48A/240W

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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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(_)
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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)
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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
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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
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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)
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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.
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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
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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
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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.
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Doc.# 005-0006472 Rev. A 10/22/2014
Page 20