MCOTS-C-270-3R3-HT Single Output Half-brick MILITARY COTS DC-DC CONVERTER 155-425V Continuous Input 155-475V Transient Input 3.3V Output 60A Output 86% @ 30A / 86% @ 60A Efficiency Operation: -55°C to +100°C Mil-COTS 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 S-F -HT-N70-3R3 2 C S 60A MCOT ONVERTER V T@ C 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. V)IN 3.3 DC/DC 55-425 270V (1 OU 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 half-brick pin-out configuration • Size: 2.49” x 2.39” x 0.50” (63.1 x 60.6 x 12.6 mm) • Total weight: 4.7 oz (134 g) • Flanged baseplate version available Control Features Protection Features • • • • • Input under-voltage lockout/over-voltage shutdown Output current limit and short circuit protection Active back bias limit Output over-voltage protection Thermal shutdown Specification Compliance MCOTS series converters (with an MCOTS filter) are designed to meet: • 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) Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 High efficiency, 86% at full rated load current Operating input voltage range: 155-425 V Fixed frequency switching provides predictable EMI No minimum load requirement • • • • • • On/Off control referenced to input return 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) Screening/Qualification • • • • • 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.# 005-0006041 Rev. D 02/27/15 Page 1 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Diagrams BLOCK DIAGRAM REGULATION STAGE ISOLATION STAGE CURRENT SENSE 1 POSITIVE INPUT 8 T1 T1 3 T2 POSITIVE OUTPUT T2 NEGATIVE INPUT ISOLATION BARRIER 4 GATE DRIVERS UVLO OVSD CURRENT LIMIT 2 ON/OFF OPTO-ISOLATION PRIMARY CONTROL A NEGATIVE OUTPUT GATE CONTROL 6 TRIM SECONDARY CONTROL 7 + SENSE Clock Sync (Full Feature Option) B 5 Start Sync (Full Feature Option) − SENSE DATA COUPLING C IShare (Full Feature Option) TYPICAL CONNECTION DIAGRAM Vin(+) Vin External Input Filter Electrolytic Capacitor Vout(+) Vsense(+) ON/OFF Trim Vsense(_) Vin(_) Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Rtrim-up or Rtrim-down Cload Iload Vout(_) Doc.# 005-0006041 Rev. D 02/27/15 Page 2 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Specification MCOTS-C-270-3R3-HT ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 270dc unless otherwise noted; full operating temperature range is -55 °C to +125 °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 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 EFFICIENCY 100% Load 50% Load Typ. Max. Units Notes & Conditions 600 425 475 V V V Continuous Continuous 1 s transient, square wave 4250 2300 2300 +125 +135 18 V dc V dc V dc °C °C V 425 155 147 525 475 5 V V V V V µF µH\µF A mA mA V mA A 3.3 3.333 V ±0.1 ±0.1 ±0.3 ±0.3 20 3.383 % % mV V 240 90 60 84 25000 mV mV A A V A mA µF 10 10 4.4 mV µs % % V 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 8&4; Figure C; see Note 3 Across Pins 8&4 Over full temp range % % See Figure 1 for efficiency curve See Figure 1 for efficiency curve -1 -55 -65 -2 155 145 133 475 430 270 150 140 500 453 3.3 28/0.41 50 5 0.15 40 3.267 -20 3.217 120 45 66 75 1.6 5 3 2.0 60 10 75 350 -20 3.8 4.1 86 86 Baseplate temperature 475V transient for 1 s Typical ESR 8 Ω see Note 1 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 2 Full load Full load Subject to thermal derating Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) Note 1: An input capacitor with series resistance is necessary to provide system stability. Note 2: 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 3: 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. Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 3 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Specification MCOTS-C-270-3R3-HT ELECTRICAL CHARACTERISTICS Tb = 25 °C, Vin = 270dc unless otherwise noted; full operating temperature range is -55 °C to +125 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units DYNAMIC CHARACTERISTICS Turn-On Transient Turn-On Time 42 ms Start-Up Inhibit Time 360 400 440 ms Output Voltage Overshoot 0 % ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) 4250 V dc Isolation Resistance 10 MΩ Isolation Capacitance (input to output) N/A pF TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature 125 °C Board Temperature 125 °C Transformer Temperature 125 °C Maximum Baseplate Temperature, Tb 100 °C FEATURE CHARACTERISTICS Switching Frequency 506 550 594 kHz ON/OFF Control Off-State Voltage 2.4 18 V On-State Voltage -1 0.8 V ON/OFF Control Pull-Up Voltage 5 V Pull-Up Resistance 68.1 kΩ Over-Temperature Shutdown OTP Trip Point 125 °C Over-Temperature Shutdown Restart Hysteresis 10 °C FULL FEATURE OPTION Clock Sync 600 615 630 kHz Current Share 2 V RELIABILITY CHARACTERISTICS Calculated MTBF per MIL-HDBK-217F 4.1 106 Hrs. Calculated MTBF per MIL-HDBK-217F 0.97 106 Hrs. 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, also do not apply clock sync or 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 Isolation stage switching freq. is half this Application notes Figures A & B Average PCB Temperature See Note 2 Half load Ground Benign, 70°C Tb Ground Mobile, 70°C Tb change frequency while unit is running. 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 IEC 61000-4-2 ESD test, 8 kV - NP, 15 kV air - NP (Normal Performance) 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-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 4 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Charts 95 95 90 90 Efficiency (%) Efficiency (%) 85 80 75 85 80 75 70 155 Vin 155 Vin 270 Vin 65 270 Vin 70 425 Vin 425 Vin 65 -55ºC 60 0 10 20 30 Load Current (A) 40 50 60 Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 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. 40 30 Power Dissipation (W) Power Dissipation (W) 25 30 20 10 155 Vin 20 15 10 155 Vin 5 270 Vin 270 Vin 425 Vin 425 Vin 0 -55ºC 0 0 10 20 30 Load Current (A) 40 50 60 70 3.5 60 3.0 50 2.5 40 30 20 2.0 1.5 1.0 155 Vin Vin = 155V 10 Vin = 270V 270 Vin 0.5 425 Vin Vin = 425V 0 50 60 70 80 90 100 110 0.0 0 Base Plate Temperature (°C) Figure 5: Maximum output current vs. base plate temperature. Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 100ºC Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. case temperature for minimum, nominal, and maximum input voltage. Output Voltage (V) Iout (A) Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at TCASE =25°C. 25ºC Case Temperature (ºC) 10 20 30 40 50 Load Current (A) 60 70 80 Figure 6: Output voltage vs. load current showing typical current limit curves. See Current Limit section in the Application Notes. www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 5 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Charts Figure 7: Typical startup waveform. Input voltage pre-applied, ON/OFF Pin on Ch 1. 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). Ch 3: Vout (1V/div). Figure 9: Input terminal current ripple, iC, at full rated output current and nominal input voltage with 100µH source impedance and 47µF electrolytic capacitor (100 mA/div). Bandwidth: 20MHz. 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 15µF tantalum capacitor. Bandwidth: 10 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 (50mV/div), Ch 2: Iout (20A/div). Figure 12: Output voltage response to step-change in input voltage (155V-425V155V) with 250us rise/fall time. Load cap: 1µF ceramic and 15µF tantalum capacitors. Ch 1: Vout (500mV/div), Ch 2: Vin (100V/div). Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 6 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Technical Charts 0 0.1 Forward Transmission (dB) Output Impedance (ohms) -10 0.01 0.001 155Vin 270Vin 0.0001 100 1,000 10,000 -30 -40 -50 -60 -70 155Vin -80 270Vin -90 425Vin 10 -20 425Vin -100 100,000 10 Hz 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) 100 -20 -30 -40 155Vin -50 100 10 155Vin 270Vin 270Vin 425Vin 425Vin 1 -60 10 100 1,000 Hz 10,000 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 iC VSOURCE 100 100 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-270-3R3-HT Phone 1-888-567-9596 Figure 18: Load current (50A/div) as a function of time (10ms/div and 100ms/ div) when the converter attempts to turn on into a 10 mΩ short circuit. www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 7 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Application Section 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. 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/OFF ON/OFF CONTROL FEATURES REMOTE ON/OFF (Pin 2): The ON/OFF input, Pin 2, permits the user to control when the converter is on or off. This input is referenced to the return terminal of the input bus, Vin(-). The ON/OFF signal is active low (meaning that a low turns the converter on). Figure A details four possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry. REMOTE SENSE(+) (Pins 7 and 5): The SENSE(+) inputs correct for voltage drops along the conductors that connect the converter’s output pins to the load. Pin 7 should be connected to Vout(+) and Pin 5 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 Pins 7 and 5 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 specified value. Note: the output over-voltage protection circuit senses the voltage across the output (pins 8 and 4) to determine when it should trigger, not the voltage across the converter’s sense leads (pins 7 and 5). Therefore, the resistive drop on the board should be small enough so that output OVP does not trigger, even during load transients. 5V 68.1k Vin(_) Vin( ) _ Remote Enable Circuit ON/OFF Negative Logic (Permanently Enabled) 5V ON/OFF TTL/ CMOS 124k TTL 249k 2200pF ON/OFF Vin(-) Figure B: Internal ON/OFF pin circuitry Vin(_) Vin(_) Open Collector Enable Circuit Direct Logic Drive Figure A: Various circuits for driving the ON/OFF pin. Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 OUTPUT VOLTAGE TRIM (Pin 6): The TRIM input permits the user to adjust the output voltage across the sense leads up or down according to the trim range specifications. To decrease the output voltage, the user should connect a resistor between Pin 6 (TRIM) and Pin 5 (SENSE(-) input). For a desired decrease of the nominal output voltage, the value of the resistor should be www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 8 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Application Section Rtrim-down = ( 90.9 Δ% ) - 0.909 (kΩ) Protection Features where Δ% = | Vnominal – Vdesired Vnominal | x 100% To increase the output voltage, the user should connect a resistor between Pin 6 (TRIM) and Pin 7 (SENSE(+) input). For a desired increase of the nominal output voltage, the value of the resistor should be: ( Rtrim-up = 1.0VOUT x (100+Δ%) 1.225Δ% - 90.9 Δ% - 0.909 ) (kΩ) where 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. 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. Trim Resistance (kΩ) 10,000 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. 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 maximum current limit 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 “hiccup” mode where it repeatedly turns on and off at a 2.23 Hz (nominal) frequency with 11% duty cycle until the short circuit condition is removed. This prevents excessive heating of the converter or the load board. 1,000 100 10 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 % Increase in Vout % Decrease in Vout Figure C: Trim graph for trim-up, trim down. Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 9 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Application Section 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 Vout(+) Vsense(+) ON/OFF Trim Vsense(_) Vin(_) Rtrim-up or Rtrim-down 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(+) C Vin(_) Figure E: Internal Input Filter Diagram (Component values listed on page 3) Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 10 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Application Section 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 2.23 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: 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: 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. Pdiss max = 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. 