MQFL-28E-2R5S Single Output H IGH R ELIABILITY DC-DC C ONVERTER 16-80V 2.5V 40A 88% @ 20A / 87% @ 40A Continuous Input Transient Input Output Output Efficiency a pu d bl va ic n at ce io d n 16-70V F ULL P OWER O PERATION : -55ºC TO +125ºC The MilQor® series of high-reliability DC-DC converters brings SynQor’s field proven high-efficiency synchronous rectifier technology to the Military/Aerospace industry. SynQor’s innovative QorSealTM packaging approach ensures survivability in the most hostile environments. Compatible with the industry standard format, these converters operate B Y-H 5S- at a fixed frequency, have no opto-isolators, and follow 2R 8E- 2 ter ver 0A on t @ 4 C u C o D / V DC in 2.5 28V FL- MQ conservative component derating guidelines. They are designed and manufactured to comply with a wide range of military standards. Design Process MQFL series converters are: • Designed for reliability per NAVSO-P3641-A guidelines • Designed with components derated per: — MIL-HDBK-1547A — NAVSO P-3641A Qualification Process MQFL series converters are qualified to: • MIL-STD-810F — consistent with RTCA/D0-160E • SynQor’s First Article Qualification — consistent with MIL-STD-883F • SynQor’s Long-Term Storage Survivability Qualification • SynQor’s on-going life test DESIGNED & MANUFACTURED IN THE USA FEATURING QORSEAL™ HI-REL ASSEMBLY Features • • • • • • • • Fixed switching frequency No opto-isolators Parallel operation with current share Remote sense Clock synchronization Primary and secondary referenced enable Continuous short circuit and overload protection Input under-voltage lockout/over-voltage shutdown Specification Compliance In-Line Manufacturing Process • • • • • • AS9100 and ISO 9001:2000 certified facility Full component traceability Temperature cycling Constant acceleration 24, 96, 160 hour burn-in Three level temperature screening Product # MQFL-28E-2R5S Phone 1-888-567-9596 MQFL series converters (with MQME filter) are designed to meet: • MIL-HDBK-704-8 (A through F) • RTCA/DO-160E Section 16 • MIL-STD-1275B • DEF-STAN 61-5 (part 6)/5 • MIL-STD-461 (C, D, E) • RTCA/DO-160E Section 22 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 1 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification BLOCK DIAGRAM 7 ISOLATION STAGE a pu d bl va ic n at ce io d n REGULATION STAGE CURRENT SENSE 1 POSITIVE INPUT T1 T2 T1 POSITIVE OUTPUT T2 2 8 INPUT RETURN ISOLATION BARRIER OUTPUT RETURN 3 CASE GATE DRIVERS UVLO OVSD CURRENT LIMIT 4 GATE DRIVERS 12 ENABLE 2 11 MAGnEtIC ENABLE 1 PRIMARY CONTROL 5 SECONDARY CONTROL SHARE 10 DAtA COUPLInG SYNC OUTPUT + SENSE 6 9 SYNC INPUT - SENSE BIAS POWER CONTROL POWER tRAnSFORMER TYPICAL CONNECTION DIAGRAM 1 2 3 28 Vdc 4 + – 5 open means on Product # MQFL-28E-2R5S 6 +VIN ENA 2 IN RTN SHARE CASE + SNS ENA 1 MQFL SYNC OUT OUT RTN SYNC IN Phone 1-888-567-9596 – SNS +VOUT www.synqor.com 12 11 open means on 10 9 + Load 8 – 7 Doc.# 005-0005142 Rev. 2 04/30/09 Page 2 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification MQFL-28E-2R5S ELECTRICAL CHARACTERISTICS Parameter Min. Typ. Max. Units Notes & Conditions Group A Subgroup a pu d bl va ic n at ce io d n ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Reverse Bias (Tcase = 125ºC) Reverse Bias (Tcase = -55ºC) Isolation Voltage (I/O to case, I to O) Continuous Transient (≤100µs) Operating Case Temperature Storage Case Temperature Lead Temperature (20s) Voltage at ENA1, ENA2 INPUT CHARACTERISTICS Operating Input Voltage Range " Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Input Over-Voltage Shutdown Turn-Off Voltage Threshold Turn-On Voltage Threshold Shutdown Voltage Hysteresis Maximum Input Current No Load Input Current (operating) Disabled Input Current (ENA1) Disabled Input Current (ENA2) Input Terminal Current Ripple (pk-pk) OUTPUT CHARACTERISTICS Output Voltage Set Point (Tcase = 25ºC) Output Voltage Set Point Over Temperature Output Voltage Line Regulation Output Voltage Load Regulation Total Output Voltage Range Output Voltage Ripple and Noise Peak to Peak Operating Output Current Range Operating Output Power Range Output DC Current-Limit Inception Short Circuit Output Current Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance DYNAMIC CHARACTERISTICS Output Voltage Deviation Load Transient For a Pos. Step Change in Load Current For a Neg. Step Change in Load Current Settling Time (either case) Output Voltage Deviation Line Transient For a Pos. Step Change in Line Voltage For a Neg. Step Change in Line Voltage Settling Time (either case) Turn-On Transient Output Voltage Rise Time Output Voltage Overshoot Turn-On Delay, Rising Vin Turn-On Delay, Rising ENA1 Turn-On Delay, Rising ENA2 EFFICIENCY Iout = 40A (16Vin) Iout = 20A (16Vin) Iout = 40A (28Vin) Iout = 20A (28Vin) Iout = 40A (40Vin) Iout = 20A (40Vin) Iout = 40A (70Vin) Load Fault Power Dissipation Short Circuit Power Dissipation Vin=28V dc ±5%, Iout=40A, CL=0µF, free running (see Note 10) unless otherwise specified Product # MQFL-28E-2R5S -500 -800 -55 -65 -1.2 100 100 -0.8 -1.2 V V V V 500 800 135 135 300 50 V V °C °C °C V 16 16 28 28 70 80 V V 14.75 13.80 0.50 15.50 14.40 1.10 16.00 15.00 1.80 V V V 90 82 3 95 86 9 100 90 15 8 160 5 50 60 V V V A mA mA mA mA 2.53 2.54 20 17 2.55 60 40 100 52 53 50 10,000 V V mV mV V mV A W A A A mA µF -300 300 200 450 350 mV mV µs 250 250 250 500 mV mV µs 10 2 8.0 6.0 3.0 ms % ms ms ms 34 34 % % % % % % % W W 110 2 25 40 2.47 2.46 -20 7 2.45 0 0 41 41 -450 -250 -250 2.50 2.50 0 12 2.50 15 46 47 13 10 6 5.5 3.0 1.5 TBD TBD TBD TBD TBD TBD TBD Phone 1-888-567-9596 87 89 87 88 85 87 82 19 20 www.synqor.com See Note 1 See Note 2 Continuous Transient, 1 s See Note 3 1, 2, 3 4, 5, 6 1, 2, 3 1, 2, 3 1, 2, 3 See Note 15 Vin = 16V; Iout = 40A Vin = 16V, 28V, 70V Vin = 16V, 28V, 70V Bandwidth = 100kHz – 10MHz; see Figure 14 Vout at sense leads " " ; Vin = 16V, 28V, 70V; Iout=40A " ; Vout @ (Iout=0A) - Vout @ (Iout=40A) " Bandwidth = 10MHz; CL=11µF See Note 4 Vout ≤ 1.2V See Note 6 Total Iout step = 20A‹-›40A, 4A‹-›20A; CL=11µF " See Note 7 Vin step = 16V‹-›50V; CL=11µF; see Note 8 " " See Note 7 Vout = 0.25V-›2.25V 1 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 See Note 5 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 4, 5, 6 See Note 5 4, 5, 6 See Note 5 4, 5, 6 4, 5, 6 4, 5, 6 ENA1, ENA2 = 5V; see Notes 9 & 12 ENA2 = 5V; see Note 12 ENA1 = 5V; see Note 12 Iout at current limit inception point; See Note 4 Vout ≤ 1.2V Doc.# 005-0005142 Rev. 2 1,3 1,3 1,3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3 04/30/09 1, 1, 1, 1, 1, 1, 1, 1, 1, 2, 2, 2, 2, 2, 2, 2, 2, 2, 3 3 3 3 3 3 3 3 3 Page 3 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification MQFL-28E-2R5S ELECTRICAL CHARACTERISTICS (Continued) Parameter Min. Typ. Max. Units Notes & Conditions Vin=28V dc ±5%, Iout=40A, CL=0µF, free running (see Note 10) unless otherwise specified Group A Subgroup a pu d bl va ic n at ce io d n ISOLATION CHARACTERISTICS Isolation Voltage Dielectric strength Input RTN to Output RTN 500 V 1 Any Input Pin to Case 500 V 1 Any Output Pin to Case 500 V 1 Isolation Resistance (in rtn to out rtn) 100 MΩ 1 Isolation Resistance (any pin to case) 100 MΩ 1 Isolation Capacitance (in rtn to out rtn) 44 nF 1 FEATURE CHARACTERISTICS Switching Frequency (free running) 500 550 600 kHz 1, 2, 3 Synchronization Input Frequency Range 500 700 kHz 1, 2, 3 Logic Level High 2.0 10 V 1, 2, 3 Logic Level Low -0.5 0.8 V 1, 2, 3 Duty Cycle 20 80 % See Note Synchronization Output Pull Down Current 20 mA VSYNC OUT = 0.8V See Note Duty Cycle 25 75 % Output connected to SYNC IN of other MQFL unit See Note Enable Control (ENA1 and ENA2) Off-State Voltage 0.8 V 1, 2, 3 Module Off Pulldown Current 80 µA Current drain required to ensure module is off See Note On-State Voltage 2 V 1, 2, 3 Module On Pin Leakage Current 20 µA Imax drawn from pin allowed, module on See Note Pull-Up Voltage 3.2 4.0 4.5 V See Figure A 1, 2, 3 RELIABILITY CHARACTERISTICS Calculated MTBF (MIL-STD-217F2) GB @ Tcase = 70ºC 2800 103 Hrs. AIF @ Tcase = 70ºC 440 103 Hrs. Demonstrated MTBF TBD 103 Hrs. WEIGHT CHARACTERISTICS Device Weight 79 g Electrical Characteristics Notes 1. Converter will undergo input over-voltage shutdown. 2. Derate output power to 50% of rated power at Tcase = 135ºC (see Figure 5). 3. High or low state of input voltage must persist for about 200µs to be acted on by the lockout or shutdown circuitry. 4. Current limit inception is defined as the point where the output voltage has dropped to 90% of its nominal value. 5. Parameter not tested but guaranteed to the limit specified. 6. Load current transition time ≥ 10µs. 7. Settling time measured from start of transient to the point where the output voltage has returned to ±50mV of its final value. 8. Line voltage transition time ≥ 100µs. 9. Input voltage rise time ≤ 250µs. 10. Operating the converter at a synchronization frequency above the free running frequency will cause the converter’s efficiency to be slightly reduced and it may also cause a slight reduction in the maximum output current/power available. For more information consult the factory. 11. SHARE pin outputs a power failure warning pulse during a fault condition. See Current Share section of the Control Features description. 12. After a disable or fault event, module is inhibited from restarting for 300ms. See Shut Down section of the Control Features description. 13. Only the ES and HB grade products are tested at three temperatures. The C grade products are tested at one temperature. Please refer to the Construction and Environmental Stress Screening Options table for details. 14. These derating curves apply for the ES- and HB- grade products. The C- grade product has a maximum case temperature of 100ºC. 15. Input Over Voltage Shutdown test is run at no load, full load is beyond derating condition and could cause damage at 125ºC. Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 5 5 5 5 5 Page 4 MQFL-28E-2R5S Output: 2.5V Current: 40A a pu d bl va ic n at ce io d n Technical Specification TBD TBD Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at Tcase=25°C. Figure 2: Efficiency at nominal output voltage and 60% rated power vs. case temperature for input voltage of 16V, 28V, 40V ,and 70V. TBD TBD Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at Tcase=25°C. Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. case temperature for input voltage of 16V, 28V, 40V ,and 70V. TBD TBD Figure 5: Output Current / Output Power derating curve as a function of Tcase and the Maximum desired power MOSFET junction temperature (see Note 14). Product # MQFL-28E-2R5S Phone 1-888-567-9596 Figure 6: Output voltage vs. load current showing typical current limit curves. www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 5 MQFL-28E-2R5S Output: 2.5V Current: 40A a pu d bl va ic n at ce io d n Technical Specification TBD TBD Figure 7: Turn-on transient at full resistive load and zero output capacitance initiated by ENA1. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA1 (5V/div). Figure 8: Turn-on transient at full resistive load and 10mF output capacitance initiated by ENA1. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA1 (5V/div). TBD TBD Figure 9: Turn-on transient at full resistive load and zero output capacitance initiated by ENA2. Input voltage pre-applied. Ch 1: Vout (500mV/div). Ch 2: ENA2 (5V/div). Figure 10: Turn-on transient at full resistive load and zero output capacitance initiated by Vin. ENA1 and ENA2 both previously high. Ch 1: Vout (500mV/div). Ch 2: Vin (10V/div). TBD TBD Figure 11: Output voltage response to step-change in load current 50%-100%-50% of Iout (max). Load cap: 1µF ceramic cap and 10µF, 100mΩ ESR tantalum cap. Ch 1: Vout (200mV/div). Ch 2: Iout (20A/div). Product # MQFL-28E-2R5S Phone 1-888-567-9596 Figure 12: Output voltage response to step-change in load current 0%50%-0% of Iout (max). Load cap: 1µF ceramic cap and 10µF, 100mΩ ESR tantalum cap. Ch 1: Vout (200mV/div). Ch 2: Iout (20A/div). www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 6 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification See Fig. 16 a pu d bl va ic n at ce io d n See Fig. 15 MQME Filter TBD iC MQFL Converter VSOURCE VOUT 1µF ceramic capacitor 10µF, 100mW ESR capacitor Figure 13: Output voltage response to step-change in input voltage (16V - 50V - 16V). Load cap: 10µF, 100mΩ ESR tantalum cap and 1µF ceramic cap. Ch 1: Vout (200mV/div). Ch 2: Vin (20V/div). Figure 14: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 15) and Output Voltage Ripple (Figure 16). TBD TBD Figure 15: Input terminal current ripple, ic, at full rated output current and nominal input voltage with SynQor MQ filter module (50mA/div). Bandwidth: 20MHz. See Figure 14. Figure 16: Output voltage ripple, Vout, at nominal input voltage and rated load current (20mV/div). Load capacitance: 1μ F ceramic capacitor and 10μF tantalum capacitor. Bandwidth: 10MHz. See Figure 14. TBD TBD Figure 17: Rise of output voltage after the removal of a short circuit across the output terminals. Ch 1: Vout (500mV/div). Ch 2: Iout (20A/div). Product # MQFL-28E-2R5S Phone 1-888-567-9596 Figure 18: SYNC OUT vs. time, driving SYNC IN of a second SynQor MQFL converter. Ch1: SYNC OUT: (1V/div). www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 7 MQFL-28E-2R5S Output: 2.5V Current: 40A a pu d bl va ic n at ce io d n Technical Specification TBD TBD Figure 19: Magnitude of incremental output impedance (Zout = vout/iout) for minimum, nominal, and maximum input voltage at full rated power. Figure 20: Magnitude of incremental forward transmission (FT = vout/vin) for minimum, nominal, and maximum input voltage at full rated power. TBD TBD Figure 21: Magnitude of incremental reverse transmission (RT = iin/iout) for minimum, nominal, and maximum input voltage at full rated power. Figure 22: Magnitude of incremental input impedance (Zin = vin/iin) for minimum, nominal, and maximum input voltage at full rated power. TBD TBD Figure 23: High frequency conducted emissions of standalone MQFL28-05S, 5Vout module at 120W output, as measured with Method CE102. Limit line shown is the ‘Basic Curve’ for all applications with a 28V source. Product # MQFL-28E-2R5S Phone 1-888-567-9596 Figure 24: High frequency conducted emissions of MQFL-28-05S, 5Vout module at 120W output with MQFL-28-P filter, as measured with Method CE102. Limit line shown is the ‘Basic Curve’ for all applications with a 28V source. www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 8 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification BASIC OPERATION AND FEATURES ENABLE: The MQFL converter has two enable pins. Both must have a logic high level for the converter to be enabled. A logic low on either pin will inhibit