Hi-Rel DC/DC CONVERTER MGDM-26 : 25W POWER Hi-Rel Grade Single Output Metallic Case - 1.500 VDC Isolation * 28Vdc input compliant with MIL-STD-704 D/E * Nominal power up to 25 W * Wide temperature range : -40C/+105C case * High efficiency (typ. 83%) * Soft start * Galvanic isolation 1.500 VDC * Synchronizable, load sharing and N+1 redundancy * Integrated LC EMI filter * No load to full load operation * Permanent short circuit protection * No optocoupler for high reliability * RoHS or Leaded process option 1-General The MGDM-26 series is a complete line of DC/DC power modules designed for aerospace, military and high-end industrial applications. These modules use a high frequency fixed swiching technic at 1MHz providing excellent reliability, low noise characteristics and high power density. Standard models are available with standard input voltage range of 9-36 or 16-40 volts. The series include single output voltage choices of 3,3, 5, 12, 15 volts. The MGDM-26 series include synchronization and load sharing functions. The synchronization function allows to synchronize more than one converter to one frequency or an external source frequency. The load sharing allows parallel operation to increase power with a true N+1 redundancy. All the modules are designed with LC network filters to minimize reflected input current ripple and output voltage ripple. The modules include a soft-start, an input undervoltage lock-out and a permanent short circuit protection to ensure efficient module protections. The soft-start allows current limitation and eliminates inrush current during start-up. The short circuit protection completely protects the modules against short-circuits of any duration by a shut-down and restores to normal when the overload is removed. The design has been carried out with surface mount components and is manufactured in a fully automated process to guarantee high quality. The modules are potted with a bicomponent thermal conductive compound and package in a metallic case to ensure the module's integrity under high environmental conditions. 2-Product Selection Single output model : MGDS - 26 - input output Input Voltage Range Permanent Transient H : 9-36 VDC J : 16-40 VDC 40 VDC/100 ms * 50 VDC/100 ms * / option suffix Output B : 3.3 VDC C : 5 VDC E : 12 VDC F : 15 VDC * Consult factory Options : /T : option for -55C start up operating temperature /S : option for screening and serialization Suffix : nothing : RoHS process -L : leaded process (available in N. America) REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC99-041.01/10 Revision I For locations, phone, fax, E-Mail see back cover 4 Hi-Rel Grade MGDM-26 Series 2- Product Selection (continued) Input range Output Current Reference Options Suffix 9-36 9-36 9-36 9-36 VDC VDC VDC VDC 3,3 VDC 5 VDC 12 VDC 15 VDC 6A 5A 2,08 A 1,65 A MGDS-26-H-B MGDS-26-H-C MGDS-26-H-E MGDS-26-H-F /T /T /T /T , , , , /S /S /S /S -, -, -, -, -L -L -L -L 16-40 16-40 16-40 16-40 VDC VDC VDC VDC 3,3 VDC 5 VDC 12 VDC 15 VDC 6A 5A 2.08 A 1,65 A MGDS-26-J-B MGDS-26-J-C MGDS-26-J-E MGDS-26-J-F /T /T /T /T , , , , /S /S /S /S -, -, -, -, -L -L -L -L 4 Converter Selection Chart MGDS - 26 - J - C / T - L Number of Outputs : S : single output Input voltage range : H : 9-36 VDC J : 16-40 VDC Output voltage : See table page 1 Option : /T : -55C start up operation /S : screening & serialization (consult application note screening grades) Suffix : nothing : RoHS process -L : Leaded process (available in N. America) (c) Gaia Converter FC99-041.01/10 Revision I 2 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 3- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Input Nominal input voltage Permanent input voltage range (Ui) Transient input voltage Undervoltage lock-out (UVLO) Start up time Reflected ripple current Input current in short circuit mode (Average) No load input current Input current in inhibit mode Output Output voltage Set Point accuracy Output power Output current * 3,3V