80A/400W

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.
®
F
MNTF
5A
-0
80
@
70
-2RTER5V OUT
C
S- VE ) IN
OT CON 75V
MCC-DC425(4
D
5-
15
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
•
•
•
•
•
•
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
MCOTS series converters (with an MCOTS filter) are
designed to meet:
• MIL-HDBK-704 (A-F)
• MIL-STD-461 (C, D, E, F)
Phone 1-888-567-9596
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)
Product # MCOTS-C-270-05-FT
• 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 certified facility
Qualified to MIL-STD-810
Available with S-Grade or M-Grade screening
Pre-cap inspection per IPC-A-610, Class III
Temperature cycling per MIL-STD-883, Method 1010,
Condition B, 10 cycles
• Burn-In at 100 °C baseplate temperature
• Final visual inspection per MIL-STD-883, Method 2009
• Full component traceability
www.synqor.com
Doc.# 005-0006051 Rev. E
06/09/2016
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
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Rtrim-up
or
Rtrim-down
Cload
Iload
Vout(_)
Doc.# 005-0006051 Rev. E
06/09/2016
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 (C\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\5.5\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. E
06/09/2016
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 60950-1:2007/A2:2014
Reinforced Insulation
CAN/CSA C22.2 No. 60950-1:2007/A2:2014
EN 60950-1:2006/A2:2013
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. E
06/09/2016
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
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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. E
06/09/2016
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
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Doc.# 005-0006051 Rev. E
06/09/2016
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
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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. E
06/09/2016
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
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www.synqor.com
Doc.# 005-0006051 Rev. E
06/09/2016
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. E
06/09/2016
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
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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. E
06/09/2016
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
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Doc.# 005-0006051 Rev. E
06/09/2016
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
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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
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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.
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Doc.# 005-0006051 Rev. E
06/09/2016
Page 13
MCOTS-C-270-05-FT
Output: 5V
Current: 80A
Technical Specification
Mechanical Diagram
M3 STANDOFF
x4
SEE NOTE 8
OVERALL HEIGHT
+0.002
0.512
-0.005
+0.05
13.00
-0.12
2.486 0.020 [ 63.14 0.50]
2.00 [50.8]
[
]
1.800
1.450
1.200
0.950
0.550
0.300
0.050
0.151
[3.84]
13 14 15
12
11
10
9
8
7
0.010 [0.25]
3.900
[99.06]
4.20
[106.7]
16 17
18
3.750
[95.25]
4.686 0.020
[ 119.02 0.50]
[45.72]
[36.83]
[30.48]
[24.13]
[13.97]
[7.62]
[1.27]
4.200
[106.68]
3.600
[91.44]
3.450
[87.63]
3.300
[83.82]
3.150
[80.01]
0.243 0.020
[ 6.17 0. 50]
6
1
4 3 2 1
BOTTOMSIDE CLEARANCE
+0.007
0.017
-0.010
+0.17
0.43
-0.25
0.250 0.020 [ 6.35 0. 50]
0.493 0.020 [ 12.52 0.50]
[
0.150
0.300
0.450
0.850
1.250
]
NOTES
[3.81]
[7.62]
[11.43]
[21.59]
[31.75]
PIN DESIGNATIONS
1) Pins 1-4, 7-12 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm)
diameter standoff shoulders.
2) Pins 5-6, 13-18 are 0.080” (2.03 mm) diameter with 0.125”
(3.18mm) diameter standoff shoulders.
3) All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate
4) Undimensioned components are shown for visual reference only.
5) Applied torque per screw should not exceed 6in-lb (0.7Nm).
6) Baseplate flatness tolerance is 0.010” (0.25mm) TIR for surface.
7) Weight: 9.9oz (280g) typical
8) Threaded or non-threaded options available.
9) Workmanship: Meets or exceeds IPC-A-610 Class II
10) All dimensions in inches (mm)
Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
Product # MCOTS-C-270-05-FT
5
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Pin
Name
Function
1
SyncIn
Synchronization Input (full feature only)
2
SyncOut
Synchronization Output (full feature only)
3
ON/OFF(+)
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.
