Hi-Rel DC/DC CONVERTER MGDM-150 : 150W POWER Hi-Rel Grade 5:1 Low Input Voltage : 9-45 & 16-80 VDC Single Output Metallic case - 1 500 VDC Isolation * Ultra wide input range 16-80 Vdc, 9-45 Vdc * 28Vdc input compliant with MIL-STD-704A/D/F * Industry standard half brick package * Power up to 150 W * Wide temperature range : -40/+105C baseplate * High efficiency (typ. 86%-90%) * Soft start 1-General * Galvanic isolation 1 500 VDC * Integrated LC EMI filter * Synchronizable * Load sharing, N+1 redundancy * No load to full load operation * Fully protected by independant security * Under & overvoltage lock-out * Overvoltage protection * Current limitation protection * Over temperature protection * No optocoupler for high reliability * Leaded process The MGDM-150 low input voltage series is a complete line of high density wide input range DC/DC power modules designed for aerospace, military and high-end industrial applications. These modules use a patented fixed switching topology at 420 KHz providing ultra wide input range, low noise characteristics and high power density. Standard models are available with ultra wide input voltage range of 9-45, 16-80 volts. The series include single output voltage choices of 3,3, 5, 12, 15, 24, 28 volts. The MGDM-150 low input voltage series include synchronization load sharing, trim and sense 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. All the modules are designed with LC network filters to minimize reflected input current ripple and output voltage ripple. The modules have totally independant security functions including input undervoltage and overvoltage lock-out, output overvoltage protection, output current limitation protection, and temperature protection. Additionnally a soft-start function allows current limitation and eliminates inrush current during start-up. The design has been carried out with surface mount components, planar transformer and is manufactured in a fully automated process to guarantee high quality. The modules are potted with a bi-component thermal conductive compound and used an insulated metallic substrate to ensure optimum power dissipation under harsh environmental conditions. 2-Product Selection Single output model : MGDS - 150 - input output / option suffix Input Voltage Range Permanent H : 9-45 VDC O : 16-80 VDC Options : /T : option for -55C start up operating temperature /S : option for screening and serialization Output B C E F I J : : : : : : Suffix : -L : leaded process REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC02-009.12/13 Revision RS 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC For locations, phone, fax, E-Mail see back cover 4 Hi-Rel Grade MGDM-150 Low Input Series 2- Product Selection (continued) Input range Output Current Reference Options Suffix 9-45 9-45 9-45 9-45 9-45 9-45 VDC VDC VDC VDC VDC VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 30 A 25 A 12,5 A 10 A 6,25 A 5,35 A MGDS-150-H-B MGDS-150-H-C MGDS-150-H-E MGDS-150-H-F MGDS-150-H-I MGDS-150-H-J /T /T /T /T /T /T , , , , , , /S /S /S /S /S /S -L -L -L -L -L -L 16-80 16-80 16-80 16-80 16-80 16-80 VDC VDC VDC VDC VDC VDC 3.3 VDC 5 VDC 12 VDC 15 VDC 24 VDC 28 VDC 30 A 30 A 12,5 A 10 A 6,25 A 5,35 A MGDS-150-O-B MGDS-150-O-C MGDS-150-O-E MGDS-150-O-F MGDS-150-O-I MGDS-150-O-J /T /T /T /T /T /T , , , , , , /S /S /S /S /S /S -L -L -L -L -L -L 4 Converter Selection Chart M G D S - 150 - O - C / T - L Number of Outputs : S : single output Input voltage range : H : 9-45 VDC O : 16-80 VDC Output voltage : See table page 1 Option : /T : -55C start up operation /S : screening & serialization (consult application note screening grades) Suffix : -L : Leaded process (c) Gaia Converter FC02-009.12/13 Revision S 2 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 3- Block Diagram The MGDM-150 low input series DC/DC converter is based on a constant 420KHz pulse-width modulated forward topology designed for ultra large input range. As this auxilliary