output 5V output 12V output 15V output Ripple output voltage 3,3V and 5V output 12V output 15V output Line regulation Load regulation Output Voltage Trim Efficiency Maximum admissible Capacity load 3,3V output 5V output 12V output 15V output Conditions Limit or typical Units Full temperature range Nominal Full temperature range Full load (Consult factory) Turn-on voltage Turn-off voltage Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Ui nominal Short-circuit Ui nominal No load Ui nominal Inhibit Full temperature range Ui min. to max. 75% load Ambient temperature : 25c Ui nominal, 75% load Full temperature range Ui min. to max. Full temperature range Ui min. to max. Ui nominal Full load BW = 20MHz Ui min. to max. Full load Ui nominal No load to full load As function of output voltage Ui nominal Full load Full input voltage range Full load Per output Single Output MGDS-26 26 - H 26 - J VDC 20 28 Min. - Max. VDC 9-36 16-40 Maximum Nominal Nominal VDC/S VDC VDC 40/0,1 8,5 7,5 50/0,1 15,5 14,5 Maximum ms 30 30 Maximum mApp 50 50 Maximum mA 35 35 Maximum mA 35 35 Maximum mA 25 25 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 3,3 5 12 15 3,3 5 12 15 Maximum % +/- 2 +/- 2 Maximum W 25 25 Maximum Maximum Maximum Maximum A A A A 6 5 2,1 1,65 6 5 2,1 1,65 Maximum Maximum Maximum mVpp mVpp mVpp 50 50 60 50 50 60 Maximum % +/- 1 +/- 1 Maximum % +/- 2 +/- 2 Minimum Maximum % % - 20 + 10 - 20 + 10 Typical % Maximum Maximum Maximum Maximum F F F F 4 See on page 4 4.700 1.000 330 250 4.700 1.000 330 250 Note * : For 9-36V input range, the current is derated of 80% at 9V and increases linearly to full current at 12V. (c) Gaia Converter FC99-041.01/10 Revision I 3 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-26 Series 3- Electrical Characteristics (continued) Figure 1 : Typical efficiency versus load at various input 86 Figure 2 : Typical efficiency versus load at various input 85 82 78 74 input 36V 70 input 20V Efficiency (%) Efficiency (%) 82 input 9V 66 5 10 76 input 36V 73 input 20V input 9V 70 20 Output Power (W) 79 5 25 Figure 3 : Typical efficiency versus load at various input 84 Efficiency (%) Efficiency (%) 25 (MGDS-26-H-E module) 86 80 77 input 40V 74 input 28V input 16V 71 6.25 12.5 Output Power (W) 82 input 40V 80 input 28V 78 input 16V 76 18.75 6.25 25 86 86 84 84 Efficiency (%) 88 input 40V input 28V 80 input 16V 78 18.75 25 (MGDS-26-J-C module) 4 Figure 6 : Typical efficiency versus load at various input 88 82 12.5 Output Power (W) (MGDS-26-J-B module) Figure 5 : Typical efficiency versus load at various input Efficiency (%) 20 Figure 4 : Typical efficiency versus load at various input 83 input 40V 82 input 28V 80 input 16V 78 76 76 6.25 12.5 Output Power (W) 18.75 6.25 25 3,40 5,10 Output Voltage (VDC) 5,15 3,30 input 28V 3,25 3,20 0 8,5 Output Power (W) (c) Gaia Converter FC99-041.01/10 Revision I 16,5 25 (MGDS-26-J-B module) 18.75 25 (MGDS-26-J-F module) Figure 8 : Typical load regulation characteristics at nominal input 3,45 3,35 12.5 Output Power (W) (MGDS-26-J-E module) Figure 7 : Typical load regulation characteristics at nominal input Output Voltage (VDC) 10 Output Power (W) (MGDS-26-H-C module) 5,05 5,00 input 28V 4,95 4,90 0 8,5 Output Power (W) 16,5 25 (MGDS-26-J-C module) 4 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-26 Series 4- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load Nominal, fixed 1 MHz Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output Input to case Output to case Minimum Minimum Minimum 1.500 VDC / 1 min 500 VDC / 1 min 1.500 VDC / 1 min Isolation resistance 500 VDC Minimum 100 MOhm 5- Isolation 6- Protection Functions Characteristics Protection Device Recovery Limit or typical Specifications Input undervoltage lock-out (UVLO) Turn-on, turn-off circuit with hysteresis cycle Automatic recovery Turn-on nominal Turn-off nominal See section 3 Output short circuit protection (SCP) Hiccup circuitry with auto-recovery Automatic recovery Permanent See section 11 4 