PQ60025ETL35PKS

Technical Specification PQ60025ETL35 48 V Input 2.5 V Output 35 A Current 2250 V dc Isolation DC-DC Converter Eighth-brick The PQ60025ETL35 PowerQor® Tera 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 interfaces, it is extremely reliable. RoHS Compliant (see page 13). Operational Features • High efficiencies, 88% at full rated load current • Delivers up to 35 A of output current with minimal derating - no heatsink required • Wide input voltage range: 35V – 75 V, with 100 V 100 ms input voltage transient capability • Fixed frequency switching provides predictable EMI performance • No minimum load requirement means no preload resistors required PQ60025ETL35 Module 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 Mechanical Features • Industry standard Eighth-brick pin-out configuration • Standard size: 0.90" x 2.3" (22.9x58.4 mm) • Total height only 0.320" (8.13mm), permits better airflow and smaller card pitch • Total weight: 0.85 oz (24 g) • Flanged pins designed to permit surface mount soldering (avoid wave solder) using FPiP technique Safety Features • 2250 V, 30 MW input-to-output isolation • UL 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) Doc.# 005-2ET625F Rev. B 5/28/08 Page 1 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 # PQ60025ETL35 Phone 1-888-567-9596 www.synqor.com Technical Specification MECHANICAL DIAGRAM (58.4) (50.8) Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick 2.30 2.00 (11.43) 0.450 0.14 (3.6) 0.300 (7.62) 0.15 (3.8) Top View 0.150 (3.81) 1 2 3 (15.24) 8 7 6 5 4 0.900 +0.022 (22.86 +0.55) 0.600 0.300 (7.62) (15.24) 0.320 +0.015 (8.13 +0.38) 0.600 Overall Height (3.68) See Note 3 0.145 0.016 +0.015 (0.41 +0.38) Side View Lowest Component Load Board Flanged Pin See Note 10 Bottom Side Clearance 1) Pins 1-3, 5-7 are 0.040" (1.02mm) diameter with 0.080" (2.03 mm) 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) Recommended pin length is 0.03" (0.76mm) greater than the PCB thickness. Other pin lengths available. 4) All Pins: Material - Copper Alloy; Finish - Matte Tin over Nickel plate 5) Undimensioned components shown are for visual reference only. 6) Weight: 0.85 oz. (24 g) typical 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) Workmanship: Meets or exceeds current 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 core shown at left above is considered part of the input/primary circuit and that the two ferrite cores shown at the right above are considered part of the output/secondary circuit. 10) 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 PIN DESIGNATIONS Pin No. 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. 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 sense 1 Output voltage trim 2 Positive remote sense 3 Positive output voltage Product # PQ60025ETL35 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2ET625F Rev. B 5/28/08 Page 2 Technical Specification PQ60025ETL35 Electrical Characteristics ABSOLUTE MAXIMUM RATINGS Input Voltage Non-Operating Operating 35 Operating Transient Protection Isolation Voltage Input to Output Operating Temperature -40 Storage Temperature -55 Voltage at ON/OFF input pin -2 INPUT CHARACTERISTICS Operating Input Voltage Range 35 Input Under-Voltage Lockout Turn-On Voltage Threshold 31.5 Turn-Off Voltage Threshold 29.6 Lockout Voltage Hysteresis 1.9 Maximum Input Current No-Load Input Current 0 Disabled Input Current Inrush Current Transient Rating Response to Input Transient Input Reflected Ripple Current Input Terminal Ripple Current Recommended Input Fuse Input Filter Component Values (L\C) Recommended External Input Capacitance OUTPUT CHARACTERISTICS Output Voltage Set Point 2.475 Output Voltage Regulation Over Line Over Load Over Temperature Total Output Voltage Range 2.43 Output Voltage Ripple and Noise1 Peak-to-Peak RMS Operating Output Current Range 0 Output DC Current-Limit Inception 40 Output DC Current-Limit Shutdown Voltage Back-Drive Current Limit while Enabled Back-Drive Current Limit while Disabled Maximum Output Capacitance Electrolytic Minimum Output Capacitance Maximum Output Capacitance Ceramic DYNAMIC CHARACTERISTICS Input Voltage Ripple Rejection Output Voltage during Load Current Transient For a Step Change in Output Current (0.1A/µs) For a Step Change in Output Current (0.3A/µs) Settling Time Turn-On Transient Turn-On Time 6 Start-Up Inhibit Time 9 Restart Inhibit Time 190 Output Voltage Overshoot EFFICIENCY 100% Load 50% Load TEMPERATURE LIMITS FOR POWER DERATING CURVES Semiconductor Junction Temperature Board Temperature Transformer Temperature Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick TA = 25 °C, airflow rate = 300 LFM, VIN = 48 VDC 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. Parameter Min. Typ. 48 32.6 30.6 2.0 46 6 7.5 1.9 75 47 2.500 +0.1 \ 2.5 +0.2 \ 5.0 +15 2.500 20 7 44 1.5 12 10 70 100 100 80 9 12 200 0 88 90 Max. 100 75 100 2250 100 125 18 75 33.7 31.6 2.1 3.0 75 10 0.01 20 1.0 \ 3.3 2.525 +38 2.57 50 50 35 48 50 33 5 12 17 210 125 125 125 Units Notes & Conditions V V V Vdc °C °C V V V V V A mA mA A 2s mV mA mA A µH\µF µF V %\mV %\mV mV V mV mV A A V A mA mF mF dB mV mV µs ms ms ms % % % °C °C °C Continuous Continuous 100 ms transient, square wave Basic Insulation, Pollution Degree 2 100% Load, 35 Vin, nominal Vout 1000V/ms input transient RMS thru 10 µH inductor; Figures 13 & 15 RMS; Figures 13 & 14 Fast blow external fuse recommended Internal values; see Figure E Typical ESR 0.1-0.2 Ω; see Figure 13 Over sample, line, load, temperature & life 20MHz bandwidth; Figures 13 & 16 Full Load; see Figures 13 & 16 Full Load; see Figures 13 & 16 Subject to thermal derating; Figures 5 - 8 Output Voltage 10% Low Negative current drawn from output Negative current drawn from output 2.5Vout at 35A Resistive Load Not applicable 2.5Vout at 35A Resistive Load 120 Hz; Figure 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.; Figures 9 & 10 -40°C to +125°C; Figure F -40°C to +125°C; Figure F No 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 Note 1: Output voltage ripple can exceed maximum specification during startup when output voltage is less than 1.2V. Additional output capacitance will mitigate this startup ripple behavior. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Note 2: Higher values of isolation capacitance can be added external to the module. Product # PQ60025ETL35 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2ET625F Rev. B 5/28/08 Page 3 Technical Specification Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick PQ60025ETL35 ELECTRICAL CHARACTERISTICS (Continued) TA = 25 °C, airflow rate = 300 LFM, VIN = 48 VDC 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. ISOLATION CHARACTERISTICS Isolation Voltage (dielectric strength) Isolation Resistance Isolation Capacitance2 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 Parameter Min. 317 -2 2.4 2.4 -2 -20 120 Typ. 2250 30 3300 333 10 148 120 10 2.42 2.27 Max. 350 0.8 18 18 0.8 5 +10 +10 160 Units Notes & Conditions V MΩ pF kHz V V V V V kΩ % % % °C °C 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 Calculated MTBF (Telcordia) TR-NWT-000332 Calculated MTBF (MIL-217) MIL-HDBK-217F Field Demonstrated MTBF 106 Hrs. 80% load,300LFM, 40oC Ta 106 Hrs. 80% load, 300LFM, 40oC Ta 106 Hrs. See our website for latest values Note 1: Output voltage ripple can exceed maximum specification during startup when output voltage is less than 1.2V. Additional output capacitance will mitigate this startup ripple behavior. For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com) Note 2: Higher values of isolation capacitance can be added external to the module. 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, 8 kV - NP, 15 kV air - NP (Normal Performance) Section 7 - electrical safety, Section 9 - bonding/grounding UL/cUL 60950-1 EN60950-1 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. Contact SynQor for official safety certificates on new releases or download from the SynQor website. QUALIFICATION TESTING Parameter P QUALIFICATION TESTING # 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 100 g 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 Life Test Vibration Mechanical Shock Temperature Cycling Power/Thermal Cycling Design Marginality Humidity Solderability • Extensive characterization testing of all SynQor products and manufacturing processes is performed to ensure that we supply robust, reliable product. Contact the factory for official product family qualification documents. Product # PQ60025ETL35 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2ET625F Rev. B 5/28/08 Page 4 Technical Specification 95 93 Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick 90 92 Efficiency (%) Efficiency (%) 85 91 80 90 75 35 Vin 48 Vin 75 Vin 0 5 10 15 20 25 30 35 89 25 C 40 C 55 C 70 88 65 87 100 200 300 400 Load Current (A) Airflow (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). 7 14 12 Power Dissipation (W) 6 10 8 6 4 2 0 0 5 10 15 20 25 30 35 35 Vin 48 Vin 75 Vin 3 100 200 300 400 Efficiency (%) 5 4 25 C 40 C 55 C Load Current (A) Airflow (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). 40 35 30 25 Iout (A) 20 15 400 LFM (2.0 m/s) 10 5 0 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) Figure 5: Maximum output power-derating curves 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 # PQ60025ETL35 Phone 1-888-567-9596 www.synqor.com Figure 6: Thermal plot of converter at 35 amp load current (87.5W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from 3 to pin 1 (nominal input voltage). Doc.# 005-2ET625F Rev. B 5/28/08 Page 5 Technical Specification 40 35 30 25 Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick Iout (A) 20 15 400 LFM (2.0 m/s) 10 5 0 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) 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 pin input to output (nominal input voltage). Figure 8: Thermal plot of converter at 35 amp load current (87.5W) 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). Load cap: 10uF, 100 mΩ ESR tantalum capacitor and 1uF ceramic capacitor. Input voltage pre-applied. Ch 1: Vout (1V/div), Ch 2: ON/OFF input (5V/div). Figure 10: Turn-on transient at zero load (4 ms/div). Load cap: 10uF, 100 mΩ ESR tantalum capacitor and 1uF ceramic capacitor. 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 cap and 1µF ceramic cap. Ch 1: Vout (100mV/div), Ch 2: Iout (10A/div). Product # PQ60025ETL35 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 = 0.3 A/µs). Load cap: 10µF, 100 mΩ ESR tantalum cap and 1µF ceramic cap. Ch 1: Vout (100mV/div), Ch 2: Iout (10A/div). Doc.# 005-2ET625F Rev. B 5/28/08 Page 6 Technical Specification See Fig. 15 source impedance Input: Output: Current: Package: 35V – 75 V 2.5 V 35 A Eighth-brick 10 µH See Fig. 14 See Fig. 16 iS VSOURCE iC dc-dc Converter 1 µF VOUT 15 µF, electrolytic capacitor 47 µF,