PQ48015HTA60PRF

Technical Specification Brick Half 48Vin 1.5Vout 60A 60 Amp, No Heatsink, Isolated DC/DC Converter The PQ48015HTA60 PowerQor™ Tera converter is a next-generation, board-mountable, isolated, fixed switching frequency DC/DC converter that uses synchronous rectification toachieve extremely high 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. The Tera series converters offer the maximum useable output current for any standard “half-brick” module. The Tera units also feature active current sharing for N+1 and parallel applications. PQ48015HTA60 Module Operational Features • Ultra-high efficiency, 85% at full rated load current • Delivers up to 60 amps of output current with minimal derating - no heatsink required • Wide input voltage range: 35V – 75V meets or exceeds all 48V bus standards • Fixed frequency switching provides predictable EMI performance Protection Features • Input under-voltage lockout and over-voltage shutdown protects against abnormal input voltages • Output current limit and short circuit protection • Output over-voltage protection • Thermal shutdown Mechanical Features • Industry standard half-brick pin-out configuration • Industry standard footprint: 2.3” x 2.4” • Total height only 0.43”, permits better airflow and smaller card pitch • Total weight: 2.6 oz. (75 grams) Control 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 • 2000V, 10 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 Product # PQ48015HTA60 Phone 1-888-567-9596 Optional Features (Full-Feature modules) • Active current share for N+1 and parallel applications • External Clock Synchronization pin for better EMI characteristics • Startup Synchronization pin for more consistent startup sequence • ORing FET drive supply for efficient ORing protection Doc.# 005-2HT451F Rev. M 11/20/02 Page 1 Technical Specification Brick MECHANICAL DIAGRAM 2.30 0.19 (4.8) Half 48Vin 1.5Vout 60A 1.90 (48.3) (58.4) 0.50 (12.7) 0.300 (7.62) 0.400 (10.16) 0.400 (10.16) 0.700 (17.78) 1.000 (25.40) 0.200 (5.08) 1.400 (35.56) Top View 0.200 (5.08) 1.000 (25.40) 2.40 (61.0) 1.400 (35.56) Max. Height Bottom side Clearance See Note 10 0.43 (11.2) 0.037+/-0.029 (0.94+/-0.74) Side View Lowest Component Load Board 0.145 (3.68) See Note 4 NOTES 1) Pins 1-4, 6-8, A-C are 0.040” (1.02mm) diameter. with 0.080” (2.03mm) diameter standoff shoulders. 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. 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. PIN CONNECTIONS Pin No. Name 1 2 Vin(+) ON/OFF Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(-), with internal pull up. 3 4 5 6 7 8 9 A B C I share Vin(-) Vout(-) SENSE(-) TRIM SENSE(+) Vout(+) Clock Sync Start Sync OR Drive 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 External OR-FET drive Pins in Italics Shaded text are Optional Product # PQ48015HTA60 Phone 1-888-567-9596 Doc.# 005-2HT451F Rev. M 11/20/02 Page 2 Technical Specification Brick PQ48015HTA60 ELECTRICAL CHARACTERISTICS Parameter ABSOLUTE MAXIMUM RATINGS Half 48Vin 1.5Vout 60A 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. Min. Typ. Max. 100 80 100 2000 100 125 18 18 48 33.3 31.0 2.3 78.3 75 2 0.03 150 5 33 1.48 1.6\4\3.3 47 1.50 +0.05 \ 1 +0.1 \ 2 +15 50 10 67 0.71 +2 1.3 10 70 50 50 300 180 20 200 0 85 86 125 125 125 2000 10 3300 30 215 75 34.4 32.4 2.4 79.5 3.1 95 5 Units V V V V °C °C V V V V V V V A mA mA A 2s mV mA A µF\µH\µF µF V %\mV %\mV mV V mV mV A A V % A mA µF dB mV mV µs ms ms % % % °C °C °C V MΩ pF Notes & Conditions continuous continuous < 10µs Basic insulation level, Pollution degree 2 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 -40 -55 -2 -15 35 31.5 29.5 2.2 76.7 applies to Full Feature option only INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage Input Over-Voltage Shutdown Maximum Input Current No-Load Input Current Disabled Input Current Inrush Current Transient Rating Response to Input Transient Input Reflected-Ripple Current Recommended Input Fuse Input Filter Component Values (C1\L\C2) Recommended External Input Capacitance 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 Current Share Accuracy (2 units paralleled) Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Input Voltage Ripple Rejection Output Voltage during Load Current Transient Step Change in Output Current (0.1A/µs) Step Change in Output Current (5A/µs) Settling Time Turn-On Transient Turn-On Time Start-Up Inhibit Time Output Voltage Overshoot 100% Load 50% Load Semiconductor Junction Temperature Board Temperature Transformer Temperature Isolation Voltage Isolation Resistance Isolation Capacitance 100% Load, 35 Vin 20 see Figure 13 1000V/ms input transient RMS thru 10µH inductor; Figs. 13 & 15 fast blow external fuse recommended internal values, see Figure E OUTPUT CHARACTERISTICS 1.52 +0.1 \ 2 +0.2 \ 3 +30 1.55 100 20 60 72 +5 2.5 50 >50,000 1.45 0 62 0.5 0 over sample, line, load, temperature & life 20MHz bandwidth; Fig. 13 & 16 Full Load, see Figures 13 & 16 Full Load, see Figures 13 & 16 Output Voltage 10% Low; Fig. 17 % of rated output current Max negative current drawn from output Max negative current drawn from output 1.5Vout at 60A Resistive Load 120 Hz; Fig. 20 50% to 75% to 50% Iout max; Figure 11 50% to 75% to 50% Iout max; Figure 12 to within 1% Vout nom Full load, Vout=90% nom.; Figs. 9 & 10 -40°C to +125°C; Figure A 10,000 µF load capacitance, Iout = 0A Figures 1 - 4 Figures 1 - 4 Package rated to 150°C UL rated max operating temp 130°C See Figures 5 - 8 for derating curves DYNAMIC CHARACTERISTICS EFFICIENCY TEMPERATURE LIMITS FOR POWER DERATING CURVES ISOLATION CHARACTERISTICS Product # PQ48015HTA60 Phone 1-888-567-9596 Doc.# 005-2HT451F Rev. M 11/20/02 Page 3 Technical Specification Brick ELECTRICAL CHARACTERISTICS (Continued) Parameter P FEATURE CHARACTERISTICS Half 48Vin 1.5Vout 60A Units kHz V V V V V kΩ % % % °C °C Min. 230 -2 2.7 2.7 -2 Typ. 260 Max. 290 0.8 18 18 0.8 Notes & Conditions 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 Calculated MTBF Calculated MTBF Demonstrated MTBF -10 120 Vin/6 42 125 120 10 2.2 1.3 >20 15 +19 +19 130 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 RELIABILITY CHARACTERISTICS 106 Hrs. Telcordia TR-NWT-000332; 80% load,300LFM, 40oC Ta 106 Hrs. MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta 106 Hrs. Field demonstrated MTBF STANDARDS COMPLIANCE Parameter P STANDARDS COMPLIANCE Notes 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 Section 7 - electrical safety, Section 9 - bonding/grounding UL/cUL 60950 EN60950 72/23/EEC 93/68/EEC Needle Flame Test (IEC 695-2-2) IEC 61000-4-2 GR-1089-CORE • An external input fuse must always be used to meet these safety requirements QUALIFICATION TESTING Parameter P QUALIFICATION TESTING # Units 32 5 5 10 5 5 5 15 pins Test Conditions 10-55Hz sweep, 0.060” total excursion,1 min./sweep, 120 sweeps for 3 axis Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability 95% rated Vin and load, units at derating point, 1000 hours 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 more information about Proof of Design and Proof of Manufacturing processes. OPTIONS 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. Product # PQ48015HTA60 Phone 1-888-567-9596 PATENTS SynQor is protected under various patents, including but not limited to U.S. Patent # 5,999,417. Doc.# 005-2HT451F Rev. M 11/20/02 Page 4 Performance Curves Brick 100 95 90 Half 90 89 88 48Vin 1.5Vout 60A Efficiency (%) Efficiency (%) 85 80 75 70 65 60 0 6 12 18 24 30 36 42 48 54 60 36 Vin 48 Vin 75 Vin 87 86 85 84 83 82 0 100 200 300 400 Air Flow (LFM) 25 C 40 C 55 C 500 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). 12.0 11.0 Power Dissipation (W) 24 22 20 Power Dissipation (W) 18 16 14 12 10 8 6 4 2 0 0 6 12 18 24 30 36 42 48 10.0 9.0 8.0 7.0 6.0 5.0 4.0 25 C 40 C 55 C 36 Vin 48 Vin 75 Vin 54 60 0 100 200 300 400 500 Load Current (A) 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). 60 50 40 30 20 10 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) 0 LFM (0 m/s) Ambient Air Temperature (oC) Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 0 LFM through 400 LFM with air flowing from output to input (nominal input voltage). Product # PQ48015HTA60 Phone 1-888-567-9596 Figure 6: Thermal plot of converter at 58 amp load current with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from output to input (nominal input voltage). Doc.# 005-2HT451F Rev. M 11/20/02 Page 5 Semiconductor junction temperature is within 1°C of surface temperature Iout (A) Performance Curves Brick 60 50 40 Half 48Vin 1.5Vout 60A 30 20 10 0 0 25 40 55 o 400 LFM (2.0 m/s) 300 LFM (1.5 m/s) 200 LFM (1.0 m/s) 100 LFM (0.5 m/s) 0 LFM (0 m/s) 70 85 Ambient Air Temperature ( C) Figure 7: Maximum output power derating curves vs. ambient air temperature for airflow rates of 0 LFM through 400 LFM with air flowing from input to output (nominal input voltage). Figure 8: Thermal plot of converter at 55 amp load current 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). Top Trace: Vout (0.5V/div) Bottom Trace: ON/OFF input (5V/div) Figure 10: Turn-on transient at zero load (10 ms/div). Top Trace: Vout (0.5V/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: 15µF, 450 mΩ ESR tantalum capacitor and 1µF ceramic capacitor. Top trace: Vout (100mV/div), Bottom trace: Iout (20A/div). Product # PQ48015HTA60 Phone 1-888-567-9596 Figure 12: Output voltage response to step-change in load current (50%-75%-50% of Iout(max): dI/dt = 5A/µs). Load cap: 480µF, 15 mΩ ESR tantalum capacitor and 1µF ceramic capacitor. Top trace: Vout (200mV/div), Bottom trace: Iout (20A/div). Doc.# 005-2HT451F Rev. M 11/20/02 Page 6 Semiconductor junction temperature is within 1°C of surface temperature Iout (A) Performance Curves Brick Figure 15 10 µH Half 48Vin 1.5Vout 60A source impedance Figure 14 Figure 16 iS VSOURCE iC DC/DC Converter 1 µF VOUT 15 µF, electrolytic capacitor 47 µF,