IQ64-HPC

I REL P 18-135 V Continuous Input M ARY IN Technical Specification IQ64-HPC Family 2250 V dc Isolation 1.8-48 V Outputs 200 W Max Power Half-brick DC-DC Converter The InQor® Half-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. Each module is supplied completely encased to provide protection from the harsh environments seen in many industrial and transportation applications. Operational Features • High efficiencies, up to 90% at full rated load current • Delivers full power with minimal derating - no heatsink required • Operating input voltage range: 18 - 135 V • Fixed frequency switching provides predictable EMI • No minimum load requirement Mechanical Features • Industry standard Half-brick pin-out configuration • Standard size: 2.390" x 2.490" x 0.512" (60.6 x 63.1 x 13.0 mm) • Total weight: 5 oz (142 g) Protection Features • Input under-voltage lockout • Output current limit and short circuit protection • Active back bias limit • Output over-voltage protection • Thermal shutdown Control Features • On/Off control referenced to input side • Remote sense for the output voltage • Output voltage trim range of -20%, +10% COntentS Mechanical Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 IQ64-HPC Family Electrical Characteristics . . . . . . . . . . . . . . . . . . . . 3 - 4 IQ64-HPC Family Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 IQ64018HPC60 (1.8 V, 60 A) Available in the Future . . . . . . . . . . . . . . . . IQ64033HPC50 (3.3 V, 50 A) Available in the Future . . . . . . . . . . . . . . . . IQ64050HPC36 (5.0 V, 36 A) Characteristics and Special Figures . . . . .6 - 7 IQ64120HPC16 (12 V, 16 A) Characteristics and Figures . . . . . . . . . . .8 - 9 IQ64150HPC13 (15 V, 13 A) Characteristics and Figures . . . . . . . . . 10 - 11 IQ64240HPC08 (24 V, 8.0 A) Available in the Future . . . . . . . . . . . . . . . . IQ64280HPC07 (28 V, 7.0 A) Available in the Future . . . . . . . . . . . . . . . . IQ64400HPC05 (40 V, 5.0 A) Characteristics and Figures . . . . . . . . 12 - 13 IQ64480HPC04 (48 V, 4.0 A) Available in the Future . . . . . . . . . . . . . . . . Special Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Application Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 18 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Doc.# 005-005065 Rev. 4 10/03/08 Page No. Safety Features • 2250 V, 30 MW input-to-output isolation • UL/cUL 60950-1 recognized (US & Canada), basic insulation rating • TUV certified to EN60950-1 • Meets 72/23/EEC and 93/68/EEC directives which facilitates CE Marking in user’s end product • Board and plastic components meet UL94V-0 standard • RoHS compliant (see last page) Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Page 1 I REL P MECHANICAL DIAGRAM M ARY IN Technical Specification IQ64-HPC Family NOTES PIN DESIGNATIONS Pin N o. 1 2 3 4 5 6 7 8 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. 1) Pins 1-3, 5-7 are 0.040" (1.02 mm) diameter with 0.080" (2.03 mm) diameter standoff shoulders. 2) Pins 4 and 8 are 0.080” (2.03 mm) diameter with 0.125” (3.18 mm) diameter standoff shoulders. 3) Recommended pin length is 0.03" (0.76 mm) greater than the PCB thickness. 4) All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate 5) Weight: 5 oz. (142 g) typical 6) All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5 mm) x.xxx +/-0.010 in. (x.xx +/-0.25 mm) 7) Workmanship: Meets or exceeds current IPC-A-610 Class II 8) Applied torque per screw should not exceed 6in-lb. (0.7 Nm). 9) Baseplate flatness tolerance is 0.004" (.10 mm) TIR for surface. Name Vin (+) ON/OFF Vin (-) Vout (-) SENSE (-) TRIM SENSE (+) Vout (+) Function Positive input voltage TTL input to turn converter on and off, referenced to V in (-) with internal pull up Negative input voltage Negative output voltage Negative remote sense 1 Output voltage trim 2 Positive remote sense 3 Positive output voltage Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 2 I REL P M ARY IN Technical Specification IQ64-HPC Family IQ64-HPC FAMILY eLeCtRICAL CHARACteRIStICS (all output voltages) Ta = 25 °C, airflow rate = 300 LFM, Vin = 64 V 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 ABSOLUte MAXIMUM RAtInGS Input Voltage Non-Operating 150 V Continuous Operating 135 V Continuous Operating Transient Protection V Isolation Voltage Input to Output 2250 V dc Input to Base-Plate 2250 V dc Output to Base-Plate 2250 V dc Operating Temperature -40 100 °C Baseplate temperature Storage Temperature -55 125 °C Voltage at ON/OFF input pin -2 18 V InPUt CHARACteRIStICS Operating Input Voltage Range 18 64 135 V See Note 1 for low-line operation Input Under-Voltage Lockout Turn-On Voltage Threshold 17.1 17.5 17.9 V Turn-Off Voltage Threshold 15.1 15.5 15.9 V Lockout Voltage Hysteresis 2.0 V Input Over-Voltage Shutdown V Not Available µF Recommended External Input Capacitance 470 Typical ESR 0.1-0.2 Ω Input Filter Component Values (L\C) 1.1\1.8 µH\µF Internal values; see Figure E DYnAMIC CHARACteRIStICS Turn-On Transient Turn-On Time 10 ms Full load, Vout=90% nom. Start-Up Inhibit Time 200 230 250 ms Figure F Output Voltage Overshoot 0 % Maximum Output Capacitance ISOLAtIOn CHARACteRIStICS Isolation Voltage (dielectric strength) See Absolute Maximum Ratings Isolation Resistance 30 MΩ Isolation Capacitance (input to output) 1000 pF See Note 2 teMPeRAtURe LIMItS FOR POWeR DeRAtInG CURVeS Semiconductor Junction Temperature 125 °C Package rated to 150 °C Board Temperature 125 °C UL rated max operating temp 130 °C Transformer Temperature 125 °C 100 °C Maximum Baseplate Temperature, Tb FeAtURe CHARACteRIStICS Switching Frequency 255 275 295 kHz Isolation stage switching freq. is half this ON/OFF Control Off-State Voltage 2.4 18 V On-State Voltage -2 0.8 ON/OFF Control Application notes Figures A & B Pull-Up Voltage 5 V Pull-Up Resistance 50 kΩ Over-Temperature Shutdown OTP Trip Point 125 °C Average PCB Temperature Over-Temperature Shutdown Restart Hysteresis 10 °C ReLIABILItY CHARACteRIStICS Calculated MTBF (Telcordia) TR-NWT-000332 TBD 106 Hrs. 80% load, 200LFM, 40 °C Ta Calculated MTBF (MIL-217) MIL-HDBK-217F TBD 106 Hrs. 80% load, 200LFM, 40 °C Ta Field Demonstrated MTBF 106 Hrs. See our website for details Note 1: Output voltage regulation can not be achieved on certain output voltages at low line voltages. See Special Figures before the App. Notes. Note 2: Higher values of isolation capacitance can be added external to the module. Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 3 I REL P STANDARDS COMPLIANCE STANDARDS COMPLIANCE UL/cUL 60950-1 EN60950-1 Needle Flame Test (IEC 695-2-2) IEC 61000-4-2 M ARY IN Technical Specification IQ64-HPC Family Parameter Notes & Conditions File # E194341, Basic insulation Certified by TUV Test on entire assembly; board & plastic components UL94V-0 compliant 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. QUALIFICATION TESTING QUALIFICATION TESTING Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability Parameter # Units 32 5 5 10 5 5 5 15 pins Test Conditions 95% rated Vin and load, units at derating point, 1000 hours 10-55 Hz 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, continuous Vin applied except 5 min/day MIL-STD-883, method 2003 Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 4 I REL P M ARY IN Technical Specification IQ64-HPC Family IQ64 FAMILY FIGUReS (all output voltages) 120 Nominal Vout Typical Current Limit Inception Point 100 Output Voltage (%) 80 Typical Output Voltage at Shutdown 60 40 Vin min 20 Vin nom Vin max 0 5.00 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Load Current (% ) Common Figure 1: Typical startup waveform. Input voltage pre-applied, ON/OFF Pin on Ch 2. Common Figure 2: Output voltage vs. load current showing typical current limit curves and converter shutdown points. 1,000,000 100,000 Trim Resistance (kOhms) 10,000 Trim Resistance (kOhms) 0 1 2 3 4 5 6 7 8 9 10 100,000 1,000 10,000 100 1,000 10 100 0 1 2 3 4 5 6 7 8 9 10 1.8 V 3.3 V 5V 12 V 15 V 24 V 28 V 40V 48 V Common Figure 3: Trim graph for trim-up 1.8 to 12 V outputs. 10,000.0 % Decrease in Vout (All voltages) Common Figure 4: Trim graph for trim-up 15 to 48 V outputs. 120 Typical Current Limit Inception Point 100 Trim Resistance (kOhms) 1,000.0 Output Voltage (%) 80 Typical Output Voltage at Shutdown 60 100.0 40 Vin max Extended operation in this area should be avoided at an input voltage > 100 V. See app. notes for details. 20 10.0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 % Decrease in Vout (All voltages) Load Current (% ) Common Figure 5: Trim graph for trim down. Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Common Figure 6: Safe operating range limitations. Doc.# 005-005065 Rev. 4 10/03/08 Page 5 Technical Specification P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 5.0 V 36 A IQ64050HPC36 IQ64050HPC36 eLeCtRICAL CHARACteRIStICS (5.