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Doc.# 005-0006051 Rev. E
06/09/2016
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]
0.010 [0.25]
2.486±0.020 [ 63.14 ±0.50]
0.950[24.130]
0.550[13.970]
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 M3 or 4-40 screw should not exceed 6in-lb
Pin
Name
Function
(0.7Nm).
1
SyncIn
Synchronization Input (full feature only)
2) Pins 1-4, 7-12 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm)
2
SyncOut
Synchronization Output (full feature only)
diameter standoff shoulders.
3
ON/OFF(+)
Turn converter on and off, referenced to – ON/OFF
3) Pins 5-6, 13-18 are 0.080” (2.03 mm) diameter with 0.125” (3.18mm)
4
ON/OFF(–)
Fully isolated ground
diameter standoff shoulders.
5
Vin(+)
Positive
input voltage
4) All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate
6
Vin(–)
Negative input voltage
5) Undimensioned components are shown for visual reference only.
7
Vaux
Auxiliary power, referenced to Vout(–)
6) Baseplate flatness tolerance is 0.010” (.25mm) TIR for surface.
8
Start Sync
Startup synchronization (full feature only)
7) Weight: 10.3oz (293g) typical
9
I Share
Single wire parallel signal (full feature only)
8) Workmanship: Meets or exceeds IPC-A-610 Class II
10
TRIM
Output voltage trim (see note 1)
9) All dimensions in inches (mm)
11
SENSE(+)
Positive remote sense (see note 2)
Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm)
12
SENSE(–)
Negative remote sense (see note 3)
x.xxx +/-0.010 in. (x.xx +/-0.25mm)
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.
Product # MCOTS-C-270-05-FT
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Doc.# 005-0006051 Rev. E
06/09/2016
Page 15
MCOTS-C-270-05-FT
Output: 5V
Current: 80A
Technical Specification
Mil-COTS Qualification
# Tested
(# Failed)
Visual, mechanical and electrical testing before, during and after 1000
15
hour burn-in @ full load
(0)
Visual, mechanical and electrical testing before, during and after shock
5
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)
7
-65 ˚C to +110 ˚C across full line and load specifications in 5 ˚C steps
(0)
2
70,000 feet (21 km), see Note
(0)
Test Name
Details
Life Testing
Shock-Vibration
Humidity
Temperature
Cycling
Solderability
DMT
Altitude
Consistent with
MIL-STD-883F Method
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 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-A-610, Class III
MIL-STD-883F, Method 1010,
Condition B, 10 Cycles
Temperature Cycling
Burn-In
100 ˚C Baseplate
12 Hours
96 Hours
100%
25 ˚C
-55 ˚C, +25 ˚C, +100 ˚C
MIL-STD-883F, Method 2009
●
●
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: 70,000 ft / 2 hr duration
500.5 - Procedure II
Operating: 70,000 ft / 2 hr duration; Ambient Temperature
Rapid Decompression
500.5 - Procedure III
Storage: 8,000 ft to 40,000 ft
Acceleration
513.6 - Procedure II
Operating: 15 g
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: -65 °C / 4 hrs
502.5 - Procedure II
Operating: -55 °C / 3 hrs
Temperature Shock
503.5 - Procedure I - C
Storage: -65 °C to 135 °C; 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 (54.6 grms), duration = 1 hr/axis
516.6 - Procedure I
20 g peak, 11 ms, 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, 4 hrs/axis, 20 g (sine sweep from 10 - 500 Hz)
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
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Doc.# 005-0006051 Rev. E
06/09/2016
Page 16
MCOTS-C-270-05-FT
Output: 5V
Current: 80A
Technical Specification
Ordering Information/ Part Numbering
Example MCOTS-C-270-05-FT-N-M-F
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
A variety of application notes and technical white papers can be downloaded in pdf format from our website.
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
PATENTS
SynQor holds numerous U.S. patents, one or more of which apply to most of its power conversion
products. Any that apply to the product(s) listed in this document are identified by markings on
the product(s) or on internal components of the product(s) in accordance with U.S. patent laws.
SynQor’s patents include the following:
5,999,417
6,222,742
6,545,890
6,594,159
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
9,143,042
Warranty
SynQor offers a two (2) year limited warranty. Complete warranty
information is listed on our website or is available upon request from
SynQor.
www.synqor.com
Doc.# 005-0006051 Rev. E
06/09/2016
Page 17