 [SENSE(+)]. For a desired increase of the nominal output voltage, the value of the resistor should be: Rtrim-up = 2 ) (kΩ) where Vout = Nominal Output Voltage It is not necessary for the user to add capacitance at the Trim pin. The node is internally bypassed to eliminate noise. 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.Note if the unit is started at no load the output voltage may, under some conditions, regulate above its rated value. This condition will be corrected once the load is increased above 1%, and it will stay corrected even if the load is lowered to zero. The trim graphs show the relationship between the trim resistor value and the percentage decrease or increase of the output voltage relative to thenominal output voltage set point. The graphs also show the total range the output voltage can be trimmed up or down. 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 overvoltage protection circuit to engage, particularly during transients. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 9 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Protection Features Input Under-Voltage Lockout: The converter is designed to turn off when the input voltage is too low, helping avoid an input system instability problem, described in more detail in the application note titled “Input System Instability” available on www.SynQor.com . 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 (listed on the specification page) 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 Over-Voltage Limit: If the voltage across the output pins exceeds the Output Over-Voltage Protection threshold, the converter will immediately stop switching. This prevents damage to the load circuit due to 1) excessive series resistance in output current path from converter output pins to sense point, 2) a release of a short-circuit condition, or 3) a release of a current limit condition. Load capacitance determines exactly how high the output voltage will rise in response to these conditions. After 400 ms the converter will automatically restart. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 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 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. Output Current Limit: The output current remains constant as the output voltage drops. However, once the impedance of the load across the output is small enough to make the output voltage drop below the specified Output DC Current-Limit Shutdown Voltage, the converter turns off. The converter then enters a “auto-restart” mode where it repeatedly turns on and off at a 2.5 Hz (nominal) frequency until the overload condition is removed. This prevents excessive heating of the converter or the load board. www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 10 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification APPLICATION CONSIDERATIONS 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. Application Circuits: Figure D provides a typical circuit diagram which details the input filtering and voltage trimming. Electrolytic Capacitor Vin Vout(+) Vin(+) Vsense(+) ON/OFF (+) External Input Filter Trim ON/OFF (-) Rtrim-up or Rtrim-down Vsense(_) Vin(_) Cload Iload Vout(_) Figure D: Typical application circuit (negative logic unit, permanently enabled). Input Filtering and External Capacitance: Figure E provides a diagram showing the internal input filter components. This filter dramatically reduces input terminal ripple current, which otherwise could exceed the rating of the converter's external electrolytic input capacitor. The recommended external input capacitance is specified in the Input Characteristics section on the Electrical Characteristics page. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. L Vin(+) C2 C1 Vin(_) Figure E: Internal Input Filter Diagram (Component values listed on page 3) Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 11 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Startup Inhibit Period: The Startup Inhibit Period ensures that the converter will remain off for approximately 400 ms when it is shut down for any reason. For example, when an output short is present the module will shutdown, remain off for the startup inhibit period, and then attempt to restart. This results in a 2.5Hz auto restart mode of operation which prevents the converter from overheating. In all, there are seven ways that the converter can be shut down, initiating a Startup Inhibit Period: • Input Under-Voltage Lockout • Input Over-Voltage Lockout • Output Over-Voltage Protection • Over Temperature Shutdown • Current Limit • Short Circuit Protection • Turned off by the ON/OFF input Figure F shows three turn-on scenarios, where a Startup Inhibit Period is initiated at t0, t1, and t2: Before time t0, when the input voltage is below the UVL threshold, the unit is disabled by the Input Under-Voltage Lockout feature. When the input voltage rises above the UVL threshold, the Input Under-Voltage lockout is released, and a Startup Inhibit Period is initiated. At the end of this delay, the ON/OFF pin is evaluated, and since it is active, the unit turns on. When the ON/OFF pin goes high after t2, the Startup Inhibit Period has elapsed, and the output turns on within the typical Turn-On Time. Thermal Considerations: The maximum operating baseplate temperature, TB, is 100 ºC. Refer to the thermal derating curve figure to see the available output current at baseplate temperatures below 100 ºC. A power derating curve can be calculated for any heatsink that is attached to the base-plate of the converter. It is only necessary to determine the thermal resistance, RTHBA, of the chosen heatsink between the base-plate and the ambient air for a given airflow rate. This information is usually available from the heatsink vendor. The following formula can then be used to determine the maximum power the converter can dissipate for a given thermal condition: max Pdiss TB - TA RTHBA = This value of power dissipation can then be used in conjunction with the data shown in Figure 3 to determine the maximum load current (and power) that the converter can deliver in the given thermal condition. At time t1, the unit is disabled by the ON/OFF pin, and it cannot be enabled again until the Startup Inhibit Period has elapsed. Vin Under-Voltage Lockout Turn-On Threshold ON/OFF (Negative logic) ON OFF OFF ON ON 90ms (typical turn on time) Vout 140ms 400ms (initial start-up inhibit period) (typical start-up inhibit period) t0 t1 400ms t t2 Figure F: Startup Inhibit Period (turn-on time not to scale) Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 12 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Full-Featured Application Notes This section provides some basic application information for the full-feature version of the MCOTS series converter. All units in this product family include back-drive protection to simplify the use of multiple converters in a parallel or sequencing application. However, any voltage applied to the output of the converter should be kept below the rated output voltage of the converter. In addition to back-drive protection, these units include the following features (pins): I Share (pin 9)-Active Current Share: Some applications benefit from connecting the outputs of multiple converters in parallel. Typical applications include systems that require power levels higher than the rated power of one converter, or systems that require N+1(less than 30) redundancy for increased reliability and availability. The active current share feature of this converter is a secondary side referenced circuit that ensures that modules configured to operate in parallel will share load current to a significant degree (±5% typical at full rated current). This feature is implemented by directly connecting the I share pins and the Start Sync pins of multiple units together. Note also that it is important to connect the SENSE(+) and SENSE(-) pins of each of the parallel modules in the same physical location to ensure the most accurate level of current sharing. The voltage at the I Share pin will range from approximately 1volt (at no load) to 2.2 volts (at full rated current), referenced to the secondary-side ground, VSENSE(-). For best performance in