the converter. a pu d bl va ic n at ce io d n The MQFL DC/DC converter uses a two-stage power conversion topology. The first, or regulation, stage is a buck-converter that keeps the output voltage constant over variations in line, load, and temperature. The second, or isolation, stage uses transformers to provide the functions of input/output isolation and voltage transformation to achieve the output voltage required. CONTROL FEATURES Both the regulation and the isolation stages switch at a fixed frequency for predictable EMI performance. The isolation stage switches at one half the frequency of the regulation stage, but due to the push-pull nature of this stage it creates a ripple at double its switching frequency. As a result, both the input and the output of the converter have a fundamental ripple frequency of about 550 kHz in the free-running mode. Rectification of the isolation stage’s output is accomplished with synchronous rectifiers. These devices, which are MOSFETs with a very low resistance, dissipate far less energy than would Schottky diodes. This is the primary reason why the MQFL converters have such high efficiency, particularly at low output voltages. Besides improving efficiency, the synchronous rectifiers permit operation down to zero load current. There is no longer a need for a minimum load, as is typical for converters that use diodes for rectification. The synchronous rectifiers actually permit a negative load current to flow back into the converter’s output terminals if the load is a source of short or long term energy. The MQFL converters employ a “back-drive current limit” to keep this negative output terminal current small. There is a control circuit on both the input and output sides of the MQFL converter that determines the conduction state of the power switches. These circuits communicate with each other across the isolation barrier through a magnetically coupled device. No opto-isolators are used. A separate bias supply provides power to both the input and output control circuits. Among other things, this bias supply permits the converter to operate indefinitely into a short circuit and to avoid a hiccup mode, even under a tough start-up condition. An input under-voltage lockout feature with hysteresis is provided, as well as an input over-voltage shutdown. There is also an output current limit that is nearly constant as the load impedance decreases to a short circuit (i.e., there is not fold-back or foldforward characteristic to the output current under this condition). When a load fault is removed, the output voltage rises exponentially to its nominal value without an overshoot. The MQFL converter’s control circuit does not implement an output over-voltage limit or an over-temperature shutdown. The ENA1 pin (pin 4) is referenced with respect to the converter’s input return (pin 2). The ENA2 pin (pin 12) is referenced with respect to the converter’s output return (pin 8). This permits the converter to be inhibited from either the input or the output side. Regardless of which pin is used to inhibit the converter, the regulation and the isolation stages are turned off. However, when the converter is inhibited through the ENA1 pin, the bias supply is also turned off, whereas this supply remains on when the converter is inhibited through the ENA2 pin. A higher input standby current therefore results in the latter case. Both enable pins are internally pulled high so that an open connection on both pins will enable the converter. Figure A shows the equivalent circuit looking into either enable pins. It is TTL compatible. 5.6V 82K 1N4148 PIN 4 (or PIN 12) ENABLE TO ENABLE CIRCUITRY 250K 2N3904 125K PIN 2 (or PIN 8) IN RTN Figure A: Equivalent circuit looking into either the ENA1 or ENA2 pins with respect to its corresponding return pin. SHUT DOWN: The MQFL converter will shut down in response to only four conditions: ENA1 input low, ENA2 input low, VIN input below under-voltage lockout threshold, or VIN input above over-voltage shutdown threshold. Following a shutdown event, there is a startup inhibit delay which will prevent the converter from restarting for approximately 300ms. After the 300ms delay elapses, if the enable inputs are high and the input voltage is within the operating range, the converter will restart. If the VIN input is brought down to nearly 0V and back into the operating range, there is no startup inhibit, and the output voltage will rise according to the “Turn-On Delay, Rising Vin” specification. The following sections describe the use and operation of additional control features provided by the MQFL converter. Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 9 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification synchronization signal at the SYNC IN pin, or the synchronization frequency if there is. The SYNC OUT signal is available only when the DC input voltage is above approximately 12V and when the converter is not inhibited through the ENA1 pin. An inhibit through the ENA2 pin will not turn the SYNC OUT signal off. a pu d bl va ic n at ce io d n REMOTE SENSE: The purpose of the remote sense pins is to correct for the voltage drop along the conductors that connect the converter’s output to the load. To achieve this goal, a separate conductor should be used to connect the +SENSE pin (pin 10) directly to the positive terminal of the load, as shown in the connection diagram on Page 2. Similarly, the –SENSE pin (pin 9) should be connected through a separate conductor to the return terminal of the load. NOTE: Even if remote sensing of the load voltage is not desired, the +SENSE and the -SENSE pins must be connected to +Vout (pin 7) and OUTPUT RETURN (pin 8), respectively, to get proper regulation of the converter’s output. If they are left open, the converter will have an output voltage that is approximately 200mV higher than its specified value. If only the +SENSE pin is left open, the output voltage will be approximately 25mV too high. NOTE: An MQFL converter that has its SYNC IN pin driven by the SYNC OUT pin of a second MQFL converter will have its start of its switching cycle delayed approximately 180 degrees relative to that of the second converter. Figure B shows the equivalent circuit looking into the SYNC IN pin. Figure C shows the equivalent circuit looking into the SYNC OUT pin. 5V Inside the converter, +SENSE is connected to +Vout with a resistor value from 100W to 274W, depending on output voltage, and –SENSE is connected to OUTPUT RETURN with a 10W resistor. It is also important to note that when remote sense is used, the voltage across the converter’s output terminals (pins 7 and 8) will be higher than the converter’s nominal output voltage due to resistive drops along the connecting wires. This higher voltage at the terminals produces a greater voltage stress on the converter’s internal components and may cause the converter to fail to deliver the desired output voltage at the low end of the input voltage range at the higher end of the load current and temperature range. Please consult the factory for details. SYNCHRONIZATION: The MQFL converter’s switching frequency can be synchronized to an external frequency source that is in the 500 kHz to 700 kHz range. A pulse train at the desired frequency should be applied to the SYNC IN pin (pin 6) with respect to the INPUT RETURN (pin 2). This pulse train should have a duty cycle in the 20% to 80% range. Its low value should be below 0.8V to be guaranteed to be interpreted as a logic low, and its high value should be above 2.0V to be guaranteed to be interpreted as a logic high. The transition time between the two states should be less than 300ns. If the MQFL converter is not to be synchronized, the SYNC IN pin should be left open circuit. The converter will then operate in its free-running mode at a frequency of approximately 550 kHz. If, due to a fault, the SYNC IN pin is held in either a logic low or logic high state continuously, the MQFL converter will revert to its free-running frequency. The MQFL converter also has a SYNC OUT pin (pin 5). This output can be used to drive the SYNC IN pins of as many as ten (10) other MQFL converters. The pulse train coming out of SYNC OUT has a duty cycle of 50% and a frequency that matches the switching frequency of the converter with which it is associated. This frequency is either the free-running frequency if there is no Product # MQFL-28E-2R5S Phone 1-888-567-9596 5K TO SYNC CIRCUITRY PIN 6 SYNC IN PIN 2 5K IN RTN Figure B: Equivalent circuit looking into the SYNC IN pin with respect to the IN RTN (input return) pin. 5V 5K SYNC OUT FROM SYNC CIRCUITRY IN RTN OPEN COLLECTOR OUTPUT PIN 5 PIN 2 Figure C: Equivalent circuit looking into SYNC OUT pin with respect to the IN RTN (input return) pin. CURRENT SHARE: When several MQFL converters are placed in parallel to achieve either a higher total load power or N+1 redundancy, their SHARE pins (pin 11) should be connected together. The voltage on this common SHARE node represents the average current delivered by all of the paralleled converters. Each converter monitors this average value and adjusts itself so that its output current closely matches that of the average. www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 10 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification trim Resistance (ohms) 100,000 a pu d bl va ic n at ce io d n Since the SHARE pin is monitored with respect to the OUTPUT RETURN (pin 8) by each converter, it is important to connect all of the converters’ OUTPUT RETURN pins together through a low DC and AC impedance. When this is done correctly, the converters will deliver their appropriate fraction of the total load current to within +/- 10% at full rated load. Whether or not converters are paralleled, the voltage at the SHARE pin could be used to monitor