Industrial DC/DC CONVERTER MGDI-60 Wide Input : 60W POWER. 4:1 & 5:1 Wide Input Single Output Metallic Case VDC Isolation.

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1 DCDC CONVERTER MGDI-60 Wide Input : 60W POWER 4: & : Wide Input Single Output Metallic Case - 00 Isolation Wide input range power up to 60 W High efficiency (typ. 88%) Soft start Galvanic isolation.00 according to EN 6090 Integrated LC input filter -General Permanent short circuit protection External synchronisation External trim and sense adjustment : -0+0% No optocoupler for high reliability RoHS process The MGDI-60 wide input series is a full family of DCDC power modules designed for use in distributed power architecture where variable input voltage and transient are prevalent making them ideal particularly for transportation, railways or high-end industrial applications. These modules use a high frequency fixed swiching topology at 60KHz providing excellent reliability, low noise characteristics and high power density. Standard models are available with wide input voltage range of 4- and volts for 43670V batteries. The serie includes single output voltage choices of., 3.3,,, and 6 volts (for 4Vdc applications). The MGDI-60 serie is designed in conformity withsafety standards EN6090 and UL90. All the modules are designed with LC network filters to minimize reflected input current ripple and output voltage ripple according to ease EN0 and FCC Part J standard. The modules include a soft-start, an input undervoltage and overvoltage lock-out, a permanent short circuit protection, a thermal protection and an output overvoltage protection to ensure efficient module protections. The softstart 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 shutdown and restores to normal when the overload is removed. -Product Selection Single output model : MGDSI input output Input ltage Range Output Permanent G : 4- Q : Extended Range 7 B : 3.3 C : E : F : 6 : 6 (for 4 application) For lower output voltage below 3.3V please consult factory REDEFINING THE SOURCE OF POWER

2 - Product Selection (continued) Input range Output Current Reference Options ,3 6 A A A 4 A,3 A -G-B -G-C -G-E -G-F -G ,3 6 A A A 4 A,3 A -Q-B -Q-C -Q-E -Q-F -Q-6 Converter Selection Chart MGDS I -60 -Q - C Number of Outputs : S : single output Input voltage range : G : 4- Q : Output voltage : See table page Option :

3 3- Electrical Specifications Data are valid at + C, unless otherwise specified. Parameter Input Conditions Limit or typical Note () : A 47KOhm resistance need to be connected accross pins and UVLO and 68KOhm for -G-F and -G-6 (see section -) 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 0 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 external decoupling capacitor connected between and ut. These capacitance should be layed-out as close as possible from the converter. The ripple output voltage is measured by connecting a ceramic chip capacitor Co accross and pins (C=00µF if <Vdc C=0µF if >Vdc) Units Single Output 60 - G 60 - Q input voltage Full temperature range 4 7 Permanent input voltage range (Ui) Extended permanent input voltage range Transient input voltage Undervoltage lock-out (UVLO) Overvoltage lock-out (OVLO) Start up time Reflected ripple current No load input power Standby input power Output Output voltage * Set Point accuracy * Output power ** Output current ** 3,3V output V output V output V output 6V output Ripple output voltage *** 3,3V and V output V output V output 6V output Output regulation* (Line + load + thermal) output ltage Trim Efficiency Full temperature range Min. - Max Full temperature range (Consult factory) Full load (Consult factory) Turn-on voltage Turn-off voltage Turn-on voltage Turn-off voltage Ui nominal within 3 ms output Full load : resistive Ui nominal, full load at switching freq. BW = 0MHz Ui min. to max. No load Ui min. to max. No load Full temperature range Ui min. to max. 7% load Ambient temperature : + c Ui nominal, 7% load Full temperature range Ui min. to max. Full temperature range Ui min. to max. Ui nominal Full load BW = 0MHz Ui min. to max. 0% to full load As a function of output voltage Ui nominal Full load Min. - Max S 60 NA 3, (), () NA ms mapp TBD TBD W for <=Vdc : 0W for >Vdc : W W 3,3 6 3,3 6 % W see section 0 A A A A A mvpp mvpp mvpp mvpp 4, , % Minimum % % Typical %