current shared mode,the following connections must be implemented: • I share pins of multiple units must be connected together. • Start Sync pins of multiple units must be connected together (see details below) • SENSE(+) and SENSE(-) pins of each module must be tied together at the same physical location, preferably at the end of power out cable or trace. Start Sync (pin 8) - Start Synchronization:The Start Synchronization feature is a secondary side referenced circuit that will allow a more consistent start-up sequence when the output of multiple modules are connected in parallel. To operate this feature, connect together the StartSync pins of multiple current-sharing units. This will permit immediate start-up with loads greater than the current limit of a single unit. Without this connection, any set of converters attempting to asynchronously start (or re-start) with a load greater than the current limit of a single unit will go into an auto-restart mode of operation that will continue until one converter attempts a start at the same time as the minimum number of additional units necessary to sustain the load condition. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 For example, three 50 amp units starting into a 90 amp load would require two units to simultaneously attempt a start. The Start Sync connection synchronizes these starting attempts and provides a more consistent and reliable startup sequence. For details about the auto-restart mode or repeated startup attempts, please see the “Startup Inhibit Period” note in the Technical Specification. SyncIn (pin 1) – External Clock Synchronization: The Clock Synchronization is a primary side referenced feature which allows the user to control the EMI signature and synchronize sensitive circuitry to quiet periods in the converter operation. With this option, the converter can be synchronized to an external clock signal whose frequency is within the limits specified in the Electrical Characteristics Table. Note that increasing the converter’s frequency will tend to reduce efficiency. The Clock Synchronization feature allows the user the following choices: • Change the switching frequency of the converter from the factory pre-set value to any other value in the specified range. • Synchronize the switching of all converters in a current shared mode to a common external frequency. • Synchronize the switching frequency of each module to an external frequency. • Improve susceptibility of an adjacent sensitive circuit by moving the converter frequency away from its most sensitive frequency.All the above are also effective means of designing and managing EMI filtering to comply with the specified EMC standards. • All synchronization signals (including an external clock) should be referenced to the negative terminal of input voltage, Vin(-). • The high level of the signal should be between 3.5V and 5.0V. • The low level should be between -0.5V and +1.2V. • The duty cycle of a signal applied to the SyncIn pin should be between 20% and 80%. SyncOut (pin2) Synchronization Output: The Synchronization Output is a primary side referenced feature which provides the ability for a user to access a waveform switching synchronously with the pulse width modulator (pwm) clock of the module. The SyncOut signal of one module can be used as the input to multiple other modules. www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 13 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Mechanical Diagram M3 STANDOFF x4 SEE NOTE 8 OVERALL HEIGHT 0.512 +0.002 -0.05 [13.00 +0.05 -0.12] 2.486±0.020 [ 63.14±0.50 ] 2.00 [50.8] 0.151 [3.83] 12 11 10 9 8 7 0.010 [0.25] 3.900 [99.06] 4.20 [106.7] 13 14 15 16 17 18 5 4 3 2 1 1.800 1.450 1.200 0.950 0.550 0.300 0.050 [45.72] [36.83] [30.48] [24.13] [13.97] [7.62] [1.27] 0.150 0.300 0.450 0.850 1.250 [3.81] [7.62] [11.43] [21.59] [31.75] 3.750 [95.25] 4.686±0.020 [ 119.02±0.50 ] 4.20 [106.7] 3.600 [91.44] 3.450 [87.63] 3.300 [83.82] 3.150 [80.01] 6 1 0.250±0.020 [ 6.35±0.50 ] 0.493±0.020 [ 12.52±0.50 ] 0.243±0.020 [ 6.17±0.50 ] NOTES 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) PIN DESIGNATIONS Name Function Pins 1-4, 7-12 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm) Pin 1 SyncIn Synchronization Input (full feature only) diameter standoff shoulders. 