Technical Specification RQ1BxxxHPXxx Rail Grade DC-DC Power Supply 66-160V 200V 5.0-24V 255W Continuous Input Transient Input Outputs Max Power 3000Vdc REINFORCED Insulation Half-brick DC-DC Converter ™ The RailQor half-brick converter series is composed of nextgeneration, board-mountable, isolated (REINFORCED), fixed switching frequency dc-dc converters that use synchronous rectification to achieve extremely high power conversion efficiency. Each module is supplied completely encased to provide protection from the harsh environments seen in many industrial and transportation applications. Protection Features ►Input under-voltage lockout ►Output current limit and short circuit protection ►Active back bias limit ►Output over-voltage protection ►Thermal shutdown Control Features Safety Features ►On/Off control referenced to input side ►Remote sense for the output voltage ►Output voltage trim range of -20%, +10% Operational Features ►High efficiency, 91% at full rated load current ►Delivers full power with minimal derating - no heatsink required ►Operating input voltage range: 66-160V ►Fixed frequency switching provides predictable EMI ► No minimum load requirement ►Meets requirements of standard EN 50155 Mechanical Features ►Industry standard half-brick pin-out configuration ►Size: 2.386" × 2.486" × 0.512", (60.6 × 63.14 × 13.00 mm) ►Total weight: 4.7 oz (133 g) ►Flanged baseplate version available Product # RQ1BxxxHPXxx Phone 1-888-567-9596 Reinforced Insulation ►Input-to-output isolation 3000V ►UL 60950-1/R:2011-12 ►CAN/CSA C22.2 No. 60950-1/A1:2011 ►EN60950-1/A2:2013 ►CE Marked ►RoHS compliant (see last page) Contents Family Electrical Characteristics........................................................................2 Electrical Characteristics (5.0Vout) & Figures...................................................4 Electrical Characteristics (12Vout) & Figures....................................................6 Electrical Characteristics (15Vout) & Figures....................................................8 Electrical Characteristics (24Vout) & Figures..................................................10 Application Section...........................................................................................12 Standard Mechanical Diagram..........................................................................17 Flanged Mechanical Diagram...........................................................................18 Standards & Qualification Testing....................................................................19 Ordering Information........................................................................................20 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 1 Technical Specification RQ1BxxxHPXxx RQ1B-HP Family Electrical Characteristics (all output voltages) Ta = 25 °C, airflow rate = 300 LFM, Vin = 110V dc unless otherwise noted; full operating temperature range is -40 °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 -0.5 Operating Operating Transient Protection Isolation Voltage Input to Output Input to Base-Plate Output to Base-Plate Operating Temperature -40 Storage Temperature -45 Voltage at ON/OFF input pin -2 INPUT CHARACTERISTICS Operating Input Voltage Range 66 Input Under-Voltage Lockout Turn-On Voltage Threshold 62.0 Turn-Off Voltage Threshold 59 Lockout Voltage Hysteresis Input Over-Voltage Shutdown Recommended External Input Capacitance Input Filter Component Values (L\C) DYNAMIC CHARACTERISTICS Turn-On Transient Turn-On Time Start-Up Inhibit Time 180 Output Voltage Overshoot ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance 100 Isolation Capacitance (input to output) TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature Maximum Baseplate Temperature, Tb FEATURE CHARACTERISTICS Switching Frequency 255 ON/OFF Control Off-State Voltage 2.4 On-State Voltage -2 ON/OFF Control Pull-Up Voltage Pull-Up Resistance Over-Temperature Shutdown OTP Trip Point Over-Temperature Shutdown Restart Hysteresis RELIABILITY