Technical Specification
Quarter
Brick
48Vin 2.5Vout 40A
40 Amp, No Heatsink, Isolated DC/DC Converter
The PQ60025QTA40 PowerQor™ Tera quarter-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 connections, it is extremely reliable.
The Tera series offers the maximum useable output cur-
rent for any standard “quarter-brick” module.
PQ60025QTA40 Module
Operational Features
• Ultra-high efficiency, 91% at 20 amp load, 88% at
40 amp load current
• Delivers up to 40 amps of output current with mini-
mal derating - no heatsink required
• Wide input voltage range: 35V – 75V, with 100V
100ms input voltage transient withstand
• Fixed frequency switching provides predictable EMI
performance
• No minimum load requirement means no preload
resistors required
Protection Features
• Input under-voltage lockout disables converter at
low input voltage conditions
• Output current limit and short circuit protection
protects converter from excessive load current or
short circuits
• Output over-voltage protection protects load from
damaging voltages
• Thermal shutdown protects converter from abnor-
mal environmental conditions
Mechanical Features
• Industry standard quarter-brick pin-out configuration
• Industry standard size: 1.45” x 2.3”
• Total height less than 0.43”, permits better airflow
and smaller card pitch
• Total weight: 42 grams (1.5 oz.), lower mass great-
ly reduces vibration and shock problems
Safety Features
• 2000V, 10 MΩ input-to-output isolation provides
input/output ground separation
• UL/cUL 60950 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 flam-
mability 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 # PQ60025QTA40
Phone 1-888-567-9596
Doc.# 005-2QT625C Rev. B
3/6/03
Page 1
Technical Specification
Quarter
Brick
MECHANICAL
DIAGRAM
2.30
(58.4)
48Vin 2.5Vout 40A
0.14
(3.6)
2.00
(50.8)
0.300
(7.62)
0.150
0.43
(10.9)
(3.81)
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+.55/-.81)
Side View
Lowest
Component
Load Board
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 - 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: 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 consid-
ered part of the input/primary circuit.
PIN CONNECTIONS
Pin No.
1
2
3
4
5
6
7
8
Notes:
1. Pin 5 must be connected to Vout(-).
2. Leave Pin 6 open for nominal output voltage.
3. Pin 7 must be connected to Vout(+).
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 # PQ60025QTA40
Phone 1-888-567-9596
Doc.# 005-2QT625C Rev. B
3/6/03
Page 2
Technical Specification
Quarter
Brick
PQ60025QTA40 ELECTRICAL CHARACTERISTICS
Parameter
ABSOLUTE MAXIMUM RATINGS
48Vin 2.5Vout 40A
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.
Typ.
Max.
100
80
100
2000
100
125
18
48
33
29.5
3.5
55
1.6
0.01
150
10
33
2.475
1\5\3
47
2.500
+0.1 \ 2
+0.1 \ 2
+13
50
10
47.5
1.36
1.8
10
71
80
190
400
180
86
89
4
200
0
88
91
125
125
125
2000
10
8
215
75
34
30.5
4.5
4.5
75
3
Units
V
V
V
V
°C
°C
V
V
V
V
V
A
mA
mA
A
2
s
mV
mA
A
µF\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; Figure 17
Basic 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
Operating Input Voltage Range
Input Under-Voltage Lockout
Turn-On Voltage Threshold
Turn-Off Voltage Threshold
Lockout Hysteresis Voltage
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 (C
1
\L\C
2
)
Recommended External Input Capacitance
-40
-55
-2
35
32
28.5
2.5
INPUT CHARACTERISTICS
100% Load, 35 Vin
7
see Figure 13
1000V/ms input transient; Figure 17
P-P thru 10µH inductor; Figs. 13 & 15
fast blow external fuse recommended
internal values, see Figure E
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
Input Voltage Ripple Rejection
Output Voltage during Load Current Transient
Step Change in Output Current (0.1A/µs)
Step Change in Output Current (1A/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
Isolation Resistance
Isolation Capacitance
2.525
+0.2 \ 5
+0.2 \ 5
+38
2.573
100
20
40
51
2.5
50
25,000
2.427
0
44
0.5
0
over sample, line, load, temperature & life
500MHz bandwidth; Fig. 13 & 16
Full Load, see Figures 13 & 16
Full Load, see Figures 13 & 16
Output Voltage 10% Low
Max negative current drawn from output
Max negative current drawn from output
2.5Vout at 40A Resistive Load
120 Hz; Fig. 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.; Figs. 9 & 10
-40°C to +125°C; Figure F
10,000 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
DYNAMIC CHARACTERISTICS
EFFICIENCY
TEMPERATURE LIMITS FOR POWER DERATING CURVES
ISOLATION CHARACTERISTICS
470
Product # PQ60025QTA40
Phone 1-888-567-9596
Doc.# 005-2QT625C Rev. B
3/6/03
Page 3
Technical Specification
Quarter
Brick
ELECTRICAL CHARACTERISTICS (Continued)
Parameter
P
FEATURE CHARACTERISTICS
48Vin 2.5Vout 40A
Units
kHz
V
V
V
V
V
kΩ
%
%
%
°C
°C
Min.
180
-2
2.4
2.4
-2
Typ.
210
Max.
240
0.8
18
18
0.8
Notes & Conditions
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
Calculated MTBF
Calculated MTBF
Demonstrated MTBF
-20
117
Vin/6.5
40
122
125
10
2.1
1.75
TBD
9.2
+10
+10
127
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
RELIABILITY CHARACTERISTICS
10
6
Hrs.
Telcordia TR-NWT-000332; 80% load,300LFM, 40oC Ta
10
6
Hrs.
MIL-HDBK-217F; 80% load, 300LFM, 40oC Ta
10
6
Hrs. Field demonstrated MTBF
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
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
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 more information about Proof of Design and Proof of Manufacturing processes.
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 # PQ60025QTA40
Phone 1-888-567-9596
PATENTS
SynQor is protected under various patents, including but not lim-
ited to U.S. Patent # 5,999,417.
Doc.# 005-2QT625C Rev. B
3/6/03
Page 4
Performance Curves
Quarter
Brick
95
94
93
92
Efficiency (%)
100
95
90
48Vin 2.5Vout 40A
Efficiency (%)
85
80
75
70
65
60
0
4
8
12
16
20
24
28
32
36 Vin
48 Vin
75 Vin
36
40
91
90
89
88
87
86
85
0
100
200
300
400
Air Flow (LFM)
25 C
40 C
55 C
500
Load Current (A)
Figure 1:
Efficiency at nominal output voltage vs. load current for min-
imum, nominal, and maximum input voltage at 25
°
C.
14
12
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).
8.0
7.0
Power Dissipation (W)
Power Dissipation (W)
10
8
6
4
2
0
0
4
8
12
16
20
24
28
32
36
40
6.0
5.0
4.0
3.0
2.0
0
100
200
300
400
Air Flow (LFM)
25 C
40 C
55 C
36 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).
40
35
30
25
I
out
(A)
20
15
10
5
0
0
25
40
55
70
85
400 LFM (2.0 m/s)
300 LFM (1.5 m/s)
200 LFM (1.0 m/s)
100 LFM (0.5 m/s)
0 LFM (0 m/s)
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 0 LFM through 400 LFM with air flowing
across the converter from pin 3 to pin 1 (nominal input voltage).
Product # PQ60025QTA40
Phone 1-888-567-9596
Figure 6:
Thermal plot of converter at 36 amp load current 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.# 005-2QT625C Rev. B
3/6/03
Page 5
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