4 4- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load, fixed 60 KHz - Isolation Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output Minimum 00 min Isolation resistance Input to case 00 Output to case 00 Minimum Minimum 00 MOhm 00 MOhm 6- Protection Functions Characteristics Protection Device Recovery Limit or typical Specifications Input undervoltage lock-out (UVLO) Input overvoltage lock-out (OVLO) Output current limitation protection (OCP) Output overvoltage protection (OVP) Over temperature protection (OTP) Turn-on, turn-off circuit with hysteresis cycle Turn-on, turn-off circuit with hysteresis cycle Straight line current limitation Overvoltage protection limitation Thermal device with hysteresis cycle Automatic recovery Automatic recovery Automatic recovery Automatic recovery Automatic recovery Turn-on nominal Turn-off nominal Turn-on nominal Turn-off nominal 30% Min. - max. See section 3 See section 3 0% +-% of output voltage C 7- Reliability Data Characteristics Conditions Temperature Specifications Mean Time Between Failure (MTBF) According to MIL-HDBK-7F Ground fixed (Gf) Ground mobile (Gm) Case at 40 C Case at 70 C Case at 40 C Case at 70 C Hrs Hrs Hrs Hrs Mean Time Between Failure (MTBF) According to IEC-6380-TR Railway, Payphone Ambient at C 00% time on Hrs 4

5 8- Electromagnetic Interference Electromagnetic interference requirements according to EN0 class A and class B can be easily achieved as indicated in the following table : Conducted noise emission Radiated noise emission Models Models Configuration All models Configuration All models Electromagnetic Interference according to EN0 With a common mode capacitor C c = 0nF and external filter Class A With a common mode capacitor C c = 0 nf and external filter Class B 8- Module Compliance with EN0 class Aclass B Standard Electromagnetic interference requirements according to EN0 class A or class B can be easily achieved by adding an external common mode noise capacitance (C C = 0nFrated voltage depending on isolation requirement) and an external filter. The common mode noise capacitance C C should be layed-out as close as possible from the DCDC converter. Please consult factory for details. VI VI EMI input Filter MGDI-60-series GI GI Cc

6 9- Surge Susceptibility EN & EN0 Surge susceptibility requirements according to EN0, EN and electromagnetic interference requirements of EN0 class A can easily be achieved using : an input limitor filter : see following schematics of discret components, to sustain the following surge levels : Characteristics Standards Levels Spikes Line to line Spikes Line to earth EN EN 0 EN EN 0 Level 4 with V waveform 0 µs, impedance Ohm Level 800 V waveform 0 µs, impedance 00 and Ohm Level V waveform 0. µs, impedance 00 Ohm Level 4 with V waveform 0 µs, impedance Ohm Level 800 V waveform 0 µs, impedance 00 and Ohm Level V waveform 0. µs, impedance 00 Ohm F LMC L D VI B P R C C C4 C6 C8 C9 D D MGDI-60-series C3 L C7 D3 D 3 GI BP Cc Please consult EN0 TransientEMI Filter desing note for further details. * Note : Value of common mode noise capacitance rated voltage depends on isolation requirements. 6

7 0- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range Operating case temperature range at full load Storage temperature range Thermal resistance Ambient temperature Case temperature Non functionning Rth case to ambient in free air natural convection Minimum Minimum Minimum - 40 C see below - 40 C see curves herafter - 40 C + C Typical 6 C W The following discussion will help designer to determine the thermal characteristics and the operating temperature. Heat can be removed from the baseplate via three basic mechanisms : Radiation transfert : radiation is counting for less than % 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, we will consider that heat will be removed from the baseplate either with : heatsink, forced air cooling, both heatsink and forced air cooling. To calculate the maximum admissible ambient temperature the following method can be used. Knowing the power used Pout and the efficiency η: determine the power dissipated by the module Pdiss that should be evacuated : Pdiss = Pout(η - ) (A) then determine the thermal dissipation : Tdiss = 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 0.4 CW for no interface down to 0. CW 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. The table hereafter gives some example of thermal resistance for different heat transfert configurations. Heat transfert Thermal resistance heatsink to air Rth(h-a) Thermal resistance baseplate to heatsink Rth(b-h) Global resistance Free air cooling only Forced air cooling 00 LFM Forced air cooling 400 LFM No Heatsink baseplate only : 6 CW No need of thermal pad 6 CW Heatsink Aavid Thermalloy 8433B030 3,9 CW Bergquist Silpad* : 0,3 CW 4,03 CW No Heatsink baseplate only : 3,8 CW No need of thermal pad 3,8 CW Heatsink Aavid Thermalloy 8433B030, CW Bergquist Silpad* : 0,3 CW,3 CW No Heatsink baseplate only :,63 CW No need of thermal pad,63 CW Heatsink Aavid Thermalloy 8433B030, CW Bergquist Silpad* : 0,3 CW,63 CW Forced air cooling 000 LFM No Heatsink baseplate only :,4 CW No need of thermal pad,4 CW Heatsink Aavid Thermalloy 8433B030 CW Bergquist Silpad* : 0,3 CW,3 CW Aavid Thermalloy is a heasink manufacturers. «Silpad» is a registered trademark of Bergquist. Note* : Silpad performance are for Silpad 400 with pressure conditions of 0 Psi. 7