the approximate average current delivered by the converter(s). A nominal voltage of 1.0V represents zero current and a nominal voltage of 2.2V represents the maximum rated current, with a linear relationship in between. The internal source resistance of a converter’s SHARE pin signal is 2.5 kW. During an input voltage fault or primary disable event, the SHARE pin outputs a power failure warning pulse. The SHARE pin will go to 3V for approximately 14ms as the output voltage falls. NOTE: Converters operating from separate input filters with reverse polarity protection (such as the MQME-28-T filter) with their outputs connected in parallel may exhibit hiccup operation at light loads. Consult factory for details. OUTPUT VOLTAGE TRIM: If desired, it is possible to increase the MQFL converter’s output voltage above its nominal value. To do this, use the +SENSE pin (pin 10) for this trim function instead of for its normal remote sense function, as shown in Figure D. In this case, a resistor connects the +SENSE pin to the –SENSE pin (which should still be connected to the output return, either remotely or locally). The value of the trim resistor should be chosen according to the following equation or from Figure E: Rtrim = 407.5 Vout – Vnom – 0.025 where: Vnom = the converter’s nominal output voltage, Vout = the desired output voltage (greater than Vnom), and Rtrim is in Ohms. 1 2 3 28 Vdc 4 + – 5 open means on 6 10,000 1,000 100 0.00 0.05 0.10 0.15 0.20 0.25 0.30 Increase in vout (v) Figure E: Output Voltage Trim Graph As the output voltage is trimmed up, it produces a greater voltage stress on the converter’s internal components and may cause the converter to fail to deliver the desired output voltage at the low end of the input voltage range at the higher end of the load current and temperature range. Please consult the factory for details. Factory trimmed converters are available by request. INPUT UNDER-VOLTAGE LOCKOUT: The MQFL converter has an under-voltage lockout feature that ensures the converter will be off if the input voltage is too low. The threshold of input voltage at which the converter will turn on is higher that the threshold at which it will turn off. In addition, the MQFL converter will not respond to a state of the input voltage unless it has remained in that state for more than about 200µs. This hysteresis and the delay ensure proper operation when the source impedance is high or in a noisy environment. INPUT OVER-VOLTAGE SHUTDOWN: The MQFL converter also has an over-voltage feature that ensures the converter will be off if the input voltage is too high. It also has a hysteresis and time delay to ensure proper operation. +VIN ENA 2 IN RTN SHARE CASE + SNS ENA 1 – SNS SYNC OUT SYNC IN OUT RTN +VOUT 12 11 10 9 Rtrim – 8 7 Load + Figure D: Typical connection for output voltage trimming. Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 11 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification The Mil-HDBK-1547A component derating guideline calls for a maximum component temperature of 105ºC. Figure 5 therefore has one power derating curve that ensures this limit is maintained. It has been SynQor’s extensive experience that reliable long-term converter operation can be achieved with a maximum component temperature of 125ºC. In extreme cases, a maximum temperature of 145ºC is permissible, but not recommended for long-term operation where high reliability is required. Derating curves for these higher temperature limits are also included in Figure 5. The maximum case temperature at which the converter should be operated is 135ºC. a pu d bl va ic n at ce io d n BACK-DRIVE CURRENT LIMIT: Converters that use MOSFETs as synchronous rectifiers are capable of drawing a negative current from the load if the load is a source of short- or long-term energy. This negative current is referred to as a “back-drive current”. Conditions where back-drive current might occur include paralleled converters that do not employ current sharing, or where the current share feature does not adequately ensure sharing during the startup or shutdown transitions. It can also occur when converters having different output voltages are connected together through either explicit or parasitic diodes that, while normally off, become conductive during startup or shutdown. Finally, some loads, such as motors, can return energy to their power rail. Even a load capacitor is a source of back-drive energy for some period of time during a shutdown transient. To avoid any problems that might arise due to back-drive current, the MQFL converters limit the negative current that the converter can draw from its output terminals. The threshold for this backdrive current limit is placed sufficiently below zero so that the converter may operate properly down to zero load, but its absolute value (see the Electrical Characteristics page) is small compared to the converter’s rated output current. THERMAL CONSIDERATIONS: Figure 5 shows the suggested Power Derating Curves for this converter as a function of the case temperature, input voltage and the maximum desired power MOSFET junction temperature. All other components within the converter are cooler than the hottest MOSFET. . Product # MQFL-28E-2R5S Phone 1-888-567-9596 When the converter is mounted on a metal plate, the plate will help to make the converter’s case bottom a uniform temperature. How well it does so depends on the thickness of the plate and on the thermal conductance of the interface layer (e.g. thermal grease, thermal pad, etc.) between the case and the plate. Unless this is done very well, it is important not to mistake the plate’s temperature for the maximum case temperature. It is easy for them to be as much as 5-10ºC different at full power and at high temperatures. It is suggested that a thermocouple be attached directly to the converter’s case through a small hole in the plate when investigating how hot the converter is getting. Care must also be made to ensure that there is not a large thermal resistance between the thermocouple and the case due to whatever adhesive might be used to hold the thermocouple in place. INPUT SYSTEM INSTABILITY: This condition can occur because any DC/DC converter appears incrementally as a negative resistance load. A detailed application note titled “Input System Instability” is available on the SynQor website which provides an understanding of why this instability arises, and shows the preferred solution for correcting it. www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 12 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification CONSTRUCTION AND ENVIRONMENTAL STRESS SCREENING OPTIONS Consistent with MIL-StD-883F C-Grade (-40 ºC to +100 ºC) ES-Grade (-55 ºC to +125 ºC) (Element Evaluation) HB-Grade (-55 ºC to +125 ºC) (Element Evaluation) a pu d bl va ic n at ce io d n Screening Internal visual * Yes Yes Yes temperature Cycle Method 1010 no Condition B (-55 ºC to +125 ºC) Condition C (-65 ºC to +150 ºC) Constant Acceleration Method 2001 (Y1 Direction) no 500g Condition A (5000g) Burn-in Method 1015 Load Cycled • 10s period • 2s @ 100% Load • 8s @ 0% Load 24 Hrs @ +125 ºC 96 Hrs @ +125 ºC 160 Hrs @ +125 ºC Final Electrical test Method 5005 (Group A) +25 ºC -45, +25, +100 ºC -55, +25, +125 ºC Full QorSeal Full QorSeal Full QorSeal * Yes Yes QorSeal QorSeal QorSeal Mechanical Seal, thermal, and Coating Process External visual 2009 Construction Process * Per IPC-A-610 (Rev. D) Class 3 MilQor converters and filters are offered in four variations of construction technique and environmental stress screening options. The three highest grades, C, ES, and HB, all use SynQor’s proprietary QorSeal™ Hi-Rel assembly process that includes a Parylene-C coating of the circuit, a high performance thermal compound filler, and a nickel barrier gold plated aluminum case. Each successively higher grade has more stringent mechanical and electrical testing, as well as a longer burn-in cycle. The ES- and HB-Grades are also constructed of components that have been procured through an element evaluation process that pre-qualifies each new batch of devices. Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 13 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification 0.093 [2.36] +VIN ENA 2 12 11 10 9 8 7 0.250 [6.35] a pu d bl va ic n at ce io d n 1 2 3 4 5 6 IN RTN CASE ENA 1 SYNC OUT SYNC IN SHARE +SNS MQFL-28E-2R5S-X-HB DC/DC CONVERTER 28Vin 2.5Vout @ 40A -SNS MADE IN USA S/N 0000000 D/C 3205-301 CAGE 1WX10 OUT RTN +VOUT 1.50 [38.10] 1.260 [32.00] 0.200 [5.08] TYP. NON-CUM. 0.040 [1.02] PIN 2.50 [63.50] 2.76 [70.10] 3.00 [76.20] 0.050 [1.27] 0.128 [3.25] 0.220 [5.59] 2.96 [75.2] 0.228 [5.79] 0.390 [9.91] Case X 0.093 [2.36] 1 2 3 4 5 6 +VIN ENA 2 IN RTN CASE ENA 1 SHARE MQFL-28E-2R5S-U-HB SYNC OUT SYNC IN +SNS DC/DC CONVERTER 28Vin 2.5Vout @ 40A -SNS MADE IN USA S/N 0000000 D/C 3205-301 CAGE 1WX10 OUT RTN +VOUT 2.50 [63.50] 2.76 [70.10] 3.00 [76.20] 12 11 10 9 8 7 0.250 [6.35] 0.200 [5.08] TYP. NON-CUM. 1.50 [38.10] 1.260 [32.00] 0.040 [1.02] PIN 0.42 [10.7] 0.128 [3.25] 0.050 [1.27] 0.220 [5.59] 2.80 [71.1] Case U 0.390 [9.91] NOTES PIN DESIGNATIONS 1) Pins 0.040” (1.02mm) diameter 2) Pins Material: Copper Finish: Gold over Nickel plate 1 Positive input 7 Positive output 3) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 2 Input return 8 Output return Weight: 2.8 oz (78.5 g) typical 3 CASE 9 - Sense 4) 5) Workmanship: Meets or exceeds IPC-A-610C Class III 4 Enable 1 10 + Sense 6) Print Labeling on Top Surface per Product Label Format Drawing 5 Sync output 11 Share 6 Sync input 12 Enable 2 Product # MQFL-28E-2R5S Phone 1-888-567-9596 Pin Function www.synqor.com Doc.# 005-0005142 Rev. 2 Pin Function 04/30/09 Page 14 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification +VIN ENA 2 0.250 [6.35] 12 2.00 11 [50.80] 10 1.50 9 [38.10] 8 1.750 7 [44.45] a pu d bl va ic n at ce io d n 1 2 3 4 5 6 0.300 [7.62] 0.140 [3.56] 1.15 [29.21] 0.250 [6.35] TYP IN RTN SHARE CASE ENA 1 +SNS MQFL-28E-2R5S-Y-HB DC/DC CONVERTER 28Vin 2.5Vout @ 40A -SNS SYNC OUT SYNC IN MADE IN USA S/N 0000000 D/C 3205-301 CAGE 1WX10 OUT RTN +VOUT 1.750 [44.45] 0.200 [5.08] TYP. NON-CUM. 0.040 [1.02] PIN 0.050 [1.27] 0.375 [9.52] 2.50 [63.50] 0.220 [5.59] 2.96 [75.2] 0.228 [5.79] Case Y 0.390 [9.91] Case Z (variant of Y) 0.250 [6.35] Case W (variant of Y) 0.250 [6.35] 0.200 [5.08] TYP. NON-CUM. 0.200 [5.08] TYP. NON-CUM. 0.040 [1.02] PIN 0.040 [1.02] PIN 0.220 [5.59] 0.050 [1.27] 0.420 [10.7] 0.050 [1.27] 0.220 [5.59] 0.36 [9.2] 2.80 [71.1] 0.525 [13.33] 0.390 [9.91] 0.390 [9.91] 0.525 [13.33] 2.80 [71.1] PIN DESIGNATIONS NOTES 1) 2) 3) 4) 5) 6) Pins 0.040” (1.02mm) diameter Pins Material: Copper Finish: Gold over Nickel plate All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) Weight: 2.8 oz (78.5 g) typical Workmanship: Meets or exceeds IPC-A-610C Class III Print Labeling on Top Surface per Product Label Format Drawing Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Pin Function 1 2 3 4 5 6 Positive input Input return CASE Enable 1 Sync output Sync input Doc.# 005-0005142 Rev. 2 Pin Function 7 8 9 10 11 12 Positive output Output return - Sense + Sense Share Enable 2 04/30/09 Page 15 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification MilQor Converter FAMILY MATRIX a pu d bl va ic n at ce io d n The tables below show the array of MQFL converters available. When ordering SynQor converters, please ensure that you use the complete part number according to the table in the last page. Contact the factory for other requirements. Dual Output † Single Output Full Size 1.5V (1R5S) 1.8V (1R8S) 2.5V (2R5S) 3.3V (3R3S) 5V (05S) 6V (06S) 7.5V (7R5S) 9V (09S) 12V (12S) 15V (15S) 28V (28S) ±5V (05D) ±12V (12D) ±15V (15D) 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 40A 40A 40A 30A 20A 17A 13A 11A 8A 6.5A 3.3A 20A Total 8A Total 6.5A Total 40A 40A 40A 30A 20A 17A 13A 11A 8A 6.5A 3.3A 20A Total 8A Total 6.5A Total 40A 40A 40A 30A 24A 20A 16A 13A 10A 8A 4A 24A Total 10A Total 8A Total 1.5V (1R5S) 1.8V (1R8S) 2.5V (2R5S) 3.3V (3R3S) 5V (05S) 6V (06S) 7.5V (7R5S) 9V (09S) 12V (12S) 15V (15S) 28V (28S) ±5V (05D) ±12V (12D) ±15V (15D) 20A 20A 20A 15A 10A 8A 6.6A 5.5A 4A 3.3A 1.8A 10A Total 4A Total 3.3A Total 20A 20A 20A 15A 10A 8A 6.6A 5.5A 4A 3.3A 1.8A 10A Total 4A Total 3.3A Total 10A 10A 10A 7.5A 5A 4A 3.3A 2.75A 2A 1.65A 0.9A 5A Total 2A Total 1.65A Total 10A 10A 10A 7.5A 5A 4A 3.3A 2.75A 2A 1.65A 0.9A 5A Total 2A Total 1.65A Total MQFL-28 16-40Vin Cont. 16-50Vin 1s Trans.* Absolute Max Vin = 60V MQFL-28E 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin =100V MQFL-28v 16-40Vin Cont. 5.5-50Vin 1s Trans.* Absolute Max Vin = 60V MQFL-28vE 16-70Vin Cont. 5.5-80Vin 1s Trans.* Absolute Max Vin = 100V MQFL-270 155-400Vin Cont. 155-475Vin 0.1s Trans.* Absolute Max Vin = 550V Dual Output † Single Output Half Size MQHL-28 (50W) 16-40Vin Cont. 16-50Vin 1s Trans.* Absolute Max Vin = 60V MQHL-28E (50W) 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin =100V MQHR-28 (25W) 16-40Vin Cont. 16-50Vin 1s Trans.* Absolute Max Vin = 60V MQHR-28E (25W) 16-70Vin Cont. 16-80Vin 1s Trans.* Absolute Max Vin =100V Check with factory for availability. Product # MQFL-28E-2R5S Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 16 MQFL-28E-2R5S Output: 2.5V Current: 40A Technical Specification PART NUMBERING SYSTEM The part numbering system for SynQor’s MilQor DC-DC converters follows the format shown in the table below. Output voltage(s) a pu d bl va ic n at ce io d n Model name MQFL MQHL MQHR Input voltage Range 28 28E 28v 28vE 270 Single Output Dual Output 1R5S 1R8S 2R5S 3R3S 05S 06S 7R5S 09S 12S 15S 28S 05D 12D 15D Example: Package Outline/ Pin Configuration U X Y W Z Screening Grade C ES HB MQFL-28E-2R5S–Y–ES APPLICATION NOTES A variety of application notes and technical white papers can be downloaded in pdf format from the SynQor website. PATENTS SynQor holds the following patents, one or more of which might apply to this product: 5,999,417 6,927,987 6,222,742 7,050,309 6,545,890 7,072,190 6,577,109 7,085,146 6,594,159 7,119,524 6,731,520 7,269,034 6,894,468 7,272,021 6,896,526 7,272,023 Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: Product # MQFL-28E-2R5S 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 USA Phone 1-888-567-9596 Warranty SynQor offers a two (2) year limited warranty. Complete warranty information is listed on our website or is available upon request from SynQor. Information furnished by SynQor is believed to be accurate and reliable. However, no responsibility is assumed by SynQor for its use, nor for any infringements of patents or other rights of third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of SynQor. www.synqor.com Doc.# 005-0005142 Rev. 2 04/30/09 Page 17