MCOTS-C-270H-28-FP Single Output Full-brick MILITARY COTS DC/DC CONVERTER 240-425V Continuous Input 240-475V Transient Input 28V Output 28.6A Output 92%@14.3A / 91% @28.6A 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. FP 28 M O U T @ D C 24 C/D OT 0- C S 42 C -C 5( ON 47 VE 27 5) RT 0 V E H R IN 28 28 V - .6 A -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 .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-270H-28-FP High efficiency, 91% at full rated load current Operating input voltage range: 240-425 V Fixed frequency switching provides predictable EMI Trim Range: -50% to +10% Protection Features • • • • • Fully Isolated On/Off control Remote sense for the output voltage Output voltage trim range of +10%, -50% 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) • • • • • • • • • 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.# 005-0006311 Rev. B 08/26/2014 Page 1 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification BLOCK DIAGRAM REGULATION STAGE ISOLATION STAGE CURRENT SENSE 5 POSITIVE INPUT 16-18 POSITIVE OUTPUT T1 T1 6 T2 T2 NEGATIVE INPUT ISOLATION BARRIER 13-15 GATE DRIVERS CURRENT LIMIT UVLO OVSD 3 4 GATE CONTROL 7 VAUX 10 ISOLATION PRIMARY CONTROL ON/OFF + NEGATIVE OUTPUT SECONDARY CONTROL ON /OFF - TRIM 11 + SENSE 12 1 − SENSE SyncOut (Full Feature Option ) 8 DATA COUPLING 2 Start Sync (Full Feature Option) SyncIn (Full Feature Option) 9 PARALLEL (Full Feature Option) TYPICAL CONNECTION DIAGRAM Vin(+) Vin External Input Filter Electrolytic Capacitor ON/OFF(+) Vsense(+) Trim ON/OFF(-) Vin(-) Product # MCOTS-C-270H-28-FP Vout(+) Phone 1-888-567-9596 www.synqor.com Vsense(-) Rtrim-up or Rtrim-down Cload Iload Vout(-) Doc.# 005-0006311 Rev. B 08/26/2014 Page 2 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification MCOTS-C-270H-28-FP ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 385Vdc 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. Units Notes & Conditions ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating -0.5 600 V Continuous Operating 425 V Continuous Operating Transient Protection 475 V 1 s transient, square wave Isolation Voltage Input to Output 4250 V dc Input to Base-Plate 2300 V dc Output to Base-Plate 2300 V dc Operating Temperature -55 +100 °C Baseplate temperature Storage Temperature -65 +135 °C Voltage at ON/OFF input pin -2 18 V INPUT CHARACTERISTICS Operating Input Voltage Range 240 385 425 V 475V transient for 1 s Input Under-Voltage Turn-On Threshold 221 229 237 V Input Under-Voltage Turn-Off Threshold 204 215 226 V Input Over-Voltage Turn-Off Threshold 490 503 516 V Input Over-Voltage Turn-On Threshold 463 470 477 V µF Recommended External Input Capacitance 7 Typical ESR 1Ω, see Note 2 Input Filter Component Values (C\L\C) 0.3/5.5/1.3 µF\µH\µF Internal values; see Figure E Maximum Input Current 3.6 A Vin min; trim up; in current limit No-Load Input Current 49 70 mA Disabled Input Current 5 13 mA Response to Input Transient 600 mV See Figure 12 Input Terminal Ripple Current 550 mA RMS Recommended Input Fuse 5 A Fast acting external fuse recommended OUTPUT CHARACTERISTICS Output Voltage Set Point 27.72 28.00 28.28 V Output Voltage Regulation Over Line ±0.1 ±0.3 % Over Load ±0.1 ±0.3 % Over Temperature -75 75 mV Total Output Voltage Range 27.3 28.7 V Over sample, line, load, temperature & life Output Voltage Ripple and Noise 20 MHz bandwidth; see Note 1 Peak-to-Peak 375 mV Full load (See Figure 10) RMS 55 mV Full load Operating Output Current Range 28.6 A Subject to thermal derating Output DC Current-Limit Inception 32 36 40 A Output voltage 10% Low Output DC Current-Limit Shutdown Voltage 11 V Back-Drive Current Limit while Enabled 1 A Negative current drawn from output Back-Drive Current Limit while Disabled 150 mA Negative current drawn from output Maximum Output Capacitance 3,000 µF Vout nominal at full load (resistive load) Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) 300 mV 50% to 75% to 50% Iout max Settling Time 600 µs To within 0.1% Vout nom Output Voltage Trim Range -50 10 % Across Pins 13&18; Figure C; see Note 3 Output Voltage Remote Sense Range 10 % Across Pins 13&18 Output Over-Voltage Protection 31.5 35 38.5 V Over full temp range Auxiliary power 5\50 V\mA Referenced to Vout(–) EFFICIENCY 100% Load 91 % 50% Load 92 % 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 Note 2: An input capacitor with series resistance is necessary to provide system stability. Note 3: Maximum Trim-up is 10%. Applying more than 6.2V between trim pin and Vout(-) may damage the unit. Product # MCOTS-C-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 3 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification MCOTS-C-270H-28-FP ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 385Vdc 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 60 Start-Up Inhibit Time 360 400 Output Voltage Overshoot 0 ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance 100 Isolation Capacitance (input to output) 500 TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature Maximum Baseplate Temperature, Tb FEATURE CHARACTERISTICS Switching Frequency 350 375 ON/OFF Control Off-State Voltage 2.4 On-State Voltage -1 ON/OFF Control Input Resistance 3 Over-Temperature Shutdown OTP Trip Point 125 Over-Temperature Shutdown Restart Hysteresis 10 FULL FEATURE OPTION Clock Sync 350 375 Current Share Pin Voltage Voltage at No Load 1 Voltage at Full Load 2.2 RELIABILITY CHARACTERISTICS Calculated MTBF per MIL-HDBK-217F 1.2 Calculated MTBF per MIL-HDBK-217F 154 Note 1: Additional input to output isolation capacitance external to the module Note 2: Do not apply a clock signal lower than specified frequency. 440 4250 Units ms ms % V dc MΩ pF 125 125 125 100 °C °C °C °C 400 kHz 18 0.8 V V Notes & Conditions Full load, Enable Transition to 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 Application notes Figures A & B 400 kΩ °C °C Average PCB Temperature kHz See Note 2 V V 106 Hrs. 103 Hrs. is recommended. Relative to VsenseRelative to VsenseGround Benign, 70°C Tb Ground Mobile, 70°C Tb STANDARDS COMPLIANCE Parameter Notes & Conditions STANDARDS COMPLIANCE UL 60950-1/R:2011-12 Reinforced Insulation CAN/CSA-C22.2 No. 60950-1/A1:2011 EN60950-1/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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 4 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 93 93 92 92 91 91 90 90 89 89 Efficiency (%) Efficiency (%) Technical Specification 88 87 86 85 240 Vin 84 385 Vin 83 425 Vin 82 5 10 15 20 25 88 87 86 85 240 Vin 84 385 Vin 83 425 Vin 82 -55ºC 30 25ºC Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 60 80 55 Power Dissipation (W) 70 Power Dissipation (W) Figure 2: Efficiency at nominal output voltage and 60% rated power vs. case temperature for minimum, nominal, and maximum input voltage. 90 60 50 40 30 20 425 Vin 50 45 40 35 30 240 Vin 385 Vin 25 385 Vin 10 0 425 Vin 240 Vin 0 5 10 15 20 25 20 -55ºC 30 25ºC 100ºC Case Temperature (ºC) Load Current (A) Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at TCASE=25°C. 35 Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. case temperature for minimum, nominal, and maximum input voltage. 30.0 30 25.0 25 20.0 Output Voltage (V) Iout (A) 100ºC Case Temperature (ºC) Load Current (A) 20 15.0 15 10.0 10 240 Vin 0 385Vin 5.0 5 425 Vin 50 60 70 80 90 100 110 0.0 Base Plate Temperature (°C) Phone 1-888-567-9596 5 10 15 20 25 30 35 40 45 Load Current (A) Figure 5: Maximum output current vs. base plate temperature (nominal input voltage). Product # MCOTS-C-270H-28-FP 0 Figure 6: Output voltage vs. load current showing typical current limit curves. See Current Limit section in the Application Notes. www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 5 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification Figure 7: Typical startup waveform with 0% load. Input voltage pre-applied. Ch 1: Vout (5V/div). Ch2: ON/OFF Pin (2V/div). Horizontal Scale: 20ms/div Figure 8: Turn-on transient at full resistive load and zero output capacitance initiated by Vin. ON/OFF Pin previously low. Ch 1: Vin (200V/div). Ch2: Vout (10V/div). Figure 9: Input terminal current ripple, iC, at full rated output current and nominal input voltage (500 mA/div). Bandwidth: 20MHz. See Figure 17. Figure 10: Output voltage ripple, Vout, at nominal input voltage and rated load current (50 mV/div). Load capacitance: 10µF tantalum capacitor. Bandwidth: 20 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 (500mV/div), Ch 2: Iout (10A/div). Figure 12: Output voltage response to step-change in input voltage (1000V/ms). Ch 1: Vin (200V/div), Ch 2: Vout (500mV/div). Product # MCOTS-C-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 6 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification 0 Forward Transmission (dB) Output Impedance (ohms) 1 0.1 0.01 0.001 385Vin -20 -40 -60 -80 385Vin -100 425Vin 425Vin 240Vin 240Vin 0.0001 10 100 1,000 10,000 -120 100,000 100 1,000 Hz Figure 13: Magnitude of incremental output impedance (Zout = vout/iout) for minimum, nominal, and maximum input voltage at full rated power. 