8 0- Thermal Characteristics (continued) The two formulas (A) and (B) described in previous page : Pdiss = Pout(η - ) (A) Tdiss = Rth(b-a) x Pdiss (B) conduct to determine the maximum ambient temperature admissible as a function of the maximum baseplate temperature of the module. Knowing the maximum baseplate temparature Tmax baseplate the maximum ambient temperature is given by the following formula : Ta = Tmax baseplate - Tdiss (C) MGDI-60-G-x Series Baseplate Temperature Versus % of Output Power Baseplate Temperature ( C) =4 =4 = % of Output Power (%) Baseplate Temperature ( C) MGDI-60-Q-x Series Baseplate Temperature Versus % of Output Power =36V =7V =0V % of Output Power (%) 8

9 - Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Climatic Qualifications Life at high temperature Humidity steady Temperature cycling Temperature shock Duration Temperature Status of unit Damp heat Temperature Duration Status of unit Number of cycles Temperature change Transfert time Steady state time Status of unit Number of shocks Temperature change Transfert time Steady state time Status of unit 000 Hrs 9 C case unit operating 93 % relative humidity 40 C 6 days unit not operating C +7 C 40 min. 0 min. unit not operating 0-40 C +0 C 0 sec. 0 min. unit not operating IEC 68-- IEC Test Ca IEC Test N IEC Test Na Mechanical Qualifications Vibration (Sinusoidal) Shock (Half sinus) Bump (Half sinus) Number of cycles Frequency : amplitude Frequency : acceleration Amplitude acceleration Duration Status of unit Number of shocks Peak acceleration Duration Shock form Status of unit Number of bumps Peak acceleration Duration Status of unit 0 cycles in each axis 0 to 60 Hz 0.7 mm 60 to 000 Hz 0 g 0.7 mm0 g h 30 min. per axis unit not operating 3 shocks in each axis 00 g 6 ms sinusoidal unit not operating 000 bumps in each axis g 6 ms unit not operating IEC Test Fc IEC Test Ea IEC Test Eb Electrical Immunity Qualifications Electrical discharge susceptibility Electrical field susceptibility Electrical fast transient susceptibility Surge Susceptibility Number of discharges Air discharge level Contact discharge level Air discharge level Contact discharge level Antenna position Electromagnetic field Wave form signal Frequency range Burst form Wave form signal Impedance Level Level 3 Surge form Impedance Level 4 0 positive & 0 negative discharges 4 kv : sanction A Kk : sanction A 8 Kk : sanction B 4 kv : sanction B at m 0 Vm AM 80%, khz 6 MHz to GHz 0 ns khz with ms burst duration period 300 ms 0 Ohm 0, kv : sanction A kv : sanction B,0 µs Ohm 4 kv : with transient protection (see section surge) EN08- with : EN IEC 80- EN08- with : EN IEC80-3 EN08- with : EN IEC80-4 EN EN0 9

10 - Description of Protections The MGDI-60 series include types of protection devices. - Input Undervoltage Lockout (UVLO) and Overvoltage Lockout (OVLO) -- Undervoltage Lockout (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 turnon threshold. On The input undervoltage lock-out threshold (UVLO) can be trimmed up by connecting a resistor between UVLO anf Gi pins. This resistance can be calculated as folow : R UVLO = a x ( + b - n) where n = UVLO trim Off UVLO UVLO Turn-off Turn-on OVLO OVLO Turn-on Turn-off (n - ) UVLO threshold a b Input G NA NA Input Q Vi 0,, -- Overvoltage Lockout (OVLO) An input overvoltage protection will inhibit the module when input voltage reaches the overvoltage lockout turn-off threshold (see section 3 for value) and restores to normal operation automatically when the input voltage drops below the overvoltage Lockout turn on threshold. Gi RUVLO 3 UVLO Sync 6 S+ Trim 7 S- 8 4,, 6 3, 4, - Output Over Current Protection (OCP) The MGDI-60 Series incorporates a straight line current limit and protection circuit. When the output current reaches 30% of it s full-rated current (Icurrent limit), the output voltage decreases down to 7% of nominal output voltage. Below this threshold the converter falls in hiccup mode by testing periodically if an overload is applied. The module restart automatically to normal operation when overcurrent is removed. ut nom 7% nom -3 Output Overvoltage Protection (OVP) The MGDI-60 series has an internal overvoltage protection circuit that monitors the voltage accross the output power terminals. It is designed to limit the converter at 0% (+-%) of output voltage. 30% of full rated current Iout -4 Over Temperature Protection (OTP) On A thermal protection device adjusted at C (+-%) internal temperature with 0 C 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. Off 0 c c Baseplate Temperature 0

