MQFL-28-1R5S Single Output H igH R eliability DC-DC C onveRteR 16-40V 16-50V 1.5V 40A 84% @ 20A / 81% @ 40A Continuous Input Transient Input Output Output Efficiency F ull P oweR o PeRation : -55ºC to +125ºC The MilQor® series of high-reliability DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectifier technology to the Military/Aerospace industry. SynQor’s innovative QorSeal® packaging approach ensures survivability in the most hostile environments. Compatible 2 ENA with the industry standard format, these converters operate RE SHA at a fixed frequency, have no opto-isolators, and follow conservative component derating guidelines. -ES S-Y 5 8-1R +VIN They are E CAS designed and manufactured to comply with a wide range of 1 ENA E AG DC.5Vo 1C in 1 5-30 320 28V D/C T C OU SYN C IN SYN military standards. R tE 2 FL- VER MQ DC Con ut@40A N IN RT +SNS -SNS RTN OUT T +VOU X10 1W 0 000 000 S/n Design Process MQFL series converters are: • Designed for reliability per NAVSO-P3641-A guidelines • Designed with components derated per: — MIL-HDBK-1547A — NAVSO P-3641A Qualification Process MQFL series converters are qualified to: • MIL-STD-810F — consistent with RTCA/D0-160E • SynQor’s First Article Qualification — consistent with MIL-STD-883F • SynQor’s Long-Term Storage Survivability Qualification • SynQor’s on-going life test In-Line Manufacturing Process • AS9100 and ISO 9001 certified facility • Full component traceability • Temperature cycling • Constant acceleration • 24, 96, 160 hour burn-in • Three level temperature screening Product# MQFL-28-1R5S Phone 1-888-567-9596 DesigneD & ManufactureD in the usa featuring Qorseal® hi-rel asseMbly Features • • • • • • • • Fixed switching frequency No opto-isolators Parallel operation with current share Remote sense Clock synchronization Primary and secondary referenced enable Continuous short circuit and overload protection Input under-voltage and over-voltage shutdown Specification Compliance MQFL series converters (with MQME filter) are designed to meet: • MIL-HDBK-704-8 (A through F) • RTCA/DO-160 Section 16, 17, 18 • MIL-STD-1275 (B, D) • DEF-STAN 61-5 (part 6)/(5, 6) • MIL-STD-461 (C, D, E, F) • RTCA/DO-160(E, F, G) Section 22 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 1 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Specification BLOCK DIAGRAM 1 INPUT RETURN 2 CASE CURRENT SENSE 3 GATE DRIVERS CURRENT LIMIT UVLO ENABLE 1 4 SYNC OUT 5 SYNC IN 6 ISOLATION STAGE ISOLATION BARRIER REGULATION STAGE POSITIVE INPUT MAGNETIC PRIMARY CONTROL 7 POSITIVE OUTPUT 8 OUTPUT RETURN GATE DRIVERS 12 ENABLE 2 11 SHARE SECONDARY CONTROL 10 + SENSE FEEDBACK 9 − SENSE CONTROL POWER TYPICAL CONNECTION DIAGRAM 28 Vdc + _ open means on Product# MQFL-28-1R5S ENA 2 12 SHARE 11 1 +VIN 2 IN RTN 3 CASE 4 ENA 1 5 SYNC OUT 6 SYNC IN Phone 1-888-567-9596 MQFL www.SynQor.com +SNS 10 -SNS 9 OUT RTN 8 +VOUT 7 Doc.# 005-2MQ1R5S Rev. F open means on + Load 01/04/16 _ Page 2 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Specification MQFL-28-1R5S ELECTRICAL CHARACTERISTICS Parameter Min. Typ. Max. Units Notes & Conditions ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Reverse Bias (Tcase = 125ºC) Reverse Bias (Tcase = -55ºC) Isolation Voltage (I/O to case, I to O) Continuous Transient (≤100µs) Operating Case Temperature Storage Case Temperature Lead Temperature (20s) Voltage at ENA1, ENA2 INPUT CHARACTERISTICS Operating Input Voltage Range “ Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Input Over-Voltage Shutdown Turn-Off Voltage Threshold Turn-On Voltage Threshold Shutdown Voltage Hysteresis Input Filter Component Values (L\C) Maximum Input Current No Load Input Current (operating) Disabled Input Current (ENA1) Disabled Input Current (ENA2) Input Terminal Current Ripple (pk-pk) OUTPUT CHARACTERISTICS Output Voltage Set Point (Tcase = 25ºC) Output Voltage Set Point Over Temperature Output Voltage Line Regulation Output Voltage Load Regulation Total Output Voltage Range Output Voltage Ripple and Noise Peak to Peak Operating Output Current Range Operating Output Power Range Output DC Current-Limit Inception Short Circuit Output Current Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance DYNAMIC CHARACTERISTICS Output Voltage Deviation Load Transient For a Pos. Step Change in Load Current For a Neg. Step Change in Load Current Settling Time (either case) Output Voltage Deviation Line Transient For a Pos. Step Change in Line Voltage For a Neg. Step Change in Line Voltage Settling Time (either case) Turn-On Transient Output Voltage Rise Time Output Voltage Overshoot Turn-On Delay, Rising Vin Turn-On Delay, Rising ENA1 Turn-On Delay, Rising ENA2 EFFICIENCY Iout = 40A (16Vin) Iout = 20A (16Vin) Iout = 40A (28Vin) Iout = 20A (28Vin) Iout = 40A (40Vin) Iout = 20A (40Vin) Load Fault Power Dissipation Short Circuit Power Dissipation Product# MQFL-28-1R5S Group A Subgroup Vin=28V dc ±5%, Iout=40A, CL=0µF, free running (see Note 10) unless otherwise specified Specifications subject to change without notice -500 -800 -55 -65 -1.2 60 60 -0.8 -1.2 V V V V 500 800 125 135 300 50 V V °C °C °C V 16 16 28 28 40 50 V V 14.75 13.80 0.50 15.50 14.40 1.10 16.00 15.00 1.80 V V V 54.0 50.0 2.0 1.48 1.47 -20 3 1.46 0 0 41 41 -450 -150 -150 56.8 60.0 51.4 54.0 5.3 8.0 2.0\24.6 5 110 160 2 