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 64 V 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 InPUt CHARACteRIStICS Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Terminal Ripple Current Recommended Input Fuse OUtPUt CHARACteRIStICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection eFFICIenCY 100% Load 50% Load Min. typ. 80 3 0.3 1100 Max. 15.4 100 4 Units notes & Conditions A mA mA V mA A V % % mV V mV mV A A V A mA µF mV µs % % V % % Vin min; trim up; in current limit 20 4.95 5 ±0.1 ±0.1 -75 4.875 130 20 0 39.6 43.2 2.2 0.6 0.4 5.05 ±0.3 ±0.3 75 5.125 260 40 36 46.8 See Figure 6 RMS Fast acting external fuse recommended Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 1 Full load Full load Subject to thermal derating Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 8&4; Common Figures 3-5; see Note 2 Across Pins 8&4 Over full temp range See Figure 1 for efficiency curve See Figure 1 for efficiency curve 8,000 160 100 -20 5.9 6.1 86 89 10 10 6.4 Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Note 2: Trim-up range is limited below 10% near low line. Note 3: Output voltage regulation cannot be achieved for an input voltage less than 19V. See Special Figures Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 6 Technical Specification 100 95 P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 5.0 V 36 A IQ64050HPC36 35 30 Power Dissipation (W) 20 Vin 64 Vin 135 Vin 90 25 20 15 10 5 0 20 Vin 64 Vin 135 Vin Efficiency (%) 85 80 75 70 65 60 0 3 6 9 12 15 18 21 24 27 30 33 36 0 3 6 9 12 15 18 21 24 27 30 33 36 Load Current (A) 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: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 40 36 32 28 40 36 32 28 Iout (A) 20 16 12 8 4 0 25 40 55 70 85 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Iout (A) 24 24 20 16 12 8 4 0 25 40 55 70 85 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Ambient Air Temperature (°C) Ambient Air Temperature (°C) Figure 3: Encased converter (without heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 4: Encased converter (with 1/2” heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: Output voltage response to step-change in load current (50%75%-50% of Iout(max); dI/dt = 0.1 A/µs). Load cap: 1 µF ceramic capacitor. Ch 1: Vout (200 mV/div), Ch 2: Iout (10 A/div). Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Figure 6: Output voltage response to step-change in input voltage (500 V/ms). Load cap: 100 µF, electrolytic output capacitance. Ch 1: Vout (500 mV/div), Ch 2: Vin (50 V/div). Doc.# 005-005065 Rev. 4 10/03/08 Page 7 Technical Specification P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 12 V 16 A IQ64120HPC16 IQ64120HPC16 eLeCtRICAL CHARACteRIStICS (12.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 64 V 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 InPUt CHARACteRIStICS Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Terminal Ripple Current Recommended Input Fuse OUtPUt CHARACteRIStICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection eFFICIenCY 100% Load 50% Load Min. typ. 90 3 0.7 1100 Max. 15.7 110 4 Units notes & Conditions A mA mA V mA A V % % mV V mV mV A A V A mA µF mV µs % % V % % see Note 3 see Note 3 Vin min; trim up; in current limit 20 11.88 12 ±0.1 ±0.1 -180 11.70 90 20 0 17.6 19.2 6 0.5 1 12.12 ±0.3 ±0.3 180 12.30 180 40 16 20.8 See Figure 6 RMS Fast acting external fuse recommended Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 1 Full load Full load Subject to thermal derating Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 8&4; Common Figures 3-5; see Note 2 Across Pins 8&4 Over full temp range See Figure 1 for efficiency curve See Figure 1 for efficiency curve 1,500 270 80 -20 14.0 14.6 90 91 10 10 15.2 Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Note 2: Trim-up range is limited below 10% near low line. Note 3: Output voltage regulation cannot be achieved for an input voltage less than 20V. See Special Figures Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 8 Technical Specification 100 95 P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 12 V 16 A IQ64120HPC16 30 27 24 Power Dissipation (W) 20 Vin 64 Vin 135 Vin 90 21 18 15 12 9 6 3 0 20 Vin 64 Vin 135 Vin 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Efficiency (%) 85 80 75 70 65 60 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Load Current (A) 