Technical S pecification PQ60525HTA04 48V in 52.5Vout 200W 2250Vdc Half-brick Input Output Power Isolation DC/DC Conver ter The PQ60525HTA04 PowerQor ™ Tera converter is a nextgeneration, board-m mountable, isolated, fixed switching fre quency DC/DC converter that uses synchronous rectification to achieve extremely high conversion efficiency. The module is ideally suited to support the IEEE 802.3af standard for Power Over LAN and VoIP applications. The Tera series converters offer the maximum useable output current for any standard “half-bbrick” module. The Tera units also feature active current sharing for N+1 and parallel applications. PQ60525HTA04 Module Operational Features • Ultra-high efficiency, 92% at full rated load current • Delivers up to 200 Watts of output power with minimal derating - no heatsink required • Wide input voltage range: 35V – 75V, with 100V 100ms input voltage transient capability • Fixed frequency switching provides predictable EMI performance Mechanical Features Contr ol Features • On/Off control referenced to input side (positive and negative logic options are available) • Remote sense for the output voltage compensates for output distribution drops • Output voltage trim permits custom voltages and voltage margining Safety Features • Industry standard half-brick pin-out configuration • Industry standard size: 2.3” x 2.4” (58.4 x 61.0mm) • Total height only 0.43” (11.2mm), permits better airflow and smaller card pitch • Total weight: 2.6 oz. (75 grams) • 2250V, 30 MΩ input-to-output isolation • UL/cUL 60950 recognized (US & Canada), basic insulation rating • TUV certified to EN60950 • Meets 72/23/EEC and 93/68/EEC directives • Meets UL94V-0 flammability requirements Pr otection Features • Input under-voltage lockout disables converter at low input voltage conditions • Output current limit and short circuit protection • Active back bias limit prevents damage to converter from external load induced pre-bias • Output over-voltage protection • Thermal shutdown Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Optional Features (full-feature) • Active current share for N+1 and parallel applications • External Clock Synchronization pin for better EMI characteristics • Startup Synchronization pin for more consistent start-up sequence • ORing FET drive supply for efficient ORing protection Doc.# 005-2HT652F Rev. B 03/08/05 Page 1 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick 2.30 MECHANICAL DIAGRAM (58.4) 0.50 (15.24) 0.800 0.700 (48.3) (17.78) 0.19 0.600 (20.32) 0.400 (10.16) 1.90 (12.7) (4.8) 0.400 (10.16) 1.000 1.000 (25.40) (25.40) 1.400 Top View (35.56) 2.40 (61.0) 1.400 (35.56) Side View Bottom side Clearance See Note 10 0.037+/-0.029 (0.94+/-0.74) Lowest Component 0.43 Load Board 15 character “8” alternate bottom side clearance option (See ordering options on Pge 14) (11.2) 0.145 (3.68) See Note 4 15 character “8” alternate bottom side clearance option (See ordering options on Pge 14) 0.475(12.06) maximum height 0.060+/-0.030 (1.52+/-0.76) NOTES PIN DESIGNATIONS 1) Pins 1-4, 6-8, A-C are 0.040” (1.02mm) diameter. with 0.080” (2.03mm) diameter standoff shoulders. Pin No. Name 2) Pins 5 and 9 are 0.080” (2.03 mm) diameter with 0.125” (3.18mm) diameter standoff shoulders. 3) Pins 3, A, B & C only included in Full-Feature models. 4) Other pin extension lengths available. Recommended pin length is 0.03” (0.76mm) greater than the PCB thickness. 1 Vin(+) Positive input voltage 2 ON/OFF TTL input to turn converter on and off, referenced to Vin(-), with internal pull up. 3 4 5 6 7 8 9 A B I share Vin(-) Vout(-) SENSE(-) TRIM SENSE(+) Vout(+) Clock Sync Start Sync Single wire parallel signal Negative input voltage Negative output voltage Return remote sense Output voltage trim Positive remote sense Positive output voltage Clock synchronization Startup synchronization 5) All Pins: Material - Copper Alloy Finish - Tin/Lead over Nickel plate 6) Undimensioned components are shown for visual reference only. 7) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 8) Weight: 2.6 oz. (75g) typical 9) Workmanship: Meets or exceeds IPC-A-610C Class II 10) UL/TUV standards require a clearance greater than 0.04” (1.02mm) between input and output for Basic insulation. This issue should be considered if