5 25 50 40 60 1.50 1.50 0 7 1.50 15 75 10,000 -200 200 200 450 350 mV mV µs 250 150 150 500 mV mV µs 6 0 5.5 3.0 1.5 10 2 8.0 6.0 3.0 ms % ms ms ms 30 30 % % % % % % W W 76 81 76 80 75 78 Phone 1-888-567-9596 82 85 81 84 80 82 18 20 See Note 1 HB Grade Products, See Notes 2 & 15 Continuous Transient, 1s See Note 3 1, 2, 3 1, 2, 3 1, 2, 3 See Note 3 V V V μH\μF Internal Values A Vin = 16V; Iout = 40A mA mA mA mA Bandwidth = 100kHz – 10MHz; see Figure 14 V V mV mV V mV A W A A A mA µF 46 47 11 10 1.52 1.53 20 11 1.54 50 40 60 52 53 (see Note 13) See Note 5 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 Vout at sense leads “ “ “ ; Vout @ (Iout=0A) - Vout @ (Iout=40A) “ Bandwidth = 10MHz; CL=11µF 1 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 See Note 5 1, 2, 3 1, 2, 3 See Note 5 See Note 4 Vout ≤ 1.2V See Note 6 Total Iout step = 20A‹-›40A, 4A‹-›20A; CL=11µF “ See Note 7 Vin step = 16V‹-›50V; CL=11µF; see Note 8 “ “ See Note 7 4, 5, 6 4, 5, 6 Vout = 0.15V-›1.35V 4, 5, 6 See Note 5 4, 5, 6 4, 5, 6 4, 5, 6 ENA1, ENA2 = 5V; see Notes 9 & 11 ENA2 = 5V; see Note 11 ENA1 = 5V; see Note 11 1, 2, 3 Iout at current limit inception point; See Note 4 Vout ≤ 1.2V www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 1 1 01/04/16 Page 3 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Specification MQFL-28-1R5S ELECTRICAL CHARACTERISTICS (Continued) Parameter Min. Typ. Max. Units Notes & Conditions Vin=28V dc ±5%, Iout=40A, CL=0µF, free running (see Note 10) unless otherwise specified Specifications subject to change without notice ISOLATION CHARACTERISTICS Isolation Voltage Input RTN to Output RTN Any Input Pin to Case Any Output Pin to Case Isolation Resistance (in rtn to out rtn) Isolation Resistance (any pin to case) Isolation Capacitance (in rtn to out rtn) FEATURE CHARACTERISTICS Switching Frequency (free running) Synchronization Input Frequency Range Logic Level High Logic Level Low Duty Cycle Synchronization Output Pull Down Current Duty Cycle Enable Control (ENA1 and ENA2) Off-State Voltage Module Off Pulldown Current On-State Voltage Module On Pin Leakage Current Pull-Up Voltage RELIABILITY CHARACTERISTICS Calculated MTBF (MIL-STD-217F2) GB @ Tcase = 70ºC AIF @ Tcase = 70ºC WEIGHT CHARACTERISTICS Device Weight Group A Subgroup (See Note 13) Dielectric strength 500 500 500 100 100 V V V MΩ MΩ nF 1 1 1 1 1 1 600 kHz 1, 2, 3 500 2 -0.5 20 700 10 0.8 80 kHz V V % 1, 2, 3 1, 2, 3 1, 2, 3 See Note 5 20 25 75 mA % 44 500 550 0.8 80 2 3.2 4.0 20 4.5 V µA V µA V 2800 440 103 Hrs. 103 Hrs. 79 g VSYNC OUT = 0.8V Output connected to SYNC IN of other MQFL unit See Note 5 See Note 5 1, 2, 3 See Note 5 1, 2, 3 See Note 5 1, 2, 3 Current drain required to ensure module is off Imax drawn from pin allowed, module on See Figure A Electrical Characteristics Notes 1. Converter will undergo input over-voltage shutdown. 2. Derate output power to 50% of rated power at Tcase = 135ºC. 135ºC is above specified operating range. 3. High or low state of input voltage must persist for about 200µs to be acted on by the lockout or shutdown circuitry. 4. Current limit inception is defined as the point where the output voltage has dropped to 90% of its nominal value. 5. Parameter not tested but guaranteed to the limit specified. 6. Load current transition time ≥ 10µs. 7. Settling time measured from start of transient to the point where the output voltage has returned to ±50mV of its final value. 8. Line voltage transition time ≥ 100µs. 9. Input voltage rise time ≤ 250µs. 10. Operating the converter at a synchronization frequency above the free running frequency will cause the converter’s efficiency to be slightly reduced and it may also cause a slight reduction in the maximum output current/power available. For more information consult the factory. 11. After a disable or fault event, module is inhibited from restarting for 300ms. See Shut Down section of the Control Features description. 12. SHARE pin outputs a power failure warning pulse during a fault condition. See Current Share section of the Control Features description. 13. Only the ES and HB grade products are tested at three temperatures. The C- grade products are tested at one temperature. Please refer to the Construction and Environmental Stress Screening Options table for details. 14. These derating curves apply for the ES and HB grade products. The C- grade product has a maximum case temperature of 70ºC and a maximum junction temperature rise of 20ºC above TCASE. 15. The specified operating case temperature for ES grade products is -45ºC to 100ºC. The specified operating case temperature for C- grade products is 0ºC to 70ºC. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 4 MQFL-28-1R5S Output: 1.5V Current: 40A 100 100 95 95 90 90 Efficiency (%) Efficiency (%) Technical Figures 85 80 75 70 85 80 75 70 16 Vin 28 Vin 65 16 Vin 28 Vin 65 40 Vin 40 Vin 60 60 0 5 10 15 20 25 30 35 -55ºC 40 25ºC Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at Tcase=25°C. Figure 2: Efficiency at nominal output voltage and 60% rated power vs. case temperature for input voltage of 16V, 28V, and 40V. 16 20 18 14 Power Dissipation (W) Power Dissipation (W) 16 14 12 10 8 6 16 Vin 4 12 10 8 6 4 28 Vin 2 40 Vin 0 5 10 15 20 25 30 35 16 Vin 28 Vin 2 0 40 Vin 0 40 -55ºC 25ºC Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. case temperature for input voltage of 16V, 28V, and 40V. 75 1.8 45 68 1.6 40 60 1.4 35 53 30 45 25 38 20 30 15 23 Tjmax = 105º C Tjmax = 125º C 5 Tjmax = 145º C 25 45 65 85 105 125 145 Output Voltage (V) 50 Pout (W) Iout (A) Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at Tcase=25°C. 10 1.2 1 0.8 0.6 15 0.4 8 0.2 0 0 Figure 5: Output Current / Output Power derating curve as a function of Tcase and the Maximum desired power MOSFET junction temperature at Vin = 28V (see Note 14). Phone 1-888-567-9596 28 Vin 0 Case Temperature (ºC) Product# MQFL-28-1R5S 125ºC Case Temperature (ºC) Load Current (A) 0 125ºC Case Temperature (ºC) Load Current (A) 5 10 15 20 25 30 Load Current (A) 35 40 45 50 Figure 6: Output voltage vs. load current showing typical current limit curves. www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 5 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Figures Figure 7: Turn-on transient at full resistive load and zero output capacitance initiated by ENA1. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA1 (5V/div). Figure 8: Turn-on transient at full resistive load and 10mF output capacitance initiated by ENA1. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA1 (5V/div). Figure 9: Turn-on transient at full resistive load and zero output capacitance initiated by ENA2. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA2 (5V/div). Figure 10: Turn-on transient at full resistive load and zero output capacitance initiated by Vin. ENA1 and ENA2 both previously high. Ch 1: Vout (500mV/div). Ch 2: Vin (10V/div). Figure 11: Output voltage response to step-change in load current 50%100%-50% of Iout (max). Load cap: 1µF ceramic cap and 10µF, 100mΩ ESR tantalum cap. Ch 1: Vout (200mV/div). Ch 2: Iout (20A/div). Figure 12: Output voltage response to step-change in load current 0%50%-0% of Iout (max). Load cap: 1µF ceramic cap and 10µF, 100mΩ ESR tantalum cap. Ch 1: Vout (200mV/div). Ch 2: Iout (20A/div). Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 6 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Figures Figure 13: Output voltage response to step-change in input voltage (16V 50V - 16V). Load cap: 10µF, 100mΩ ESR tantalum cap and 1µF ceramic cap. Ch 1: Vout (200mV/div). Ch 2: Vin (20V/div). Figure 14: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 15) and Output Voltage Ripple (Figure 16). Figure 15: Input terminal current ripple, ic, at full rated output current and nominal input voltage with SynQor MQ filter module (50 mA/div). Bandwidth: 20MHz. See Figure 14. Figure 16: Output voltage ripple, Vout, at nominal input voltage and rated load current (20mV/div). Load capacitance: 1µF ceramic capacitor and 10µF tantalum capacitor. Bandwidth: 10MHz. See Figure 14. Figure 17: Rise of output voltage after the removal of a short circuit across the output terminals. Ch 1: Vout (500mV/div). Ch 2: Iout (20A/ div). Figure 18: SYNC OUT vs. time, driving SYNC IN of a second SynQor MQFL converter. Ch1: SYNC OUT: (1V/div). Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 7 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Figures 0 0.1 Forward Transmission (dB) Output Impedance (ohms) -10 0.01 0.001 16Vin 28Vin 40Vin 0.0001 10 100 1,000 Hz 10,000 10 -30 -40 -50 -60 -70 -80 16Vin -90 40Vin 28Vin -100 100,000 Figure 19: Magnitude of incremental output impedance (Zout = vout/iout) for minimum, nominal, and maximum input voltage at full rated power. -20 10 100 1,000 Hz 10,000 100,000 Figure 20: Magnitude of incremental forward transmission (FT = vout/ vin) for minimum, nominal, and maximum input voltage at full rated power. 100 Input Impedance (ohms) Reverse Transmission (dB) 0 -10 -20 -30 16Vin -40 10 1 16Vin 28Vin 0.1 40Vin 28Vin 40Vin -50 10 100 1,000 10,000 100,000 0.01 10 Hz 100 1,000 Hz 10,000 100,000 Figure 21: Magnitude of incremental reverse transmission (RT = iin/iout) for minimum, nominal, and maximum input voltage at full rated power. Figure 22: Magnitude of incremental input impedance (Zin = vin/iin) for minimum, nominal, and maximum input voltage at full rated power. Figure 23: High frequency conducted emissions of standalone MQFL28-05S, 5Vout module at 120W output, as measured with Method CE102. Limit line shown is the ‘Basic Curve’ for all applications with a 28V source. Figure 24: High frequency conducted emissions of MQFL-28-05S, 5Vout module at 120W output with MQME-28-P filter, as measured with Method CE102. Limit line shown is the ‘Basic Curve’ for all applications with a 28V source. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 8 MQFL-28-1R5S Output: 1.5V Current: 40A Application Section BASIC OPERATION AND FEATURES tional control features provided by the MQFL converter. The MQFL DC/DC converter uses a two-stage power conversion topology. The first, or regulation, stage is a buck-converter that keeps the output voltage constant over variations in line, load, and temperature. The second, or isolation, stage uses transformers to provide the functions of input/output isolation and voltage transformation to achieve the output voltage required. CONTROL FEATURES Both the regulation and the isolation stages switch at a fixed frequency for predictable EMI performance. The isolation stage switches at one half the frequency of the regulation stage, but due to the push-pull nature of this stage it creates a ripple at double its switching frequency. As a result, both the input and the output of the converter have a fundamental ripple frequency of about 550 kHz in the free-running mode. Rectification of the isolation stage’s output is accomplished with synchronous rectifiers. These devices, which are MOSFETs with a very low resistance, dissipate far less energy than would Schottky diodes. This is the primary reason why the MQFL converters have such high efficiency, particularly at low output voltages. Besides improving efficiency, the synchronous rectifiers permit operation down to zero load current. There is no longer a need for a minimum load, as is typical for converters that use diodes for rectification. The synchronous rectifiers actually permit a negative load current to flow back into the converter’s output terminals if the load is a source of short or long term energy. The MQFL converters employ a “back-drive current limit” to keep this negative output terminal current small. There is a control circuit on both the input and output sides of the MQFL converter that determines the conduction state of the power switches. These circuits communicate with each other across the isolation barrier through a magnetically coupled device. No opto-isolators are used. A separate bias supply provides power to both the input and output control circuits. Among other things, this bias supply permits the converter to operate indefinitely into a short circuit and to avoid a hiccup mode, even under a tough start-up condition. An input under-voltage lockout feature with hysteresis is provided, as well as an input over-voltage shutdown. There is also an output current limit that is nearly constant as the load impedance decreases to a short circuit (i.e., there is not fold-back or fold-forward characteristic to the output current under this condition). When a load fault is removed, the output voltage rises exponentially to its nominal value without an overshoot. The MQFL converter’s control circuit does not implement an output over-voltage limit or an over-temperature shutdown. The following sections describe the use and operation of addiProduct# MQFL-28-1R5S Phone 1-888-567-9596 ENABLE: The MQFL converter has two enable pins. Both must have a logic high level for the converter to be enabled. A logic low on either pin will inhibit the converter. The ENA1 pin (pin 4) is referenced with respect to the converter’s input return (pin 2). The ENA2 pin (pin 12) is referenced with respect to the converter’s output return (pin 8). This permits the converter to be inhibited from either the input or the output side. Regardless of which pin is used to inhibit the converter, the regulation and the isolation stages are turned off. However, when the converter is inhibited through the ENA1 pin, the bias supply is also turned off, whereas this supply remains on when the converter is inhibited through the ENA2 pin. A higher input standby current therefore results in the latter case. Both enable pins are internally pulled high so that an open connection on both pins will enable the converter. Figure A shows the equivalent circuit looking into either enable pins. It is TTL compatible. 5.6V PIN 4 (OR PIN 12) 1N4148 82K TO ENABLE CIRCUITRY ENABLE 250K 2N3904 125K PIN 2 (OR PIN 8) IN RTN Figure A: Circuit diagram shown for reference only, actual circuit components may differ from values shown for equivalent circuit. SHUT DOWN: The MQFL converter will shut down in response to only four conditions: ENA1 input low, ENA2 input low, VIN input below under-voltage lockout threshold, or VIN input above over-voltage shutdown threshold. Following a shutdown event, there is a startup inhibit delay which will prevent the converter from restarting for approximately 300ms. After the 300ms delay elapses, if the enable inputs are high and the input voltage is within the operating range, the converter will restart. If the VIN input is brought down to nearly 0V and back into the operating range, there is no startup inhibit, and the output voltage will rise according to the “Turn-On Delay, Rising Vin” specification. www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 9 MQFL-28-1R5S Output: 1.5V Current: 40A Application Section REMOTE SENSE: The purpose of the remote sense pins is to correct for the voltage drop along the conductors that connect the converter’s output to the load. To achieve this goal, a separate conductor should be used to connect the +SENSE pin (pin 10) directly to the positive terminal of the load, as shown in the connection diagram on Page 2. Similarly, the –SENSE pin (pin 9) should be connected through a separate conductor to the return terminal of the load. NOTE: Even if remote sensing of the load voltage is not desired, the +SENSE and the -SENSE pins must be connected to +Vout (pin 7) and OUTPUT RETURN (pin 8), respectively, to get proper regulation of the converter’s output. If they are left open, the converter will have an output voltage that is approximately 200mV higher than its specified value. If only the +SENSE pin is left open, the output voltage will be approximately 25mV too high. Inside the converter, +SENSE is connected to +Vout with a resistor value from 100W to 274W, depending on output voltage, and –SENSE is connected to OUTPUT RETURN with a 10W resistor. It is also important to note that when remote sense is used, the voltage across the converter’s output terminals (pins 7 and 8) will be higher than the converter’s nominal output voltage due to resistive drops along the connecting wires. This higher voltage at the terminals produces a greater voltage stress on the converter’s internal components and may cause the converter to fail to deliver the desired output voltage at the low end of the input voltage range at the higher end of the load current and temperature range. Please consult the factory for details. SYNCHRONIZATION: The MQFL converter’s switching frequency can be synchronized to an external frequency source that is in the 500 kHz to 700 kHz range. A pulse train at the desired frequency should be applied to the SYNC IN pin (pin 6) with respect to the INPUT RETURN (pin 2). This pulse train should have a duty cycle in the 20% to 80% range. Its low value should be below 0.8V to be guaranteed to be interpreted as a logic low, and its high value should be above 2.0V to be guaranteed to be interpreted as a logic high. The transition time between the two states should be less than 300ns. If the MQFL converter is not to be synchronized, the SYNC IN pin should be left open circuit. The converter will then operate in its free-running mode at a frequency of approximately 550 kHz. If, due to a fault, the SYNC IN pin is held in either a logic low or logic high state continuously, the MQFL converter will revert to its free-running frequency. The MQFL converter also has a SYNC OUT pin (pin 5). This output can be used to drive the SYNC IN pins of as many as ten (10) other MQFL converters. The pulse train coming out Product# MQFL-28-1R5S Phone 1-888-567-9596 of SYNC OUT has a duty cycle of 50% and a frequency that matches the switching frequency of the converter with which it is associated. This frequency is either the free-running frequency if there is no synchronization signal at the SYNC IN pin, or the synchronization frequency if there is. The SYNC OUT signal is available only when the DC input voltage is above approximately 12V and when the converter is not inhibited through the ENA1 pin. An inhibit through the ENA2 pin will not turn the SYNC OUT signal off. NOTE: An MQFL converter that has its SYNC IN pin driven by the SYNC OUT pin of a second MQFL converter will have its start of its switching cycle delayed approximately 180 degrees relative to that of the second converter. Figure B shows the equivalent circuit looking into the SYNC IN pin. Figure C shows the equivalent circuit looking into the SYNC OUT pin. 5V 5K PIN 6 SYNC IN PIN 2 TO SYNC CIRCUITRY 5K IN RTN Figure B: Equivalent circuit looking into the SYNC IN pin with respect to the IN RTN (input return) pin. 5V 5K SYNC OUT FROM SYNC CIRCUITRY IN RTN OPEN COLLECTOR OUTPUT PIN 5 PIN 2 Figure C: Equivalent circuit looking into SYNC OUT pin with respect to the IN RTN (input return) pin. CURRENT SHARE: When several MQFL converters are placed in parallel to achieve either a higher total load power or N+1 redundancy, their SHARE pins (pin 11) should be connected together. The voltage on this common SHARE node represents the average current delivered by all of the paralleled converters. www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 10 MQFL-28-1R5S Output: 1.5V Current: 40A Application Section Since the SHARE pin is monitored with respect to the OUTPUT RETURN (pin 8) by each converter, it is important to connect all of the converters’ OUTPUT RETURN pins together through a low DC and AC impedance. When this is done correctly, the converters will deliver their appropriate fraction of the total load current to within +/- 10% at full rated load. Whether or not converters are paralleled, the voltage at the SHARE pin could be used to monitor the approximate average current delivered by the converter(s). A nominal voltage of 1.0V represents zero current and a nominal voltage of 2.2V represents the maximum rated current, with a linear relationship in between. The internal source resistance of a converter’s SHARE pin signal is 2.5 kW. During an input voltage fault or primary disable event, the SHARE pin outputs a power failure warning pulse. The SHARE pin will go to 3V for approximately 14ms as the output voltage falls. NOTE: Converters operating from separate input filters with reverse polarity protection (such as the MQME-28-T filter) with their outputs connected in parallel may exhibit hiccup operation at light loads. Consult factory for details. OUTPUT VOLTAGE TRIM: If desired, it is possible to increase the MQFL converter’s output voltage above its nominal value. To do this, use the +SENSE pin (pin 10) for this trim function instead of for its normal remote sense function, as shown in Figure D. In this case, a resistor connects the +SENSE pin to the –SENSE pin (which should still be connected to the output return, either remotely or locally). The value of the trim resistor should be chosen according to the following equation or from Figure E: 407.5 Rtrim = 28 Vdc Vout - Vnom - 0.025 + _ open means on 1 +VIN 2 IN RTN 3 CASE 4 ENA 1 5 SYNC OUT 6 SYNC IN 100,000 Trim Resistance (ohms) Each converter monitors this average value and adjusts itself so that its output current closely matches that of the average. 