CHARACTERISTICS Calculated MTBF (MIL-217) MIL-HDBK-217F Calculated MTBF (Telcordia) TR-NWT-000332 For Field Demonstrated MTBF see our website Product # RQ1BxxxHPXxx Phone 1-888-567-9596 Typ. Max. Units Notes & Conditions 200 160 200 V V V 3000 3000 3000 100 125 18 V dc V dc V dc °C °C V 110 160 V 64.0 61 3.0 100 1.1\1.8 66.0 63 V V V V µF µH\µF Not Available Typical ESR 0.1-0.2 Ω Internal values; see Figure D ms ms % Full load, Vout=90% nom. Figure E Maximum Output Capacitance 10 200 0 220 Continuous Continuous 1s Baseplate temperature See Absolute Maximum Ratings MΩ pF 1000 275 125 125 125 100 °C °C °C °C Package rated to 150 °C UL rated max operating temp 130 °C 295 kHz Isolation stage switching freq. is half this 18 0.8 V Application notes Figures A & B 5 50 125 10 1.20 1.44 V kΩ °C °C Average PCB Temperature 106 Hrs. Tb = 70°C 106 Hrs. Tb = 70°C www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 2 Technical Specification RQ1BxxxHPXxx 120 Typical Current Limit Inception Point Output Voltage (%) 100 80 Typical Output Voltage at Shutdown 60 40 Vin min Vin nom 20 Vin max 0 0 Common Figure 1: Typical startup waveform. Input voltage pre-applied, ON/ OFF Pin on Ch 2. 10 20 30 40 50 60 70 80 90 Load Current (%) 100 110 120 130 140 150 Common Figure 2: Output voltage vs. load current showing typical current limit curves and converter shutdown points. 100,000.0 10,000.0 5V All voltages 15V 10,000.0 Trim Resistance (KΩs) Trim Resistance (KΩs) 12 V 24 V 1,000.0 100.0 0 1 2 3 4 5 6 7 8 9 10 1,000.0 100.0 10.0 0 Increase in Vout (%) Common Figure 3: Trim graph for trim-up 5 to 24V outputs. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Decrease in Vout (%) Common Figure 4: Trim graph for trim down. www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 3 Input:66-160V Output:5.0V Current:48A Part No.:RQ1B050HPx48 RQ1B050HPx48 Electrical Characteristics(5.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 110V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units Notes & Conditions INPUT CHARACTERISTICS Maximum Input Current 5.6 A Vin min; trim up; in current limit No-Load Input Current 50 70 mA Disabled Input Current 2 5 mA Response to Input Transient 0.17 V See Figure 6 Input Terminal Ripple Current 170 mA RMS Recommended Input Fuse 8 A Fast acting external fuse recommended OUTPUT CHARACTERISTICS Output Voltage Set Point 4.950 5.000 5.050 V Output Voltage Regulation Over Line ±0.1 ±0.3 % Over Load ±0.1 ±0.3 % Over Temperature -75 75 mV Total Output Voltage Range 4.875 5.125 V Over sample, line, load, temperature & life Output Voltage Ripple and Noise 20 MHz bandwidth; see Note 1 Peak-to-Peak 180 360 mV Full load RMS 30 60 mV Full load A Operating Output Current Range 0 48 Subject to thermal derating Output DC Current-Limit Inception 52.8 57.6 62.4 A Output voltage 10% Low Output DC Current-Limit Shutdown Voltage 2.2 V Back-Drive Current Limit while Enabled 1 A Negative current drawn from output Back-Drive Current Limit while Disabled 2 mA Negative current drawn from output Maximum Output Capacitance 8,000 µF Vout nominal at full load (resistive load) Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) 150 mV 50% to 75% to 50% Iout max Settling Time 200 µs To within 1% Vout nom Output Voltage Trim Range -20 10 % Across Pins 8&4; Common Figures 3-5;see Note 2 Output Voltage Remote Sense Range 10 % Across Pins 8&4 Output Over-Voltage Protection 5.9 6.1 6.4 V Over full temp range EFFICIENCY 100% Load 86 % See Figure 1 for efficiency curve 50% Load 90 % See Figure 1 for efficiency curve Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 2: Trim-up range is limited below 10% at low line and full load. Contact SynQor applications support for more detail. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 4 Input:66-160V Output:5.0V Current:48A Part No.:RQ1B050HPx48 100 45 95 40 35 Power Dissipation (W) Efficiency (%) 90 85 80 75 70 66Vin 25 20 15 10 110Vin 65 30 160Vin 60 0 4 8 12 16 20 24 28 Load Current (A) 32 36 40 44 66Vin 110Vin 5 48 Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 160Vin 0 0 4 8 12 16 20 24 28 Load Current (A) 32 36 40 44 48 Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 50 50 40 40 Iout (A) Iout(A) 30 20 30 400LFM 20 300LFM 200LFM 100LFM 10 10 0 0 60 70 80 90 100 25 40 55 70 85 Ambient Temperature(oC) 110 Base Plate Temperature(oC) Figure 3: Maximum output current vs. base plate temperature (nominal input voltage). Figure 4: Encased Converter (0.7" heatsink) max. output current derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: 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, Ch 2: Iout (10A/div.) Figure 6: Output voltage response to step-change in input voltage (1V/µs). Load cap: 1 μF ceramic and 15 μF tantalum capacitors. Ch 1: Vout, Ch 2: Vin. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 5 Input:66-160V Output:12V Current:21A Part No.:RQ1B120HPx21 RQ1B120HPx21 Electrical Characteristics(12.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 110V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units Notes & Conditions INPUT CHARACTERISTICS Maximum Input Current 5.5 A Vin min; Vout nom; in current limit No-Load Input Current 50 70 mA Disabled Input Current 3 5 mA Response to Input Transient 0.35 V See Figure 6 Input Terminal Ripple Current 170 mA RMS Recommended Input Fuse 8 A Fast acting external fuse recommended OUTPUT CHARACTERISTICS Output Voltage Set Point 11.88 12.00 12.12 V Output Voltage Regulation Over Line ±0.1 ±0.3 % Over Load ±0.1 ±0.3 % Over Temperature -180 180 mV Total Output Voltage Range 11.70 12.30 V Over sample, line, load, temperature & life Output Voltage Ripple and Noise 20 MHz bandwidth; see Note 1 Peak-to-Peak 120 240 mV Full load RMS 20 40 mV Full load A Operating Output Current Range 0 21 Subject to thermal derating Output DC Current-Limit Inception 23.1 25.2 27.3 A Output voltage 10% Low Output DC Current-Limit Shutdown Voltage 6.6 V Back-Drive Current Limit while Enabled 0.5 A Negative current drawn from output Back-Drive Current Limit while Disabled 2 mA Negative current drawn from output Maximum Output Capacitance 1,500 µF Vout nominal at full load (resistive load) Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) 350 mV 50% to 75% to 50% Iout max Settling Time 100 µs To within 1% Vout nom Output Voltage Trim Range -20 10 % Across Pins 8&4; Common Figures 3-5;see Note 2 Output Voltage Remote Sense Range 10 % Across Pins 8&4 Output Over-Voltage Protection 14.0 14.6 15.2 V Over full temp range EFFICIENCY 100% Load 91 % See Figure 1 for efficiency curve 50% Load 93 % See Figure 1 for efficiency curve Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 2: Trim-up range is limited below 10% at low line and full load. Contact SynQor applications support for more detail. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 6 Input:66-160V Output:12V Current:21A Part No.:RQ1B120HPx21 30 100 95 25 Power Dissipation (W) Efficiency (%) 90 85 80 ` 75 70 20 15 10 66Vin 66Vin 110Vin 65 160Vin 3 6 9 12 Load Current (A) 15 18 160Vin 0 60 0 110Vin 5 0 21 Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 3 6 9 12 15 Load Current (A) 18 21 Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 24 21 25 18 20 15 12 Iout (A) Iout (A) 15 9 10 6 400LFM 5 300LFM 200LFM 3 100LFM 0 0 60 70 80 90 100 25 40 55 70 85 Ambient Temperature (oC) 110 Base Plate Temperature (oC) Figure 3: Maximum output current vs. base plate temperature (nominal input voltage). Figure 4: Encased Converter (0.7" heatsink) max. output current derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: 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, Ch 2: Iout (5A/div.) Figure 6: Output voltage response to step-change in input voltage (1V/µs). Load cap: 1 μF ceramic and 15 μF tantalum capacitors. Ch 1: Vout, Ch 2: Vin. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 7 Input:66-160V Output:15V Current:17A Part No.:RQ1B150HPx17 RQ1B150HPx17 Electrical Characteristics(15.