PQ60025EGL20PKS

Technical Specification Eighth Brick 48Vin 2.5Vout 20A 20 Amp, No Heatsink, Isolated DC/DC Converter The PQ60025EGL20 PowerQor™ Giga eighth-brick converter is a next-generation, board-mountable, isolated, fixed switching frequency DC/DC converter that uses synchronous rectification to achieve 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. 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 connections, it is extremely reliable. PQ60025EGL20 Module Operational Features • High efficiency, 87% at full rated load current • Delivers up to 20 amps of output current with minimal derating - no heatsink required • Wide input voltage range: 35V – 75V, with 100V 100ms input voltage transient protection • Fixed frequency switching provides predictable EMI performance • No minimum load requirement means no preload resistors required Protection Features • Input under-voltage lockout disables converter at low input voltage conditions • Output current limit and short circuit protection protects converter from excessive load current or short circuits • Output over-voltage protection protects load from damaging voltages • Thermal shutdown protects converter from abnormal environmental conditions Mechanical Features • Industry standard eighth-brick pin-out configuration • Industry standard size: 0.90” x 2.3” • Total height less than 0.335” (8.5mm), permits better airflow and smaller card pitch • Total weight: 19 grams (0.68 oz.), lower mass greatly reduces vibration and shock problems Safety Features • 2000V, 10 MΩ input-to-output isolation provides input/output ground separation • UL 1950 recognized (US & Canada), basic insulation rating • TUV certified to EN60950 • 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 flammability requirements 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 Product # PQ60025EGL20 Phone 1-888-567-9596 Doc.# 005-2EG625D Rev. C 11/6/03 Page 1 Technical Specification Eighth Brick MECHANICAL DIAGRAM 0.14 0.150 (3.81) (3.6) 48Vin 2.5Vout 20A 2.30 (58.4) 2.00 (50.8) 0.150 (3.81) 0.300 0.90 (22.9) 0.600 (15.24) (7.62) Top View 0.300 (7.62) 0.450 (11.43) 0.600 (15.24) Max. Height Bottom side Clearance See Note 9 0.335 (8.5) 0.019+/-0.013 (0.48+/-0.33) Side View Lowest Component Load Board 0.145 (3.68) See Note 3 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 - Tin/Lead over Nickel plate 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: 0.68 oz. (19 g) typical 8) Workmanship: Meets or exceeds IPC-A-610C Class II 9) 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. 1 2 3 4 5 6 7 8 Notes: 1. Pin 5 must be connected to Vout(-). 2. Leave Pin 6 open for nominal output voltage. 3. Pin 7 must be connected to Vout(+). Name Vin(+) ON/OFF Vin(-) Vout(-) SENSE(-) TRIM SENSE(+) Vout(+) Function Positive input voltage TTL input to turn converter on and off, referenced to Vin(-), with internal pull up. Negative input voltage Negative output voltage Negative remote sense1 Output voltage trim2 Positive remote sense3 Positive output voltage Product # PQ60025EGL20 Phone 1-888-567-9596 Doc.# 005-2EG625D Rev. C 11/6/03 Page 2 Technical Specification Eighth Brick PQ60025EGL20 ELECTRICAL CHARACTERISTICS Parameter ABSOLUTE MAXIMUM RATINGS 48Vin 2.5Vout 20A 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 48 33.3 31.0 2.8 32 2 0.01 150 4.2 33 2.475 1.0\4.7 47 2.50 75 34.4 32.4 3.2 2.0 5 Units V V V V °C °C V V V V V A mA mA A 2s mV mA A µF\µH µF V %\mV %\mV mV V mV mV A A V A mA µF dB mV mV µs Notes & Conditions continuous continuous 100ms transient Basic 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 Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Hysteresis Voltage 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 (C\L) Recommended External Input Capacitance -40 -55 -2 35 31.5 29.5 2.4 INPUT CHARACTERISTICS 100% Load, 35 Vin 10 internal values, see Figure E see Figure 13 1000V/ms input transient RMS thru 10µH inductor; Figs. 13 & 15 fast blow external fuse recommended 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 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 2.525 2.43 +0.1 \ 2.5 +0.15 \ 5 +0.1 \ 2.5 +0.15 \ 5 +13 +38 2.57 70 17 23 1.2 0.45 10 72 120 180 200 130 30 20 26.5 50 35,000 0 20.5 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 Negative current drawn from output Negative current drawn from output 2.5Vout at 20A 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 F 40,000 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 180 8 200 0 87 89 12 240 ms ms % % % EFFICIENCY TEMPERATURE LIMITS FOR POWER DERATING CURVES 125 125 125 2000 10 470 °C °C °C V MΩ pF ISOLATION CHARACTERISTICS Product # PQ60025EGL20 Phone 1-888-567-9596 Doc.# 005-2EG625D Rev. C 11/6/03 Page 3 Technical Specification Eighth Brick ELECTRICAL CHARACTERISTICS (Continued) Parameter P FEATURE CHARACTERISTICS 48Vin 2.5Vout 20A Units kHz V V V V V kΩ % % % °C °C Min. 220 -2 2.4 2.4 -2 Typ. 250 Max. 280 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 (Telcordia) Calculated MTBF (MIL-217) Demonstrated MTBF -20 120 Vin/6 40 125 125 10 2.5 1.1 TBD 15 +10 +10 130 Figures A, B Measured across Pins 8 & 4; Figure C Measured across Pins 8 & 4 Over full temp range; % of nominal Vout Average PCB Temperature RELIABILITY CHARACTERISTICS 106 Hrs. 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 (Normal Performance) 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 Telcordia (Bellcore) GR-513 • 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 Enable Logic and Pin Length for this family of DC/DC converters. Please consult the last page of this specification sheet for information on available options. PATENTS SynQor is protected under various patents, including but not limited to U.S. Patent # 5,999,417. Product # PQ60025EGL20 Phone 1-888-567-9596 Doc.# 005-2EG625D Rev. C 11/6/03 Page 4 Performance Curves Eighth Brick 92 91 90 Efficiency (%) 95 90 85 48Vin 2.5Vout 20A Efficiency (%) 89 88 87 86 85 84 25 C 40 C 55 C 80 75 70 65 60 0 2 4 6 8 10 12 14 16 18 20 35 Vin 48 Vin 75 Vin 0 100 200 300 400 500 Load Current (A) 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). 5.0 9 8 Power Dissipation (W) 6 5 4 3 2 1 0 0 2 4 6 8 10 12 14 16 18 20 35 Vin 48 Vin 75 Vin Power Dissipation (W) 7 4.0 3.0 2.0 25 C 40 C 55 C 1.0 0.0 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). 20 18 16 14 Iout (A) 12 10 8 6 4 2 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) 50 LFM (0.25 m/s) Ambient Air Temperature (oC) Semiconductor junction temperature is within 1°C of surface temperature Figure 5: Maximum output power derating curves vs. ambient air temperature for airflow rates of 50 LFM through 400 LFM with air flowing across the converter from pin 3 to pin 1 (nominal input voltage). Product # PQ60025EGL20 Phone 1-888-567-9596 Figure 6: Thermal plot of converter at 20 amp load current with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter sideways from pin 3 to pin 1 (nominal input voltage). Doc.# 005-2EG625D Rev. C 11/6/03 Page 5 Performance Curves Eighth Brick 20 18 16 14 48Vin 2.5Vout 20A Iout (A) 12 10 8 6 4 2 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) 50 LFM (0.25 m/s) Ambient Air Temperature (oC) Semiconductor junction temperature is within 1°C of surface temperature Figure 7: 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). Figure 8: Thermal plot of converter at 19 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) (4 ms/div). Ch 1: Vout (1V/div) Ch 2: ON/OFF input (5V/div) Figure 10: Turn-on transient at zero load (4 ms/div). Ch 1: Vout (1V/div) Ch 2: 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: 10µF, 100 mΩ ESR tantalum capacitor and 1µF ceramic capacitor. Ch 1: Vout (100mV/div), Ch 2: Iout (5A/div). Product # PQ60025EGL20 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: 470µF, 30 mΩ ESR tantalum capacitor and 1µF ceramic cap. Ch 1: Vout (200mV/div), Ch 2: Iout (5A/div). Doc.# 005-2EG625D Rev. C 11/6/03 Page 6 Performance Curves Eighth Brick 48Vin 2.5Vout 20A Figure 15 10 µH source impedance Figure 14 Figure 16 iS VSOURCE iC DC/DC Converter 1 µF VOUT 10 µF, electrolytic capacitor 47 µF,