FEATURES • • • • • • • • • • • HR700 SERIES 70 WATT DC/DC CONVERTERS 28 VOLT INPUT –40°C to + 85°C operation 19 to 40 VDC input Fully Isolated Optocoupler feedback Fixed frequency, 245 kHz typical Topology – Push-Pull Forward 50 V for up to 50 ms transient protection Inhibit/sync function Indefinite short circuit protection Remote sense on single models Up to 84% efficiency MODELS VDC OUTPUT SINGLE 5 12 15 DUAL ±12 ±15 TRIPLE +5 & ±12 +5 & ±15 Size (max.): 3.20 x 2.46 x 0.595 inches (81.3 x 62.5 x 15.11 mm) See Section B8, case L, for dimensions. Weight: 140 grams typical Screening: Standard only. See Section B9 for screening description. DESCRIPTION HR700 Series DC/DC converters offer up to 70 watts of power from single, dual, or triple outputs in one package. The converters combine the small size and high reliability of hybrid-based components, the high efficiency of switching regulators, and the isolation, regulation, and low noise characteristics of linear regulators. SMALL SIZE The HR700 converters are manufactured using techniques that provide very small size and low profile components. Each converter uses less than eight square inches of board areas and is 0.595 inches high or less. The overall power density is 20 watts per cubic inch. HIGH RELIABILITY Assembled using thick-film technology, the HR700 parts use the same manufacturing procedures and quality controls that we apply to converters designed for commercial airliners, the space shuttle, advanced fighter aircraft, and other high reliability applications. The steel cases are hermetically sealed in a dry nitrogen environment and are guaranteed a maximum leak rate of less than 10-3 atmcc/sec. All devices are 100% electrically tested. HIGH PERFORMANCE The HR700 series parts are high efficiency, low noise, pulse-width modulated converters which use a quasi-square wave forward converter design with a nominal switching frequency of 245 kHz. Isolation between input an output is provided with a transformer in the forward power loop and a wide band, temperature insensitive, optical link in the feedback control loop. Short circuit protection is provided by detecting peak primary switching current on a cycle basis and limiting it to approximately 130% of the full load input current. This method results in quick and positive current limiting under short circuit conditions. HR700 Series DC/DC converters are designed to provide full power operation over the input voltage range of 19 to 40 VDC. Operation below an input of 19 volts is possible with derated output power. Outputs are available as 5, 12, and 15 VDC single, dual and triple outputs. The converters typically provide greater than 80% efficiency over the entire input range. Line regulation is typically within 0.1% and load regulation within 0.2%. LOW NOISE The HR700 Series converters offer low noise on both the input and output lines. A two section, four pole, LC input filter is included to provide very low reflected line ripple current. Output ripple is maintained at less than 50 mV p-p for single and dual models and 85 mV p-p for triple output models. INHIBIT/SYNC FEATURE An inhibit/sync pin is standard on all models of the HR700 Series converters. The pin serves as both an output inhibit and as a synchronization input. In the inhibit mode an open collector TTL compatible low (<0.8 V) will disable internal switching thereby inhibiting the unit’s output. Inhibiting in this manner results in an extremely low quiescent current. B4-33 HR700 SERIES 70 WATT DC/DC CONVERTERS ABSOLUTE MAXIMUM RATINGS Output Power • 60 to 70 watts depending on model Lead Soldering Temperature (10 sec per lead) • 300°C Storage Temperature