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 110V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units Notes & Conditions INPUT CHARACTERISTICS Maximum Input Current 5.6 A Vin min; Vout nom; in current limit No-Load Input Current 50 60 mA Disabled Input Current 3 5 mA Response to Input Transient 0.45 V See Figure 6 Input Terminal Ripple Current 180 mA RMS Recommended Input Fuse 8 A Fast acting external fuse recommended OUTPUT CHARACTERISTICS Output Voltage Set Point 14.85 15.00 15.15 V Output Voltage Regulation Over Line ±0.1 ±0.3 % Over Load ±0.1 ±0.3 % Over Temperature -225 225 mV Total Output Voltage Range 14.62 15.38 V Over sample, line, load, temperature & life Output Voltage Ripple and Noise 20 MHz bandwidth; see Note 1 Peak-to-Peak 160 320 mV Full load RMS 20 40 mV Full load A Operating Output Current Range 0 17 Subject to thermal derating Output DC Current-Limit Inception 18.7 20.4 22.1 A Output voltage 10% Low Output DC Current-Limit Shutdown Voltage 8 V Back-Drive Current Limit while Enabled 0.5 A Negative current drawn from output Back-Drive Current Limit while Disabled 3 mA Negative current drawn from output Maximum Output Capacitance 1,000 µF Vout nominal at full load (resistive load) Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) 500 mV 50% to 75% to 50% Iout max Settling Time 100 µs To within 1% Vout nom Output Voltage Trim Range -20 10 % Across Pins 8&4; Common Figures 3-5 Output Voltage Remote Sense Range 10 % Across Pins 8&4 Output Over-Voltage Protection 17.0 18.3 19.4 V Over full temp range EFFICIENCY 100% Load 91 % See Figure 1 for efficiency curve 50% Load 93 % See Figure 1 for efficiency curve Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 8 Input:66-160V Output:15V Current:17A Part No.:RQ1B150HPx17 100 35 95 30 Power Dissipation (W) Efficiency (%) 90 85 80 75 70 66Vin 65 160Vin 25 20 15 10 66Vin 110Vin 60 0 1 2 3 4 5 6 7 8 9 110Vin 5 160Vin 0 10 11 12 13 14 15 16 17 0 Load Current (A) Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Load Current (A) Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 18 20 15 15 Iout (A) Iout (A) 12 9 10 6 5 400LFM 300LFM 200LFM 3 100LFM 0 25 0 60 70 80 90 Base Plate Temperature(oC) 100 40 55 70 85 Ambient Temperature (oC) 110 Figure 3: Maximum output current vs. base plate temperature (nominal input voltage). Figure 4: Encased Converter (0.7" heatsink) max. output current derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: 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, Ch 2: Iout (2.5 A/div). Figure 6: Output voltage response to step-change in input voltage (1V/µs). Load cap: 1 μF ceramic and 15 μF tantalum capacitors. Ch 1: Vout, Ch 2: Vin. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 9 Input:66-160V Output:24V Current:10A Part No.:RQ1B240HPx10 RQ1B240HPx10 Electrical Characteristics(24.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 110V dc unless otherwise noted; full operating temperature range is -40 °C to +100 °C baseplate temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units Notes & Conditions INPUT CHARACTERISTICS Maximum Input Current 5.3 A Vin min; trim up; in current limit No-Load Input Current 50 60 mA Disabled Input Current 3 5 mA Response to Input Transient 0.8 V See Figure 6 Input Terminal Ripple Current 170 mA RMS Recommended Input Fuse 8 A Fast acting external fuse recommended OUTPUT CHARACTERISTICS Output Voltage Set Point 23.76 24.00 24.24 V Output Voltage Regulation Over Line ±0.1 ±0.3 % Over Load ±0.1 ±0.3 % Over Temperature -360 360 mV Total Output Voltage Range 23.40 24.60 V Over sample, line, load, temperature & life Output Voltage Ripple and Noise 20 MHz bandwidth; see Note 1 Peak-to-Peak 120 240 mV Full load RMS 40 80 mV Full load A Operating Output Current Range 0 10 Subject to thermal derating Output DC Current-Limit Inception 11.0 12.0 13.2 A Output voltage 10% Low Output DC Current-Limit Shutdown Voltage 12 V Back-Drive Current Limit while Enabled 0.2 A Negative current drawn from output Back-Drive Current Limit while Disabled 4 mA Negative current drawn from output Maximum Output Capacitance 400 µF Vout nominal at full load (resistive load) Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) 1100 mV 50% to 75% to 50% Iout max Settling Time 100 µs To within 1% Vout nom Output Voltage Trim Range -20 10 % Across Pins 8&4; Common Figures 3-5 Output Voltage Remote Sense Range 10 % Across Pins 8&4 Output Over-Voltage Protection 28.1 29.3 30.5 V Over full temp range EFFICIENCY 100% Load 90 % See Figure 1 for efficiency curve 50% Load 92 % See Figure 1 for efficiency curve Note 1: Output is terminated with 1 µF ceramic capacitor. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 10 Input:66-160V Output:24V Current:10A Part No.:RQ1B240HPx10 100 35 95 30 Power Dissipation (W) 90 Efficiency (%) 85 80 75 66Vin 70 110Vin 25 20 15 10 66Vin 5 160Vin 160Vin 65 60 110Vin 0 0 1 2 3 4 5 6 Load Current (A) 7 8 9 10 Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 0 1 2 3 4 5 6 7 Load Current (A) 8 9 10 Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltages at 25°C. 12 10 10 8 8 6 6 Iout (A) Iout (A) 12 4 4 400LFM 2 300LFM 200LFM 2 100LFM 0 0 60 70 80 Base Plate 90 100 25 40 55 70 85 Ambient Temperature (oC) 110 Temperature(oC) Figure 3: Maximum output current vs. base plate temperature (nominal input voltage). Figure 4: Encased Converter (0.7" heatsink) max. output current derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: 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 capacitor. Ch 1: Vout, Ch 2: Iout (2.5A/div.) Figure 6: Output voltage response to step-change in input voltage (1V/ms). Load cap: 1 μF ceramic capacitor. Ch 1: Vout, Ch 2: Vin. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 11 Technical Specification RQ1BxxxHPXxx Application Section BASIC OPERATION AND FEATURES CONTROL FEATURES This 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. 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(-). 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. Conductive cooling design can be used with heat sink or cold plate cooling systems. Full power is available with baseplate temperature up to 100°C. This series of converters use the industry standard footprint and pin-out configuration. ON/OFF The ON/OFF signal is active low (meaning that a low voltage turns the converter on). Figure A details four possible circuits for driving the ON/OFF pin. 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. ON/OFF 5V Vin(_) Vin(_) Remote Enable Circuit ON/ OFF Negative Logic (Permanently Enabled) 5V ON/OFF TTL/ CMOS Open Collector Enable Circuit Phone 1-888-567-9596 TTL 100pF Direct Logic Drive Figure A: Various circuits for driving the ON/OFF pin. Product # RQ1BxxxHPXxx 50k ON/OFF Vin(_) Vin(_ ) 50k -Vin Figure B: Internal ON/OFF pin circuitry www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 12 Technical Specification Application Section 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 and Pin 5 (SENSE(-) input). For a desired decrease of the nominal output voltage, the value of the resistor should be: Rtrim-down = ( Δ% = | ) - 10.22 [kΩ] 511 Δ% where Vnominal – Vdesired Vnominal | x 100% To increase the output voltage, the user should connect a resistor between Pin 6 and Pin 7 (SENSE(+) input). For a desired increase of the nominal output voltage, the value of the resistor should be: Rtrim-up = ( 5.11VOUT x (100+Δ%) 1.225Δ% - 511 Δ% - 10.22 ) [kΩ] 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 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. RQ1BxxxHPXxx Protection Features Input Under-Voltage Lockout: 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 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* 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: 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 CurrentLimit Shutdown Voltage, the converter turns off. The converter then enters a “hiccup mode” where it repeatedly turns on and off at a 5 Hz (nominal) frequency with a 5% duty cycle until the short circuit condition is removed. This prevents excessive heating of the converter or the load board. 