7- Reliability Data Characteristics Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR (c) Gaia Converter FC99-041.01/10 Revision I Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 85C 750.000 Hrs 300.000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40C Case at 85C 410.000 Hrs 185.000 Hrs Avionics Military Cargo / Consult factory 5 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 8- Electromagnetic Interference Electromagnetic Interference requirements according to MIL-STD-461C/D/E standards can be easily achieved as indicated in the following section. The following table resumes the different sections covered by these standards. MIL-STD-461C Standard MIL-STD-461D/E Standard Conducted emission (CE) : Low frequency High frequency CE 01 CE 03 CE 101 CE 102 compliant module stand-alone compliant with additionnal filter Conducted susceptibility (CS) : Low frequency High frequency CS 01 CS 02 CS 101 CS114 compliant with additionnal filter compliant with additionnal filter Radiated emission (RE) : Magnetic field Electrical field RE 01 RE 02 RE 101 RE 102 compliant module stand-alone compliant module stand-alone Radiated susceptibility (RS) : Magnetic field Electrical field RS 01 RS 03 RS 101 RS 103 compliant module stand-alone compliant module stand-alone Standard Requirements Compliance with GAIA Converter Module & common mode capacitance 4 8-1 Module Compliance with MIL-STD-461C/D/E Standards To meet the latest US military standards MIL-STD-461D/E (and also the MIL-STD-461C) requirements and in particular the conducted noise emission CE102 (and also CE03) requirements, Gaia Converter can propose a stand-alone ready-to-use EMI filter module. This EMI filter module has to be used together with a common mode noise capacitance C c (10nF/rated voltage depending on isolation requirement) connected between Gin and Gout. EMI Filter module reference : FGDS-2A-50V. Please consult EMI filter datasheet for further details. VI Vo EMI input Filter GI Go Vo VI MGDM-series GI Go Cc (c) Gaia Converter FC99-041.01/10 Revision I 6 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 9- Thermal Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Characteristics Ambient temperature * Minimum Maximum - 40C + 85C Operating case temperature range at full load Case temperature Minimum Maximum - 40C + 105C Storage temperature range Non functionning Minimum Maximum - 55C + 125C Thermal resistance Rth case to ambient in free air natural convection Typical 7C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105C. The MGDM-26 series operating case temperature must not exceed 105C. The maximum ambient temperature admissible for the DC/DC converter corresponding to the maximum operating case temperature of 105C depends on the ambient airflow, the mounting/orientation, the cooling features and the power dissipated. To calculate a maximum admissible ambient temperature the following method can be used. Knowing the maximum case temparature Tcase = 105C of the module, the power used Pout and the efficiency : * determine the power dissipated by the module Pdiss that should be evacuated : - 1) Pdiss = Pout(1/ * determine the maximum ambient temperature : Ta = 105C - Rth x Pdiss where Rth is the thermal resistance from the case to ambient. 4 The previous thermal calculation shows two areas of operation : * a normal operation area in a free natural ambient convection (grey area in this following graph), * an area with cooling features (air flow or heatsink) ensuring a maximum case temperature below the maximum operating case temperature of 105C (white area in the following graph). Power (W) 100% Additionnal cooling operation area 75% 50% Natural convection operation area 25% 10 20 30 40 50 60 70 80 90 100 110 Temperature (C) Full load ambient temperature without derating : 85C Maximum case temperature : 105C Maximum storage temperature : 125C (c) Gaia Converter FC99-041.01/10 Revision I 7 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 10- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Duration Temperature / status of unit Test D : 1.000 Hrs @ 105C case, unit operating @ 125C ambient, unit not operating MIL-STD-202G Method 108A Altitude Altitude level C Duration Climb up Stabilization Status of unit 40.000 ft@-55C 30 min. 1.000 ft/min to 70.000 f@-55C, 30 min. unit operating MIL-STD-810E Method 500.3 Humidity cyclic Number of cycle Cycle duration Relative humidity variation Temperature variation Status of unit 10 Cycle I : 24 Hrs 60 % to 88 % 31C to 41C unit not operating MIL-STD-810E Method 507.3 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40C 56 days unit not operating MIL-STD-202G Method 103B Salt atmosphere Temperature Concentration NaCl Duration Status of unit 35C 5% 48 Hrs unit not operating MIL-STD-810E Method 509.3 Temperature cycling Number of cycles Temperature change Transfert time Steady state time Status of unit 200 -40C / +85C 40 min. 20 min. unit operating MIL-STD-202A Method 102A Temperature shock Number of shocks Temperature change Transfert time Steady state time Status of unit 100 -55C / +105C 10 sec. 20 min. unit not operating MIL-STD-202G Method 107G Climatic Qualifications Life at high temperature 4 Mechanical Qualifications Vibration (Sinusoidal) Number of cycles Frequency / amplitude Frequency / acceleration Duration Status of unit 10 cycles in each axis 10 to 60 Hz / 0.7 mm 60 to 2000 Hz / 10 g 2h 30 min. per axis unit not operating MIL-STD-810D Method 514.3 Shock (Half sinus) Number of shocks Peak acceleration Duration Shock form Status of unit 3 shocks in each axis 100 g 6 ms 1/2 sinusoidal unit not operating MIL-STD-810D Method 516.3 Bump (Half sinus) Number of bumps Peak acceleration Duration Status of unit 2000 bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 516.3 (c) Gaia Converter FC99-041.01/10 Revision I 8 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 11- Description of Protections 11-1 Input Undervoltage Lock-out (UVLO) An input undervoltage protection will inhibit the module when input voltage drops below the lock-out turn-off threshold (see section 3 for value) and restores to normal operation automatically when the input voltage rises the lock-out turn-on threshold. On Off UVLO UVLO Turn-off Turn-on 11-2 Output Short Circuit Protection (SCP) The short circuit protection device protects the module against short circuit of any duration and restores the module to normal operation when the short circuit is removed. It operates in hiccup mode by testing periodically if an overload is applied (typically every 1s recovery time). The overload detection threshold is typically 200% of maximum current with a detection time lower than 5ms. Vin Vo (%) 100 detection time x time recovery time recovery time 4 (c) Gaia Converter FC99-041.01/10 Revision I 9 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-26 Series 12- Description of Functions 13-1 Trim Function The primary output voltage Vo may be trimmed at -20%/ +10% via a single external trimpot or fixed resistor. The trimpot should be connected as shown in figure hereafter. Value of the trim resistance is given in the following table. 1 VI +Vo 0 Share S+ 4 Cont Vo P1 Value 3,3 V 4,7 KOhm 5V 10 KOhm 12 V 12 KOhm 15 V 22 KOhm MGDS26 3 Case 6 5 Trim 7 S- 2 GI Go 1 VI +Vo P1 Load 9 8 For other Vo1 Output value consult Factory 12-2 Sense Function If the load is separated from the output by any line lenght, some of these performance characteristics will be degraded at the load terminals by an amount proportional to the impedance of the load leads. Sense connections enable to compensate the line drop at a maximum of +/-10% of output voltage. Connection is described in figure herein. S+ 0 Share 4 Cont MGDS26 3 Case 5 Trim 7 S- 2 GI 6 Go 9 8 4 12-3 On/Off Function The control pin 4 (On/Off) can be used for applications requiring On/Off operation. This may be done with an open collector transistor, a switch, a relay or an optocoupler. Several converters may