Technical
S pecification
PQ60525HTA04
48V in
Input
52.5Vout
Output
200W
Power
2250Vdc
Isolation
Half-brick
DC/DC Conver ter
The PQ60525HTA04 PowerQor
™
Tera converter is a next-
generation, 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 mini-
mal 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 air-
flow and smaller card pitch
• Total weight: 2.6 oz. (75 grams)
Safety Features
• 2250V, 30 M
Ω
input-to-output isolation
• UL/cUL 60950 recognized (US & Canada), basic insu-
lation 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)
• Active current share for N+1 and parallel applications
• External Clock Synchronization pin for better EMI char-
acteristics
• 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:
Output:
Current:
Package:
(58.4)
35-75 V
52.5 V
3.8 A
(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 clear-
ance 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)
Half-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
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
2
s
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 Noise
1
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 Capacitance
2
-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
M
Ω
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)
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
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
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 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 lim-
ited 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)
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 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).
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
o
70
85
Ambient Air Temperature ( C)
Figure 5:
Maximum output power derating curves vs. ambient air tem-
perature 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
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