CBAM™ PQ-28
1
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
Features
The Power Quality Module (PQ-28) is a single
input power conditioning module
1/2 brick package (2.28” x 2.4” x 0.50”)
Designed for 200 Watts
Designed to interface with MIL-STD-1275B,
28VDC Power Bus
100VDC input capability
Automatic recovery for output short circuit
Aluminum substrate technology
All applicable materials used are a minimum of
UL94V-0 rated. Designed to meet UL60950
All ceramic solution
Excellent MTBF
Five year warranty
Available with RoHS compliant construction
part number: PQ-28 (RoHS)
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Description
The Power Quality Module PQ-28 is a single input power
conditioning module. Built in a 1/2 brick size package
that operates over a 11 - 100VDC input, the PQ-28 is
designed for 200 Watts and features automatic recovery
for output short circuit.
Figure 1. Block Diagram
Figure 2. Input - Output DC Voltage
CBAM™ PQ-28
2
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
Input Parameters (Note 1)
Model PQ-28 Units
Input Voltage Range MIN
TYP
MAX
11
28
100
VDC
Input Current, No Load TYP 90 mA
Input Current, 28VDC, 200W Load TYP 7.4 A
Efficiency 28VDC. 200W Load TYP 95 %
Under Voltage Lock Out
Turn-on
Turn-off
TYP
TYP
10
9.5
VDC
VDC
Turn-on time
Delay before rise
Rise time
Overshoot
TYP
TYP
TYP
180 - 420
25
3
ms
ms
%
Switching Frequency TYP 200 kHz
Input Fuse (2)
Input Reverse Polarity Protection (2)
Notes:
(1) All parameters measured at Tamb=25ºC, Vin=28VDC, Full Power
Out, 100µF Bus Capacitor unless otherwise noted. Refer to the
Calex Application Notes for the definition of terms, measurement
circuits, and other information.
(2) Refer to Calex Application notes for information on fusing. Fuse
is only required for system protection, and input reverse polarity
protection.
(3) Load regulation is defined as the output voltage change when
changing load power from maximum to minimum.
(4) Isolation is measured by applying a DC voltage between the
baseplate and pins.
(5) Thermal shutdown occurs at about +112ºC on the baseplate. The
unit will autostart at about +110ºC.
(6) The thermal impedance is defined as the temperature rise above
ambient per package watt dissipated. Baseplate not connected to
an external heatsink.
(7) MTBF is calculated based on MIL-HDBK-217F under the following
conditions:
Reliability prediction method = Part Stress Analysis
Baseplate temperature = 40ºC
Environment = Ground, Benign
(8) Torque fasteners into threaded mounting inserts at 12 in.oz. or
less. Greater torque may result in damage to the unit and void the
warranty.
(9) Calex CBAM™ modules are designed to withstand most
solder/wash processes. Careful attention should be used
when assessing the applicability in your specific manufacturing
process. The CBAM™ modules are not hermetically sealed.
(10) Available with RoHS and Non-RoHS construction, contact factory
for details.
RoHS Compliance means conformity to EU Directive 2002/95/
EC of 27 January 2003, on the restriction of the use of certain
hazardous substances in electrical and electronic equipment,
lead, cadmium, mercury, hexavalent chromium, polybrominated
biphenyls, and polybrominated diphenyl ethers are not present
in quantities exceeding the following maximum concentrations in
any homogeneous material, except for applicable exemptions.
0.1% (by weight of homogeneous material) lead, mercury,
hexavalent chromium, polybrominated biphenyls, polybrominated
diphenyl ethers, or 0.01% (by weight of homogeneous material)
cadmium.
The RoHS marking is as follows.
Performance Features (Note 1)
Model PQ-28 Units
Output Power
MAX
MIN
See
Derating
0
W
Input to Output Voltage Drop, 11VDC, 100W TYP 2.8 VDC
Load Regulation (45-100VDC) TYP
MAX
0.1
1%
Temperature Coefficient (45 -100VDC) TYP 150 ppm/ºC
Short Circuit Protection
+Output to -Output
Auto
Restart
CBAM™ PQ-28
3
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
General Specifications
Model PQ-28 Units
Isolation
Baseplate to pins (4) MIN 700 VDC
Environmental
Baseplate Operating Temperature Range (5) MIN
MAX
-40
+100 ºC
Storage Temperature Range MIN
MAX
-40
+120 ºC
Thermal Impedance (6) TYP 7 ºC/Watt
MTBF MIL-HDBK-217F (7) MIN 170,750 h
General
Unit Weight TYP 100 g
Case Dimension 2.28” x 2.4” x 0.50”
Torque on Mounting Inserts (8) MAX 12 in. oz.
BOTTOM VIEW SIDE VIEW
Pin Function Pin Dia.
1 -INPUT (COMMON) 0.080”
3 BASEPLATE 0.040”
4 +INPUT 0.080”
5 -OUTPUT (COMMON) 0.080”
9 +OUTPUT 0.080”
Mechanical tolerances unless otherwise noted:
X.XX dimensions ±0.020 inches
X.XXX dimensions ±0.005 inches
CBAM™ PQ-28
4
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
PQ-28 Application Section
Circuit Description
The PQ-28 consists of an Input filter to interface with MIL-
STD-1275B. See Fig. 1. The next section of the circuit is
a DC/DC converter with an integral output filter. For input
voltages of 11V up to about 40V, the DC/DC follows the
input voltage in a semi-regulated mode, where the output
voltage will reduce as the output power is increased. At
about 40V input and higher the output will be regulated
to 36V nominal.
A typical application, Figure 3. shows a PQ-28 driving a
HEW DC/DC converter. A Bus Capacitor is required at
the output of the PQ-28. Suggested types or equivalent
as shown in the table.
Figure 3. TYPICAL APPLICATION
Nippon Chemi-Con 100µF, 100V, ESR=0.15Ω,
Aluminum Radial Thru Hole,
EXLV101__101MK20S
NIC Components 100µF 100V, ESR=0.17Ω,
Aluminum Surface Mount
NACK101M100V16x17TR13F
Input Reverse Polarity Protection
Input Reverse Polarity Protection is achieved by the
internal TVS diode which is part of the Input Filter (see
Fig. 1, Block Diagram). If the Input is connected in the
reverse polarity then the TVS diode provides a low
impedance path to blow the external input fuse.
The fuse rating should be about 130% of the nominal
running current. If the application has too wide an input
current range, then the designer should consider using
an external series diode to provide the Input Reverse
Polarity Protection.
Derating
The output power derating graph is shown in Fig. 4.
The full 200W ouput is available over the range of 20
to 75V input. The output in the dashed area is limited to
a 10 second ON time at a 1% duty cycle. At the lower
input voltages the power loss is due to copper loss,
while at the higher input voltages the power loss is due
to the switching losses. At 11V input the output is semi-
regulated and reduces as the load is increased, see fig.
5 & 6. To have 200W output at 11V input requires a load
of about 25A, and the output voltage will be drifting lower
during the test as the internal components heat up.
Sufficient heatsinking is required to keep the baseplate
below the 100ºC specification.
Figure 4. Derating Curve
CBAM™ PQ-28
5
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
Performance Data
Figs. 5, 6 & 7 show the output voltage for various input
voltages and loads. Fig. 8 shows Efficiency vs. Input
Voltage. Note that with 11V input to the PQ-28, it can
handle an HEW with up to about a 75W output load.
For higher power loads on the HEW, the PQ must have
higher input voltages so that the input to the HEW does
not drop below it’s UVLO dropout of 9V.