2 SyncOut Synchronization Output (full feature only) Pins 5-6, 13-18 are 0.080” (2.03 mm) diameter with 0.125” 3 ON/OFF(+) Turn converter on and off, referenced to – ON/OFF (3.18mm) diameter standoff shoulders. 4 ON/OFF(–) Fully isolated ground All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate 5 Vin(+) Positive input voltage Undimensioned components are shown for visual reference only. 6 Vin(–) Negative input voltage Applied torque per screw should not exceed 6in-lb (0.7Nm). 7 Vaux Auxiliary power, referenced to Vout(–) Baseplate flatness tolerance is 0.010” (0.25mm) TIR for surface. 8 Start Sync Startup synchronization (full feature only) Weight: 9.9oz (280g) typical 9 I Share Single wire parallel signal (full feature only) Threaded or non-threaded options available. 10 TRIM Output voltage trim (see note 1) Workmanship: Meets or exceeds IPC-A-610 Class II 11 SENSE(+) Positive remote sense (see note 2) All dimensions in inches (mm) 12 SENSE(–) Negative remote sense (see note 3) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) 13 Vout(–) Negative output voltage x.xxx +/-0.010 in. (x.xx +/-0.25mm) 14 Vout(–) Negative output voltage 15 Vout(–) Negative output voltage 16 Vout(+) Positive output voltage 17 Vout(+) Positive output voltage 18 Vout(+) Positive output voltage Pin Designations Notes: 1 Leave TRIM pin open for nominal output voltage. 2 SENSE(+) should be connected to Vout(+) remotely or at converter. 3 SENSE(–) should be connected to Vout(–) remotely or at converter. 4 Pins 1, 2, 8, and 9 are populated on full feature versions only. Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 14 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Flanged Mechanical Diagram 1.450[36.830] 1.200[30.480] OVERALL HEIGHT 0.495±0.015 [ 12.57±0.38 ] 3.150±0.020 [ 80.01 ±0.50] 2.950±0.020 [ 74.93 ±0.50] 0.950[24.130] 0.550[13.970] 0.010 [0.25] 2.486±0.020 [ 63.14 ±0.50] 0.300[7.620] 0.168 [4.27] 0.050[1.270] USE 4-40 OR M3 SCREW (6x) 12 11 RECOM TORQUE 3in-lb 4.686 ± 0.020 [ 119.02 ±0.50 ] Ø.13[3.3] 13 14 15 17 16 18 10 9 8 7 4.17 [105.8] 3.900 [99.06] 3.750 [95.25] 3.00 [76.2] 3.600 [91.44] 4.200 [106.68] 3.450 [87.63] 3.300 [83.82] 1.50 [38.1] 0.60 [15.24] 3.150 [80.01] 6 1 5 4 3 2 1 0.017±0.020 [ 0.43±0.50 ] 0.243±0.020 [ 6.17±0.50 ] 0.493 ±0.020 [ 12.52 ±0.50 ] 0.125 [3.18] 0.150 [3.81] 0.725 ±0.020 [ 18.42 ±0.50 ] 0.300 [7.62] 0.825 ±0.020 [ 20.96 ±0.50 ] 0.450 [11.43] 0.850 [21.59] 1.250 [31.75] NOTES PIN DESIGNATIONS 1) Applied torque per screw should not exceed 5in-lb (0.7Nm), 3in-lb (0.4Nm) recommended. 2) Pins 1-4, 7-12 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm) diameter standoff shoulders. 3) Pins 5-6, 13-18 are 0.080” (2.03 mm) diameter with 0.125” (3.18mm) diameter standoff shoulders. 4) All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate 5) Undimensioned components are shown for visual reference only. 6) Baseplate flatness tolerance is 0.010” (.25mm) TIR for surface. 7) Weight: 10.3oz (293g) typical 8) Workmanship: Meets or exceeds IPC-A-610 Class II 9) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 Pin Name 1 2 SyncIn SyncOut 3 ON/OFF(+) Function Synchronization Input (full feature only) Synchronization Output (full feature only) Turn converter on and off, referenced to – ON/OFF 4 ON/OFF(–) Fully isolated ground 5 Vin(+) Positive input voltage 6 Vin(–) Negative input voltage 7 Vaux Auxiliary power, referenced to Vout(–) 8 Start Sync Startup synchronization (full feature only) 9 I Share Single wire parallel signal (full feature only) 10 TRIM Output voltage trim (see note 1) 11 SENSE(+) Positive remote sense (see note 2) 12 SENSE(–) Negative remote sense (see note 3) 13 Vout(–) Negative output voltage 14 Vout(–) Negative output voltage 15 Vout(–) Negative output voltage 16 Vout(+) Positive output voltage 17 Vout(+) Positive output voltage 18 Vout(+) Positive output voltage Pin Designations Notes: 1 Leave TRIM pin open for nominal output voltage. 