be disabled with a single switch by connecting all On/Off pins together. * The converter is disabled by pulling low the pin 4. * No connection or high impedance on pin 4 enables the converter. By releasing the On/Off function, the converter will restart within the start up time specifications given in table section 3. For further details please consult `'Logic On/Off'' application note. On/Off Command GI 1 VI S+ 5 +Vo 6 0 Share 4 Cont 12-4 Synchronization Function MGDS26 3 Case The MGDM-26 series provide a bi-directionnal synchronization function trough pin 4 (CONT) to enable automatic synchronisation between several converters. The converters lock into the highest switching frequency if more than one converter is used or on an external clock for a frequency in the range between 105% and 115% of the converter's free frequency. Trim 7 Go 8 2 GI S- 9 1 VI S+ 5 +Vo 6 0 Share 4 Cont On/Off 3 Case 2 GI (c) Gaia Converter FC99-041.01/10 Revision I Load MGDS26 Trim 7 Go 8 S- 9 10 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-26 Series 13- Application Notes 13-1 Connection of Modules in Series The output of single output units can be connected in series without any precautions to provide higher output voltage level. Nevertheless, GAIA Converter recommends to protect each individual output by a low power shottky diode rated with the maximum current of the converter to avoid reverse polarity at any output. Reverse polarity may occur at start up if the output voltages do not rise at the same time. 1 VI +Vo 0 Share S+ 4 Cont MGDS26 3 Case SGo 1 VI +Vo 0 Share S+ MGDS26 3 Case 9 8 6 5 Trim 7 S- 2 GI 5 Trim 7 2 GI 4 Cont 6 Go 9 8 4 13-2 Connection of Modules in Parallel The MGDM-26 series features parallel (load sharing) operations to increase output power with a true N+1 redundancy. Up to 4 converters can be parallelized through the "SHARE" pins as described in the following schematic 1 VI +Vo S+ 0 Share 4 Cont MGDS26 S- +Vo S+ 0 Share MGDS26 S- (c) Gaia Converter FC99-041.01/10 Revision I 6 5 Trim 7 3 Case 2 GI 9 Go 8 1 VI 4 Cont 5 Trim 7 3 Case 2 GI 6 9 Go 8 11 For locations, phone, fax, E-Mail see back cover MGDM-26 Series Hi-Rel Grade 14- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 65 grams (2.3 Ozs) max. 3,05 (0.12) 15,39 +/-0,4 (0.6 +/-0.015) 0,5 (0.019) 45,7 (1.8) R2 10,5 (0.41) ,4 ) .1 (0 5,08 5,08 5,08 5,08 12,86 +/-0,4 (0.2) (0.2) (0.2) (0.2) (0.5) 51,1 (2.00) 2,69 (0.106) 5,08 5,08 5,08 5,08 (0.2) (0.2) (0.2) (0.2) 3,05 (0.12) 4 x mouting threaded holes M3 51,1 (2.00) 5,5 +1,5/-1 (0.22) +/-1 Pin 3 : round pin O 0,83 mm (0.032") length : 4 mm +1,5/-1 All other pins : square pin 0,91mm (0.036") length : 5,5 mm 4 15- Materials Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 16- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference : MGDx-26-X-Y. Date code : year and week of manufacturing, suffix, /option. 17- Connections 5 6 0 7 1 8 2 Pin 9 3 4 Single Output 0 Share 1 + Input (Vi) 2 - Input (Gi) 3 Case 4 Control (Cont) 5 Sense + (S+) 6 + Output (Vo) 7 Trim (Trim) 8 - Output (Go) 9 Sense - (S-) Bottom view (c) Gaia Converter FC99-041.01/10 Revision I 12 For locations, phone, fax, E-Mail see back cover International Headquarters GAIA Converter - France ZI de la Morandiere 33185 LE HAILLAN - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAIA Converter Canada, Inc 4038 Le Corbusier Blvd LAVAL, QUEBEC - CANADA H7L 5R2 Tel. : (514)-333-3169 Fax : (514)-333-4519 Represented by : Information given in this datasheet is believed to be accurate and reliable. However, no responsibility is assumed for the consequence of its use nor for any infringement of patents or other rights of third parties which may result from its use. These products are sold only according to GAIA Converter general conditions of sale, unless otherwise confirmed by writing. Specifications subject to change without notice. Printed in France by GAIA Converter FC99-041.01/10 Revision I Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :