MCOTS-C-28-15-HZ Single Output Half-brick MILITARY COTS DC/DC CONVERTER 16-40V Continuous Input 16-50V Transient Input 15V Output 34A Output 95% @ 17A / 94% @ 34A Efficiency Full Power 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 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. Z-N-M-F -28-15-H MCOTS-C NVERTER O DC-DC C @ 34A 28 IN 15V OUT Safety Features • 2250V, 30 MΩ input-to-output isolation • Certified 60950-1 requirement for basic insulation (see Standards and Qualifications page) Designed and Manufactured in the USA Control Features • • • • Mechanical Features • Industry standard half-brick pin-out • Size: 2.49” x 2.39” x 0.51” (63.1 x 60.6 x 13.0 mm) • Total weight: 4.9 oz. (139 g) • Flanged baseplate version available Protection Features • • • • • Operational Features • High efficiency, 94% at full rated load current • Operating input voltage range: 16-40V • Fixed frequency switching provides predictable EMI • No minimum load requirement MCOTS series converters (with an MCOTS filter) are designed to meet: Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 Input under-voltage lockout Output current limit and short circuit protection Active back bias limit Auto-recovery output over-voltage protection Thermal shutdown Screening/Qualification Specification Compliance • 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) On/Off control referenced to input return Remote sense for the output voltage Wide output voltage trim range of +10%, -50% Optional: Active current share for parallel applications • • • • AS9100 and ISO 9001:2008 certified facility Qualified to MIL-STD-810 Available with S-Grade or M-Grade screening 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.# 005-0006073 Rev. E 08/12/2014 Page 1 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification BLOCK DIAGRAM REGULATION STAGE ISOLATION STAGE 9 CURRENT SENSE 1 Vout(+) Vin(+) 4 5 IN RTN ISOLATION BARRIER OUT RTN GATE DRIVERS CURRENT LIMIT UVLO 2 GATE CONTROL 7 OPTO-ISOLATION ON/OFF PRIMARY CONTROL 3 TRIM SECONDARY CONTROL 8 SENSE(+) Share (-) (Full Feature Option) B 6 Share (+) (Full Feature Option) SENSE(-) DATA COUPLING TYPICAL CONNECTION DIAGRAM Vin(+) Vin External Input Filter Electrolytic Capacitor Vout(+) Vsense(+) ON/OFF Trim Vsense(_) Vin(_) Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Rtrim-up or Rtrim-down Cload Iload Vout(_) Doc.# 005-0006073 Rev. E 08/12/2014 Page 2 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification MCOTS-C-28-15-HZ ELECTRICAL CHARACTERISTICS Ta = 25 °C, Vin = 28dc 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 Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Recommended External Input Capacitance Input Filter Component Values (C1\Lin\C2) 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 -1 -55 -65 -2 Product # MCOTS-C-28-15-HZ Max. Units 60 40 50 V V V 2250 2250 2250 100 135 18 Vdc Vdc Vdc °C °C V 16 28 40 V 15.1 14.2 0.5 15.4 14.5 0.9 470 47\0.34\23 15.7 14.8 1.5 50 V V V µF nF\µH\µF A mA mA V mA A 15.21 V ±0.375 15.45 %\mV %\mV V V 340 5 2.5 500 14.75 15.00 46 400 8 Notes & Conditions Continuous Continuous 100 ms transient, square wave Basic Insulation, Pollution Degree 2 Baseplate temperature 50V transient for 100 ms Typical ESR 0.1-0.2 Ω Internal values; see Figure E At low line, Full load and 10% trim up 0.25 V/us input transient; See Figure 12 RMS Fast acting external fuse recommended See Note 1 ±0.25\38 ±0.25\38 ±0.120 14.55 100 20 0 37.4 3 0 40.8 6 5 3 200 40 34 44.2 7 6 10 500 250 Step Change in Output Current (0.1 A-5 A/µs) Settling Time Output Voltage Trim Range Output Over-Voltage Protection EFFICIENCY 100% Load 50% Load Typ. -50 17.7 #N/A! Phone 1-888-567-9596 18.5 #N/A! 94 95 10 19.2 #N/A! www.synqor.com mV mV A A V A mA mF mV µs % V #N/A! % % Over sample, line, load, temperature & life 20 MHz bandwidth; See Note 2 Full Load Full Load Subject to thermal derating Output Voltage 10% Low See Note 3 Negative current drawn from output Negative current drawn from output 34 A Resistive Load 50% to 75% to 50% IOUT max, 100 µF load cap To within 1% VOUT nom Across Pins 8 & 6; Figure C Over full temp range #N/A! See Figure 1 for efficiency curve See Figure 1 for efficiency curve Doc.