8
11
14
17
20
23
26
29
32
35
38
11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101
INPUT (VDC)
OUTPUT (VDC)
200W
NO LOAD
100W
50W
8
9
10
11
12
13
14
15
16
11 12 13 14 15 16
OUTPUT (VDC)
NO LOAD 50W 100W
150W 200W
8
10
12
14
16
18
20
22
24
26
28
30
32
34
0 50 100 150 200
POWER OUT (W)
OUTPUT (VDC)
24Vin 28Vin
11Vin 12Vin
15Vin 20Vin
30Vin 35Vin
Figure 5. Output (V) vs Input Voltage (V)
11V to 100V Input for various power out levels
Figure 6. Output (V) vs Input Voltage (V)
11V to 16V Input for various power out levels
Figure 7. Output (V) vs Power (W)
over 11-35V input range
80%
82%
84%
86%
88%
90%
92%
94%
96%
98%
100%
11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101
INPUT (VDC)
EFFICIENCY (%)
50W
100W
200W
Figure 8. Efficiency (%) vs. Input (V) for
various loads.
CBAM™ PQ-28
6
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 11. Negative 250V Spike
Voltage Surges Imported into EDUT
The MIL-STD-1275B calls for the input to surge up to
+100V which is the Single Fault value. This will not
harm the PQ-28 as it is rated for 100V input. Figure 12
shows the Surge Test Setup. The PS MAIN power supply
supplies the normal 28VDC to the PQ-28 input. The PS
Surge power supply is set to 100V and when the FET
SWITCH is closed, the +IN of the PQ-28 will go to +100V.
The diodes isolate the 2 power supplies.
Note that MIL-STD-1275B calls out for a 1ms rise or
fall time. Significantly faster rises (shorter rise time) will
cause the output of the PQ-28 to overshoot more than
shown. The fall time of the Calex tester could no be
reduced to less than the 3 1/2 ms shown.
Figure 12. Surge Test Setup
MIL-STD-1275B Testing
Testing to MIL-STD-1275B was done using non-certified
Calex in-house designed and built testers. The test circuits
provide stresses to the PQ-28 that are comparable to
those indicated in the MIL-STD-1275B.
Spikes Imported Into EDUT
The PS MAIN power supply provides the steady state DC
voltage to the PQ-28 input. The PS SPIKE power supply
charges a 0.47µF capacitor to a selectable +250V or
-250V, which stores the 15mJ energy required for the test.
±250V pulses are the Single Fault values. The capacitor
is then switched onto the PQ-28 Input. The input circuit
of the PQ-28 contains about 3.5µF of ceramic capacitors,
which reduces the transferred voltage to about a 25V
change at the PQ-28 Input. Figure 9 shows the Spike
Test Setup.
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 10. Positive 250V Spike
Figure 9. Spike Test Setup
CBAM™ PQ-28
7
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 13. Positive slope input
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 14. Negative slope input
Ripple Voltage Imported into EDUT
The MIL-STD-1275B single fault condition calls out for a
±7V signal over the frequency range of 50Hz to 200kHz
to be superimposed onto the DC Input voltage. Several
testing problems arise. At about 8-10kHz the input is a
low impedance due to the series resonance of the internal
inductor and output capacitors. At 200kHz the input is a
low impedance due to the internal input capacitor array.
The problem is to find a generator that can supply the
current at the required voltage and frequency. The Calex
tester could only produce a ±1.3V signal at the series
resonance of 8-10kHz which resulted in a ±7A into the
PQ-28 input. If a generator with a ±7V is available,
it would have to be capable of supplying ±37A. Not a
simple task.
At 200kHz the input of the PQ-28 is the internal capacitor
array of 4.3µF which equates to 0.18Ω. This would
require a generator with a ±38A capability at ±7V. The
Calex tester could only produce a ±0.8V at the PQ-28
input.
Figure 15. Ripple Tester Block Diagram
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 16. 50Hz Ripple Signal
CBAM™ PQ-28
8
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
5/7/12
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 17. 1kHz Ripple Signal
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 18. 12kHz Ripple Signal
Adding an EMI filter in to the PQ-28
Input.
The EFIL-28 is not designed to meet the requirements of
MIL-STD-1275B. Consult the factory for information on
adding an EMI Filter.
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 19. 48kHz Ripple Signal
28VDC Input, CBus=100µF, 24S12.12HEW
Output load = 8A.
CH1: PQ Input CH2: PQ Output
CH3: HEW Output
Figure 20. 200kHz Ripple Signal