2 SENSE(+) should be connected to Vout(+) remotely or at converter. 3 SENSE(–) should be connected to Vout(–) remotely or at converter. 4 Pins 1, 2, 8, and 9 are populated on full feature versions only. www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 15 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Mil-COTS Qualification Test Name # Tested (# Failed) Visual, mechanical and electrical testing before, during and 15 after 1000 hour burn-in @ full load (0) Visual, mechanical and electrical testing before, during and 5 after shock and vibration tests (0) 8 +85˚C, 95% RH, 1000 hours, 2 minutes on / 6 hours off (0) 500 cycles of -55˚C to +100˚C 10 (30 minute dwell at each temperature) (0) 15 15 pins (0) -65˚C to +110˚C across full line and load specifications in 7 5˚C steps (0) 2 70,000 feet (21 km), see Note (0) Details Life Testing Shock-Vibration Humidity Temperature Cycling Solderability DMT Altitude Consistent with MILSTD-883F Method Consistent with MILSTD-883F Method 5005 Method 1005.8 MIL-STD-202, Methods 201A & 213B Method 1004.7 Method 1010.8 Condition A Method 2003 Note: A conductive cooling design is generally needed for high altitude applications because of naturally poor convective cooling at rare atmospheres. Mil-COTS DC-DC Converter and Filter Screening Screening Process Description S-Grade M-Grade Baseplate Operating Temperature -55˚C to +100˚C -55˚C to +100˚C Storage Temperature -65˚C to +135˚C -65˚C to +135˚C ● ● Pre-Cap Inspection IPC-610, Class III Temperature Cycling Method 1010, Condition B, 10 Cycles Burn-In 100˚C Baseplate 12 Hours 96 Hours 100% 25˚C -55˚C, +25˚C, +100˚C MIL-STD-2008 ● ● Final Electrical Test Final Visual Inspection ● Mil-COTS MIL-STD-810G Qualification Testing MIL-STD-810G Test Fungus Method 508.6 Description Table 508.6-I 500.5 - Procedure I Storage: 70,000ft. / 2 Hr. duration 500.5 - Procedure II Operating; 70,000ft. / 2 Hr. duration; Ambient Temperature Rapid Decompression 500.5 - Procedure III Storage: 8,000ft. to 40,000ft. Acceleration 513.6 - Procedure II Operating - 15g's Salt Fog 509.5 Storage 501.5 - Procedure I Storage: 135°C / 3 hrs 501.5 - Procedure II Operating: 100°C / 3 hrs 502.5 - Procedure I Storage: -65C / 4 hrs 502.5 - Procedure II Operating: -55C / 3 hrs Temperature Shock 503.5 - Procedure I - C Storage: -65C to 135C; 12 cycles Rain 506.5 - Procedure I Wind Blown Rain Immersion 512.5 - Procedure I Non-Operating Humidity 507.5 - Procedure II Aggravated cycle @ 95% RH (Figure 507.5-7 aggravated temp - humidity cycle, 15 cycles) Random Vibration 514.6 - Procedure I 10-2000 Hz, PSD level of 1.5 g2/Hz(54.6grms), duration = 1 hr/axis 516.6 - Procedure I 20g's peak, 11ms, Functional Shock (Operating no load) (saw tooth) 516.6 - Procedure VI 514.6 - Category 14 510.5 - Procedure I Bench Handling Shock Rotary wing aircraft - helicopter, 4hrs/axis, 20g's (sine sweep from 10 - 500HZ) Blowing Dust 510.5 - Procedure II Blowing Sand Altitude High Temperature Low Temperature Shock Sinusoidal vibration Sand and Dust Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006051 Rev. D 08/06/2014 Page 16 MCOTS-C-270-05-FT Output: 5V Current: 80A Technical Specification Ordering Information/ Part Numbering Example MCOTS-C-270-05-FT-N-S Not all combinations make valid part numbers, please contact SynQor for availability. See the website for details. Family MCOTS Product Input Voltage C: Converter 270: 155-425V Output Voltage 05: 12: 15: 24: 28: 48: Heatsink Option Package Screening Level N: Normal Threaded 5V 12V 15V 24V 28V 48V FT: Full Brick Tera [ ]: Standard Feature S: S-Grade F: Flanged Options M: M-Grade F: Full Feature D: Normal NonThreaded APPLICATION NOTES PATENTS A variety of application notes and technical white papers can be downloaded in pdf format from our website. 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: 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 USA Product # MCOTS-C-270-05-FT Phone 1-888-567-9596 5,999,417 6,222,742 6,545,890 6,577,109 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 two (2) 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.# 005-0006051 Rev. D 08/06/2014 Page 17