# 005-0006073 Rev. E 08/12/2014 Page 3 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification MCOTS-C-28-15-HZ ELECTRICAL CHARACTERISTICS Ta = 25 °C, Vin = 28dc 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 DYNAMIC CHARACTERISTICS Turn-On Transient Turn-On Time 24 35 40 ms Full load, Vout=90% nom; See Note 5 Output Voltage Overshoot 5 % No Load, 10mF load cap ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) 2250 V Isolation Resistance 30 MΩ Isolation Capacitance (input to output) 1000 pF See Note 4 TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature 125 °C Package rated to 150 °C Board Temperature 125 °C UL rated max operating temp 130 °C Transformer Temperature 125 °C Maximum Baseplate Temperature, Tb 100 °C FEATURE CHARACTERISTICS Switching Frequency 230 240 250 kHz Isolation stage switching freq. is half this ON/OFF Control Off-State Voltage 2.4 18.0 V On-State Voltage -2.0 0.8 V ON/OFF Control Pull-Up Voltage 15 18 V Pull-Up Resistance 50 kΩ Over-Temperature Shutdown OTP Trip Point 120 °C Average PCB Temperature Over-Temperature Shutdown Restart Hysteresis 10 °C RELIABILITY CHARACTERISTICS Calculated MTBF per MIL-HDBK-217F (GB) 4.1 106 Hrs. Tb = 70 °C Calculated MTBF per MIL-HDBK-217F (GM) 0.92 106 Hrs. Tb = 70 °C Field Demonstrated MTBF 106 Hrs. See our website for details Note 1: Line and load regulation is limited by duty cycle quantization and does not indicate a shift in the internal voltage reference. Note 2: For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]). Note 3: If the output voltage falls below the Output DC Current Limit Shutdown Voltage for more than 50ms, then the unit will enter into hiccup mode, with a 500ms off-time. Note 4: Higher values of isolation capacitance can be added external to the module. Note 5: Add 25ms to Full-Featured Turn-On Enable time to allow synchronization STANDARDS COMPLIANCE Parameter Notes & Conditions STANDARDS COMPLIANCE UL 60950-1/R:2011-12 CAN/CSA-C22.2 No. 60950-1/A1:2011 EN60950-1/A12:2011 Basic Insulation 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-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 4 MCOTS-C-28-15-HZ Output: 15V Current: 34A 100 100 95 95 90 90 Efficiency (%) Efficiency (%) Technical Specification 85 80 75 85 80 75 70 70 40 Vin 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 Load Current (A) 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. 60 50 50 Power Dissipation (W) 60 40 30 20 40 30 20 16 Vin 16 Vin 10 40 Vin 60 -55ºC 60 0 28 Vin 65 28 Vin 65 Power Dissipation (W) 16 Vin 16 Vin 10 28 Vin 28 Vin 40 Vin 40 Vin 0 -55ºC 0 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 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. 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. 40 18 35 30 Output Voltage (V) 15 Iout (A) 25 20 15 12 10 6 16 Vin 28 Vin 3 5 0 9 50 60 70 80 90 100 0 110 0 Base Plate Temperature (°C) Figure 5: Thermal Derating (maximum output current vs. base plate temperature) at nominal input voltage. Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 40 Vin 10 20 30 Load Current (A) 40 50 60 Figure 6: Output I-V Characteristics (output voltage vs. load current) showing typical current limit curves. See Current Limit section in the Application Notes. www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 5 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification Figure 7: Typical Startup Waveform, input voltage pre-applied, ON/OFF Pin on Ch 2. Figure 8: Turn-On Transient at full resistive load and zero output capacitance initiated by Vin. Ch 1: Vout (5V/div). Ch 2: Vin (20V/div). Figure 9: Input Terminal Current Ripple, iC, at full rated output current and nominal input voltage with 470 µF electrolytic capacitor (1 A/div). Bandwidth: 20MHz. See Figure 13. Figure 10: Output Voltage Ripple, Vout, at nominal input voltage and rated load current (100 mV/div). Load capacitance: 1µF ceramic capacitor and 100µF eletrolytic capacitor. Bandwidth: 20 MHz. See Figure 13. Figure 11: Output Voltage Response to Step-Change in Load Current (50%75%-50% of Iout(max); dI/dt = 5 A/µs). Load cap: 1 µF ceramic and 100 µF electrolytic capacitors. Ch 1: Vout (1V/div), Ch 2: Iout (10A/div). Figure 12: Output Voltage Response to Step-Change in Input Voltage (250V/ ms). Load cap: 100 µF electrolytic output capacitance. Ch 1: Vin (5V/div), Ch 2: Vin (20V/div). Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 6 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification 1 µF ceramic capacitor 3.3 µH source impedance i VSOURCE DC-DC Converter C 470 µF, 0.2Ω ESR electrolytic capacitor VOUT 100 µF, 180mΩ ESR electrolytic capacitor Figure 13: Test Set-up Diagram showing measurement points for Input Terminal Ripple Current (Figure 9) and Output Voltage Ripple (Figure 10). Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 Figure 14: Output Short Load Current (20A/div) as a function of time (20ms/ div) when the converter attempts to turn on into a 1 mΩ short circuit. www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 7 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification BASIC OPERATION AND FEATURES CONTROL FEATURES This converter series uses a two-stage power conversion topology. The first stage 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 stepdown to achieve the low output voltage required. 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(-). In the negative logic version, the ON/OFF signal is active low (meaning that a low voltage turns the converter on). Figure A details possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry. REMOTE SENSE Pins 8(+) and 6(-): The SENSE(+) and SENSE(-) inputs correct for voltage drops along the conductors that connect the converter’s output pins to the load. Pin 8 should be connected to Vout(+) and Pin 6 should be connected to Vout(-) at the point on the board where regulation is desired. 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 9 and 5) to determine when it should trigger, not the voltage across the converter’s sense leads (Pins 8 and 6). Therefore, the resistive drop on the board should be small enough so that output OVP does not trigger, even during load transients. 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 significantly less energy than Schottky diodes, enabling the converter to achieve high efficiency. 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. To further withstand harsh environments and thermally demanding applications, the converter is available totally encased. See Ordering Information page for available thermal design options. SynQor half-brick converters use the industry standard footprint and pin-out. ON/OFF ON/OFF Vin(_) Vin(_) Remote Enable Circuit OUTPUT VOLTAGE TRIM (Pin 7): The TRIM input permits the user to adjust the output voltage across the sense leads up or down according to the trim range specifications. SynQor uses industry standard trim equations. To decrease the output voltage, the user should connect a resistor between Pin 7 (TRIM) and Pin 6 (SENSE(-) input). For a desired decrease of the nominal output voltage, the value of the resistor should be: Negative Logic (Permanently Enabled) 5V ON/OFF Vin(_) Direct Logic Drive Figure A: Various Circuits for Driving the ON/OFF Pin Δ% = | Vnominal – Vdesired ) kΩ | × 100% Vnominal To increase the output voltage, the user should connect a resistor between Pin 7 (TRIM) and Pin 8 (SENSE(+) input). For a desired increase of the nominal output voltage, the value of the resistor should be: 5V Rtrim-up = 50k ON/OFF 100% –2 Δ% ON/OFF Vin(_ ) 18V(max) ( where TTL/ CMOS Open Collector Enable Circuit Rtrim-down = ( ) Vnominal – 2 × Vdesired + Vnominal 1.225 Vdesired – Vnominal kΩ 10k TTL Vin(_) Figure B: Internal ON/OFF Pin Circuitry Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 8 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification The Trim Graph in Figure C shows 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 over-voltage 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 filtered 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. 100,000.0 Trim Resistance (kOhms) 10,000.0 1,000.0 100.0 10.0 1.0 0.1 0.0 0 5 10 15 20 25 % Increase in Vout 30 35 40 % Decrease in Vout Figure C: Trim Graph 45 50 Protection Features Input Under-Voltage Lockout (UVLO): The converter is designed to turn off when the input voltage is too low, helping to avoid an input system instability problem, which is described in more detail in the application note titled “Input System Instability” on the SynQor website. 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* 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 Current Limit (OCP): If the output current exceeds the “Output DC Current Limit Inception” value*, then a fast linear current limit controller will reduce the output voltage to maintain a constant output current. If as a result, the output voltage falls below the “Output DC Current Limit Shutdown Voltage”* for more than 50 ms**, then the unit will enter into hiccup mode, with a 500 ms off-time. The unit will then automatically attempt to restart. Back-Drive Current Limit: If there is negative output current of a magnitude larger than the “Back-Drive Current Limit while Enabled” specification*, then a fast back-drive limit controller will increase the output voltage to maintain a constant output current. If this results in the output voltage exceeding the “Output OverVoltage Protection” threshold*, then the unit will shut down. Output Over-Voltage Limit (OVP): 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 500 ms the converter will automatically restart. Over-Temperature Shutdown (OTP): 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 “OverTemperature 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*. Startup Inhibit Period: The Startup Inhibit Period ensures that the converter will remain off for approximately 500 ms when it is shut down due to a fault. This generates a 2 Hz “hiccup mode,” which prevents the converter from overheating. In all, there are three ways that the converter can be shut down, initiating a Startup Inhibit Period: • Output Over-Voltage Protection • Current Limit • Short Circuit Protection * See Electrical Characteristics section. ** Certain models may have an extended on-time, longer than 50 ms. See Electrical Characteristics section. Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 9 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification APPLICATION CONSIDERATIONS Thermal Considerations: For baseplated and encased versions, the max operating baseplate temperature, TB, is 100ºC. Refer to the Thermal Derating Curves in the Technical Figures section to see the available output current at baseplate temperatures below 100ºC. 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. 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 baseplate and the ambient air for a given airflow rate. This information is usually available from the heatsink vendor. The following formula can the be used to determine the maximum power the converter can dissipate for a given thermal condition if its base-plate is to be no higher than 100ºC. Application Circuits: A typical circuit diagram, Figure D below details the input filtering and voltage trimming. Input Filtering and External Input Capacitance: Figure E below shows the internal input filter components. This filter dramatically reduces input terminal ripple current, which otherwise could exceed the rating of an external electrolytic input capacitor. The recommended external input capacitance is specified in the Input Characteristics section of the Electrical Specifications. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. max Pdiss RTHBA For convenience, Thermal Derating Curves are provided in the Technical Figures section. Vin(+) Vout(+) Vsense(+) Electrolytic Capacitor External Input Filter 100ºC - TA This value of maximum power dissipation can then be used in conjunction with the data shown in the Power Dissipation Curves in the Technical Figures section to determine the maximum load current (and power) that the converter can deliver in the given thermal condition. Output Filtering and External Output Capacitance: The internal output filter components are shown in Figure E below. This filter dramatically reduces output voltage ripple. Some minimum external output capacitance is required, as specified in the Output Characteristics area of the Electrical Characteristics section. No damage will occur without this capacitor connected, but peak output voltage ripple will be much higher. Vin = ON/OFF Trim Vsense(_) Vin(_) Rtrim-up or Rtrim-down Cload Iload Vout(_) Figure D: Typical Application Circuit (negative logic unit, permanently enabled) Lin Vin(+) Vout(+) C1 C2 Regulation Stage Current Sense Isolation Stage Vin(_) Vout(-) Figure E: Internal Input and Output Filter Diagram (component values listed in Electrical Characteristics section) Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 10 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification Active Current Share Application Section Overview: The full-featured option, which is specified by an “F” as the last character of the part number, supports current sharing by adding two additional pins: SHARE(+) and SHARE(-) Connection of Paralleled Units: Up to 100 units can be placed in parallel. In this current share architecture, one unit is dynamically chosen to act as a master, controlling all other units. It cannot be predicted which unit will become the master at any given time, so units should be wired symmetrically (see Figures F & G). • Input power pins and output power pins should be tied together between units, preferably with wide overlapping copper planes, after any input common-mode choke. • The SHARE(+) and SHARE(-) pins should be routed between all paralleled units as a differential pair. • The ON/OFF pins should be connected in parallel, and rise/fall times should be kept below 2ms. • The SENSE(+) and SENSE(-) pins should be connected either locally at each unit or separately to a common sense point. If an output common-mode choke is used, sense lines should be connected on the module-side of the choke. • If the TRIM pin is used, then each unit should have its own trim resistor connected locally between TRIM and SENSE(+) or SENSE(-). Vin(+) Sense(+) On/Off ≥1 nF Elec. Cap. A A Share(+) Trim ≥10 μF Share(-) Sense(-) Vin(-) Vout(-) Vin(+) Vout(+) Sense(+) On/Off Electrolytic Capacitor 470 nH (nom) Vout(+) Share(+) Load B B 470 nH (nom) A Trim ≥10 μF Share(-) Sense(-) Vin(-) B Vout(-) Up to 100 Units Vin(+) On/Off Electrolytic Capacitor Share(+) 470 nH (nom) Vout(+) Sense(+) A Trim ≥10 μF Share(-) Sense(-) Vin(-) B Vout(-) Figure F: Typical Application Circuit for Paralleling of Full-Featured Units with an Input Common-Mode Choke. If an input common-mode choke is used, Vin(-) MUST be tied together AFTER the choke for all units. 470 nH (nominal) inductor or an output common-mode choke is required for outputs >18 V. See Figure G for output common-mode choke configuration. Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 11 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification Automatic Configuration: The micro-controller inside each power converter unit is programmed at the factory with a unique chip number. In every other respect, each shared unit is identical and has the same orderable part number. On initial startup (or after the master is disabled or shuts down), each unit determines the chip number of every other unit currently connected to the shared serial bus formed by the SHARE(+) and SHARE(-) pins. The unit with the highest chip number dynamically reconfigures itself from slave to master. The rest of the units (that do not have the highest chip number) become slaves. The master unit then broadcasts its control state over the shared serial bus on a cycle-by-cycle basis. The slave units interpret and implement the control commands sent by the master, mirroring every action of the master unit. If the master is disabled or encounters a fault condition, all units will immediately shut down, and if the master unit is unable to restart, then the unit with the next highest chip number will become master. If a slave unit is disabled or encounters a fault condition, all other units continue to run, and the slave unit can restart seamlessly. Automatic Interleaving: The slave units automatically lock frequency with the master, and interleave the phase of their switching transitions for improved EMI performance. To obtain the phase angle relative to the master, each slave divides 360 degrees by the total number of connected units, and multiples the result by its rank among chip numbers of connected units. ORing Diodes placed in series with the converter outputs must also have a resistor smaller than 500 Ω placed in parallel. This resistor keeps the output voltage of a temporarily disabled slave unit consistent with the active master unit. If the output voltage of the slave unit were allowed to totally discharge, and the slave unit tried to restart, it would fail because the slave reproduces the duty cycle of the master unit, which is running in steady state and cannot repeat an output voltage soft-start. Common-Mode Filtering must be either a single primary side choke handling the inputs from all the paralleled units, or multiple chokes placed on the secondary side. This ensures that a solid Vin(-) plane is maintained between units. Adding a common-mode choke at the output eliminates the need for the 470 nH indcutor at the output of shared units when Vout > 18 V. If an output common-mode choke is used, sense connections must be made on the module-side of the choke. Resonance Between Output Capacitors is Possible: When multiple higher-voltage modules are paralleled, it is possible to excite a series resonance between the output capacitors internal to the module and the parasitic inductance of the module output pins. This is especially likely at higher output voltages where the module internal capacitance is relatively small. This problem is independent of external output capacitance. For modules with an output voltage greater than 18 V, to ensure that this resonant frequency is below the switching frequency it is recommended to add a nominal 470 nH of inductance, located close to the module, in series with each converter output. There must be at least 10 μF of capacitance per converter, located on the load-side of that inductor. The inductance could be from the leakage inductance of a secondary-side common-mode choke; in which case the output capacitor should be appropriately sized for the chosen choke. When using an output common-mode choke, the Sense lines must be connected on the module-side of the common-mode choke (see Figure G). Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 RS-485 Physical Layer: The internal RS-485 transceiver includes many advanced protection features for enhanced reliability: • Current Limiting and Thermal Shutdown for Driver Overload Protection • IEC61000 ESD Protection to +/- 16.5 kV • Hot Plug Circuitry – SHARE(+) and SHARE(-) Outputs Remain Tri-State During Power-up/Power-down Internal Schottky Diode Termination: Despite signaling at high speed with fast edges, external termination resistors are not necessary. Each receiver has four Schottky diodes built in, two for each line in the differential pair. These diodes clamp any ringing caused by transmission line reflections, preventing the voltage from going above about 5.5 V or below about -0.5 V. Any subsequent ringing then inherently takes place between 4.5 and 5.5 V or between -0.5 and 0.5 V. Since each receiver on the bus contains a set of clamping diodes to clamp any possible transmission line reflection, the bus does not necessarily need to be routed as a daisy-chain. Pins SHARE(+) and SHARE(-) are referenced to Vin(-), and therefore should be routed as a differential pair near the Vin(-) plane for optimal signal integrity. The maximum difference in voltage between Vin(-) pins of all units on the share-bus should be kept within 0.3 V to prevent steady-state conduction of the termination diodes. Therefore, the Vin(-) connections to each unit must be common, preferably connected by a single copper plane. Share Accuracy: Inside each converter micro-controller, the duty cycle is generated digitally, making for excellent duty cycle matching between connected units. Some small duty cycle mismatch is caused by (well controlled) process variations in the MOSFET gate drivers. However, the voltage difference induced by this duty cycle mismatch appears across the impedance of the entire power converter, from input to output, multiplied by two, since the differential current flows out of one converter and into another. So, a small duty cycle mismatch yields very small differential currents, which remain small even when 100 units are placed in parallel. In other current-sharing schemes, it is common to have a current-sharing control loop in each unit. However, due to the limited bandwidth of this loop, units do not necessarily share current on startup or during transients before this loop has a chance to respond. In contrast, the current-sharing scheme used in this product has no control dynamics: control signals are transmitted fast enough that the slave units can mirror the control state of the master unit on a cycle-by-cycle basis, and the current simply shares properly, from the first switching cycle to the last. www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 12 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification Vin(+) Vout(+) Sense(+) On/Off ≥1 nF Elec. Cap. Share(+) Trim Load Share(-) Sense(-) Vin(-) Vout(-) Vin(+) Vout(+) Sense(+) On/Off Electrolytic Capacitor Trim Share(+) Share(-) Sense(-) Vin(-) Vout(-) Up to 100 Units Vin(+) Vout(+) On/Off Electrolytic Capacitor Sense(+) Share(+) Trim Share(-) Sense(-) Vin(-) Vout(-) Figure G: Typical Application Circuit for Paralleling of Full-Featured Units with an Output Common-Mode Choke. When using an output common-mode choke, SENSE lines must be connected on the module-side of the choke. See Figure F for configuration with an input common-mode choke. Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 13 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification 2.486 [63.14] SEATING PLANE HEIGHT 0.512 0.005 [ 13.00 0.12] 2.000 [50.80] PIN EXTENSION 0.163 [4.14] 0.700 [17.78] 5 TOP VIEW 6 7 8 9 0.004 [0.10] 1.900 2.386 [48.26] [60.60] 1.900 [48.26] 0.01 [0.3] 4 3 B 1 0.30 [7.6] 1 0.400 [10.16] THRU HOLE STANDOFFS SEE NOTE 1 (4 PLCS) 0.800 [20.32] 1.000 [25.40] 1.400 [35.56] PIN DESIGNATIONS NOTES 1) THREADED: APPLIED TORQUE PER M3 SCREW 4in-lb RECOMMENDED (5in-lb LIMIT). NONTHREADED: DIA 0.125” (3.18mm) 2) BASEPLATE FLATNESS TOLERANCE IS 0.004”(.10mm) TIR FOR SURFACE. 3) PINS 1-4, B AND 6-8 ARE 0.040” (1.02mm) DIA. WITH 0.080” (2.03mm) DIA. STANDOFFS. 4) PINS 5 AND 9 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. (139 g) 7) ALL DIMENSIONS IN INCHES(mm) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Product # MCOTS-C-28-15-HZ 2 Phone 1-888-567-9596 Pin 1 2 Name Vin(+) ON/OFF B 3 4 5 6 7 8 9 SHARE(+) 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. Active current share differential pair (see FullFeature Application Notes) (Note 4) Input Return Ouput 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) On standard product, Pin B & Pin 3 are absent www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 14 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification 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] 5 7 6 8 9 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] 4 1 0.775±0.020 [ 19.69±0.50 ] 3 B 2 1 0.400 [10.16] .130 [3.30] SEE NOTE 1 (6 PLCS) 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 1-4, 6-8 AND B ARE 0.040” (1.02mm) DIA. WITH 0.080” (2.03mm) DIA. STANDOFFS. 4) PINS 5 AND 9 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: 5.11 oz. (145 g) 7) ALL DIMENSIONS IN INCHES(mm) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Product # MCOTS-C-28-15-HZ Phone 1-888-567-9596 Pin 1 2 Name Vin(+) ON/OFF B 3 4 5 6 7 8 9 SHARE(+) 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. Active current share differential pair (see FullFeature Application Notes) (Note 4) Input Return Ouput 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) On standard product, Pin B & Pin 3 are absent www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 15 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification 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 ● 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 Method Description Fungus 508.6 Table 508.6-I 500.5 - Procedure I Storage: 70,000ft. / 2 Hr. duration Altitude 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-28-15-HZ Phone 1-888-567-9596 www.synqor.com Doc.# 005-0006073 Rev. E 08/12/2014 Page 16 MCOTS-C-28-15-HZ Output: 15V Current: 34A Technical Specification Ordering Information/ Part Numbering Example MCOTS-C-28-15-HZ-N-S Not all combinations make valid part numbers, please contact SynQor for availability. See product summary page for details. Family MCOTS Product C: Converter Input Voltage Output Voltage 28: 16-40V 28E: 16-70V 28V: 9-40V 28VE: 9-70V 48: 34-75V 05: 5V 9R6: 9.6V 12: 12V 15: 15V 24: 24V 28: 28V 40: 40V 50: 50V 135:135V Heatsink Option Package HZ: Half Brick Zeta N: Normal Threaded D: Normal NonThreaded F: Flanged Screening Level Options S: S-Grade M: M-Grade [ ]: 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. 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 Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: Product # MCOTS-C-28-15-HZ 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 USA Phone 1-888-567-9596 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.# 005-0006073 Rev. E 08/12/2014 Page 17