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 200 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 “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*. Transient and Surge Protection: The wide input range of the RailQor line of converters covers all transient requirements of EN 50155. For short duration transients and surges found in other standards (such as RIA 12) that exceed the maximum input voltage rating of the converter, SynQor has provided a design guide for a transient suppression circuit. Please consult the application note "Rail Power Applications" on our website www.synqor.com. * See Electrical Characteristics page. Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 13 Technical Specification RQ1BxxxHPXxx 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 C below provides a typical circuit diagram which details the input filtering and voltage trimming. Vout(+) Vin(+) Vin External Input Filter Electrolytic Capacitor Vsense(+) Rtrim-up Trim ON/OFF or Rtrim-down Vsense(_) Vin(_) Cload Iload Vout(_) Figure C: Typical application circuit (negative logic unit, permanently enabled). Input Filtering and External Input Capacitance: Figure D 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 on the Electrical Specifications page. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. L Vin(+) C Vin(_) Figure D: Internal Input and Output Filter Diagram (component values listed on specifications page). L Vin(+) C Product # RQ1BxxxHPXxx Vin(_) Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 14 Technical Specification RQ1BxxxHPXxx Application Section Startup Inhibit Period: The Startup Inhibit Period ensures that the converter will remain off for approximately 200 ms when it is shut down for any reason. When an output short is present, this generates a 5 Hz “hiccup mode,” which prevents the converter from overheating. In all, there are six 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. As long as the user’s thermal system keeps TB < 100 ºC, the converter can deliver its full rated power. Input Under-Voltage Lockout Output Over-Voltage Protection Over Temperature Shutdown Current Limit Short Circuit Protection Turned off by the ON/OFF input 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, RTH-BA, 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 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 100 ºC. Figure E shows three turn-on scenarios, where a Startup Inhibit Period is initiated at t0, t1, and t2: Pdiss max = 100 ºC - TA RTH-BA 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. This value of power dissipation can then be used in conjunction with the data shown in Figure 2 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. For convenience, power derating curves for an encased converter without a heatsink are provided for each output voltage. Vin Under-Voltage Lockout Turn-On Threshold ON/OFF (neg logic) ON OFF ON OFF ON 10ms (initial start-up inhibit period) Vout 200ms 215ms t1 t0 (typical turn on time) (typical start-up inhibit period) 200ms t2 t Figure E: Startup Inhibit Period (turn-on time not to scale) Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 15 Technical Specification Application Section Designing for Maximizing Available Power: RailQor products have been designed for full power operation in demanding thermal environments. However, there are techniques that can be applied external to the converter to ensure the best possible thermal performance. These include correctly applying a heatsink to the baseplate of the converter and maximizing the heat transferred through the pins. The following discussions are only guidelines and may not be necessary depending on the application Optimal Heatsink Application: There are two key components to maximizing the thermal dissipation when using a heatsink. One is minimizing the thermal resistance between the converter and the heatsink itself. There are imperfections between the mating surfaces that reduce contact area between the two. A suitable thermally conductive interface material should be used to maintain