1000 Input Impedance (Ohms) Reverse Transmission (dB) 100,000 Figure 14: Magnitude of incremental forward transmission (FT = vout/vin) for minimum, nominal, and maximum input voltage at full rated power. -10 -20 -30 -40 385Vin 100 10 385Vin 425Vin 425Vin 240Vin 240Vin -50 10,000 Hz 10 1 100 1,000 10,000 100,000 100 1,000 10,000 100,000 Hz 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 4.5 µH source impedance i VSOURCE 10 C 7 µF,ceramic capacitor in sereis with 1Ω Resistor 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-270H-28-FP Phone 1-888-567-9596 Figure 18: Load current (10A/div) as a function of time (2ms/div and 100ms/div) when the converter attempts to turn on into a 10 mΩ short circuit. www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 7 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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 Sense Range % x Vout Pins 11 and 12 must be connected regulation of the output voltage. If these are not made, the converter will deliver voltage that is slightly higher than its for proper connections an output 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(+) (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(-)] ≤ 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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 8 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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 = ( 167 Δ% 100,000 10,000 Trim Resistance (kΩ) 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. ) (kΩ) -3.04 1,000 100 10 1 where 0 Δ% = | Vnominal – Vdesired Vnominal [( (100+Δ%) Δ% )( | x 100% Vout - 1.67 1.25 ) - 1.37 ] 5 10 15 20 25 % Increase in Vout 30 35 40 45 50 % Decrease in 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 = 0 (kΩ) where 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 that a 1% load is required to ensure that the output voltage regulation and monotonic startup. Vout = Nominal Output Voltage Trim graphs show the relationship between the trim resistor value and Rtrim-up and Rtrim-down, showing 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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 9 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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-270H-28-FP 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.# 005-0006311 Rev. B 08/26/2014 Page 10 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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. Vin(+) Vin External Input Filter Electrolytic Capacitor ON/OFF(+) Vout(+) Vsense(+) Trim ON/OFF(-) Vsense(-) Vin(-) Rtrim-up or Rtrim-down Cload Iload Vout(-) Figure D: Typical application circuit 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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 11 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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. When an output short is present, this generates a 2.5 Hz “hiccup” mode, 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. 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. 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 base-plate temperature, TB, is 100 ºC. Refer to the thermal derating curve, Figure 5, 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 - T = A 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. Vin Under-Voltage Lockout Turn-On Threshold ON/OFF (Negative logic) ON OFF OFF ON ON 60ms (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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 12 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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-270H-28-FP 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.# 005-0006311 Rev. B 08/26/2014 Page 13 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 14 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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-270H-28-FP 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.# 005-0006311 Rev. B 08/26/2014 Page 15 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A 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-270H-28-FP Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006311 Rev. B 08/26/2014 Page 16 MCOTS-C-270H-28-FP Output: 28V Current: 28.6A Technical Specification Ordering Information/ Part Numbering Example MCOTS-C-270H-28-FP-N-S Not all combinations make valid part numbers, please contact SynQor for availability. See the website for details. Family MCOTS Input Voltage Product C: Converter 270H: 240-425V Output Voltage 05: 5V 28: 28V 36: 36V Heatsink Option Package FP: Full Brick Peta Screening Level N: Normal Threaded F: Flanged S: S-Grade D: Normal NonThreaded M: M-Grade Options [ ]: Standard Feature F: Full Feature 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-270H-28-FP 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.# 005-0006311 Rev. B 08/26/2014 Page 17