any copper traces are on the top side of the user’s board. Note that the ferrite cores are considered part of the input/primary circuit. Pins in Italics Shaded text are optional 11) The flanged pins are designed to permit surface mount soldering (avoiding the wave soldering process) through the use of the flanged pin-in-paste technique. Product # PQ60525HTA04 Phone 1-888-567-9596 Function www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 2 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick PQ60525HTA04 ELECTRICAL CHARACTERISTICS TA=25°C, airflow rate=300 LFM, Vin=48Vdc unless otherwise noted; full operating temperature range is -40°C to +100°C ambient temperature with appropriate power derating. Specifications subject to change without notice. Parameter Min. Typ. Max. Units 100 80 100 2250 100 125 18 18 V V V V °C °C V V Notes & Conditions ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Operating Transient Protection Isolation Voltage (input to output) Operating Temperature Storage Temperature Voltage at ON/OFF input pin Voltage at Clock Sync pin INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Maximum Input Current No-Load Input Current Disabled Input Current Inrush Current Transient Rating Response to Input Transient Input Reflected Ripple Current Input Terminal Ripple Current Recommended Input Fuse Input Filter Component Values (L\C) Recommended External Input Capacitance OUTPUT CHARACTERISTICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise1 Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Current Share Accuracy (2 units paralleled) Maximum Output Capacitance -40 -55 -2 -15 35 48 75 V 30.6 28.6 1.9 32.5 30.5 2.0 34.4 32.4 2.1 7.0 110 5 0.01 V V V A mA mA A 2s mV mA mA A µH\µF µF 90 2 500 3 150 1\11 47 52.00 51.5 0.385 4.2 DYNAMIC CHARACTERISTICS Input Voltage Ripple Rejection Output Voltage during Load Current Transient For a Step Change in Output Current (0.1A/µs) For a Step Change in Output Current (5A/µs) Settling Time Turn-On Transient Turn-On Time Start-Up Inhibit Time Output Voltage Overshoot EFFICIENCY 100% Load 50% Load 180 52.50 20 53.00 +0.05 \ 20 +0.1 \ 50 +0.1 \ 40 +0.15 \ 75 +150 +300 53.5 100 20 4.7 30 +2 150 50 3.85 5.2 +5 1,500 100% Load, 35 Vin, trim up 10% 1000V/ms input trans; 330µF cap; Figure 17 RMS thru 10µH inductor; Figures 13 & 15 RMS; Figures 13 & 14 fast blow external fuse recommended internal values, see Figure E Typical ESR 0.1-0.2Ω, see Figure 13 V %\mV %\mV mV V mV mV A A V % µF over sample, line, load, temperature & life 20MHz bandwidth; Figures 13 & 16 Full Load, see Figures 13 & 16 Full Load, see Figures 13 & 16 Subject to thermal derating; Figures 5-8 Output Voltage 10% Low; Figure 23 % of rated output current 52.5Vout at 3.8A Resistive Load dB 120 Hz; Figure 20 400 400 500 mV mV µs 50-75-50% Iout max; 330µF cap; Figure 11 50-75-50% Iout max; 330µF cap; Figure 12 to within 1% Vout nom ms ms % Full load, Vout=90% nom.; Figures 9 & 10 -40°C to +125°C; Figure A 1,500 µF load capacitance, Iout = 0A % % Figures 1 - 4 Figures 1 - 4 °C °C °C Package rated to 150°C UL rated max operating temp 130°C See Figures 5 - 8 for derating curves 25 200 0 TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature Isolation Voltage (dielectric strength) Isolation Resistance Isolation Capacitance2 applies to Full Feature option only 60 40 240 92.3 91.7 ISOLATION CHARACTERISTICS continuous continuous 100ms transient, square wave Basic insulation level, Pollution degree 2 125 125 125 2250 30 3300 V MΩ pF Note 1: For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 2: Higher values of isolation capacitance can be added external to the module. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 3 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick ELECTRICAL CHARACTERISTICS (Continued) Parameter P FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control (Option P) Off-State Voltage On-State Voltage ON/OFF Control (Option N) Off-State Voltage On-State Voltage ON/OFF Control (Either Option) Pull-Up Voltage Pull-Up Resistance Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection Over-Temperature Shutdown Over-Temperature Shutdown Restart Hysteresis Load Current Scale Factor Min. Typ. Max. Units 275 300 325 kHz -2 2.7 0.8 18 V V 2.7 -2 18 0.8 V V 15 V kΩ % % % °C °C -20 Vin/6 42 117 120 10 TBD RELIABILITY CHARACTERISTICS Calculated MTBF (Telcordia) Calculated MTBF (MIL-217) Field Demonstrated MTBF +10 +10 Notes & Conditions Regulation and Isolation stages Figures A, B Measured across Pins 9 & 5; Figure C Measured across Pins 9 & 5 Over full temp range; % of nominal Vout Average PCB Temperature See App Note: Output Load Current Calc. 10 Hrs. TR-NWT-000332; 80% load,300LFM, 40oC Ta 106 Hrs. MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta 106 Hrs. See website for latest values 6 2.2 1.3 STANDARDS COMPLIANCE Parameter P Notes STANDARDS COMPLIANCE UL/cUL 60950 EN60950 72/23/EEC 93/68/EEC Needle Flame Test (IEC 695-2-2) IEC 61000-4-2 GR-1089-CORE Telcordia (Bellcore) GR-513 File # E194341, Basic insulation & pollution degree 2 Certified by TUV test on entire assembly; board & plastic components UL94V-0 compliant ESD test, 8kV - NP, 15kV air - NP (Normal Performance) Section 7 - electrical safety, Section 9 - bonding/grounding • 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 P QUALIFICATION TESTING Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability # Units 32 5 5 10 5 5 5 15 pins Test Conditions 95% rated Vin and load, units at derating point, 1000 hours 10-55Hz sweep, 0.060” total excursion,1 min./sweep, 120 sweeps for 3 axis 100g minimum, 2 drops in x and y axis, 1 drop in z axis -40°C to 100°C, unit temp. ramp 15°C/min., 500 cycles Toperating = min to max, Vin = min to max, full load, 100 cycles Tmin-10°C to Tmax+10°C, 5°C steps, Vin = min to max, 0-105% load 85°C, 85% RH, 1000 hours, 2 minutes on and 6 hours off MIL-STD-883, method 2003 • Extensive characterization testing of all SynQor products and manufacturing processes is performed to ensure that we supply robust, reliable product. Contact factory for official product family qualification document. OPTIONS PATENTS SynQor provides various options for Logic Sense, Pin Length and Feature Set for this family of DC/DC converters. Please consult the last page of this specification sheet for information on available options. SynQor is protected under various patents, including but not limited to U.S. Patent #s 5,999,417; 6,222,742 B1; 6,594,159 B2; 6,545,890 B2. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 4 Input: Output: Current: Package: Technical Specification 100 94 95 93 92 Efficiency (%) 90 Efficiency (%) 35-75 V 52.5 V 3.8 A (200W) Half-brick 85 80 75 90 89 88 35 Vin 70 91 48 Vin 25 C 40 C 87 75 Vin 65 55 C 86 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 0 4.0 100 300 400 500 Air Flow (LFM) Load Current (A) Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 2: Efficiency at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (nominal input voltage). 20 12.0 18 11.0 16 Power Dissipation (W) Power Dissipation (W) 200 14 12 10 8 6 35 Vin 4 48 Vin 2 75 Vin 0.5 1.0 1.5 2.0 2.5 3.0 3.5 9.0 8.0 7.0 6.0 25 C 40 C 55 C 5.0 4.0 0 0.0 10.0 0 4.0 100 200 300 400 500 Air Flow (LFM) Load Current (A) Figure 3: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 4: Power dissipation at nominal output voltage and 60% rated power vs. airflow rate for ambient air temperatures of 25°C, 40°C, and 55°C (nominal input voltage). 4.0 3.5 Semiconductor junction temperature is within 1°C of surface temperature 3.0 Iout (A) 2.5 2.0 1.5 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 1.0 200 LFM (1.0 m/s) 0.5 100 LFM (0.5 m/s) 50 LFM (0.25 m/s) 0.0 0 25 40 55 70 85 Ambient Air Temperature (oC) Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 50 LFM through 400 LFM with air flowing from input to output (nominal input voltage). Product # PQ60525HTA04 Phone 1-888-567-9596 Figure 6: Thermal plot of converter at 3.4 amp load current (179W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from input to output (nominal input voltage). www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 5 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick 4.0 3.5 Semiconductor junction temperature is within 1°C of surface temperature 3.0 Iout (A) 2.5 2.0 1.5 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 1.0 200 LFM (1.0 m/s) 0.5 100 LFM (0.5 m/s) 50 LFM (0.25 m/s) 0.0 0 25 40 55 70 85 o Ambient Air Temperature ( C) Figure 7: Maximum output power derating curves vs. ambient air temperature for airflow