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: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 18 16 14 12 18 16 14 12 Iout (A) 10 8 6 400 LFM (2.0 m/s) 4 2 0 25 40 55 70 85 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Iout (A) 10 8 6 400 LFM (2.0 m/s) 4 2 0 25 40 55 70 85 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Ambient Air Temperature (°C) Ambient Air Temperature (°C) Figure 3: Encased converter (without heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 4: Encased converter (with 1/2” heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: Output voltage response to step-change in load current (50%-75%50% of Iout(max); dI/dt = 0.1 A/µs). Load cap: 1 µF ceramic capacitor. Ch 1: Vout (500 mV/div), Ch 2: Iout (2 A/div). Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Figure 6: Output voltage response to step-change in input voltage (500 V/ms). Load cap: 100 µF, electrolytic output capacitance. Ch 1: Vout (500 mV/div), Ch 2: Vin (50 V/div). Doc.# 005-005065 Rev. 4 10/03/08 Page 9 Technical Specification P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 15 V 13 A IQ64150HPC13 IQ64150HPC13 eLeCtRICAL CHARACteRIStICS (15.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 64 V 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 InPUt CHARACteRIStICS Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Terminal Ripple Current Recommended Input Fuse OUtPUt CHARACteRIStICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection eFFICIenCY 100% Load 50% Load Min. typ. 90 3 0.8 1200 Max. 16.0 110 4 Units notes & Conditions A mA mA V mA A V % % mV V mV mV A A V A mA µF mV µs % % V % % see Note 3 see Note 3 Vin min; trim up; in current limit 20 14.85 15 ±0.1 ±0.1 -225 14.63 110 23 0 14.3 15.6 7.5 0.3 1.5 15.15 ±0.3 ±0.3 225 15.38 220 50 13 16.9 See Figure 6 RMS Fast acting external fuse recommended Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 1 Full load Full load Subject to thermal derating Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 8&4; Common Figures 3-5; see Note 2 Across Pins 8&4 Over full temp range See Figure 1 for efficiency curve See Figure 1 for efficiency curve 1,000 420 80 -20 17.6 18.3 89 91 10 10 19.1 Note 1: Output is terminated with 1 µF ceramic and 15 µF low-ESR tantalum capacitors. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Note 2: Trim-up range is limited below 10% at an input voltage less than 20 V. Note 3: Output voltage regulation cannot be achieved for an input voltage less than 19V. See Special Figures Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 10 Technical Specification 100 95 P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 15 V 13 A IQ64150HPC13 30 27 24 Power Dissipation (W) 20 Vin 64 Vin 135 Vin 90 21 18 15 12 9 6 3 0 20 Vin 64 Vin 135 Vin 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Efficiency (%) 85 80 75 70 65 60 0 1 2 3 4 5 6 7 8 9 10 11 12 13 Load Current (A) 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: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. 14 12 10 14 12 10 Iout (A) 8 6 4 2 0 25 40 55 70 85 Iout (A) 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) 8 6 4 2 0 25 40 55 70 85 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Ambient Air Temperature (°C) Ambient Air Temperature (°C) Figure 3: Encased converter (without heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 4: Encased converter (with 1/2” heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: Output voltage response to step-change in load current (50%-75%50% of Iout(max); dI/dt = 0.1 A/µs). Load cap: 1 µF ceramic capacitor. Ch 1: Vout (1 V/div), Ch 2: Iout (5 A/div). Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Figure 6: Output voltage response to step-change in input voltage (500 V/ms). Load cap: 100 µF, electrolytic output capacitance. Ch 1: Vout (1 V/div), Ch 2: Vin (50 V/div). Doc.# 005-005065 Rev. 4 10/03/08 Page 11 Technical Specification P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 40 V 5.0 A IQ64400HPC05 IQ64400HPC05 eLeCtRICAL CHARACteRIStICS (40.0 Vout) Ta = 25 °C, airflow rate = 300 LFM, Vin = 64 V 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 InPUt CHARACteRIStICS Maximum Input Current No-Load Input Current Disabled Input Current Response to Input Transient Input Terminal Ripple Current Recommended Input Fuse OUtPUt CHARACteRIStICS Output Voltage Set Point Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range Output Voltage Ripple and Noise Peak-to-Peak RMS Operating Output Current Range Output DC Current-Limit Inception Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Output Voltage during Load Current Transient Step Change in Output Current (0.1 A/µs) Settling Time Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection eFFICIenCY 100% Load 50% Load Min. typ. 80 3 1.2 1400 Max. 16.8 100 4 Units notes & Conditions A mA mA V mA A V % % mV V mV mV A A V A mA µF mV µs % % V % % Vin min; trim up; in current limit 20 39.6 40 ±0.1 ±0.1 -600 39.00 50 15 0 5.5 6.0 19 0.13 4 40.4 ±0.3 ±0.3 600 41.00 100 30 5 6.5 See Figure 6 RMS Fast acting external fuse recommended Over sample, line, load, temperature & life 20 MHz bandwidth; see Note 1 Full load Full load Subject to thermal derating Output voltage 10% Low Negative current drawn from output Negative current drawn from output Vout nominal at full load (resistive load) 50% to 75% to 50% Iout max To within 1% Vout nom Across Pins 8&4; Common Figures 3-5 Across Pins 8&4 Over full temp range See Figure 1 for efficiency curve See Figure 1 for efficiency curve 150 1900 80 -20 46.8 48.8 88 90 10 10 50.8 Note 1: Output is terminated with 1 µF ceramic capacitor. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 12 Technical Specification 100 95 P M ELI R I ARY N Input: Output: Current: Part no.: 18 - 135 V 40 V 5.0 A IQ64400HPC05 35 30 Power Dissipation (W) 18 Vin 64 Vin 135 Vin 90 25 20 15 10 5 0 18 Vin 64 Vin 135 Vin Efficiency (%) 85 80 75 70 65 60 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Load Current (A) Load Current (A) Figure 1: Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. (Preliminary) Figure 2: Power dissipation at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. (Preliminary) 5.5 5.0 4.5 4.0 3.5 5.5 5.0 4.5 4.0 3.5 Iout (A) 3.0 2.5 2.0 1.5 1.0 0.5 0.0 25 40 55 70 85 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Iout (A) 3.0 2.5 2.0 1.5 1.0 0.5 0.0 25 40 55 70 85 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) Ambient Air Temperature (°C) Ambient Air Temperature (°C) Figure 3: Encased converter (without heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 4: Encased converter (with 1/2” heatsink) max. output power derating vs. ambient air temperature for airflow rates of 100 LFM through 400 LFM. Air flows across the converter from input to output (nominal input voltage). Figure 5: Output voltage response to step-change in load current (50%-75%50% of Iout(max); dI/dt = 0.05 A/µs). Load cap: 1 µF ceramic capacitor. Ch 1: Vout (2 V/div), Ch 2: Iout (2 A/div). Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Figure 6: Output voltage response to step-change in input voltage (1000 V/ms). Load cap: 100 µF, electrolytic output capacitance. Ch 1: Vout (1 V/div), Ch 2: Vin (50 V/div). Doc.# 005-005065 Rev. 4 10/03/08 Page 13 I REL P 10 8 6 4 Vout Trim (%) 2 0 -2 -4 -6 M ARY IN Technical Specification IQ64-HPC Family 10 8 6 4 2 0 -2 -4 -6 Vout Trim (%) 100% Load 50% Load No Load -8 -10 100% Load 50% Load No Load -8 -10 21 20 19 Vin (V) 18 17 21 20 19 Vin (V) 18 17 Special Figure 1: Output voltage regulation (trim-up limit) near lowline input for 5 Vout. (Preliminary data) Special Figure 2: Output voltage regulation (trim-up limit) near lowline input for 12 Vout. (Preliminary data) 10 8 6 4 2 0 -2 -4 -6 Vout Trim (%) 100% Load 50% Load No Load -8 -10 21 20 19 Vin (V) 18 17 Special Figure 3: Output voltage regulation (trim-up limit) near lowline input for 15 Vout. (Preliminary data) Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 14 I REL P BASIC OPERATION AND FEATURES This converter series uses a two-stage power conversion topology. The first stage is a buck-converter that keeps the output voltage constant over variations in line, load, and temperature. The second stage uses a transformer to provide the functions of input/output isolation and voltage step-up or step-down to achieve the output voltage required. Both the first stage and the second stage switch at a fixed frequency for predictable EMI performance. Rectification of the transformer’s output is accomplished with synchronous rectifiers. These devices, which are MOSFETs with a very low on-state resistance, dissipate far less energy than Schottky diodes. This is the primary reason that the converter has such high efficiency, even at very low output voltages and very high output currents. These converters are offered totally encased to withstand harsh environments and thermally demanding applications. Dissipation throughout the converter is so low that it does not require a heatsink for operation in many applications; however, adding a heatsink provides improved thermal derating performance in extreme situations. This series of converters use the industry standard footprint and pin-out configuration. M ARY IN Technical Specification IQ64-HPC Family 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(-). The ON/OFF signal is active low (meaning that a low turns the converter on). Figure A details four 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 Vin(_) Remote Enable Circuit Vin(_) Negative Logic (Permanently Enabled) ON/OFF TTL/ CMOS 5V 50k ON/OFF ON/OFF 50k TTL 5V 100pF Vin(_) Open Collector Enable Circuit Vin(_) Direct Logic Drive Vin(_) Figure A: Various circuits for driving the ON/OFF pin. Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Figure B: Internal ON/OFF pin circuitry Doc.# 005-005065 Rev. 4 10/03/08 Page 15 I REL P 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 M ARY IN Technical Specification IQ64-HPC Family 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” on our website. The lockout circuitry is a comparator with dc hysteresis. When the input voltage is rising, it must exceed the typical TurnOn Voltage Threshold value (listed on the specifications 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: The maximum current limit remains constant as the output voltage drops. However, once the impedance of the load across the output is small enough to make the output voltage drop below the specified Output DC CurrentLimit Shutdown Voltage, the converter turns off. The converter then enters a “hiccup mode” where it repeatedly turns on and off at a 5 Hz (nominal) frequency with a 5% duty cycle until the short circuit condition is removed. This prevents excessive heating of the converter or the load board. Output Over-Voltage Limit: If the voltage across the output pins exceeds the Output Over-Voltage Protection threshold, the converter will immediately stop switching. This prevents damage to the load circuit due to 1) excessive series resistance in output current path from converter output pins to sense point, 2) a release of a short-circuit condition, or 3) a release of a current limit condition. Load capacitance determines exactly how high the output voltage will rise in response to these conditions. After 200 ms the converter will automatically restart. Over-temperature Shutdown: A temperature sensor on the converter senses the average temperature of the module. The thermal shutdown circuit is designed to turn the converter off when the temperature at the sensed location reaches the 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. Safe Operating Range Limitations: When the converter is in the current limit, the output voltage is continuously reduced until the converter shuts down. If the converter is deliberately operated for extended time (> 1 s) in the region where the output voltage is reduced and the input voltage is near its maximum (> 100 V) extreme operating conditions are created inside the converter which may lead to internal failure before the Over Temperature Protection gets activated. (Contact factory for specifications.) Rtrim-down = where (511)- 10.22 ∆% (kW) ∆% = 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 = where ( 5.11VOUT x (100+∆%) 1.225∆% _ 511 _ 10.22 ∆% ) (kW) Vout = Nominal Output Voltage Trim graphs show the relationship between the trim resistor value and Rtrim-up and Rtrim-down, showing the total range the output voltage can be trimmed up or down. Note: the TRIM feature does not affect the voltage at which the output over-voltage protection circuit is triggered. Trimming the output voltage too high may cause the over-voltage protection circuit to engage, particularly during transients. It is not necessary for the user to add capacitance at the Trim pin. The node is internally bypassed to eliminate noise. total DC Variation of VOUt: For the converter to meet its full specifications, the maximum variation of the dc value of VOUT, due to both trimming and remote load voltage drops, should not be greater than that specified for the output voltage trim range. Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 16 I REL P 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 provides a typical circuit diagram which details the input filtering and voltage trimming. Input Filtering and external Capacitance: Figure E 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 electrolytic input capacitor. The recommended external input capacitance is specified in the Input Characteristics section on the Electrical Characteristics page. More detailed information is available in the application note titled “EMI Characteristics” on the SynQor website. M ARY IN Technical Specification IQ64-HPC Family Startup Inhibit Period: The Startup Inhibit Period ensures that the converter will remain off for approximately 200 ms when it is shut down for any reason. When an output short is present, this generates a 5 Hz “hiccup mode,” which prevents the converter from overheating. In all, there are seven ways that the converter can be shut down, initiating a Startup Inhibit Period: • Input Under-Voltage Lockout • Input Over-Voltage Shutdown • 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: Vin(+) External Input Filter Electrolytic Capacitor Vout(+) Vsense(+) Rtrim-up or Vin ON/OFF Trim Vsense(_) Vin(_) Vout(_) Rtrim-down Cload Iload 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 # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 17 I REL P 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. When the ON/OFF pin goes high after t2, the Startup Inhibit Period has elapsed, and the output turns on within the typical Turn-On Time. thermal Considerations: The maximum operating baseplate temperature, TB, is 100 ºC. As long as the user’s thermal system keeps TB < 100 ºC, the converter can deliver its full rated power. A power derating curve can be calculated for any heatsink that is attached to the base-plate of the converter. It is only necessary to determine the thermal resistance, RTHBA, of the chosen heatsink between the base-plate and the ambient air for a given airflow rate. This information is usually available from the heatsink vendor. The following formula can the be used to determine the M ARY IN Technical Specification IQ64-HPC Family maximum power the converter can dissipate for a given thermal condition if its base-plate is to be no higher than 100 ºC. 100 ºC - TA max Pdiss = RTHBA This value of power dissipation can then be used in conjunction with the data shown in Figure 2 to determine the maximum load current (and power) that the converter can deliver in the given thermal condition. For convenience, power derating curves for an encased converter without a heatsink and with a typical heatsink are provided for each output voltage. Vin Under-Voltage Lockout TurnOn Threshold ON/OFF (neg logic) ON OFF ON OFF ON 9ms (typical turn on time) Vout (typical start-up inhibit period) 200ms 200ms 200ms t0 t1 t2 t Figure F: Startup Inhibit Period (turn-on time not to scale) Product # IQ64xxxHPCxx Phone 1-888-567-9596 www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 18 I REL P PARt nUMBeRInG SYSteM The part numbering system for SynQor’s dc-dc converters follows the format shown in the example below. IQ 64 400 H P C 0 5 n R S - G 6/6 RoHS Options (see Ordering Information) Output Current Thermal Design Performance Level Package Size Output Voltage Input Voltage Product Family M ARY IN Technical Specification IQ64-HPC Family ORDeRInG InFORMAtIOn 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. A “-G” suffix indicates the product is 6/6 RoHS compliant. Model Number IQ64018HPC60xyz IQ64033HPC50xyz IQ64050HPC36xyz IQ64120HPC16xyz IQ64150HPC13xyz IQ64240HPC08xyz IQ64280HPC07xyz IQ64400HPC05xyz IQ64480HPC04xyz Continuous Input Voltage 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V 18 - 135 V Output Voltage 1.8 V 3.3 V 5.0 V 12 V 15 V 24 V 28 V 40 V 48 V Maximum Output Current 60 A 50 A 36 A 16 A 13 A 8.0 A 7.0 A 5.0 A 4.0 A 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. The following options must be included in place of the x y z spaces in the model numbers listed above. Options Description: x y z Enable Logic N - Negative Pin Style R - 0.180" Feature Set S - Standard 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 rohs@synqor.com. Not all combinations make valid part numbers, please contact SynQor for availability. 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: 978-849-0600 888-567-9596 978-849-0602 p ower@synqor.com 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. Product # IQ64xxxHPCxx www.synqor.com Doc.# 005-005065 Rev. 4 10/03/08 Page 19