power is independent from the main power supply, the module features an extreme wide trim windows from 10% to 110% of the nominal output voltage. The output voltage is monitored on the secondary side avoiding the use of optocoupler to optimize long-term reliability and provide good immunity against radiations. The main power transformer designed for more than 150W power is a multi-layer planar transformer which allows 100% reproductibility for optized module efficiencies. An auxilliary supply is implemented to feed independently all security functions such as the input undervoltage lock-out (UVLO), overvoltage lock-out (OVLO), the output overload protection (OCP), the output overvoltage protection (OVP) and the thermal protection (OTP). The controlled feedback regulation is located at the secondary side allowing a high regulation bandwidth and a very fast response to load changes. 4 (c) Gaia Converter FC02-009.12/13 Revision S 3 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 4- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Conditions Limit or typical Units Full temperature range Nominal Full temperature range Single Output MGDS-150 150 - H 150 - O VDC 24 28 Min. - Max. VDC 9 - 45 16 - 80 Maximum VDC/min. 50/1 100/1 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 8,5 7,5 45 46 15,5 14,5 80 81 Maximum ms 30 30 Maximum mApp 200 500 Typical A 1 1 Maximum mA 30 30 Maximum mA 15 15 Nominal Nominal Nominal Nominal Nominal Nominal VDC VDC VDC VDC VDC VDC 3,3 5 12 15 24 28 3,3 5 12 15 24 28 Maximum % +/- 2 +/- 2 Maximum W 100 to 150 100 to 150 Full temperature range Ui min. to max. Maximum Maximum Maximum Maximum Maximum Maximum A A A A A A 30 25 12,5 10 6,25 5,35 30 30 12,5 10 6,25 5,35 Ui nominal Full load BW = 20MHz Typical Typical Typical Typical mVpp mVpp mVpp mVpp 50 100 150 250 50 100 150 250 Ui min. to max. 0% to full load Maximum % +/- 1 +/- 1 Output Voltage Trim As function of output voltage Minimum Maximum % % 10 ** 110 10 ** 110 Efficiency Ui nominal Full load Typical % Input Nominal input voltage Permanent input voltage range (Ui) Input surge withstand Undervoltage lock-out (UVLO) Overvoltage lock-out (OVLO) 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 24V output 28V output Ripple output voltage *** 3,3V and 5V output 12V output 15V output 24V and 28V output Output regulation * (Line + load + thermal) Above OVLO converter Turns - off Turn-on voltage Turn-off voltage Turn-on voltage Turn-off voltage Ui nominal Nominal output Full load : resistive Ui nominal, full load BW = 20MHz Ui nominal Short-circuit Ui nominal No load Ui nominal Inhibit Ui min. to max. Ambient temperature : +25c Ui nominal, 75% load At 105c baseplate Ui min. to max. 4 see curves page 5 and 6 Note * : These performances are measured with the sense line connected.. Note ** : It is recommended to mount the converter on a heatsink for this test, see section 10-3 and 10-9 for further details. Note *** : The ripple output voltage is the periodic AC component imposed on the output voltage, an aperiodic and random component (noise) has also to be considered. This noise can be reduced by adding 4 external decoupling capacitors connected between inputs and case and between outputs and case. These capacitance should be layed-out as close as possible from the converter. Please refer to page 8 for more details. (c) Gaia Converter FC02-009.12/13 Revision S 4 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 4- Electrical Characteristics (continued) MGDS-150-H-B - Efficiency vs Output Power MGDS-150-H-C - Efficiency vs Output Power 85,00% 90,00% 80,00% 85,00% 80,00% 75,00% 75,00% 70,00% Vin=9V Vin=24V Vin=45V 65,00% Vin=9V Vin=24V Vin=45V 70,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% 50,00% 10 20 30 40 50 60 70 80 90 100 10 30 50 Pout(W) 70 90 110 Pout(W) MGDS-150-H-E - Efficiency vs Output Power MGDS-150-H-F - Efficiency vs Output Power 90,00% 90,00% 85,00% 85,00% 80,00% 80,00% 75,00% 75,00% Vin=9V