Technical Specification PQ60025EKx20 48V 2.5V 20A 2000V dc Eighth-brick Input Output Current Isolation DC-DC Converter The PowerQor® Eighth-brick converter series is composed of next-generation, board-mountable, isolated, fixed switching frequency dc-dc converters that use synchronous rectification to achieve extremely high power conversion efficiency. The power dissipated by the converter is so low that a heatsink is not required, which saves cost, weight, height, and application effort. All of the power and control components are mounted to the multi-layer PCB substrate with high-yield surface mount technology. Since the PowerQor converter has no explicit thermal interfaces, it is extremely reliable. RoHS Compliant (see page 15). Operational Features • High efficiency, 86% at full load PQ60025EKA20 Module • Delivers up to 20A of output current (50W) 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 • No minimum load requirement means no preload resistors required Control Features • On/Off control referenced to input side (positive and negative logic options are available) Mechanical Features • Remote sense for the output voltage compensates for output distribution drops • Industry standard eighth-brick pin-out configuration • Output voltage trim permits custom voltages and voltage margining • Industry standard size: 0.90”x2.3” (22.9x58.4mm) • Total height only 0.320” (8.13mm), permits better airflow and smaller card pitch • Total weight: 0.85oz. (24 grams) Safety Features • 2000V, 30MΩ input-to-output isolation provides input/output ground separation • Flanged pins designed to permit surface mount soldering (avoid wave solder) using FPiP technique • UL 60950-1 recognized (US & Canada),basic insulation rating • TUV certified to EN60950-1 • Board and plastic components meet UL94V-0 flammability requirements Protection Features • Input under-voltage lockout disables converter at low input voltage conditions CONTENTS • Output current limit and short circuit protection protects converter and load from permanent damage and consequent hazardous conditions • Active back bias limit prevents damage to converter from external load induced pre-bias • Output over-voltage protection protects load from damaging voltages • Thermal shutdown protects converter from abnormal environmental conditions Product # PQ60025EKx20 Phone 1-888-567-9596 Page No. Mechanical Drawing - Open frame - EKA & EKL (low Profile) . . . . . . . . . 2 Mechanical Drawing - Encased . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PQ60025EKA20 Electrical Characteristics . . . . . . . . . . . . . . . . . . . . . . 4-5 PQ60025EKx20 Standards & Qualification Testing . . . . . . . . . . . . . . . . . 6 PQ60025EKx20 Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Application Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 1 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 MECHANICAL DRAWING - OPEN FRAME - EKA & EKL (LOW PROFILE) .900 (22.86) 0.600 (15.24) 0.450 (11.43) 0.300 (7.62) 0.150 (3.81) 8 7 6 5 0.340 ± 0.014 (8.64 ± 0.35) Overall Height 0.410 ± 0.014 (10.41 ± 0.35) Overall Height 4 0.145 (3.68) 0.145 (3.68) 2.30 (58.4) Side View Top View 2.00 (50.8) 1 2 3 .14 (3.6) 0.121±.017 (3.07±0.43) Bottom Side Clearance 0.150 (3.8) 0.300 (7.62) 0.051±.017 (1.3±0.43) Bottom Side Clearance EKA Side View 0.600 (15.24) NOTES EKL Side View PIN DESIGNATIONS 1) Pins 1-3, 5-7 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm) diameter standoff shoulders. Pin Name Function 1 Vin(+) Positive input voltage 3) Other pin extension lengths available. Recommended pin length is 0.03” (0.76mm) greater than the PCB thickness. 2 ON/OFF 4) All Pins: Material - Copper Alloy- Finish (RoHS 6/6) - Matte Tin over Nickel plate 3 Vin(–) 2) Pins 4 and 8 are 0.062” (1.57 mm) diameter with 0.100" (2.54 mm) diameter standoff shoulders. 5) Undimensioned components are shown for visual reference only. 6) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 7) Weight: 0.85 oz (24 g) typical Negative input voltage 4 Vout(–) Negative output voltage 5 SENSE(–) Negative remote sense1 6 TRIM 7 8) Workmanship: Meets or exceeds IPC-A-610C Class II TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Output voltage trim2 SENSE(+) Positive remote sense3 8 Vout(+) Positive output voltage 9) The flanged pins are designed to permit surface mount soldering (allowing to avoid the wave soldering process) through the use of the flanged pin-in-paste technique. Notes: 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 core shown at left above is considered part of the input/primary circuit. 