Technical
Specification
PQ60240QGA05
35 - 75 V
Input
24 V
Output
5.0 A
Current
2000 Vdc
Isolation
Quarter-brick
DC/DC Converter
The PQ60240QGA05 PowerQor
®
Giga quarter-brick
converter is a next-generation, board-mountable, isolated,
fixed switching frequency DC/DC converter. 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.
The Giga series offers the maximum useable output
current for any standard “quarter-brick” module. RoHS
Compliant see last page.
Operational
Features
• Ultra-high efficiency, 92% at full rated load current
• Delivers up to 5 amps of output current (120W) with
minimal derating - no heatsink required
• Wide input voltage range: 35 - 75 V, with 100 V
100ms input voltage transient capability
• Fixed frequency switching provides predictable EMI per-
formance
• No minimum load requirement means no preload resis-
tors required
PQ60240QGA05 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 conse-
quent hazardous conditions
• Active back bias limit prevents damage to converter
from external load induced pre-bias
• Output over-voltage protection protects load from dam-
aging voltages
• Thermal shutdown protects converter from abnormal
environmental conditions
Mechanical
Features
• Industry standard quarter-brick pin-out configuration
• Industry standard size: 1.45” x 2.3” (36.8x58.4mm)
• Total height less than 0.43” (10.9mm), permits better
airflow and smaller card pitch
• Total weight: 1.5 oz. (42 grams)
• Flanged pins designed to permit surface mount soldering
(allows to avoiding wave solder) using FPiP technique
Safety
Features
• 2000V, 30 MW input-to-output isolation provides input/
output ground separation
• UL/cUL 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 flammabil-
ity 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 # PQ60240QGA05
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2-QGA624D Rev. B
10/01/08
Page 1
Technical Specification
MECHANICAL
DIAGRAM
0.14
(3.6)
Input:
Output:
Current:
Package:
35 - 75 V
24 V
5.0 A
Quarter-brick
2.30
(58.4)
2.00
(50.8)
0.300
(7.62)
0.150
(3.81)
0.43
(10.9)
1.45
(36.8)
0.300
0.600
(15.24)
(7.62)
0.450
Top View
(11.43)
0.600
(15.24)
Bottom side
Clearance
See Note 9
0.43
(10.9)
0.060+.022/-.032
(1.52+.56/-.81)
Lowest
Component
Load Board
Flanged Pin
See Note 10
Side View
0.145
(3.68)
See Note 3
NOTES
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) 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: 1.5 oz. (42 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 DESIGNATIONS
Pin No. Name
1
2
3
4
5
6
7
8
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
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.# 005-2-QGA624D Rev. B
10/01/08
Page 2
10) The flanged pins are designed to permit surface mount solder-
ing (allowing to avoid the wave soldering process) through the
use of the flanged pin-in-paste technique.
Product # PQ60240QGA05
Phone 1-888-567-9596
www.synqor.com
Technical Specification
PQ60240QGA05 ELECTRICAL CHARACTERISTICS
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
Recommended Input Fuse
Input Filter Component Values (L\C)
Recommended External Input Capacitance
OUTPUT CHARACTERISTICS
Output Voltage Set Point
Output Voltage Regulation
Over Line
1
Over Load
1
Over Temperature
Total Output Voltage Range
Output Voltage Ripple and Noise
2
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
DYNAMIC CHARACTERISTICS
Input Voltage Ripple Rejection
Output Voltage during Load Current Transient
For a Step Change in Output C urrent (0.1A/µs)
Settling Time
Turn-On Transient
Turn-On Time
Start-Up Inhibit Time
Output Voltage Overshoot
EFFICIENCY
100% Load
50% Load
TEMPERATURE LIMITS FOR POWER DERATING CURVES
Semiconductor Junction Temperature
Board Temperature
Transformer Temperature
ISOLATION CHARACTERISTICS
Isolation Voltage (dielectric strength)
Isolation Resistance
Isolation Capacitance
3
Input:
Output:
Current:
Package:
35 - 75 V
24 V
5.0 A
Quarter-brick
T
A
=25°C, airflow rate=300 LFM, V
in
=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.
-40
-55
-2
35
31.5
28.5
2.5
23.5
23.2
0
6.2
200
Typ.
48
32.8
29.5
3.5
100
2
0.65
11
2.46\4.7
47
24.00
+0.008\2
+0.008\2
+
140
10
4
7.0
9.5
0.5
26
18
1200
800
24
220
0
92
92
2000
30
470
Max.
100
80
100
2000
100
125
18
75
34.5
31.5
4.5
4.2
130
5
0.01
20
24.5
+
0.2\24
+
0.2\24
+
240
24.8
150
60
5
7.6
0.9
50
1
240
125
125
125
Units
V
V
V
V
°C
°C
V
V
V
V
V
A
mA
mA
A
2
s
V
mA
A
µH\µF
µF
V
%\mV
%\mV
mV
V
mV
mV
A
A
V
A
mA
mF
dB
mV
µs
ms
ms
%
%
%
°C
°C
°C
V
MW
pF
Notes & Conditions
Continuous
Continuous
100ms transient, square wave
Basic insulation, Pollution Degree 2
100V transient for 100ms
100% Load, 35 Vin, trimmed up 5%
1000V/ms input transient
P-P thru 10µH inductor; Figures 13 & 15
Fast blow external fuse recommended
Internal values; Figure E (Lin\C2)
Typical ESR 0.1-0.2W; Figure 13
Over sample, line, load, temperature & life
500MHz bandwidth; Figures 13 & 16
Full Load; Figures 13 & 16
Full Load; Figures 13 & 16
Subject to thermal derating; Figures 5 - 8
Output Voltage 10% Low
Negative current drawn from output source
Negative current drawn from output source
24Vout at 5A Resistive Load
120 Hz; Figure 20
50% to 75% to 50% Iout max
To within 1% Vout nom
Full load, ON/OFF to Vout=90% nom.; Figures 9 - 10
-40°C to +125°C; Figure E
1 mF load capacitance, Iout = 0A
Figures 1 & 4
Figures 1 & 4
Package rated to 150°C
UL rated max operating temp 130°C
See Figures 3 - 6 for derating curves
Note 1: Line and load regulation is limited by duty cycle quantization and does not indicate a shift in the internal voltage reference.
Note 2: For applications requiring reduced output voltage ripple and noise, consult SynQor applications support (e-mail: support@synqor.com).
Note 3: Higher values of isolation capacitance can be added external to the module.
Product # PQ60240QGA05
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2-QGA624D Rev. B
10/01/08
Page 3
Technical Specification
ELECTRICAL CHARACTERISTICS (Continued)
Parameter
P
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
Input:
Output:
Current:
Package:
35 - 75 V
24 V
5.0 A
Quarter-brick
Min.
321
-2
2.4
2.4
-2
-20
112
Typ.
383
Vin/6.5
40
115
125
10
2.8
1.8
Max.
459
0.8
18
18
0.8
9.2
+10
+10
130
Units
kHz
V
V
V
V
V
kW
%
%
%
°C
°C
Notes & Conditions
Regulation and Isolation stage
Figures A & B
Measured across Pins 8 & 4; see trim section
Measured across Pins 8 & 4
Over full temp range; % of nominal Vout
Average PCB Temperature
10
6
Hrs. TR-NWT-000332; 80% load,300LFM, 40oC Ta
10
6
Hrs. MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta
10
6
Hrs. See website for details
STANDARDS COMPLIANCE
Parameter
P
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
STANDARDS COMPLIANCE
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
# 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 axes
QUALIFICATION TESTING
Life Test
Vibration
Mechanical Shock
Temperature Cycling
Power/Thermal Cycling
Design Marginality
Humidity
Solderability
95% rated V
in
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
T
operating
= min to max, V
in
= min to max, full load, 100 cycles
T
min
-10°C to T
max
+10°C, 5°C steps, V
in
= 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 the factory for official product family qualification documents.
Product # PQ60240QGA05
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2-QGA624D Rev. B
10/01/08
Page 4
Technical Specification
100
95
93
90
95
Input:
Output:
Current:
Package:
35 - 75 V
24 V
5.0 A
Quarter-brick
Efficiency (%)
Efficiency (%)
35 Vin
48 Vin
75 Vin
85
80
75
70
65
60
0
1
2
3
4
5
91
89
87
25º C
40º C
55º C
85
100
200
300
400
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
12
10
Power Dissipation (W)
8
6
Power Dissipation (W)
7
6
4
35 Vin
48 Vin
75 Vin
0
0
1
2
3
4
5
5
2
25º C
40º C
55º C
4
100
200
300
400
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).
6
5
4
Iout (A)
3
2
400 LFM (2.0 m/s)
300 LFM (1.5 m/s)
200 LFM (1.0 m/s)
100 LFM (0.5 m/s)
1
0
25
40
55
70
85
Ambient Air Temperature (°C)
Semiconductor junction temperature is
within 1°C of surface temperature
Figure 5:
Maximum output power derating curves vs. ambient air tem-
perature for airflow rates of 100 LFM through 400 LFM with air flow-
ing across the converter from input to output (nominal input voltage).
Product # PQ60240QGA05
Phone 1-888-567-9596
Figure 6:
Thermal plot of converter at 5 amp load current (120W) with
55
°
C air flowing at the rate of 200 LFM. Air is flowing across the con-
verter from input to output (nominal input voltage).
Doc.# 005-2-QGA624D Rev. B
10/01/08
Page 5
www.synqor.com
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