Vin=24V Vin=45V 70,00% 65,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% Vin=9V Vin=24V Vin=45V 70,00% 4 50,00% 10 30 50 70 90 110 130 150 10 30 50 Pout(W) 70 90 110 130 150 Pout(W) MGDS-150-H-I - Efficiency vs Output Power MGDS150-H-J - Efficiency vs Output Power 90,00% 90,00% 85,00% 85,00% 80,00% 80,00% 75,00% 75,00% Vin=9V Vin=24V Vin=45V 70,00% 65,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% Vin=9V Vin=24V Vin=45V 70,00% 50,00% 10 30 50 70 90 110 130 150 10 30 50 Pout(W) (c) Gaia Converter FC02-009.12/13 Revision S 70 90 110 130 150 Pout(W) 5 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 4- Electrical Characteristics (continued) MGDS150-O-B - Efficiency vs Output Power MGDS-150-O-C - Efficiency vs Output Power 85,00% 90,00% 80,00% 85,00% 80,00% 75,00% 75,00% 70,00% Vin=16V Vin=28V Vin=80V 65,00% Vin=16V Vin=28V Vin=80V 70,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% 50,00% 10 20 30 40 50 60 70 80 90 100 10 30 50 Pout(W) 70 90 110 130 150 Pout(W) MGDS-150-O-E - Efficiency vs Output Power MGDS-150-O-F - Efficiency vs Output Power 90,00% 90,00% 85,00% 85,00% 80,00% 80,00% 75,00% 75,00% Vin=16V Vin=28V Vin=80V 70,00% 65,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% Vin=16V Vin=28V Vin=80V 70,00% 4 50,00% 10 30 50 70 90 110 130 150 10 30 50 Pout(W) 70 90 110 130 150 Pout(W) MGDS-150-O-I - Efficiency vs Output Power MGDS-150-O-J - Efficiency vs Output Power 90,00% 95,00% 85,00% 90,00% 85,00% 80,00% 80,00% 75,00% Vin=16V Vin=28V Vin=80V 70,00% Vin=16V Vin=28V Vin=80V 75,00% 70,00% 65,00% 65,00% 60,00% 60,00% 55,00% 55,00% 50,00% 50,00% 10 30 50 70 90 110 130 150 10 30 50 Pout(W) (c) Gaia Converter FC02-009.12/13 Revision S 70 90 110 130 150 Pout(W) 6 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 5- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load Nominal, fixed 420 KHz 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 1 500 VDC / 1 min 1 500 VDC / 1 min Isolation resistance 500 VDC Minimum 100 MOhm 6- Isolation 7- 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 4 Input overvoltage lock-out (OVLO) Turn-on, turn-off circuit with hysteresis cycle Automatic recovery Turn-on nominal Turn-off nominal See section 4 Output current limitation protection (OCP) Foldback current limitation Automatic recovery Maximum 110% of output current Output overvoltage protection (OVP) Overvoltage protection device with latch-up Resetable Typical 115% to 135% of output voltage Over temperature protection (OTP) Thermal device with hysteresis cycle Automatic recovery Maximum 115C 4 8- 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 FC02-009.12/13 Revision S Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 85C 400 000 Hrs 130 000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40C Case at 85C 225 000 Hrs 82 000 Hrs Civilian avionics, calculators Ambient at 55C 100% time on 360 000 Hrs 7 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 9- 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 9-1 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 4 external decoupling capacitance C c (10nF/rated voltage depending on isolation requirement) connected between input and case and output and case. EMI filter module reference : FGDS-10A-50V or FGDS-20A-50V. Please consult EMI filter datasheet for further details. Cc VI Vo VI EMI input Filter GI Cc BP BP Vo MGDM-series Go GI Go BP BP Cc Cc BP: Base Plate (c) Gaia Converter FC02-009.12/13 Revision S 8 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 10- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Ambient temperature * Minimum Maximum - 40C see below Baseplate temperature Base plate temperature Minimum Maximum - 40C + 105C Storage temperature range Non functionning Minimum Maximum - 55C + 125C Thermal resistance Baseplate to ambient Rth(b-a) free air Typical 8C/W Note * : The upper temperature range depends on configuration, the user must ensure a max. baseplate temperature of + 105C. The following