rates of 50 LFM through 400 LFM with air flowing from output to input (nominal input voltage). Figure 8: Thermal plot of converter at 3.2 amp load current (168W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from output to input (nominal input voltage). Figure 9: Turn-on transient at full load (resistive load) (10 ms/div). Input voltage pre-applied. Top Trace: Vout (20V/div). Bottom Trace: ON/OFF input (5V/div) Figure 10: Turn-on transient at zero load (10 ms/div). Top Trace: Vout (20V/div). Bottom Trace: ON/OFF input (5V/div). Figure 11: Output voltage response to step-change in load current (50%75%-50% of Iout(max); dI/dt = 0.1A/µs). Load cap: 330µF, electrolytic output capacitance. Top trace: Vout (200mV/div), Bottom trace: Iout (1A/div). Figure 12: Output voltage response to step-change in load current (50%75%-50% of Iout(max): dI/dt = 5A/µs). Load cap: 330µF, electrolytic output capacitance. Top trace: Vout (200mV/div), Bottom trace: Iout (1A/div). Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 6 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick See Fig. 15 10 µH source impedance See Fig. 14 See Fig. 16 iS VSOURCE iC 47 µF, <1Ω ESR electrolytic capacitor DC/DC Converter VOUT 1 µF 15 µF, ceramic 450mΩ ESR capacitor tantalum capacitor Figure 13: Test set-up diagram showing measurement points for Input Terminal Ripple Current (Figure 14), Input Reflected Ripple Current (Figure 15) and Output Voltage Ripple (Figure 16). Figure 14: Input Terminal Ripple Current, ic, at full rated output current and nominal input voltage with 10µH source impedance and 47µF electrolytic capacitor (500 mA/div). (See Figure 13) Figure 15: Input reflected ripple current, is, through a 10 µH source inductor at nominal input voltage and rated load current (10 mA/div). (See Figure 13) Figure 16: Output voltage ripple at nominal input voltage and rated load current (20 mV/div). Load capacitance: 1µF ceramic capacitor and 15µF tantalum capacitor. Bandwidth: 20 MHz. (See Figure 13) Figure 17: Output voltage response to step-change in input voltage (1000V/ms). Load cap: 330µF, electrolytic output capacitance. Ch 1: Vin (20V/div), Ch 2: Vout (500mV/div). Figure 18: Load current (2A/div) as a function of time when the converter attempts to turn on into a 10 mΩ short circuit. Top trace (2ms/div) is an expansion of the on-time portion of the bottom trace. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 7 Input: Output: Current: Package: Technical Specification 10 35-75 V 52.5 V 3.8 A (200W) Half-brick 0 Output Impedance (Ω ) 35 Vin 0.1 48 Vin 75 Vin 0.01 Forward Transmission (dB) -10 1 -20 -30 35 Vin -40 48 Vin 75 Vin -50 -60 -70 0.001 -80 10 100 1,000 10,000 100,000 10 100 Hz 1,000 10,000 100,000 Hz 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. 30 100 10 35 Vin 0 48 Vin 75 Vin -10 Input Impedance (Ω ) Reverse Transmission (dB) 20 10 35 Vin 48 Vin 75 Vin 1 -20 -30 10 100 1,000 10,000 0.1 100,000 10 Hz Figure 21: Magnitude of incremental reverse transmission (RT = iin/iout) for minimum, nominal, and maximum input voltage at full rated power. 100 1,000 Hz 10,000 100,000 Figure 22: Magnitude of incremental input impedance (Zin = vin/iin) for minimum, nominal, and maximum input voltage at full rated power. 60 Output Voltage (V) 50 40 30 20 35 V 48 V 10 75 V 0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 Load Current (A) Figure 23: Output voltage vs. load current showing typical current limit curves and converter shutdown points. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 8 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick BASIC OPERATION AND FEATURES CONTROL FEATURES The PowerQor series converter 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-down to achieve the low 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(-). There are two versions of the converter that differ by the sense of the logic used for the ON/OFF input. 