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 42ms (typical turn on time) Vout 215ms 400ms (initial start-up inhibit period) t0 400ms (typical start-up inhibit period) t1 t t2 Figure F: Startup Inhibit Period (turn-on time not to scale) Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 11 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Application Section 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 120% of the rated output voltage of the converter. In addition to back-drive protection, these units include the following features (pins): Current Share (pin C): The active current share feature allows for N+1 and parallel applications. To achieve load sharing, directly connect the I share pins of multiple units. The load current will share equally among the multiple units (±5% at full rated current). It is important that the Vin(-) pins of the sharing units be directly connected and NOT placed outside of an EMI filter or other impedance path. The voltage at the I Share pin will range from 0 to 5 volts (at full rated current), referenced to the primary-side ground, Vin(-). Start Sync (pin B): The Start Synchronization pin will allow a more consistent start-up sequence. To operate this feature, connect together the Start-Sync 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 “hiccup”. This “hiccup” mode 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. 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 start-up sequence. For details about the “hiccup” mode or repeated startup attempts, please see the “Startup Inhibit Period” note in the Technical Specification. Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 Clock Sync (pin A): The External Clock Synchronization pin provides the ability for 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 greater than that of the free-running internal clock. However, substantially raising the converter’s frequency will reduce its efficiency. Therefore, the recommended frequency range for the external clock synchronization signal applied to this pin is listed in the Technical Specification. The following requirements should also be met: • The external clock signal should be referenced to the negative 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. • Do not apply a clock sync or change frequency while unit is running. • Do not apply a clock signal lower than the specified frequency. • For using more than 5 units in parallel Contact SynQor. www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 12 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Standard Mechanical Drawing 2.486 [63.14] 2.000 [50.80] SEATING PLANE HEIGHT 0.495±0.025 [ 12.57±0.63 ] PIN EXTENSION 0.180 [4.57] 0.700 [17.78] 7 6 5 4 8 0.004 [0.10] TOP VIEW 1.900 2.386 [48.26] [60.60] 1.900 [48.26] 0.01 [0.3] 3 1 0.30 [7.6] B A 2 1 0.400 [10.16] THREADED INSERT SEE NOTE 1 (4 PLCS) 0.600 0.800 1.000 1.400 [15.24] [20.32] [25.40] [35.56] PIN DESIGNATIONS NOTES 1) APPLIED TORQUE PER M3 SCREW 4in-lb RECOMMENDED (5in-lb LIMIT) SCREW SHOULD NOT EXCEED 0.100” (2.54mm) DEPTH BELOW THE SURFACE OF THE BASEPLATE. 2) BASEPLATE FLATNESS TOLERANCE IS 0.004” (.10mm) TIR FOR SURFACE. 3) PINS 1-3, 5-7, A, B, AND C ARE 0.040” (1.02mm) DIA. WITH 0.080” (2.03mm) DIA. STANDOFFS. 4) PINS 4 AND 8 ARE 0.080” (2.03mm) DIA. WITH 0.125” (3.18mm) DIA STANDOFFS 5) ALL PINS: MATERIAL: COPPER ALLOY FINISH: MATTE TIN OVER NICKEL PLATE 6) WEIGHT: 4.7 oz. (134 g) TYPICAL 7) ALL DIMENSIONS IN INCHES(mm) 8) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Product # MCOTS-C-270-3R3-HT C Phone 1-888-567-9596 Pin 1 2 Name Vin(+) ON/OFF A B C 3 4 5 6 7 8 CLOCK SYNC START SYNC I SHARE IN RTN OUT RTN SENSE(–) TRIM SENSE(+) Vout(+) Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Clock synchronization Startup synchronization Single wire parallel signal Input Return Output Return Negative remote sense1 Output voltage trim2 Positive remote sense3 Positive output voltage Notes: 1) SENSE(–) should be connected to Vout(–) either remotely or at the converter. 