10,000 1,000 100 0.00 0.03 0.06 0.09 0.12 0.15 0.18 Increase in Vout (V) Figure E: Output Voltage Trim Graph where: Vnom = the converter’s nominal output voltage, Vout = the desired output voltage (greater than Vnom), and Rtrim is in Ohms. As the output voltage is trimmed up, it produces a greater voltage stress on the converter’s internal components and may cause the converter to fail to deliver the desired output voltage at the low end of the input voltage range at the higher end of the load current and temperature range. Please consult the factory for details. INPUT UNDER-VOLTAGE LOCKOUT: The MQFL converter has an under-voltage lockout feature that ensures the converter will be off if the input voltage is too low. The threshold of input voltage at which the converter will turn on is higher that the threshold at which it will turn off. In addition, the MQFL converter will not respond to a state of the input voltage unless it has remained in that state for more than about 200µs. This hysteresis and the delay ensure proper operation when the source impedance is high or in a noisy environment. ENA 2 12 SHARE 11 MQFL +SNS 10 -SNS 9 OUT RTN 8 +VOUT 7 Rtrim _ Load + Figure D: Typical connection for output voltage trimming. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 11 MQFL-28-1R5S Output: 1.5V Current: 40A Application Section INPUT OVER-VOLTAGE SHUTDOWN: The MQFL converter also has an over-voltage feature that ensures the converter will be off if the input voltage is too high. It also has a hysteresis and time delay to ensure proper operation. BACK-DRIVE CURRENT LIMIT: Converters that use MOSFETs as synchronous rectifiers are capable of drawing a negative current from the load if the load is a source of short- or long-term energy. This negative current is referred to as a “back-drive current”. Conditions where back-drive current might occur include paralleled converters that do not employ current sharing, or where the current share feature does not adequately ensure sharing during the startup or shutdown transitions. It can also occur when converters having different output voltages are connected together through either explicit or parasitic diodes that, while normally off, become conductive during startup or shutdown. Finally, some loads, such as motors, can return energy to their power rail. Even a load capacitor is a source of back-drive energy for some period of time during a shutdown transient. To avoid any problems that might arise due to back-drive current, the MQFL converters limit the negative current that the converter can draw from its output terminals. The threshold for this back-drive current limit is placed sufficiently below zero so that the converter may operate properly down to zero load, but its absolute value (see the Electrical Characteristics page) is small compared to the converter’s rated output current. When the converter is mounted on a metal plate, the plate will help to make the converter’s case bottom a uniform temperature. How well it does so depends on the thickness of the plate and on the thermal conductance of the interface layer (e.g. thermal grease, thermal pad, etc.) between the case and the plate. Unless this is done very well, it is important not to mistake the plate’s temperature for the maximum case temperature. It is easy for them to be as much as 5-10ºC different at full power and at high temperatures. It is suggested that a thermocouple be attached directly to the converter’s case through a small hole in the plate when investigating how hot the converter is getting. Care must also be made to ensure that there is not a large thermal resistance between the thermocouple and the case due to whatever adhesive might be used to hold the thermocouple in place. 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. THERMAL CONSIDERATIONS: Figure 5 shows the suggested Power Derating Curves for this converter as a function of the case temperature, input voltage and the maximum desired power MOSFET junction temperature. All other components within the converter are cooler than its hottest MOSFET. The Mil-HDBK-1547A component derating guideline calls for a maximum component temperature of 105ºC. Figure 5 therefore has one power derating curve that ensures this limit is maintained. It has been SynQor’s extensive experience that reliable long-term converter operation can be achieved with a maximum component temperature of 125ºC. In extreme cases, a maximum temperature of 145ºC is permissible, but not recommended for long-term operation where high reliability is required. Derating curves for these higher temperature limits are also included in Figure 5. The maximum case temperature at which the converter should be operated is 135ºC. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 12 MQFL-28-1R5S Output: 1.5V Current: 40A Stress Screening CONSTRUCTION AND ENVIRONMENTAL STRESS SCREENING OPTIONS Consistent with MIL-STD-883F Screening C-Grade ES-Grade from ( specified 0 °C to +70 °C ) Element Evaluation HB-Grade from from ( -45specified ( -55specified °C to +100 °C ) °C to +125 °C ) No Yes Yes Yes Yes Internal Visual * Yes Temperature Cycle Method 1010 No Constant Acceleration Method 2001 (Y1 Direction) No 500g Condition A (5000g) Burn-in Method 1015 24 Hrs @ +125 °C 96 Hrs @ +125 °C 160 Hrs @ +125 °C Final Electrical Test Method 5005 (Group A) +25 °C -45, +25, +100 °C -55, +25, +125 °C Full QorSeal Full QorSeal Yes Yes QorSeal QorSeal Mechanical Seal, Thermal, and Coating Process External Visual 2009 * Construction Process Condition B Condition C (-55 °C to +125 °C) (-65 °C to +150 °C) * Per IPC-A-610 Class 3 MilQor® Hi-Rel converters and filters are offered in three variations of environmental stress screening options. All ES-Grade and HB-Grade MilQor Hi-Rel converters use SynQor’s proprietary QorSeal® Hi-Rel assembly process that includes a Parylene-C coating of the circuit, a high performance thermal compound filler, and a nickel barrier gold plated aluminum case. Each successively higher grade has more stringent mechanical and electrical testing, as well as a longer burn-in cycle. The ES- and HB-Grades are also constructed of components that have been procured through an element evaluation process that pre-qualifies each new batch of devices. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 13 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Specifications MIL-STD-810F Qualification Testing MIL-STD-810F Test Fungus Method Description 508.5 Table 508.5-I 500.4 - Procedure I Storage: 70,000 ft / 2 hr duration 500.4 - Procedure II Operating: 70,000 ft / 2 hr duration; Ambient Temperature Rapid Decompression 500.4 - Procedure III Storage: 8,000 ft to 40,000 ft Acceleration 513.5 - Procedure II Operating: 15 g Salt Fog 509.4 Storage 501.4 - Procedure I Storage: 135°C / 3 hrs 501.4 - Procedure II Operating: 100°C / 3 hrs 502.4 - Procedure I Storage: -65°C / 4 hrs 502.4 - Procedure II Operating: -55°C / 3 hrs Altitude High Temperature Low Temperature Temperature Shock 503.4 - Procedure I - C Storage: -65°C to 135°C; 12 cycles Rain 506.4 - Procedure I Wind Blown Rain Immersion 512.4 - Procedure I Non-Operating Humidity 507.4 - Procedure II Random Vibration 514.5 - Procedure I 10 - 2000 Hz, PSD level of 1.5 g2/Hz (54.6 grms), duration = 1 hr/axis 516.5 - Procedure I 20 g peak, 11 ms, Functional Shock (Operating no load) (saw tooth) 516.5 - Procedure VI Bench Handling Shock Shock Sinusoidal vibration Sand and Dust Product# MQFL-28-1R5S 514.5 - Category 14 Aggravated cycle @ 95% RH (Figure 507.5-7 aggravated temp humidity cycle, 15 cycles) Rotary wing aircraft - helicopter, 4 hrs/axis, 20 g (sine sweep from 10 - 500 Hz) 510.4 - Procedure I Blowing Dust 510.4 - Procedure II Blowing Sand Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 14 MQFL-28-1R5S Output: 1.5V Current: 40A Technical Specifications First Article Testing consistent with MIL-STD-883F MIL-STD-883F Test Method Description Electrical Tests 5005 Physical Dimensions test 2016 Resistance to Solvents test 2015.13 Solderability test 2003.8 Lead Integrity test 2004.5 Salt Atmosphere test 1009.8 Adhesion of Lead Finish test 2025.4 Altitude Operation test 1001 Condition “C” ESD Sensitivity 3015.7 Class 2 Stabilization Bake test 1008.2 Condition “C” Vibration Fatigue test 2005.2 Condition “A” Random Vibration test 2026 Condition “II K” Condition “A” Sequential Test Group #1 Life Test – Steady State test 1005.8 Life Test – Intermittent Duty test 1006 Sequential Test Group #2 Temperature Cycle test 1010.8 Condition “C” Constant Acceleration test 2001.2 Condition “A” Thermal Shock test 1011.9 Condition “B” Temperature Cycle test 1010.8 Condition “C” Moisture Resistance test 1004.7 With Sub cycle Mechanical Shock test 2002.4 Condition “B” Variable Frequency Vibration test 2007.3 Condition “A” Sequential Test Group #3 Sequential Test Group #4 Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 15 MQFL-28-1R5S Output: 1.5V Current: 40A Mechanical Diagrams 1 2 3 4 5 6 SEE NOTE 7 +VIN IN RTN SHARE MQFL-28-1R5S-X-ES CASE +SNS DC-DC CONVERTER 28Vin 1.5Vout @ 40A ENA 1 -SNS SYNC OUT SYNC IN 12 11 10 9 8 7 ENA 2 MADE IN USA OUT RTN S/N 0000000 D/C 3205-301 CAGE 1WX10 +VOUT 0.250 [6.35] 1.50 [38.1] 0.040 [1.02] PIN 2.50 [63.50] 2.760 [70.10] 3.00 [76.2] 0.22 [5.6] 0.228 [5.79] 0.390 [9.91] SEE NOTE 7 6 +VIN ENA 2 IN RTN SHARE MQFL-28-1R5S-U-ES CASE +SNS DC-DC CONVERTER 28Vin 1.5Vout @ 40A ENA 1 SYNC OUT SYNC IN 0.050 [1.27] 0.128 [3.25] 2.96 [75.2] 1 2 3 4 5 0.200 [5.08] TYP. NON-CUM. 1.260 [32.00] -SNS MADE IN USA S/N 0000000 D/C 3211-301 CAGE 1WX10 OUT RTN +VOUT 12 11 10 9 8 7 2.50 [63.5] 2.760 [70.10] 3.00 [76.2] Case X 0.250 [6.35] 0.200 [5.08] TYP. NON-CUM. 1.50 [38.1] 1.260 [32.00] 0.040 [1.02] PIN 0.050 [1.27] 0.42 [10.7] 0.128 [3.25] 0.22 [5.6] 2.80 [71.1] 0.390 [9.91] PIN DESIGNATIONS NOTES 1) 2) 3) 4) 5) 6) 7) 8) Pins 0.040’’ (1.02mm) diameter Pin Material: Copper Alloy Finish: Gold over Nickel plating, followed by Sn/Pb solder dip All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) Weight: 2.8 oz (78.5 g) typical Workmanship: Meets or exceeds IPC-A-610 Class III Print Labeling on Top Surface per Product Label Format Drawing Pin 1 identification hole, not intended for mounting (case X and U) Baseplate flatness tolerance is 0.004” (.10mm) TIR for surface. Product# MQFL-28-1R5S Case U Phone 1-888-567-9596 www.SynQor.com Pin # Function 1 2 3 4 5 6 Pin # Function Positive input Input return Case Enable 1 Sync output Sync input Doc.# 005-2MQ1R5S Rev. F 7 8 9 10 11 12 Positive output Output return - Sense + Sense Share Enable 2 01/04/16 Page 16 MQFL-28-1R5S Output: 1.5V Current: 40A Mechanical Diagrams 0.300 [7.62] 0.140 [3.56] 1.150 [29.21] 0.250 [6.35] TYP 1 2 3 4 5 6 +VIN ENA 2 IN RTN SHARE MQFL-28-1R5S-Y-ES CASE ENA 1 -SNS SYNC OUT SYNC IN +SNS DC-DC CONVERTER 28Vin 1.5Vout @ 40A MADE IN USA S/N 0000000 D/C 3211-301 CAGE 1WX10 OUT RTN +VOUT 1.750 [44.45] 12 2.000 11 [50.80] 10 1.50 9 [38.1] 8 1.750 7 [44.45] 0.250 [6.35] 0.200 [5.08] TYP. NON-CUM. 0.040 [1.02] PIN 0.050 [1.27] 0.22 [5.6] 0.375 [9.52] 2.50 [63.5] 2.96 [75.2] 0.228 [5.79] 0.390 [9.91] Case Y Case Z (variant of Y) 0.250 [6.35] Case W (variant of Y) 0.250 [6.35] 0.200 [5.08] TYP. NON-CUM. 0.200 [5.08] TYP. NON-CUM. 0.040 [1.02] PIN 0.040 [1.02] PIN 0.22 [5.6] 0.050 [1.27] 0.42 [10.7] 0.36 [9.14] 0.050 [1.27] 0.22 [5.6] 2.80 [71.1] 0.525 [13.33] 0.390 [9.91] 0.525 [13.33] 0.390 [9.91] 2.80 [71.1] PIN DESIGNATIONS NOTES 1) 2) 3) 4) 5) 6) 7) 8) Pins 0.040’’ (1.02mm) diameter Pin Material: Copper Alloy Finish: Gold over Nickel plating, followed by Sn/Pb solder dip All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) Weight: 2.8 oz (78.5 g) typical Workmanship: Meets or exceeds IPC-A-610 Class III Print Labeling on Top Surface per Product Label Format Drawing Pin 1 identification hole, not intended for mounting (case X and U) Baseplate flatness tolerance is 0.004” (.10mm) TIR for surface. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Pin # Function 1 2 3 4 5 6 Pin # Function Positive input Input return Case Enable 1 Sync output Sync input Doc.# 005-2MQ1R5S Rev. F 7 8 9 10 11 12 Positive output Output return - Sense + Sense Share Enable 2 01/04/16 Page 17 MQFL-28-1R5S Output: 1.5V Current: 40A Ordering Information MilQor Converter FAMILY MATRIX The tables below show the array of MilQor converters available. When ordering SynQor converters, please ensure that you use the complete part number according to the table in the last page. Contact the factory for other requirements. Single Output Full Size MQFL-28 16-40Vin Cont. 16-50Vin 1s Trans.* Dual Output † 1.5V (1R5S) 1.8V (1R8S) 2.5V (2R5S) 3.3V (3R3S) 5V (05S) 6V (06S) 7.5V (7R5S) 9V (09S) 12V (12S) 15V (15S) 28V (28S) 5V (05D) 12V (12D) 15V (15D) 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 40A 40A 40A 30A 20A 17A 13A 11A 8A 6.5A 3.3A 40A 40A 40A 30A 20A 17A 13A 11A 8A 6.5A 3.3A 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 40A 40A 30A 22A 15A 12A 10A 8A 6A 5A 2.7A 15A Total 6A Total 5A Total 1.5V (1R5S) 1.8V (1R8S) 2.5V (2R5S) 3.3V (3R3S) 5V (05S) 6V (06S) 7.5V (7R5S) 9V (09S) 12V (12S) 15V (15S) 28V (28S) 5V (05D) 12V (12D) 15V (15D) 20A 20A 20A 15A 10A 8A 6.6A 5.5A 4A 3.3A 1.8A 10A Total 4A Total 3.3A Total 20A 20A 20A 15A 10A 8A 6.6A 5.5A 4A 3.3A 1.8A 10A Total 4A Total 3.3A Total 10A 10A 10A 7.5A 5A 4A 3.3A 2.75A 2A 1.65A 0.9A 5A Total 2A Total 1.65A Total 10A 10A 10A 7.5A 5A 4A 3.3A 2.75A 2A 1.65A 0.9A 5A Total 2A Total 1.65A Total Absolute Max Vin = 60V MQFL-28E 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin =100V MQFL-28V 16-40Vin Cont. 5.5-50Vin 1s Trans.* Absolute Max Vin = 60V MQFL-28VE 16-70Vin Cont. 5.5-80Vin 1s Trans.* Absolute Max Vin = 100V MQFL-270 155-400Vin Cont. 155-475Vin 1s Trans.* Absolute Max Vin = 550V MQFL-270L 65-350Vin Cont. 65-475Vin 1s Trans.* Absolute Max Vin = 550V Single Output Half Size MQHL-28 16-40Vin Cont. 16-50Vin 1s Trans.* Dual Output † Absolute Max Vin = 60V MQHL-28E 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin =100V MQHR-28 16-40Vin Cont. 16-50Vin 1s Trans.* Absolute Max Vin = 60V MQHR-28E 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin = 100V Check with factory for availability. †80% of total output current available on any one output. *Converters may be operated at the highest transient input voltage, but some component electrical and thermal stresses would be beyond MILHDBK-1547A guidelines. Product# MQFL-28-1R5S Phone 1-888-567-9596 www.SynQor.com Doc.# 005-2MQ1R5S Rev. F 01/04/16 Page 18 MQFL-28-1R5S Output: 1.5V Current: 40A Ordering Information PART NUMBERING SYSTEM The part numbering system for SynQor’s MilQor DC-DC converters follows the format shown in the table below. Not all combinations make valid part numbers, please contact SynQor for availability. See the Product Summary web page for more options. Example: Input Voltage Range Model Name 28 28E 28V 28VE MQFL MQHL MQHR 270 270L MQFL-28-1R5S-Y-ES Output Voltage(s) Single Output Dual Output 1R5S 1R8S 2R5S 3R3S 05S 06S 7R5S 09S 12S 15S 28S 05D 12D 15D Package Outline/ Pin Configuration Screening Grade U X Y W Z C ES HB APPLICATION NOTES A variety of application notes and technical white papers can be downloaded in pdf format from the SynQor website. Contact SynQor for further information and to order: Phone: Toll Free: Fax: E-mail: Web: Address: Product# MQFL-28-1R5S 978-849-0600 1-888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 USA Phone 1-888-567-9596 PATENTS SynQor holds numerous U.S. patents, one or more of which apply to most of its power converter 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 6,731,520 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 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.# 005-2MQ1R5S Rev. F 01/04/16 Page 19