a good thermal connection. A commonly used example is thermal grease. When utilizing the threaded inserts on the baseplate of a SynQor converter, care must be taken not to exceed the torque or screw depth guidelines found in the mechanical diagram. Two, airflow must be directed to pass between the fins of the heatsink to maximize the surface area for heat removal. Heatsinks are often available with both transverse and longitudinal fin direction to allow system flexibility. Care should be taken to avoid large external components surrounding the converter from blocking airflow. Figure F: Example of properly soldered pin joint Product # RQ1BxxxHPXxx Phone 1-888-567-9596 RQ1BxxxHPXxx Layout Considerations: Significant performance improvement can be made by designing a printed circuit board to properly sink heat away from the converter through its pins. The first step is to ensure a correctly formed solder joint at each pin. A smooth fillet and complete barrel fill should be observed at the boundary of pin and mounting hole to ensure maximum heat conduction from pin to board (Figure F). It is worth noting here that encased SynQor products are not compatible with reflow processes as it may disrupt the placement of internal components. The board itself should also have as many layers and as high of copper weight as is practical for the application. Large ground and power planes are best as the most heat will be conducted through the large power pins of the converter on both input and output sides. The heat must also have a path to conduct from the copper planes of the board to the outside environment. The typical FR4 material used in construction of a printed circuit board is greater than 1000 times less thermally conductive than copper and will act as an insulator between each copper plane. To mitigate this, generous use of thermal vias is recommended in the board area surrounding and below the converter. A proper density of vias allows heat to conduct from the board to the air while maintaining a large amount of copper area to conduct to the vias. For reference, boards used in SynQor thermal testing are 6 layer, 2 oz. copper boards with 50 mil diameter thermal vias at a density of 36/in2 (Figure G). Figure G: Image of thermal via layout surrounding converter in test board www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 16 Technical Specification RQ1BxxxHPXxx Standard Mechanical Diagram 2.486 [63.14] 2.000 [50.80] SEATING PLANE HEIGHT 0.512±0.005 [ 13.00±0.12 ] PIN EXTENSION 0.163 [4.14] 1.000 [25.40] 0.700 [17.78] 4 TOP VIEW 5 6 7 8 0.004 [0.10] 1.900 2.386 [48.26] [60.60] 0.01 [0.3] 1.900 [48.26] 3 1 0.30 [7.6] 1.400 [35.56] 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 1-3 AND 5-7 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 (133 g) 7) ALL DIMENSIONS IN INCHES(mm) TOLERANCES: X.XXIN +/-0.02 (X.Xmm +/-0.5mm) X.XXXIN +/-0.010 (X.XXmm +/-0.25mm) Phone 1-888-567-9596 1 0.400 [10.16] THRU HOLE STANDOFFS SEE NOTE 1 (4 PLCS) NOTES Product # RQ1BxxxHPXxx 2 Pin 1 Name Vin(+) 2 ON/OFF PIN DESIGNATIONS Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Negative input voltage Negative output voltage Negative remote sense(see note 1) Output voltage trim (see note 2) Positive remote sense (see note 3) Positive output voltage 3 Vin(–) 4 Vout(–) 5 SENSE(–) 6 TRIM 7 SENSE(+) 8 Vout(+) 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. www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 17 Technical Specification Flanged Mechanical Diagram SEATING PLANE HEIGHT 0.495±0.025 [ 12.57±0.63 ] 3.150 [80.01] 2.950 [74.93] 2.486 [63.14] RQ1BxxxHPXxx PIN EXTENSION 0.180 [4.57] 1.000 [25.40] 0.700 [17.78] 4 5 6 7 8 TOP VIEW 1.300 [33.02] 0.010 [0.25] 1.900 [48.26] 1.866 [47.40] 0.31 [7.9] 2.386 [60.60] 3 2 1 1 0.775±0.020 [ 19.69±0.50 ] .130 [3.30] SEE NOTE 1 (6 PLCS) 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 AND 5-7 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 (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 # RQ1BxxxHPXxx Phone 1-888-567-9596 FLANGE THICKNESS 0.125 [3.18] 0.400 [10.16] 1.400 [35.56] Pin 1 Name Vin(+) 2 ON/OFF PIN DESIGNATIONS Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Negative input voltage Negative output voltage Negative remote sense(see note 1) Output voltage trim (see note 2) Positive remote sense (see note 3) Positive output voltage 3 Vin(–) 4 Vout(–) 5 SENSE(–) 6 TRIM 7 SENSE(+) 8 Vout(+) 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. www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 18 Technical Specification Standards & Qualifications RQ1BxxxHPXxx STANDARDS COMPLIANCE Parameter STANDARDS COMPLIANCE UL 60950-1/R:2011-12 CAN/CSA C22.2 No. 60950-1/A1:2011 EN60950-1/A2:2013 CE Marked IEC 61000-4-2 Notes & Conditions Reinforced insulation 2006/95/EC Low Voltage Directive ESD test, 8kV - NP,15kV 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. QUALIFICATION TESTING Parameter # Units Test Conditions QUALIFICATION TESTING Vibration 5 EN 61373:1999 Category I, Class B, Body mounted Life Test 30 95% rated Vin and load, units at derating point, 1000 hours Cold 5 EN 60068-2-1:2007 Dry Heat 5 EN 60068-2-1:2007 Mechanical Shock 5 EN 61373:1999 Category I, Class B, Body mounted Temperature Cycling 5 -40 °C to 100 °C, unit temp. ramp 15 °C/min., 500 cycles Power/Thermal Cycling 5 Toperating = min to max, Vin = min to max, full load, 100 cycles Design Marginality 5 Tmin-10 °C to Tmax+10 °C, 5 °C steps, Vin = min to max, 0-105% load Damp Heat, Cyclic 5 EN 60068-2-30:2005 Solderability 15 pins MIL-STD-883, method 2003.8 Note: Governing Standard BS EN 50155:2007 Railway applications - Electronic equipment used on rolling stock Product # RQ1BxxxHPXxx Phone 1-888-567-9596 www.SynQor.com Doc.# 005-0006472 Rev. A 10/22/2014 Page 19 Technical Specification RQ1BxxxHPXxx Ordering Information PART NUMBERING SYSTEM ORDERING INFORMATION The part numbering system for SynQor’s dc-dc converters follows the format shown in the example below. The tables below show the valid model numbers and ordering options for converters in this product family. When ordering SynQor converters, please ensure that you use the complete 15 character part number consisting of the 12 character base part number and the additional characters for options. Add “-G” to the model number for 6/6 RoHS compliance. RQ 1 B 0 5 0 H P C 4 8 N R S - G 6/6 RoHS Options (see Ordering Information) Output Current Thermal Design Performance Level Model Number Input Voltage Output Voltage Max Output Current RQ1B050HPw48xyz 66-160V 5.0V 48A RQ1B120HPw21xyz 66-160V 12V 21A RQ1B150HPw17xyz 66-160V 15V 17A RQ1B240HPw10xyz 66-160V 24V 10A Package Size Output Voltage Input Voltage Product Family The first 12 characters comprise the base part number and the last 3 characters indicate available options. The “-G” suffix indicates 6/6 RoHS compliance. Application Notes A variety of application notes and technical white papers can be downloaded in pdf format from our website. RoHS Compliance: The EU led RoHS (Restriction of Hazardous Substances) Directive bans the use of Lead, Cadmium, Hexavalent Chromium, Mercury, Polybrominated Biphenyls (PBB), and Polybrominated Diphenyl Ether (PBDE) in Electrical and Electronic Equipment. This SynQor product is 6/6 RoHS compliant. For more information please refer to SynQor’s RoHS addendum available at our RoHS Compliance / Lead Free Initiative web page or e-mail us at [email protected]. The following options must be included in place of the w x y z spaces in the model numbers listed above. Not all combinations make valid part numbers, please contact SynQor for availability. Thermal Design w C - Encased D - Encased with Non-Threaded Baseplate V - Encased with Flanged Baseplate Options Description Enable Logic Pin Style x y N - Negative R - 0.180" Feature Set z S - Standard PATENTS 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: Product # RQ1BxxxHPXxx 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 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.# 005-0006472 Rev. A 10/22/2014 Page 20