2) Leave TRIM pin open for nominal output voltage. 3) SENSE(+) should be connected to Vout(+) either remotely or at the converter. 4) Pins A, B, and C are populated on Full Feature version only. www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 13 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Flanged Mechanical Drawing 3.150 [80.01] SEATING PLANE HEIGHT 0.495±0.025 [ 12.57±0.63 ] 2.950 [74.93] 2.486 [63.14] PIN EXTENSION 0.180 [4.57] 0.700 [17.78] 4 5 7 6 8 TOP VIEW 1.300 [33.02] 0.010 [0.25] 1.866 [47.40] 0.31 [7.9] 1.900 [48.26] 2.386 [60.60] 3 1 0.775±0.020 [ 19.69±0.50 ] .130 [3.30] SEE NOTE 1 (6 PLCS) C B A 2 FLANGE THICKNESS 0.125 [3.18] 1 0.400 [10.16] 0.600 [15.24] 0.800 [20.32] 1.000 [25.40] 1.400 [35.56] PIN DESIGNATIONS NOTES 1) APPLIED TORQUE PER M3 OR 4-40 SCREW 4in-lb RECOMMENDED (5in-lb LIMIT) 2) BASEPLATE FLATNESS TOLERANCE IS 0.010” (.25mm) TIR FOR SURFACE. 3) PINS 1-3, 5-7, A, B, AND C ARE 0.040” (1.02mm) DIA. WITH 0.080” (2.03mm) DIA. STANDOFFS. 4) PINS 4 AND 8 ARE 0.080” (2.03mm) DIA. WITH 0.125” (3.18mm) DIA STANDOFFS 5) ALL PINS: MATERIAL: COPPER ALLOY FINISH: MATTE TIN OVER NICKEL PLATE 6) WEIGHT: 4.9 oz. (140 g) TYPICAL 7) ALL DIMENSIONS IN INCHES(mm) 8) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 Pin 1 2 Name Vin(+) ON/OFF A B C 3 4 5 6 7 8 CLOCK SYNC START SYNC I SHARE IN RTN OUT RTN SENSE(–) TRIM SENSE(+) Vout(+) Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Clock synchronization Startup synchronization Single wire parallel signal Input Return Output Return Negative remote sense1 Output voltage trim2 Positive remote sense3 Positive output voltage Notes: 1) SENSE(–) should be connected to Vout(–) either remotely or at the converter. 2) Leave TRIM pin open for nominal output voltage. 3) SENSE(+) should be connected to Vout(+) either remotely or at the converter. 4) Pins A, B, and C are populated on Full Feature version only. www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 14 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Qualifications & Screening Mil-COTS Qualification Test Name # Tested Consistent with MIL(# Failed) STD-883F Method Details Life Testing Shock-Vibration Visual, mechanical and electrical testing before, during and after 1000 hour burn-in @ full load Visual, mechanical and electrical testing before, during and after shock and vibration tests Humidity +85˚C, 95% RH, 1000 hours, 2 minutes on / 6 hours off Temperature Cycling 500 cycles of -55˚C to +100˚C (30 minute dwell at each temperature) Solderability 15 pins DMT -65˚C to +110˚C across full line and load specifications in 5˚C steps Altitude 70,000 feet (21 km), see Note 15 (0) 5 (0) 8 (0) 10 (0) 15 (0) 7 (0) 2 (0) Consistent with MIL-STD883F 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 Final Electrical Test Final Visual Inspection ● 100˚C Baseplate 12 Hours 96 Hours 100% 25˚C -55˚C, +25˚C, +100˚C MIL-STD-2008 ● ● Mil-COTS MIL-STD-810G Qualification Testing MIL-STD-810G Test Fungus Altitude 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 High Temperature Low Temperature Shock Sinusoidal vibration Sand and Dust Product # MCOTS-C-270-3R3-HT Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006041 Rev. D 02/27/15 Page 15 MCOTS-C-270-3R3-HT Output: 3.3V Current: 60A Ordering Information Ordering Information/ Part Numbering Example MCOTS-C-28-1R8-QT-N-S Not all combinations make valid part numbers, please contact SynQor for availability. Family MCOTS Product Input Voltage C: Converter 270: 155-425V Output Voltage 3R3: 05: 06: 12: 15: 24: 28: 48: 3.3V 5.0V 6.0V 12V 15V 24V 28V 48V Package Half Brick HT: Tera Thermal Design Screening Level N: Normal Threaded S: S-Grade F: Flanged 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-270-3R3-HT 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.# 005-0006041 Rev. D 02/27/15 Page 16