PQ60025EKA20NNS-G

Technical Specification PQ60025EKx20 48V Input 2.5V Output 20A Current 2000V dc Isolation Eighth-brick 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 • 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 PQ60025EKA20 Module Control Features Mechanical Features • Industry standard eighth-brick pin-out configuration • 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) • Flanged pins designed to permit surface mount soldering (avoid wave solder) using FPiP technique • 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, 30MΩ input-to-output isolation provides input/output ground separation • 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 • 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 CONTENTS 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 Page No. www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 1 Technical Specification Input: Output: Current: Part No.: 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) 0.410 ± 0.014 (10.41 ± 0.35) Overall Height 0.340 ± 0.014 (8.64 ± 0.35) Overall Height 8 7 6 5 4 0.145 (3.68) 0.145 (3.68) 2.30 (58.4) 2.00 (50.8) Top View Side View 1 .14 (3.6) 2 3 0.121±.017 (3.07±0.43) Bottom Side Clearance 0.051±.017 (1.3±0.43) Bottom Side Clearance 0.150 (3.8) 0.300 (7.62) 0.600 (15.24) EKA Side View EKL Side View 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. PIN DESIGNATIONS Pin 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. Doc.# 005-0005112 Rev. C 06/12/09 Page 2 Name Vin(+) ON/OFF Vin(–) Vout(–) SENSE(–) TRIM 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 output voltage 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 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 8) Workmanship: Meets or exceeds IPC-A-610C Class II 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. 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. SENSE(+) Positive remote sense3 Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Technical Specification 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) Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKC20 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 2.00 (50.8) Side View 0.183±0.020 (4.65±0.5) 1 2 3 0.193±0.020 (4.9±0.5) 0.300 (7.62) 0.600 (15.24) 0.180±.010 (4.57±0.25) NOTES 1) 2) 3) 4) 5) 6) 7) 8) 9) Pins 1-3, 5-7 are 0.040” (1.02mm) diameter, with 0.080” (2.03mm) diameter standoff shoulders. Pins 4 and 8 are 0.062” (1.57 mm) diameter with 0.100" (2.54 mm) diameter standoff shoulders. Other pin extension lengths available. Recommended pin length is 0.03” (0.76mm) greater than the PCB thickness. All Pins: Material - Copper Alloy- Finish (RoHS 6/6) - Matte Tin over Nickel plate Undimensioned components are shown for visual reference only. All dimensions in inches (mm) Tolerances: x.xx +/-0.02 in. (x.x +/-0.5mm) x.xxx +/-0.010 in. (x.xx +/-0.25mm) Weight: 5 oz (142 g) typical Workmanship: Meets or exceeds IPC-A-610C Class II 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. PIN DESIGNATIONS Pin 1 2 3 4 5 6 7 8 Name Vin(+) ON/OFF Vin(–) Vout(–) TRIM 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 Output voltage trim2 Positive output voltage SENSE(–) Negative remote sense1 SENSE(+) Positive remote sense3 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 Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Technical Specification PQ60025EKA20 Electrical Characteristics Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKx20 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 ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating Operating Transient Protection Isolation Voltage Input to Output Operating Temperature Storage Temperature Voltage at ON/OFF input pin INPUT CHARACTERISTICS Operating Input Voltage Range Input Under-Voltage Lockout Turn-On Voltage Threshold Turn-Off Voltage Threshold Lockout Voltage Hysteresis Maximum Input Current No-Load Input Current Disabled Input Current Inrush Current Transient Rating Response to Input Transient Input Reflected Ripple Current Input Terminal Ripple Current Recommended Input Fuse Recommended External Input Capacitance Input Filter Component Values (L\C) 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 Electrolytic EFFICIENCY 100% Load 50% Load Min. Typ. Max. Units Notes & Conditions 100 75 100 2000 -40 -55 0 35 33.0 31.5 1.2 48 34.0 32.3 1.7 47 9.8 80 1.8 65 20 47 1\2.35 2.475 2.50 ±0.1\2.5 ±0.15\3.75 2.450 ±10 2.500 50 17 0 24.5 4.5 26.6 2.25 7 1.1 20 29.0 12.5 7 86 86 2.550 2.525 10.5 0.03 100 125 13.5 75 35.0 33.5 2.2 1.7 V V V V dc °C °C V V V V V A mA A2s mV mA mA A µF µH\µF V %\mV %\mV mV V mV mV A A V A mA mF % % mA Continuous Continuous 100ms transient, square wave Basic Insulation See Note 1 100% Load, 35V Vin, nominal Vout 1000V/ms input transient RMS thru 10μH inductor; Figures 13 & 15 RMS; Figures 13 & 14 Fast acting external fuse recommended Typical ESR 0.1-0.2Ω; Figure 13 Internal values; see Figure E Over sample, line, load, temperature & life 20MHz bandwidth; see Note 2 Full load; see Figures 13 & 16 Full load; see Figures 13 & 16 Subject to thermal derating; Figures 5 - 8 Negative current drawn from output Negative current drawn from output Nominal Vout at full load (resistive load) Figures 1 - 4 Figures 1 - 4 Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 4 Technical Specification Input: Output: Current: Part No.: 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 DYNAMIC CHARACTERISTICS 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 ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance Min. Typ. 87 250 200 700 21 200 0 2000 30 1000 Max. Units Notes & Conditions dB mV mV µs ms ms % V MΩ pF See Note 4 Package rated to 150°C UL rated max operating temp 130°C 120Hz See Note 3 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. -40°C to +125°C; Figure F Maximum Output Capacitance See Absolute Maximum Ratings 180 240 Isolation Capacitance (input to output) TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature FEATURE CHARACTERISTICS Switching Frequency ON/OFF Control (Option P) Off-State Voltage On-State Voltage ON/OFF Control (Option N) Off-State Voltage On-State Voltage ON/OFF Control (Either Option) Pull-Up Voltage Pull-Up Resistance Output Voltage Trim Range Output Voltage Remote Sense Range Output Over-Voltage Protection Over-Temperature Shutdown Over-Temperature Shutdown Restart Hysteresis RELIABILITY CHARACTERISTICS Calculated MTBF (Telcordia) Calculated MTBF (MIL-217) Field Demonstrated MTBF -10 125 2 0 0 2 270 125 125 125 300 330 0.8 13.5 13.5 0.8 5 10 10 138 125 10 2.5 1.1 10 148 6 °C °C °C kHz V V V V Application notes; Figures A & B V kΩ % % % °C °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 Measured across Pins 8 & 4; Figure C Measured across Pins 8 & 4 Over Full Temperature Range; % of nominial Vout Average PCB Temperature 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: support@synqor.com) 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 Technical Specification PQ60025EKx20 Standards & Qualification Testing Pending Parameter STANDARDS COMPLIANCE UL/cUL 60950-1 EN60950-1 Needle Flame Test (IEC 695-2-2) IEC 61000-4-2 File # E194341, Basic insulation Certified by TUV Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKx20 Notes & Conditions 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. Parameter QUALIFICATION TESTING Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity # Units 32 5 5 10 5 5 5 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 Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com Doc.# 005-0005112 Rev. C 06/12/09 Page 6 Technical Specification 100 95 90 91 90 89 Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKx20 Efficiency (%) 80 75 70 65 60 0 5 10 15 20 35 Vin 48 Vin 75 Vin Efficiency (%) 85 88 87 86 85 84 83 100 200 300 400 25º C 40º C 55º C 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). 8 7 14 12 Power Dissipation (W) 10 8 6 4 2 0 0 5 10 15 20 35 Vin 48 Vin 75 Vin Power Dissipation (W) 6 5 4 3 2 1 100 200 300 400 25º C 40º C 55º C 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). 25 20 Iout (A) 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 Technical Specification 25 Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKx20 20 Iout (A) 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). Product # PQ60025EKx20 Phone 1-888-567-9596 www.synqor.com 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). Doc.# 005-0005112 Rev. C 06/12/09 Page 8 Technical Specification See Fig. 15 source impedance Input: Output: Current: Part No.: 35-75V 2.5V 20A PQ60025EKx20 10 µH See Fig. 14 See Fig. 16 iS VSOURCE iC DC/DC Converter 1 µF VOUT 15 µF, electrolytic capacitor 47 µF,