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 PowerQor converter has such high efficiency, even at very low output voltages and very high output currents. Dissipation throughout the converter is so low that it does not require a heatsink for operation. Since a heatsink is not required, the PowerQor converter does not need a metal baseplate or potting material to help conduct the dissipated energy to the heatsink. The PowerQor converter can thus be built more simply and reliably using high yield surface mount techniques on a PCB substrate. The PowerQor series of half-brick, quarter-brick and eighth-brick converters uses the industry standard footprint and pin-out configuration. In the positive logic version, the ON/OFF input is active high (meaning that a high turns the converter on). In the negative logic version, the ON/OFF signal is active low (meaning that a low turns the converter on). Figure A details five possible circuits for driving the ON/OFF pin. Figure B is a detailed look of the internal ON/OFF circuitry. REMOTE SENSE(+) (Pins 8 and 6): The SENSE(+) inputs correct for voltage drops along the conductors that connect the converter’s output pins to the load. Pin 8 should be connected to Vout(+) and Pin 6 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 8 and 6 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 lower than its specified value. Note: the output over-voltage protection circuit senses the voltage ON/OFF ON/OFF ON/OFF Vin(_) Vin(_) Vin(_) Remote Enable Circuit Negative Logic (Permanently Enabled) ON/OFF Positive Logic (Permanently Enabled) 5V Vin(+) 5V 274k ON/OFF 50k TTL TTL/ CMOS ON/OFF Vin(_) Vin(_) Open Collector Enable Circuit Vin(_) Direct Logic Drive Figure A: Various circuits for driving the ON/OFF pin. Product # PQ60525HTA04 100pF 50k Phone 1-888-567-9596 www.synqor.com Figure B: Internal ON/OFF pin circuitry Doc.# 005-2HT652F Rev. B 03/08/04 Page 9 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick across the output (pins 9 and 5) to determine when it should trigger, not the voltage across the converter’s sense leads (pins 8 and 6). Therefore, the resistive drop on the board should be small enough so that output OVP does not trigger, even during load transients. output voltage too high may cause the over-voltage protection circuit to engage, particularly during transients. OUTPUT VOLTAGE TRIM (Pin 7): The TRIM input permits the user to adjust the output voltage across the sense leads up or down according to the trim range specifications. 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. To decrease the output voltage, the user should connect a resistor between Pin 7 and Pin 6 (SENSE(-) input). For a desired decrease of the nominal output voltage, the value of the resistor should be Rtrim-down = -2 (100% ∆ ) (kΩ) where ∆% = Vnominal – Vdesired Vnominal x 100% To increase the output voltage, the user should connect a resistor between Pin 7 and Pin 8 (SENSE(+) input). For a desired increase of the nominal output voltage, the value of the resistor should be Rtrim-up = nominal – 2 (V1.225 )xV DES + VNOM (kΩ) VDES - VNOM Figure C graphs 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. Trim Resistance (kOhms) 100,000 It is not necessary for the user to add capacitance at the Trim pin. The node is internally bypassed to eliminate noise. PROTECTION FEATURES Input Under-Voltage Lockout: The converter is designed to turn off when the input voltage is too low, helping avoid an input system instability problem, described in more detail in the application note titled “Input System Instability”. 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 (listed on the specification page) 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. Input Over-Voltage Shutdown: Available on PQ48 models only. The converter turns off when the input voltage is too high, allowing the converter to withstand an input voltage as high as 100V without destruction. The shutdown circuitry is a comparator with DC hysteresis. When the input voltage exceeds the typical Input Over-Voltage Shutdown value, the converter will turn off. Once the converter is off, it will turn back on when the input voltage falls below the minimum Input Over-Voltage Shutdown value. Output Current Limit: The maximum current limit remains constant as the output voltage drops. However, once the impedance of the short across the output is small enough to make the output voltage drop below the specified Output DC Current-Limit Shutdown Voltage, the converter turns off. 10,000 1,000 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. 100 10 1 0 2 4 6 8 10 % Increase in Vout 12 14 16 18 20 % Decrease in Vout Figure C: Trim Graph for 52.5Vout module Note: the TRIM feature does not affect the voltage at which the output over-voltage protection circuit is triggered. Trimming the Product # PQ60525HTA04 Phone 1-888-567-9596 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 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 10 Input: Output: Current: Package: Technical Specification 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. 35-75 V 52.5 V 3.8 A (200W) Half-brick provides a diagram showing the internal input filter components. This filter dramatically reduces input terminal ripple current, which otherwise could exceed the rating of an external input electrolytic capacitor. The recommended external input capacitance is specified in the “Input Characteristics” section. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. 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 web site (www.synqor.com) which provides an understanding of why this instability arises, and shows the preferred solution for correcting it. Application Circuits: Figure D below provides a typical circuit diagram which details the input filtering and voltage trimming. Input Filtering and External Capacitance: Figure E below Vin(+) Vin External Input Filter Electrolytic Capacitor 47µF Vout(+) Vsense(+) ON/OFF Trim Vsense(_) Vin(_) Rtrim-up or Rtrim-down Cload Iload Vout(_) Figure D: Typical application circuit (negative logic unit, permanently enabled). L Vin(+) C Vin(_) Figure E: Internal Input Filter Diagram (component values listed on page 3). Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 11 Input: Output: Current: Package: Technical Specification Startup Inhibit Period: The Startup Inhibit Period ensures that the converter will remain off for approximately 200ms when it is shut down for any reason. When an output short is present, this generates a 5Hz "hiccup mode," which prevents the converter from overheating. In all, there are seven ways that the converter can be shut down, initiating a Startup Inhibit Period: 35-75 V 52.5 V 3.8 A (200W) Half-brick 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. FULL FEATURE APPLICATION NOTES This section provides some basic application information for the full-feature version of the PowerQor series converter. The pin-out configuration for these optional feature pins is shown on page 2, and the part numbering format is shown on the last page of this specification sheet. • Input Under-Voltage Lockout • Input Over-Voltage Shutdown (not present in Quarter-brick) • Output Over-Voltage Protection • Over Temperature Shutdown • Current Limit • Short Circuit Protection • Turned off by the ON/OFF input Figure F shows three turn-on scenarios, where a Startup Inhibit Period is initiated at t0, t1, and t2: 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. 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. All units in this product family include back-drive protection to simplify the use of multiple converters in a parallel or sequencing application. However, any voltage applied to the output of the converter should be kept below 120% of the rated output voltage of the converter. In addition to back-drive protection, these units include the following features (pins): Current Share (pin 3): The active current share feature allows for N+1 and parallel applications. To achieve load sharing, directly connect the I share pins of multiple units. The load current will share equally among the multiple units (±5% at full rated current). It is important that the Vin(-) pins of the sharing units be directly connected and NOT placed outside of an EMI filter or other impedance path. The voltage at the I Share pin will range from 0 to 5 volts (at full rated current), referenced to the primary- Vin Under-Voltage Lockout Turn-On Threshold ON/OFF (pos logic) ON OFF ON OFF ON 25ms (typical Vout turn on time) 200ms (typical start-up inhibit period) t1 t0 200ms 200ms t2 t Figure F: Startup Inhibit Period (turn-on time not to scale) Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 12 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick side ground, Vin(-). Start Sync (pin B): The Start Synchronization pin will allow a more consistent start-up sequence. To operate this feature, connect together the Start-Sync pins of multiple current-sharing units. This will permit immediate start-up with loads greater than the current limit of a single unit. Without this connection, any set of converters attempting to asynchronously start (or re-start) with a load greater than the current limit of a single unit will "hiccup". This “hiccup” mode will continue until one converter attempts a start at the same time as the minimum number of additional units necessary to sustain the load condition. For example, three 50 amp units starting into a 90 amp load would require two units to simultaneously attempt a start. The Start Sync connection synchronizes these starting attempts and provides a more consistent and reliable start-up sequence. For details about the "hiccup mode" or repeated startup attempts, please see the "Startup Inhibit Period" note in this Technical Specification. Clock Sync (pin A): The External Clock Synchronization pin provides the ability for the user to control the EMI signature and synchronize sensitive circuitry to quiet periods in the converter operation. With this option, the converter can be synchronized to an external clock signal whose frequency is greater than that of the free-running internal clock. However, substantially raising the converter’s frequency will reduce its efficiency. Therefore, the recommended frequency range for the external clock synchronization signal applied to this pin would be the lowest value possible without dropping below the maximum switching frequency value listed on the Electrical Specifications page. The following requirements should also be met: • The external clock signal should be referenced to the negative input voltage, Vin(-). • The high level of the signal should be between 3.5V and 5.0V. • The low level should be between -0.5V and +1.2V. • Do not apply a clock signal lower than the specified frequency. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 13 Input: Output: Current: Package: Technical Specification 35-75 V 52.5 V 3.8 A (200W) Half-brick PART NUMBERING SYSTEM ORDERING INFORMATION The part numbering system for SynQor’s PowerQor 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 3 characters for options. PQ60 versions of the modules below indicate a unit with 100V for 100ms input voltage transient withstand (Telcordia GR-513). PQ 60 525 H T A 04 N K S Options (see Ordering Information) Output Current Thermal Design Performance Level 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. Although there are no default values for enable logic and pin length, the most common options are negative logic and 0.145” pins. These part numbers are more likely to be readily available in stock for evaluation and prototype quantities. Model Number Input Voltage PQ60012HTA60xyz PQ48015HTA60xyz PQ48018HTA60xyz PQ48020HTA60xyz PQ48025HTA60xyz PQ48033HTA50xyz PQ48050HTA33xyz PQ48120HTA14xyz PQ48150HTA11xyz PQ60180HTA09xy S PQ60260HTB10xyz PQ60525HTA04xyz 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V 35 - 75 V Output Max Output Voltage Current 1.2 V 60 A 1.5 V 60 A 1.8 V 60 A 2.0 V 60 A 2.5 V 60 A 3.3 V 50 A 5.0 V 33 A 12 V 13.75 A 15 V 11 A 18 V 9.2 A 26 V 9.6 A 52.5 V 3.8 A The following option choices must be included in place of the x y z spaces in the model numbers listed Application Notes Options Description: x y z Enable Logic A variety of application notes and technical white papers can be downloaded in pdf format at www.synqor.com. Pin Length K - 0.110" P - Positive N - 0.145" N - Negative R - 0.180" Y - 0.250" Feature Set S - Standard 8 - Standard with Alternate Bottom Side Clearance (see Note 3 below) F - Full Feature Note 3: The 15th character “8”designates an alternate minimum bottom side clearance option available on the PQ60525HTA04xxS model. Please see the mechanical drawing on Page 2 for bottom side clearance and maximum hieght for the “8” option. Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: Product # PQ60525HTA04 978-849-0600 888-567-9596 978-849-0602 [email protected] www.synqor.com 155 Swanson Road Boxborough, MA 01719 Phone 1-888-567-9596 Warranty SynQor offers a three (3) year limited warranty. Complete warranty information is listed on our web site 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.# 005-2HT652F Rev. B 03/08/04 Page 14