Technical
S pecification
PQ60015EGL25
48V in
Input
1.5Vout
Output
25Amp
Current
2000Vdc
Isolation
Eighth-brick
DC/DC Conver ter
The PQ60015EGL25 PowerQor
™
Giga eighth-brick con -
b
verter is a next-generation, board-mountable, isolated, fixed
g
m
switching frequency DC/DC converter that uses synchro -
nous rectification to achieve extremely high conversion effi -
ciency. 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 com -
ponents are mounted to the multi-llayer PCB substrate with
high-yield surface mount technology. Since the PowerQor
y
converter has no explicit thermal interfaces, it is extremely
reliable.
Operational Features
• High efficiency, >83% at full rated load current
• Delivers up to 25 amps of output current 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
PQ60015EGL25 Module
Pr otection 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 eighth-brick pin-out configuration
• Industry standard size: 0.90” x 2.3” (22.9x58.4mm)
• Total height only 0.335” (8.5mm), permits better airflow
and smaller card pitch
• Total weight: 0.68 oz. (19 grams)
• Flanged pins designed to permit surface mount solder-
ing (avoid wave solder) using FPiP technique
Safety Features
• 2000V, 30 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 flammabil-
ity requirements
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
Product # PQ60015EGL25
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2EG651D Rev. A
9/3/03
Page 1
Technical Specification
MECHANICAL
DIAGRAM
0.14
0.150
(3.81)
(3.56)
Input:
Output:
Current:
Package:
35-75 V
1.5 V
25 A
Eighth-brick
2.30
(58.42)
2.00
(50.8)
0.150
(3.81)
0.300
0.90
(22.86)
0.600
(15.24)
(7.62)
Top View
0.300
(7.62)
0.450
(11.43)
0.600
(15.24)
0.335
Side View
Bottom side
Clearance
See Note 9
(8.5)
EGA Option
0.424 (10.76)
max height
See Note 9
0.019 +0.013
(0.48 +0.33)
Lowest
Component
EGA Option
0.076 (1.93)
min clearance
See Note 9
Load Board
Flanged Pin
See Note 10
0.110
(2.79)
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) Modules can be ordered as EGA option that have different
pins to provide a minimum bottom side clearance of 0.076”
while increasing maximum height to 0.424”. See ordering
page for more information.
10) The flanged pins are designed to permit surface mount
soldeing (avoiding the wave soldering process) through
the use of the flanged pin-in-paste technique.
Product # PQ60015EGL25
Phone 1-888-567-9596
PIN DESIGNATIONS
Pin No.
1
2
3
4
5
6
7
8
Notes:
1. SENSE(-) may be connected to Vout(-) or left open.
2. Leave TRIM pin open for nominal output voltage.
3. SENSE(+) may be connected to Vout(+) or left open.
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
www.synqor.com
Doc.# 005-2EG651D Rev. A
9/3/03
Page 2
Technical Specification
PQ60015EGL25 ELECTRICAL CHARACTERISTICS
Parameter
ABSOLUTE MAXIMUM RATINGS
Input:
Output:
Current:
Package:
35-75 V
1.5 V
25 A
Eighth-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 tem-
perature 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
2.3
25
2
50
3.0
210
4.7\1.0
47
1.485
1.50
+0.05 \ 2
+0.1 \ 2
+6
75
18
28.5
0.7
0.45
10
80
80
150
300
180
14
200
0
83.5
86
125
125
125
2000
30
470
18
240
75
34.4
32.4
2.4
0.9
5
0.01
Units
V
V
V
V
°C
°C
V
V
V
V
V
A
mA
mA
A
2
s
mV
mA
mA
A
µH\µF
µF
V
%\mV
%\mV
mV
V
mV
mV
A
A
V
A
mA
µF
dB
mV
mV
µs
ms
ms
%
%
%
°C
°C
°C
V
M
Ω
pF
Notes & Conditions
continuous
continuous
100ms transient, square wave
Basic insulation, 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 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
-40
-55
-2
35
31.5
29.5
2.2
INPUT CHARACTERISTICS
100% Load, 35 Vin
10
1000V/ms input transient
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
Output Voltage Set Point
Output Voltage Regulation
Over Line
Over Load
Over Temperature
Total Output Voltage Range
Output Voltage Ripple and Noise
1
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
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 Capacitance
2
1.515
+0.1 \ 5
+0.2 \ 5
+20
1.54
130
25
25
1.46
0
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 17
Negative current drawn from output
Negative current drawn from output
1.5Vout at 25A 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
45,000 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
50
45,000
DYNAMIC CHARACTERISTICS
EFFICIENCY
TEMPERATURE LIMITS FOR POWER DERATING CURVES
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 # PQ60015EGL25
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2EG651D Rev. A
9/3/03
Page 3
Technical Specification
ELECTRICAL CHARACTERISTICS (Continued)
Parameter
P
FEATURE CHARACTERISTICS
Input:
Output:
Current:
Package:
35-75 V
1.5 V
25 A
Eighth-brick
Min.
195
-2
2.4
2.4
-2
Typ.
225
Max.
255
0.8
18
18
0.8
Units
kHz
V
V
V
V
V
kΩ
%
%
%
°C
°C
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
120
Vin/6
40
125
125
10
800
2.5
1.1
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
See App Note: Output Load Current Calc.
RELIABILITY CHARACTERISTICS
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 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 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 factory for official product family qualification document.
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 lim-
ited to U.S. Patent numbers 5,999,417; 6,222,742 B1;
6,594,159 B2; 6,545,890 B2.
Product # PQ60015EGL25
Phone 1-888-567-9596
www.synqor.com
Doc.# 005-2EG651D Rev. A
9/3/03
Page 4
Technical Specification
95
90
85
88
87
86
Input:
Output:
Current:
Package:
35-75 V
1.5 V
25 A
Eighth-brick
Efficiency (%)
Efficiency
(%)
80
75
70
35 Vin
65
60
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
20.0
22.5
25.0
48 Vin
75 Vin
85
84
83
82
81
80
0
100
200
300
400
500
25 C
40 C
55 C
Load Current (A)
Air Flow
(LFM)
Figure 1:
Efficiency at nominal output voltage vs. load current for min-
imum, 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
4.0
3.0
2.0
1.0
0.0
25 C
40 C
55 C
9
8
Power Dissipation (W)
6
5
4
3
2
1
0
0
3
5
8
10
13
15
18
20
35 Vin
48 Vin
75 Vin
23
25
Power Dissipation (W)
7
0
100
200
300
400
500
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).
26
24
22
20
18
16
I
out
(A)
14
12
10
8
6
4
2
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 (
o
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 50 LFM through 400 LFM with air flowing
across the converter from pin 3 to pin 1 (nominal input voltage).
Product # PQ60015EGL25
Phone 1-888-567-9596
Figure 6:
Thermal plot of converter at 25 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.# 005-2EG651D Rev. A
9/3/03
Page 5
www.synqor.com
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