Range (Case) • –55°C to +125°C RECOMMENDED OPERATING CONDITIONS Input Voltage Range • 19 to 40 VDC continuous (see Derating) Case Operating Temperature (Tc) • –40°C to +85°C full power SYNC AND INHIBIT TYPICAL CHARACTERISTICS Sync In (245 to 370 kHz.) • Duty cycle 70% min, 98% max. • Logic low 0.8V max • Logic high 4.5 V min • Referenced to input common • If sync is not used, leave unconnected Inhibit TTL Open Collector • Logic low (output disabled) Inhibit pin current 1 mA max • Referenced to input common • Logic high (output enabled) V = ≥ 4.5V Output Voltage Temperature Coefficient • 150 ppm/°C, typical Input to Output Capacitance • 160 pF, typical Isolation • 100 megohm minimum at 500 V Conversion Frequency • Free run mode 245 kHz, typical Inhibit Pin Voltage (unit enabled) • 4.5 to 5.5 V DERATING OUTPUT POWER/CURRENT AND INPUT VOLTAGE Temperatures are referenced to the temperature at the converter’s baseplate • Linearly derate output power/current from 100% at 85°C to 0% at 125°C. • Above 105°C linearly derate steady state input voltage to 33 volts at 125°C. • Indefinite short circuit protection is not guaranteed above 85°C case. • Operation below an input voltage of 19 volts, including operation in MILSTD-704E emergency power conditions, is possible with derated output power. See Figures 10 and 11. Electrical Characteristics: 25°C Tc, 28 VDC Vin, 100% load, free run, unless otherwise specified. SINGLE OUTPUTS HR701-2812 HR701-2815 CONDITION MIN TYP MAX MIN OUTPUT VOLTAGE FULL LOAD 4.90 5.00 5.10 11.75 12.00 12.25 OUTPUT CURRENT VIN = 19 TO 40 — — 12.00 — — 5.83 — — 4.67 A OUTPUT POWER Tc = –55°C TO +85°C — — 60 — — 70 — — 70 W OUTPUT RIPPLE FULL LOAD BW ≤ 2 MHz — 30 100 — 30 100 — 30 100 mV p-p TYP MAX MIN. TYP MAX 14.75 15.00 15.25 UNITS VDC LINE REGULATION VIN = 19 TO 40 — 10 30 — 10 30 — 10 30 mV LOAD REGULATION INPUT VOLTAGE INPUT CURRENT NO LOAD TO FULL — 10 30 — 10 30 — 10 30 mV 19 28 40 19 28 40 19 28 40 VDC — — 75 30 100 35 — — 70 30 100 35 — — 70 30 100 35 mA mA p-p INPUT REFL. RIPPLE EFFICIENCY STARTUP DELAY B4-34 HR701-2805 PARAMETER NO LOAD INHIBITED FULL LOAD BW ≤10 MHz WITH LOW IMPEDANCE SOURCE — 10 50 — 10 50 — 10 50 77 80 — 80 83 — 80 83 — % — 5 10 — 8 10 — 8 10 ms HR700 SERIES 70 WATT DC/DC CONVERTERS Electrical Characteristics: 25°C Tc, 28 VDC Vin, 100% load, free run, unless otherwise specified. DUAL AND TRIPLE OUTPUTS PARAMETER OUTPUT VOLTAGE HR702-2812 CONDITION FULL LOAD OUTPUT VIN = CURRENT1, 2 19 TO 40 MIN MAIN DUAL HR702-2815 MAX — — — ±11.75 ±12.00 ±12.25 MIN TYP HR703-28512 MAX MIN TYP HR703-28515 MAX MIN TYP MAX — — — 4.90 5.05 5.15 4.90 4.95 5.10 ±14.75 ±15.00 ±15.25 ±11.50 ±11.80 ±12.10 ±15.05 ±15.30 ±15.75 UNITS VDC — — — 2.92 — 5.5 — — — 2.33 — 4.4 — — 4.0 1.67 10.0 4.2 — — 4.0 1.33 10.0 3.33 A — — — — 35 — — 66.5 70 — — — — 35 — — 66.5 70 — — — 20 20 — 50 50 60 — — — 20 20 — 50 50 60 W MAIN DUAL — — — 30 — 100 — — — 30 — 100 — — 50 50 100 100 — — 50 50 100 100 mV p-p LINE VIN = REGULATION 19 TO 40 MAIN DUAL — — — 10 — 30 — — — 10 — 30 — — 2 100 25 225 — — 2 100 25 225 mV NO LOAD LOAD3 REGULATION TO FULL MAIN DUAL — — — 25 — 50 — — — 25 — 50 — — 5 480 30 750 — — 5 300 30 600 mV DUAL CROSS4 REGULATION +PO = 3 W TO 35 W –PO = 35 W — 1.5 3.0 — 1.5 3.0 — — — — — — — 2.0 4.0 — 2.0 3.5 — — — — — — — — — — — — — 2.3 6.0 — 2.3 5.0 OUTPUT POWER1, 2 OUTPUT RIPPLE MAIN DUAL TYP MAIN ±DUAL TOTAL FULL LOAD BW ≤ 2 MHz +PO = 20 W TO 50 W –PO = 50 W TO 20 W MAIN +PO = 30 W CROSS5 REGULATION DUAL +PO = 3 W TO 27 W –PO = 27 W TO 3 W MAIN +PO = 3 W TO 30 W DUAL ±PO = 15 W INPUT REFL. RIPPLE % — — — — — — — 5.4 9.0 — 5.0 7.0 19 28 40 19 28 40 19 28 40 19 28 40 VDC NO LOAD INHIBITED — — 75 25 100 35 — — 75 25 100 35 — — 85 30 115 35 — — 60 30 115 35 mA FULL LOAD BW ≤10 MHz — 15 50 — 15 50 — 15 50 — 15 50 mA p-p INPUT VOLTAGE INPUT CURRENT % EFFICIENCY 80 83 — 80 83 — 79 84 — 79 84 — % STARTUP DELAY — 15 25 — 15 25 — 6 10 — 6 10 ms Notes 1. On dual output models the maximum combined output power is 70 watts. A maximum of 95% (66.5 W) is available from any single output. 