discussion will help designer to determine the thermal characteristics and the operating temperature. The MGDM-150 low input series maximum baseplate temperature at full load must not exceed 105C. Heat can be removed from the baseplate via three basic mechanisms : * Radiation transfert : radiation is counting for less than 5% of total heat transfert in majority of case, for this reason the presence of radient cooling is used as a safety margin and is not considered. * Conduction transfert : in most of the applications, heat will be conducted from the baseplate into an attached heatsink or heat conducting member; heat is conducted thru the interface. * Convection transfert : convecting heat t r a n s f e r into air refers to still air or forced air cooling. In majority of the applications, heat will be removed from the baseplate either with : * heatsink, * forced air cooling, * both heatsink and forced air cooling. To calculate a maximum admissible ambient temperature the following method can be used. Knowing the maximum baseplate temperature Tbase = 105C of the module, the power used Pout and the efficiency : * determine the power dissipated by the module Pdiss that should be evacuated : - 1) (A) Pdiss = Pout(1/ * determine the maximum ambient temperature : Ta = 105C - Rth(b-a) x Pdiss (B) where Rth(b-a) is the thermal resistance from the baseplate to ambient. This thermal Rth(b-a) resistance is the summ of : * the thermal resistance of baseplate to heatsink (Rth(b-h)). The interface between baseplate and heatsink can be nothing or a conducting member, a thermal compound, a thermal pad.... The value of Rth(b-h) can range from 0.4C/W for no interface down to 0.1C/W for a thermal conductive member interface. * the thermal resistance of heatsink to ambient air (Rth(h-a)), which is depending of air flow and given by heatsink supplier. 4 The table hereafter gives some example of thermal resistance for different heat transfert configurations. Heat transfert Thermal resistance heatsink to air Rth(h-a) No Heatsink baseplate only : Free air cooling only Forced air cooling 200 LFM Forced air cooling 400 LFM Forced air cooling 1000 LFM 8C/W Thermal resistance baseplate to heatsink (Rth-b-h) No need of thermal pad 8C/W Heatsink Thermalloy 6516B : 4,4C/W Bergquist Silpad* : 0,14C/W 4,54C/W Heatsink Fischer Elektronik SK DC 5159SA : 3,8C/W Bergquist Silpad* : 0,14C/W 3,94C/W No Heatsink baseplate only : 4,5C/W No need of thermal pad Heatsink Thermalloy 6516B : 3C/W Bergquist Silpad* : 0,14C/W 3,14C/W Heatsink Fischer Elektronik SK DC 5159SA : 2,5C/W Bergquist Silpad* : 0,14C/W 2,64C/W No Heatsink baseplate only : 3,2C/W No need of thermal pad Heatsink Thermalloy 6516B : 1,75C/W Bergquist Silpad* : 0,14C/W 1,89C/W Heatsink Fischer Elektronik SK DC 5159SA : 1,7C/W Bergquist Silpad* : 0,14C/W 1,84C/W No Heatsink baseplate only : 1,7C/W No need of thermal pad Heatsink Fischer Elektronik SK DC 5159SA : 0,9C/W Bergquist Silpad* : Fischer Elektronic and Thermalloy are heasink manufacturers. Silpad (c) is a registered trademark of Bergquist. Note* : Silpad performance are for Silpad 400 with pressure conditions of 50 Psi. Surface of MGDS-150 series is 5,5 inch2. (c) Gaia Converter FC02-009.12/13 Revision S Global resistance For locations, phone, fax, E-Mail see back cover 4,5C/W 3,2C/W 1,7C/W 0,14C/W 1,04C/W 9 MGDM-150 Low Input Series Hi-Rel Grade 9- Thermal Characteristics (continued) : Heatsink Mounting To mount properly the module to heatsink, some important recommendations need to be taken into account in order to avoid overstressing conditions that might lead to premature failures. The module case is built with a copper IMS (isolated metalic substrate ) crimped on an aluminum frame that provides case rigidity. The IMS surface is the module base plate that need to be reported to heat sink to achieve proper cooling. If for some reasons like poor module report, the IMS base plate is subject to mechanical overstress, module's electrical characteristics may be definitely affected. A typical example of damageable report is the use of thick thermal interface with usual screwing torque applied on mounting screws. This combination causes a high pressure on baseplate center due to thermal interface material compression. The final consequence is a slight IMS bending that can conduct for the module to fail high voltage isolation leading to heavy electrical damage on internal circuit. Base plate overstress Heatsink Too ThickThermal Pad PCB screw Poor report not recommended Example of banned thermal interface : Bergquist Gap Pad VO Ultra Soft The good practice is to respect the 4 following recommendations: - do not exceed recommended screwing torque of 0,7 N.m (6 lbs.in) Heatsink - prefer thin thermal pad with thickness lower than 0,34 mm (0.015"). GAIA Converter recommends to use thin thermal pads instead of thermal compound like grease. Thermal Pad - take care to reflow module leads only when all assembly operations are completed. PCB - do not report module on surfaces with poor screw flatness characteristics. GAIA Converter recommends not to overflow 0,1mm/m for the surface flatness. Example of recommended thermal interface : Bergquist Silpad 400 4 Gaia converter suggests to follow the procedure hereunder for the mechanical assembly procedure in order to avoid any stress on the pins of the converters. It is good practice to be sure to mount the converters first mechanically, then solder the units in place. 1. Choice of the thermal gap pad : its shape must be the same as the module. The dimensions of the gap pad can be a little larger than the module. 2. Screw the converter to the heatsink and/or to the board. The four screws have to be screwed in a "X" sequence. * Lightly finger-tighten all screws and run several X sequences before achieving final torque to get homogeneous tightening. * Torque screws from 0,35 N.m (3 lbs.in) to 0,7 N.m (6 lbs.in). 1 4 3 2 3. Screw the heatsink to the board. 4. Solder the pins of the converters on the board. This sequence avoids mechanical stresses on the converters that could lead to stress internal components or assemblies and cause their failures. (c) Gaia Converter FC02-009.12/13 Revision S 10 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 11- 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 ft@-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 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 2 000 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 2 000 Bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 516.3 Climatic Qualifications Life at high temperature 4 Mechanical Qualifications (c) Gaia Converter FC02-009.12/13 Revision S 11 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 12- Description of Protections The MGDM-150 low input series include 5 types of protection devices that are powered and controlled by a fully independant side power stage. 12-1 Input Undervoltage Lockout (UVLO) and Overvoltage Lockout (OVLO) 12-1-1 Undervoltage Lockout (UVLO) An undervoltage protection is implemented to lock off the converter as long as the input voltage has not reached the UVLO turn-on threshold (see section 4 for value) which is the minimum input voltage required to operate without damaging the converter. On 12-1-2 Overvoltage Lockout (OVLO) An overvoltage protection will inhibit the module when input voltage reaches the overvoltage lockout turn-off threshold (see section 4 for value) and restores to normal operation automatically when the input voltage drops below the overvoltage Lockout turn on threshold. 