2) Leave TRIM pin open for nominal output voltage. Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com 1) SENSE(–) should be connected to Vout(–) either remotely or at the converter. 3) SENSE(+) should be connected to Vout(+) either remotely or at the converter. Doc.# 005-0005112 Rev. C 06/12/09 Page 2 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKC20 MECHANICAL DRAWING - ENCASED .986±0.020 (25.04±0.5) 0.600 (15.24) 0.450 (11.43) 0.300 (7.62) 0.150 (3.81) 0.500 ± 0.025 (12.7 ± 0.63) Overall Height 8 7 6 5 4 2.386±0.020 (60.6±0.5) Top View Side View 2.00 (50.8) 0.183±0.020 (4.65±0.5) 1 2 3 0.193±0.020 (4.9±0.5) 0.300 (7.62) 0.180±.010 (4.57±0.25) 0.600 (15.24) PIN DESIGNATIONS NOTES 1) Pins 1-3, 5-7 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm) diameter standoff shoulders. 2) Pins 4 and 8 are 0.062” (1.57 mm) diameter with 0.100" (2.54 mm) diameter standoff shoulders. 3) Other pin extension lengths available. Recommended pin length is 0.03” (0.76mm) greater than the PCB thickness. 4) All Pins: Material - Copper Alloy- Finish (RoHS 6/6) - Matte Tin over Nickel plate Pin Name Function 1 Vin(+) Positive input voltage 2 ON/OFF 3 Vin(–) 4 Vout(–) 5) Undimensioned components are shown for visual reference only. 6) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) 7) Weight: 5 oz (142 g) typical 7 8) Workmanship: Meets or exceeds IPC-A-610C Class II 8 9) The flanged pins are designed to permit surface mount soldering (allowing to avoid the wave soldering process) through the use of the flanged pin-in-paste technique. Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com 5 6 TTL input to turn converter on and off, referenced to Vin(–), with internal pull up. Negative input voltage Negative output voltage SENSE(–) Negative remote sense1 TRIM Output voltage trim2 SENSE(+) Positive remote sense3 Vout(+) Positive output voltage 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. Doc.# 005-0005112 Rev. C 06/12/09 Page 3 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 PQ60025EKA20 Electrical Characteristics Ta = 25°C, airflow rate = 300 LFM, Vin = 48Vdc 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 ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating 100 V Continuous Operating 75 V Continuous Operating Transient Protection 100 V 100ms transient, square wave 2000 V dc 100 °C Isolation Voltage Input to Output Operating Temperature -40 Storage Temperature -55 125 °C 0 13.5 V Voltage at ON/OFF input pin Basic Insulation INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Maximum Input Current 35 48 75 V 33.0 31.5 1.2 34.0 32.3 1.7 35.0 33.5 2.2 1.7 V V V A No-Load Input Current 47 Disabled Input Current 9.8 Inrush Current Transient Rating See Note 1 100% Load, 35V Vin, nominal Vout mA 10.5 0.03 mA A2s Response to Input Transient 80 mV 1000V/ms input transient Input Reflected Ripple Current 1.8 mA RMS thru 10μH inductor; Figures 13 & 15 Input Terminal Ripple Current 65 mA RMS; Figures 13 & 14 Fast acting external fuse recommended 47 A µF 1\2.35 µH\µF Recommended Input Fuse 20 Recommended External Input Capacitance Input Filter Component Values (L\C) Typical ESR 0.1-0.2Ω; Figure 13 Internal values; see Figure E OUTPUT CHARACTERISTICS Output Voltage Set Point 2.475 2.50 2.525 V Output Voltage Regulation Over Line ±0.1\2.5 %\mV Over Load ±0.15\3.75 %\mV Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise 2.450 ±10 2.500 2.550 mV V Over sample, line, load, temperature & life 20MHz bandwidth; see Note 2 Peak-to-Peak 50 mV Full load; see Figures 13 & 16 RMS 17 Full load; see Figures 13 & 16 20 mV A Operating Output Current Range 0 Subject to thermal derating; Figures 5 - 8 Output DC Current-Limit Inception 24.5 26.6 29.0 A Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled 4.5 2.25 7 1.1 12.5 V A mA Negative current drawn from output Negative current drawn from output 7 mF Nominal Vout at full load (resistive load) Maximum Output Capacitance Electrolytic EFFICIENCY 100% Load 86 % Figures 1 - 4 50% Load 86 % Figures 1 - 4 Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 4 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 PQ60025EKA20 Electrical Characteristics (continued) Ta = 25 °C, airflow rate = 300 LFM, Vin = 48V 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 DYNAMIC CHARACTERISTICS Input Voltage Ripple Rejection 87 dB Step Change in Output Current (0.1A/µs) 250 mV 50% to 75% to 50% Iout max; Figure 11 Step Change in Output Current (5A/µs) 200 mV 50% to 75% to 50% Iout max; Figure 12 settling time 700 µs To within 1% Vout nom ms ms % Full load, Vout=90% nom. -40°C to +125°C; Figure F Maximum Output Capacitance Output Voltage during Load Current Transient 120Hz See Note 3 Turn-On Transient Turn-On Time Start-Up Inhibit Time Output Voltage Overshoot 21 200 0 180 240 ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance Isolation Capacitance (input to output) TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature 2000 V 30 MΩ 1000 pF See Absolute Maximum Ratings See Note 4 125 °C Package rated to 150°C Board Temperature 125 °C UL rated max operating temp 130°C Transformer Temperature 125 °C 330 kHz FEATURE CHARACTERISTICS Switching Frequency 270 300 ON/OFF Control (Option P) Off-State Voltage 0 0.8 V On-State Voltage 2 13.5 V Off-State Voltage 2 13.5 V On-State Voltage 0 0.8 V 6 V ON/OFF Control (Option N) ON/OFF Control (Either Option) Application notes; Figures A & B Pull-Up Voltage 5 Pull-Up Resistance 10 Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection Over-Temperature Shutdown kΩ -10 10 % Measured across Pins 8 & 4; Figure C 125 10 148 % % °C Measured across Pins 8 & 4 Over Full Temperature Range; % of nominial Vout Average PCB Temperature Over-Temperature Shutdown Restart Hysteresis 138 125 10 RELIABILITY CHARACTERISTICS Calculated MTBF (Telcordia) 2.5 Calculated MTBF (MIL-217) 1.1 Field Demonstrated MTBF °C 106 Hrs. TR-NWT-000332; 80% load, 300LFM, 40°C Ta 106 Hrs. MIL-HDBK-217F; 80% load, 300LFM, 40°C Ta 106 Hrs. See our website for details Note 1: The UVLO values represented here are typical of lighter load conditions. The unit may shut down under high load conditions before the typical UVLO limits. Note 2: For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: [email protected]) Note 3: The module requires a minimum amount of capacitance (100μF) in order to ride through a No Load to Full Load transient (0.1A/μs) without shutdown. Note 4: Higher values of isolation capacitance can be added external to the module. Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 5 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 PQ60025EKx20 Standards & Qualification Testing Pending Parameter Notes & Conditions STANDARDS COMPLIANCE UL/cUL 60950-1 File # E194341, Basic insulation EN60950-1 Certified by TUV Needle Flame Test (IEC 695-2-2) Test on entire assembly; board & plastic components UL94V-0 compliant IEC 61000-4-2 ESD test, 8 kV - NP, 15 kV 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. Parameter # Units Test Conditions QUALIFICATION TESTING Life Test 32 95% rated Vin and load, units at derating point, 1000 hours Vibration 5 10-55 Hz sweep, 0.060" total excursion, 1 min./sweep, 120 sweeps for 3 axis Mechanical Shock 5 100g minimum, 2 drops in x and y axis, 1 drop in z axis Temperature Cycling 10 -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 Humidity 5 85 °C, 85% RH, 1000 hours, continuous Vin applied except 5 min/day Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 6 Input: Output: Current: Part No.: 100 91 95 90 90 89 85 88 Efficiency (%) Efficiency (%) Technical Specification 80 75 70 87 86 85 35 Vin 48 Vin 75 Vin 65 25º C 40º C 55º C 84 60 83 0 5 10 15 20 100 200 Load Current (A) 300 400 Air Flow (LFM) 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). 14 8 12 7 Power Dissipation (W) Power Dissipation (W) 35-75V 2.5V 20A PQ60025EKx20 10 8 6 4 35 Vin 48 Vin 2 6 5 4 3 25º C 40º C 2 55º C 75 Vin 0 1 0 5 10 15 20 Load Current (A) 100 200 300 400 Air Flow (LFM) 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). 25 Iout (A) 20 15 10 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 5 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) 0 25 40 55 70 85 Ambient Air Temperature (ºC) Figure 5: Maximum output power-derating curve vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM with air flowing from pin 3 to pin 1 (nominal input voltage). Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Figure 6: Thermal plot of converter at 17.5 A load current (43.75 W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from pin 3 to pin 1 (nominal input voltage). Doc.# 005-0005112 Rev. C 06/12/09 Page 7 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 25 Iout (A) 20 15 10 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 5 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) 0 25 40 55 70 85 Ambient Air Temperature (ºC) Figure 7: Maximum output power derating curves vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM with air flowing across the converter from input to output (nominal input voltage). Figure 8: Thermal plot of converter at 18.6 A load current (42W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from input to output (nominal input voltage). Figure 9: Turn-on transient at full load (resistive load) (10 ms/div). Load cap: 10 uF, 100 mΩ ESR tantalum capacitor and 1 uF ceramic capacitor. Input voltage pre-applied. Ch 1: Vout (1V/div), Ch 2: ON/ OFF input (5 V/div). Figure 10: Turn-on transient at zero load (10 ms/div). Load cap: 10 µF, 100 mΩ ESR tantalum capacitor and 1 µF ceramic capacitor. Ch 1: Vout (1V/div), Ch 2: ON/OFF input (5 V/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: 15µF tantalum cap and 1µF ceramic cap. Ch 1: Vout (200mV/div), Ch 2: Iout (5A/div). Figure 12: Output voltage response to step-change in load current (50%-75%-50% of Iout(max): dI/dt = 1A/µs). Load cap: 470µF, 30 mΩ ESR tantalum cap and 1µF ceramic cap. Ch 1: Vout (200mV/div), Ch 2: Iout (5A/div). Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 8 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 See Fig. 15 10 µH source impedance See Fig. 14 See Fig. 16 iS VSOURCE iC 47 µF, <1W ESR electrolytic capacitor DC/DC Converter VOUT 1 µF 15 µF, ceramic 100mW 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 (50 mA/div). See Figure 13. Figure 15: Input reflected ripple current, is, through a 10 µH source inductor, using a 47µF electrolytic input capacitor (5mA/div). See Figure 13. Figure 16: Output voltage ripple at nominal input voltage and rated load current (50 mV/div). Load capacitance: 1µF ceramic capacitor and 15µF tantalum capacitor. Bandwidth: 20 MHz. See Figure 13. 12 11 10 Vout Trim-up (%) 9 8 7 6 5 4 3 2 100% Load 50% Load 1 0% Load 0 40.0 39.5 39.0 38.5 38.0 37.5 37.0 36.6 36.0 35.5 35.0 Input Voltage (V) Figure 17: Output voltage response to step-change in input voltage (48V to 75V), at 20A load current. Load cap: 15µF tantalum capacitor and 1uF ceramic cap. Ch 1: Vout (100mV/div), Ch 2: Vin (50V/div). Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Figure 18: Achievable trim-up percentage vs. input voltage at 0%, 50% and full load. Vin=35-40V. Doc.# 005-0005112 Rev. C 06/12/09 Page 9 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 -20 1 Forward Transmission (dB) Output Impedance (ohms) -30 0.1 0.01 35 Vin 0.001 48 Vin -40 -50 -60 -70 -80 -90 35 Vin -100 48 Vin 75 Vin -110 0.0001 75 Vin -120 10 100 1,000 10,000 10 100,000 100 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. 1000 5 Input Impedance (ohms) Reverse Transmission (dB) -5 -15 -25 -35 35 Vin -45 100 10 35 Vin 1 48 Vin 48 Vin 75 Vin 75 Vin 0.1 -55 10 100 1,000 10,000 100,000 10 100 Hz 1,000 10,000 100,000 Hz 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. 4 3.5 Output Voltage (V) 3 2.5 2 1.5 35 Vin 1 48 Vin 0.5 75 Vin 0 0 5 10 15 20 25 30 Load Current (A) Figure 23: Output voltage vs. load current showing typical current limit curves and converter shutdown points. Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 10 Input: Output: Current: Part No.: Technical Specification BASIC OPERATION AND FEATURES The single stage power converter switches 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 eighth-brick, quarter-brick and halfbrick converters uses the industry standard footprint and pin-out configuration. CONTROL FEATURES 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. 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 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 ON/OFF ON/OFF Vin(_) Vin(_) Vin(_) Remote Enable Circuit Negative Logic (Permanently Enabled) ON/OFF 5V 10k ON/OFF 50k TTL ON/OFF Vin(_) Vin(_) 100pF Vin(_) Direct Logic Drive Figure A: Various circuits for driving the ON/OFF pin. Product # PQ60025EKx20 5V Positive Logic (Permanently Enabled) TTL/ CMOS Open Collector Enable Circuit 35-75V 2.5V 20A PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Figure B: Internal ON/OFF pin circuitry Doc.# 005-0005112 Rev. C 06/12/09 Page 11 Input: Output: Current: Part No.: Technical Specification 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 = ( 511 ∆%) - 10.22 (kW) 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(100+∆%) _ 511 _ 10.22 1.225∆% ∆% ) (kW) where VOUT = Nominal Output Voltage 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. 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 bypassed to eliminate noise. Trim Resistance (kOhms) 10,000 35-75V 2.5V 20A PQ60025EKx20 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. 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. Output Current Limit: Once the output current reaches the current-limit point, the converter is in the cycle-by-cycle current limit mode for a short time that the typical value is 210µs. If the over current no longer exists during this short time, the converter resumes the normal condition. If the over current still persists after this short time, the converter enters a “hiccup mode” where it repeatedly turns on and off at a 5 Hz (nominal) frequency until the over current condition is removed. The dual advantages of this design are that a short term overload will not cause a hiccup mode restart and it prevents excessive heating of the converter or the load board in extended over current condition. 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 Over-Temperature 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. 1,000 100 10 1 0 1 2 3 4 % increase Vout 5 6 7 8 9 10 % decrease Vout Figure C: C: Trim Trim Graph Graph for for 2.5 1.8Vout Figure Vout module module Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 12 Input: Output: Current: Part No.: Technical Specification 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 D below provides a typical circuit diagram which details the input filtering and voltage trimming. Input Filtering and External Capacitance: Figure E below 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. 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. In all, there are five ways that the converter can be shut down, initiating a Startup Inhibit Period: • Input Under-Voltage Lockout • Output Over-Voltage Protection • Over Temperature Shutdown • Current Limit • Turned off by the ON/OFF input Vin(+) Vin External Input Filter Vout(+) Vsense(+) Electrolytic Capacitor 47µF 35-75V 2.5V 20A PQ60025EKx20 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 the specifications page). Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 13 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 Figure F shows three turn-on scenarios, where a Startup Inhibit Period is initiated at t0, t1, and t2: 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. 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. 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. Vin Under-Voltage Lockout Turn-On Threshold ON/OFF (pos logic) ON OFF ON OFF ON 21 ms 15ms turn on time) (typical (typical turn on time) Vout 10ms (typical start-up inhibit period) 200ms 200ms t t0 t1 t2 Figure F: Startup Inhibit Period (turn-on time not to scale) Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 14 Input: Output: Current: Part No.: Technical Specification 35-75V 2.5V 20A PQ60025EKx20 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 3 characters for options. Add “-G” to the model number for 6/6 RoHS compliance. P Q 6 0 02 5 E K A 2 0 N R S - G 6/6 RoHS Options (see Ordering Information) Model Number Output Current PQ60025EKA20xyz - G PQ60025EKL20xyz - G PQ60025EKC20xyz - G Thermal Design Performance Level Continuous Input Voltage 35-75V 35-75V 35-75V Maximum Output Current 20A 20A 20A Output Voltage 2.5V 2.5V 2.5V EKA has standard height, EKL is a low profile product Package Size Output Voltage The following options must be included in place of the x y z spaces in the model numbers listed above. Input Voltage Product Family Options Description: x y z Thermal Design 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]. A - Open Frame L - Low Profile C - Encased Enable Logic Pin Style Feature Set P - Positive N - Negative K - 0.110" N - 0.145" R - 0.180" Y - 0.250" S - Standard Not all combinations make valid part numbers, please contact SynQor for availability. See the Product Summary web page for more options. PATENTS SynQor holds the following patents, one or more of which might apply to this product: 5,999,417 6,594,159 6,927,987 7,119,524 6,222,742 6,731,520 7,050,309 7,269,034 6,545,890 6,894,468 7,072,190 7,272,021 6,577,109 6,896,526 7,085,146 7,272,023 Contact SynQor for further information: Phone: Toll Free: Fax: E-mail: Web: Address: Product # PQ60025EKx20 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 three (3) 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.# 005-0005112 Rev. C 06/12/09 Page 15