2. On triple output models the maximum combined output power is 60 watts. A maximum of 50 watts is available from a single output. 3. Balanced loads 4. Regulation effect on the negative dual output during the defined conditions. 5. Regulation effect on both dual outputs during the defined conditions. B4-35 HR700 SERIES 70 WATT DC/DC CONVERTERS THERMAL MANAGEMENT CALCULATING MAXIMUM AMBIENT TEMPERATURE HEAT SINK RECOMMENDATIONS The HR700 Series of DC/DC converters has an upper operating temperature of + 85°C at the baseplate of the case. The degree of heat sinking required to remain within this limit may be determined from Figure 1 which shows the maximum allowed internal power dissipation (PDISS vs. ambient temperature for various heat sink thermal resistances. PDISS may be calculated as: An HR700 Series converter in still air (other than convective currents) and with no conductive cooling paths other than through electrical connections at the pins will exhibit a thermal resistance of approximately 4°C / watt. In cases where this value proves to be too high it is recommended that additional heat sinking be supplied. The simplest method of accomplishing this is to firmly attach the converter to a PCB thereby providing a conductive thermal path. Secondly it is recommended that airflow be provided over the converter. Although each situation requires a thorough thermal analysis these two measures can reduce the thermal resistance to as low as 2°C / watt. If calculations indicate further heat sinking is required it is recommended that additional thermal mass be provided either under the base plate or on top of the converter's mounting flanges or both. PDISS = POUT / efficiency – POUT The efficiency for all combinations of POUT and VIN for the various models may be obtained from the graphs on the preceding pages. Example: Converter = HR702-2815, TAMB = 70°C, VIN = 28 VDC, POUT = 45 watts Efficiency = 85% (From Figure 7) PDISS = (45 / 85) – 45 = 7.95 watts From Figure 1 we can see that this situation will require thermal resistance of approximately 4.5°C / watt. Conversely we may also find the maximum ambient temperature which can be tolerated if we know the heat sink thermal resistance. Example: Converter = HR701-2805, VIN = 28 VDC, POUT = 45 W. Thermal Resistance = 3°C / watt. Efficiency = 83.5% (From Figure 3) PDISS = (45 / 0.835) – 45 = 8.89 watts. From Figure 1 we can see that the maximum allowed ambient temperature is approximately 75°C. 20 W /W C/W °C/W °C/ 4°CU=3° U=2 U=0 U= Watts 15 10 5 20° 40° 60° 80° 100° 120° 140° Degrees Centigrade Internal Power Dissipation (max) vs. Ambient Temperature FIGURE 1 B4-36 HR700 SERIES 70 WATT DC/DC CONVERTERS PIN OUT Squared corner indicates pin one. 1 Pin 1 2 3 4 5 6 7, 8 9, 10 Single Output Positive Input Case Ground Input Common Inhibit/Sync In Negative Sense Positive Sense Output Common Positive Output Dual Output Positive Input Case Ground Input Common Inhibit/Sync In Negative Output Positive Output Output Common No Connection Triple Output Positive Input Case Ground Input Common Inhibit/Sync In Negative Aux. Output Positive Aux. Output Output Common Main (+5) Output 2 3 4 BOTTOM VIEW HR700 See Section B8, case L, for dimensions. 9 7 5 10 8 6 FIGURE 2: PIN OUT MODEL NUMBERING KEY HR70 2 - 28 12 Base Model Number of Outputs (1 = single, 2 = dual, 3 = triple) Input Voltage Output Voltage (Main and aux. Vout for triple models) B4-37 HR700 SERIES 70 WATT DC/DC CONVERTERS Typical Performance Curves: 25°C Tc , 28 VDC Vin, 100% load, free run, unless otherwise specified. 89 20 V 84 28 V 83 82 81 80 EFFICIENCY (%) 88 87 87 86 85 84 28 V 83 40 V 82 78 81 20 30 40 50 60 70 84 28 V 83 40 V 81 10 20 30 40 50 60 70 10 20 30 40 50 60 70 OUTPUT POWER (WATTS) OUTPUT POWER (WATTS) HR701-2805 EFFICIENCY VS. LINE & LOAD HR701-2812 EFFICIENCY VS. LINE & LOAD HR701-2815 EFFICIENCY VS. LINE & LOAD FIGURE 5 FIGURE 4 87 87 19 V 19 V 19 V 85 85 83 83 83 81 79 28 V 77 75 40 V 73 EFFICIENCY (%) 85 EFFICIENCY (%) EFFICIENCY (%) 85 OUTPUT POWER (WATTS) 87 81 79 28 V 77 75 40 V 73 10 20 30 40 50 60 OUTPUT POWER (WATTS) HR702-2812 EFFICIENCY VS. LINE & LOAD 79 28 V 77 75 40 V 71 10 70 81 73 71 71 20 30 40 50 60 10 70 20 30 40 50 60 70 OUTPUT POWER (WATTS) OUTPUT POWER (WATTS) HR702-2815 EFFICIENCY VS. LINE & LOAD HR703-28512 EFFICIENCY VS. LINE & LOAD FIGURE 8 FIGURE 7 FIGURE 6 19 87 83 81 28 V 79 77 75 40 V 73 INPUT VOLTAGE (VOLTS) 19 V 85 EFFICIENCY (%) 86 82 FIGURE 3 HR702-2815 18 HR701-2815 17 HR701-2812 16 HR701-2815 15 18 HR702-2812 17 HR703-28512 HR703-28515 16 15 71 10 20 30 40 50 60 70 OUTPUT POWER (WATTS) HR703-28515 EFFICIENCY VS. LINE & LOAD FIGURE 9 B4-38 19 V 40 V 79 10 89 19 V 88 INPUT VOLTAGE (VOLTS) EFFICIENCY (%) 85 EFFICIENCY (%) 86 10 20 30 40 50 60 70 10 20 30 40 50 60 70 OUTPUT POWER (WATTS) OUTPUT POWER (WATTS) LOW LINE DROPOUT VS LOAD (50mV DROP) LOW LINE DROPOUT VS LOAD (50mV DROP) FIGURE 10 20621-009-DTS Rev A DQ# 2008 All technical information is believed to be accurate, but no responsibility is assumed for errors or omissions. Interpoint reserves the right to make changes in products or specifications without notice. HR700 Series is a trademark of Interpoint. Copyright © 1992 - 1999 Interpoint. All rights reserved. FIGURE 11 CASES CASE L 0.060 min (1.52) CASE L TOP VIEW Cover Placement and Min/Max Dimensions See Figure 50 for pin configuration 3.20 max (81.3) 0.060 min (1.52) 2.46 max (62.5) 0.337 min (8.56) 0.337 min (8.56) Squared corner indicates pin one Materials Header Cold Rolled Steel/Nickel/Tin Cover Cold Rolled Steel/Nickel/Tin Pins #52 alloy pins 1-4, and 9-10 #52 alloy with copper core pins 5-8 ceramic seal Case dimensions in inches (mm) Tolerance ±0.005 (0.13) for three decimal places ±0.01 (0.2) for two decimal places unless otherwise specified CAUTION Heat from reflow or wave soldering may damage the device. Solder pins individually with heat application not exceeding 300°C for 10 seconds per pin. FIGURE 49: CASE L MAXIMUM DIMENSIONS B8-31 CASES CASE L CASE L MFW Series: Screening – Standard or ES HR700 Series: no screening options Squared corner indicates pin one Solder Seal 0.141 x 6 (3.58) 2.850 (72.39) 1 2 3 4 .0.040 +0.005/-0.002 (1.02 +0.13/-0.05) BOTTOM VIEW 1.600 (40.64) Solder Tip-off 9 7 5 10 8 6 0.550 (13.97) 0.350 (8.89) FIGURE 50: CASE L DIMENSIONS B8-32 2.280 (57.91) 1.625 (41.28) 1.325 (33.66) 1.425 (36.20) 1.025 (26.04) 0.825 (20.96) 0.625 (15.88) 0.00 0.180 (4.57) 0.250 +0.05/-0.00 (6.35 +1.3/-0.0) 0.000 0.040 +0.007/-0.000 (1.02 +0.18/-0.00) 0.595 max (15.11) 0.000 QA SCREENING HR PRODUCTS HR PRODUCTS TEST (HR products) PRE-CAP INSPECTION Method 2017 FINAL ELECTRICAL TEST MIL-PRF-38534, Group A Subgroups 1 and 4: +25°C case HERMETICITY TESTING Gross Leak, Dip (1 x 10-3) FINAL VISUAL INSPECTION Method 2009 STANDARD yes yes yes yes Test methods are referenced to MIL-STD-883 as determined by MILPRF-38534. Applies to the following products: HR700 Series HR300 Series HR150 Series HR120 Series HR40 Series C2-13