12-2 Output Over Current Protection (OCP) Off UVLO UVLO Turn-off Turn-on OVLO OVLO Turn-on Turn-off Vin Vout The MGDM-150 low input series incorporates a foldback current limit and protection circuit. When the output current reaches 110% of it's full-rated current (Icurrent limit), the output voltage falls and output current falls along the foldback line as described in the figure herein. The module restart automatically to normal operation when overcurrent is removed. Icurrent limit 110% of full rated current 12-3 Output Overvoltage Protection (OVP) 4 Iout Each circuit has an internal overvoltage protection circuit that monitors the voltage accross the output power terminals. It is designed to latch the converter off at 115% to 135% of output voltage. Once in OVP protection, the module will restart with the On/ Off function or with the input bus restart. 12-4 Over Temperature Protection (OTP) A thermal protection device adjusted at 115C (+/-5%) internal temperature with 10C hysteresis cycle will inhibit the module as long as the overheat is present and restores to normal operation automatically when overheat is removed. The efficiency of the OTP function is warranty with the module mounted on a heatsink. On Off 10c 115c (c) Gaia Converter FC02-009.12/13 Revision S Baseplate Temperature 12 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 13- Description of Functions 13-1 Trim Function The output voltage Vo may be trimmed in a range of 10%/110% of the nominal output voltage via a single external trimpot or fixed resistor. Trim Up Function BP 5 Vin Do not attempt to trim the module higher than 110% of nominal output voltage as the overvoltage protection may occur. Also do not exceed the maximum rated output power when the module is trimmed up. The trim up resistor must be connected to S+ pin. The trim up resistance must be calculated with the following formula : 4 Vo MGDM150 3 Share 7 Ru Error amp. 2 Sync 1 S+ On/Off 6 Trim 8 R1 R2 Vref= 2.5V 1F Load S- 9 Go 10 Gin Ru = R1 x (V0-Vref) x V0nom - R1 - R2 (V0-V0nom) x Vref Note : This formula is a reduced form of the real expression that gives an approached value. To get an accurate value, please use the trim calculator in our web site at www.gaia-converter.com/calculator.trimcalculation.php Trim Down Function 5 Vin Do not trim down more than -90% of nominal output voltage or 1 Vdc. The available output power is reduced by the same percentage that output voltage is trimmed down. The trim down resistor must be connected to S- pin. The trim down resistance must be calculated with the following formula : Rd = 4 BP Vo MGDM150 3 Share Error amp. 4 7 Trim 8 R1 Vref= 2.5V 2 Sync 1 S+ On/Off 6 Load R2 Rd 1F S- 9 Go 10 Gin (R2 + R1) x V0 - (R2 x V0nom) V0nom - V0 Note : This formula is a reduced form of the real expression that gives an approached value. To get an accurate value, please use the trim calculator in our web site at www.gaia-converter.com/calculator.trimcalculation.php 5 Vin 4 R1 Vref= 2.5V 1 6 7 Ru Error amp. 2 Sync The output voltage is given by the following formula : V0 = (1 + R1 x (Vcont - 1) ) x V0nom (R1 + R2) Vref S+ On/Off 3 Share Trim via a voltage Vo MGDM150 Trim 8 R2 1F 100nF Vcontrol S- 9 Go 10 Gin Parameter Unit Min. Typ. Max. Trim reference Vdc 2,45 2,5 2,55 Resistor R1 Ohm / 3800 / Resistor R2 Ohm / 270 / F / 1 / Trim capacitor (c) Gaia Converter FC02-009.12/13 Revision S Load BAT54 13 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 13- Description of Functions (continued) 13-2 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. The overvoltage protection will be activated and module will shut down if remote sense tries to boost output voltage above 110% of nominal output voltage. Connection is described in figure herein. 5 Vin 4 BP S+ 7 On/Off 3 Share MGDM150 2 Sync 1 Vo 6 Trim 8 Load S- 9 Go Gin 10 13-3 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 4. For further details please consult `'Logic On/Off'' application note. 5 Vin Vi 4 MGDM150 2 Sync 1 Gi Vo 6 S+ 7 On/Off 3 Share On/Off BP Trim 8 Load S- 9 Gin Go 10 4 Parameter Unit Min. Typ. Max. Notes, conditions On/Off module enable voltage Vdc 3.5 / 4 On/Off module disable voltage Vdc 0 / 0.5 The switch must be able to sink 1mA On/Off alarm level Vdc 0 / 0.5 UVLO, OVLO, OVP, OTP, faulty module On/Off module enable delay ms / / 30 The module restarts with the same delay after alarm mode removed On/Off module disable delay s / / 100 Vi nominal, full load Open, the switch must not sink more than 100A 13-4 Synchronization Function An external clock with rectangular Pull Up signals can be used to lock one or more converters. The external clock signal should have a frequency range from 860KHz to 940KHz, a low level below 0,5V a high level of 4V (+/-0.5V), a rise time of 30 ns max. and a drop time of 100ns max. 5 Vin Vi 4 100pF Vsync 2 Sync Totem pole output 4V +/- 0,5 1N4148 4.7k Gi 0V 30ns max 1 Gin Vo 6 S+ 7 On/Off 3 Share Ext. clock BP MGDM150 Trim 8 Load S- 9 Go 10 Vin T/2 100ns max (c) Gaia Converter FC02-009.12/13 Revision S T ( 860Khz < F < 940Khz ) 14 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade MGDM-150 Low Input Series 14- Application Notes 14-1 Synchronization of Modules 10nF 10nF BP The MGDM-150 low input series provides a synchronization function trough the pin 2 (Synchro) to enable automatic synchronisation between several converters. If several converters are used, they lock themselves into the highest switching frequency. The synchronization signal available on pin 2 is referenced to ground in (Gi) and the signal shape is the double of the switching frequency (i.e 2x420KHz). It is a rectangular signal with 3.5 Vp (+/-0.5V) amplitude with an impedance of 4,7 KOhm on low level. 5 Vin Vo 6 4 S+ 7 On/Off 3 Share MGDM150 2 Sync 1 Gin Trim 8 S- 9 Go 10 BP 10nF 10nF (*) 10nF 10nF BP 5 Vin 4 On/Off 3 Share On/Off MGDM150 2 Sync 1 Vo 6 S+ 7 Trim 8 S- Gin Go BP 10nF 9 10 10nF (*) BP: Base Plate 14-2 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. 10nF 10nF 5 Vin 4 100F BP Vo S+ On/Off 3 Share MGDM150 2 Sync 1 7 Trim 8 S- Gin 6 Go 9 10 BP 10nF 4 10nF (*) 10nF 10nF 5 Vin 4 100F BP Vo 6 S+ 7 On/Off 3 Share MGDM150 2 Sync 1 Trim 8 S- Gin Go BP 10nF 9 10 10nF (*) BP: Base Plate 14-3 Connection of Modules in Parallel 5 The MGDM-150 low input series features a parallel operation function to increase the output power capability of a single unit by connecting the outputs of 2 or more converters in parallel. By connecting the Share pin of each module together, the units will share the load current equally within a few percent. Up to 5 converters can be parallelized. The Share signal is a DC voltage which varies between 0Vdc and 5Vdc referenced to Sense - and depending on the output load. 10nF 10nF 4 100F BP Vin Vo S+ On/Off 3 Share MGDM150 2 Sync 1 Go BP 10nF 7 Trim 8 S- Gin 6 9 10 10nF (*) 10nF 10nF 5 Vin 4 100F BP S+ On/Off 3 Share MGDM150 2 Sync 1 10nF Vo 6 Trim 8 S- Gin Go BP 7 9 10 10nF (*) BP: Base Plate (c) Gaia Converter FC02-009.12/13 Revision S 15 For locations, phone, fax, E-Mail see back cover MGDM-150 Low Input Series Hi-Rel Grade 15- Dimensions Dimensions are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 110 grams (3,9 Ozs) max. Mouting Hole 0 3,1 (0,122) 10,16 (0.4) 7,62 (0.3) 7,62 (0.3) 10,16 (0.4) 7,62 (0.3) 0,5 (0.019) 5,08 (0.2) 9,589 (0.38) 4,826 (0.19) 9,894 (0.39) 57,912 (2.28) 48,26 (1.90) Use this side for heat sinking .4 12,7 Max (0.5) ) ,1 (0 16- Materials 5,6 min (0.22) R2 50,8 (2.00) 60,95 (2.40) CH 2x2 Pin dimensions : Pins : 1, 2, 3, 4, 5, 7, 8, 9 : O 1 mm (0.04") Pins : 6, 10 : O 2 mm (0.08") 6,8 max (0.267) 4 Frame : Aluminium alodined coating. Baseplate : Copper with tin finishing. Pins : Plated with pure matte tin over nickel underplate. 17- Product Marking Side face : Company logo, location of manufacturing. : Module reference : MGDx-150-X-Y. Date code : year and week of manufacturing, suffix, /option. 18- Connections Pin 10 1 9 2 8 3 7 4 6 5 Single Output 1 - Input (Gi) 2 Synchro (Sync) 3 Share 4 On/Off 5 + Input (Vi) 6 + Output (Vo) 7 Sense + (S+) 8 Trim (Trim) 9 Sense - (S-) 10 - Output (Go) Bottom view (c) Gaia Converter FC02-009.12/13 Revision S 16 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 FC02-009.12/13 Revision S Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :