PQ60525HTA04PRF

Technical S pecification PQ60525HTA04 48V in Input I nput 52.5Vout Output 200W Power 2250Vdc Isolation Half-brick DC/DC Conver ter The PQ60525HTA04 PowerQor ™ Tera converter is a nextgeneration, board-mountable, isolated, fixed switching fre m quency DC/DC converter that uses synchronous rectification to achieve extremely high conversion efficiency. The module is ideally suited to support the IEEE 802.3af standard for Power Over LAN and VoIP applications. The Tera series converters offer the maximum useable output current for any standard “half-brick” module. The Tera units also feature b active current sharing for N+1 and parallel applications. Operational Features • Ultra-high efficiency, 92% at full rated load current • Delivers up to 200 Watts of output power 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 PQ60525HTA04 Module Contr ol 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 Mechanical Features • Industry standard half-brick pin-out configuration • Industry standard size: 2.3” x 2.4” (58.4 x 61.0mm) • Total height only 0.43” (11.2mm), permits better airflow and smaller card pitch • Total weight: 2.6 oz. (75 grams) Safety Features • 2250V, 30 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 Pr otection Features • Input under-voltage lockout disables converter at low input voltage conditions • Output current limit and short circuit protection • Active back bias limit prevents damage to converter from external load induced pre-bias • Output over-voltage protection • Thermal shutdown Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Optional Features (full-feature) ( full-feature) • Active current share for N+1 and parallel applications • External Clock Synchronization pin for better EMI characteristics • Startup Synchronization pin for more consistent start-up sequence • ORing FET drive supply for efficient ORing protection Doc.# 005-2HT652F Rev. B 03/08/05 Page 1 Technical Specification 2.30 Input: I nput: Output: Current: Package: (58.4) 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick MECHANICAL DIAGRAM 0.50 (12.7) 0.400 (10.16) 1.90 (48.3) 0.700 (17.78) 0.600 (15.24) 0.19 (4.8) 0.800 (20.32) 0.400 (10.16) 1.000 (25.40) 1.000 (25.40) Top View 1.400 (35.56) 2.40 (61.0) 1.400 (35.56) Bottom side Clearance See Note 10 Side View Lowest Component 0.037+/-0.029 (0.94+/-0.74) 15 character “8” alternate bottom side clearance option (See ordering options on Pge 14) 0.43 Load Board 0.145 (3.68) See Note 4 (11.2) 15 character “8” alternate bottom side clearance option (See ordering options on Pge 14) 0.060+/-0.030 (1.52+/-0.76) 0.475(12.06) maximum height 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. 11) The flanged pins are designed to permit surface mount soldering (avoiding the wave soldering process) through the use of the flanged pin-in-paste technique. Product # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com PIN DESIGNATIONS 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 I share Vin(-) Vout(-) SENSE(-) TRIM SENSE(+) Vout(+) Clock Sync Start Sync 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 Pins in Italics Shaded text are optional Doc.# 005-2HT652F Rev. B 03/08/04 Page 2 Technical Specification PQ60525HTA04 ELECTRICAL CHARACTERISTICS Parameter ABSOLUTE MAXIMUM RATINGS Input: Output: Current: Package: 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick 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 2250 100 125 18 18 48 32.5 30.5 2.0 90 2 500 3 150 1\11 47 52.00 52.50 75 34.4 32.4 2.1 7.0 110 5 0.01 Units V V V V °C °C V 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 % µF dB mV mV µs Notes & Conditions continuous continuous 100ms transient, square wave 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 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 Input Filter Component Values (L\C) 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 Noise1 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) Maximum Output Capacitance 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 (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 (dielectric strength) Isolation Resistance Isolation Capacitance2 -40 -55 -2 -15 35 30.6 28.6 1.9 applies to Full Feature option only INPUT CHARACTERISTICS 100% Load, 35 Vin, trim up 10% 20 1000V/ms input trans; 330µF cap; Figure 17 RMS thru 10µH inductor; Figures 13 & 15 RMS; Figures 13 & 14 fast blow external fuse recommended internal values, see Figure E Typical ESR 0.1-0.2Ω, see Figure 13 OUTPUT CHARACTERISTICS 53.00 51.5 +0.05 \ 20 +0.1 \ 50 +0.1 \ 40 +0.15 \ 75 +150 +300 53.5 100 20 4.7 30 +2 60 400 400 500 150 50 3.85 5.2 +5 1,500 0.385 4.2 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; Figure 23 % of rated output current 52.5Vout at 3.8A Resistive Load 120 Hz; Figure 20 50-75-50% Iout max; 330µF cap; Figure 11 50-75-50% Iout max; 330µF cap; Figure 12 to within 1% Vout nom Full load, Vout=90% nom.; Figures 9 & 10 -40°C to +125°C; Figure A 1,500 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 25 200 0 92.3 91.7 40 240 ms ms % % % EFFICIENCY TEMPERATURE LIMITS FOR POWER DERATING CURVES 125 125 125 2250 30 3300 °C °C °C V MΩ pF ISOLATION CHARACTERISTICS Note 1: 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 # PQ60525HTA04 Phone 1-888-567-9596 www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 3 Technical Specification ELECTRICAL CHARACTERISTICS (Continued) Parameter P FEATURE CHARACTERISTICS Input: Output: Current: Package: 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick Min. 275 -2 2.7 2.7 -2 Typ. 300 Max. 325 0.8 18 18 0.8 Units kHz V V V V V kΩ % % % °C °C 6 Notes & Conditions Regulation and Isolation stages 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 Load Current Scale Factor Calculated MTBF (Telcordia) Calculated MTBF (MIL-217) Field Demonstrated MTBF -20 Vin/6 42 117 120 10 TBD 2.2 1.3 15 +10 +10 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 See App Note: Output Load Current Calc. RELIABILITY CHARACTERISTICS 10 Hrs. TR-NWT-000332; 80% load,300LFM, 40oC Ta 106 Hrs. MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta 106 Hrs. See website for latest values 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. 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 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 official product family qualification document. 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 # PQ60525HTA04 Phone 1-888-567-9596 PATENTS SynQor is protected under various patents, including but not limited to U.S. Patent #s 5,999,417; 6,222,742 B1; 6,594,159 B2; 6,545,890 B2. www.synqor.com Doc.# 005-2HT652F Rev. B 03/08/04 Page 4 Technical Specification 100 95 90 94 93 92 Input: Output: Current: Package: 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick Efficiency (%) Efficiency (%) 35 Vin 85 80 75 70 65 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 48 Vin 75 Vin 91 90 89 88 87 86 0 100 200 300 400 25 C 40 C 55 C 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). 12.0 11.0 Power Dissipation (W) 20 18 Power Dissipation (W) 16 14 12 10 8 6 4 2 0 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 0 100 200 300 400 Air Flow (LFM) 25 C 40 C 55 C 35 Vin 48 Vin 75 Vin 500 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). 4.0 3.5 Semiconductor junction temperature is within 1°C of surface temperature 3.0 2.5 Iout (A) 2.0 1.5 1.0 0.5 0.0 0 400 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) 25 40 55 70 85 Ambient Air Temperature (oC) Figure 5: 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). Product # PQ60525HTA04 Phone 1-888-567-9596 Figure 6: Thermal plot of converter at 3.4 amp load current (179W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from input to output (nominal input voltage). Doc.# 005-2HT652F Rev. B 03/08/04 Page 5 www.synqor.com Technical Specification 4.0 3.5 3.0 2.5 Iout (A) Input: Output: Current: Package: 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick 2.0 1.5 1.0 0.5 0.0 0 400 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) 25 40 55 o 70 85 Ambient Air Temperature ( C) Figure 7: Maximum output power derating curves vs. ambient air temperature for airflow rates of 50 LFM through 400 LFM with air flowing from output to input (nominal input voltage). Figure 8: Thermal plot of converter at 3.2 amp load current (168W) with 55°C air flowing at the rate of 200 LFM. Air is flowing across the converter from output to input (nominal input voltage). Figure 9: Turn-on transient at full load (resistive load) (10 ms/div). Input voltage pre-applied. Top Trace: Vout (20V/div). Bottom Trace: ON/OFF input (5V/div) Figure 10: Turn-on transient at zero load (10 ms/div). Top Trace: Vout (20V/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: 330µF, electrolytic output capacitance. Top trace: Vout (200mV/div), Bottom trace: Iout (1A/div). Product # PQ60525HTA04 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: 330µF, electrolytic output capacitance. Top trace: Vout (200mV/div), Bottom trace: Iout (1A/div). Doc.# 005-2HT652F Rev. B 03/08/04 Page 6 www.synqor.com Semiconductor junction temperature is within 1°C of surface temperature Technical Specification See Fig. 15 source impedance Input: Output: Current: Package: 35-75 V 52.5 V 3.8 A (200W) ( 200W) Half-brick 10 µH See Fig. 14 See Fig. 16 iS VSOURCE iC DC/DC Converter 1 µF VOUT 15 µF, electrolytic capacitor 47 µF,