11 3- Description of Functions 3- Trim Function The output voltage may be trimmed in a range of 80%0% of the nominal output voltage via a single external trimpot or fixed resistor. Trim Up Function Do not attempt to trim the module higher than 0% 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 : Ru = R x (V0 - Vref) x V0 nom - R - R (V0 - V0 nom ) x Vref 3 UVLO Sync Error amp. R R Vref C 0,, S+ 6 Trim 7 S- 8 4,, 6 3, 4, Ru Trim Down Function Do not trim down more than -0% of nominal output voltage otherwise the module may turn off. 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 = (R + R) x V0- R x V0 nom V0 nom - V0 3 UVLO Sync Error amp. R R Vref C 0,, S+ 6 Trim 7 S- 8 4,, 6 3, 4, Rd Trim via a voltage The output voltage is given by the following formula : V0 = [ + R x (Vcont - ) ] x Vnom (R + R) Vref 3 UVLO Error amp. R R 0,, S+ 6 Ru Trim 7 BAT4 00nF Sync Vref C S- 8 Vcontrol 4,, 6 3, 4, Parameter Unit Min. Typ. Max. Trim reference Vref Vdc,4,, Resistor R Ohm 39K Resistor R Ohm 70 Trim capacitor C nf 0

12 3- Description of Functions (continued) 3- 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 0% of output voltage. The overvoltage protection will be activated if remote sense tries to boost output voltage above 0% of nominal output voltage. Connection is described in figure herein. 3 UVLO Sync 0,, S+ 6 Trim 7 8 S- 4,, 6 3, 4, 3-3 Function The control pin () can be used for applications requiring 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 pins together. The converter is disabled by pulling low the pin. No connection or high impedance on pin enables the converter. By releasing the function, the converter will restart within the start up time specifications given in table section 3 Vi Gi 0,, 3 S+ UVLO Trim Sync S- 4,, 6 3, 4, Parameter Unit Min. Typ. Max. Notes, conditions module enable voltage Vdc 3. Open, the switch must not sink more than 00µA module disable voltage Vdc 0 0. The switch must be able to sink ma alarm level Vdc 0 0. OTP faulty module module enable delay ms 30 The module restarts with the same delay after alarm mode removed module disable delay µs 00 Vi nominal, full load 3-4 Synchronization Function An external clock with pulse signals can be used to lock one or more converters. The external clock signal should have a frequency range from 70KHz to 300KHz, a low level below 0,V a high level of 4V (+-0.V), a rise time of 30 ns max., a fall time of 00ns max., and a pulse width of 300 to 00 ns. Several converters can be synchronized by connecting their Sync pin together. Ext. clock Vi 3 UVLO 0,, S+ 6 Trim 7 Vsync Totem pole output Sync S- 8 4V +- 0, Gi 4,, 6 3, 4, 0V 30ns max 300 to 00ns 00ns max T ( 70Khz < F < 300Khz )

13 4- Application Notes 4- Input to Output Impedance The MGDI-60 converters have been designed to be stable with no external capacitors when used in low inductance input and output circuits. However, in many applications, the inductance associated with the distribution from the power source to the input of the converter can affect the stability of the converter. The addition of a C in =0µF electrolytic capacitor with an ESR < Ohm across the input helps ensure stability of the converter. In many applications, the user has also to use decoupling capacitance at the load. The addition of a decoupling ceramic chip capacitor Co (Co=0µF if >Vdc or Co=00µF if <=Vdc) across the output and placed close to the converter allows to achieve the output voltage ripple specified in the table page 3. Cin 3 UVLO Sync 0,, S+ 6 Trim 7 8 S- 4,, 6 3, 4, Co 4- Synchronization of Modules The MGDI-60 series provides a synchronization function trough the pin (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 is referenced to ground in (Gi). Vi 3 UVLO 0,, 6 S+ Trim 7 Sync S- 8 Gi 4,, 6 3, 4, 0,, 3 UVLO S+ 6 Trim 7 Sync S- 8 4,, 6 3, 4, 3

14 4-3 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. VI GI VI x GI - PCB Mounting Specifications The MGDI-60 series has been designed for on-board mounting. it is recommended not to lay-out any component under the module. On-board Mounting 4

15 6- Dimensions Dimension are given in mm. Tolerance : +- 0, mm ( ) unless otherwise indicated. Weight : 6 grams (.30 Ozs) max. 7,70 (.86") 4 x R3.0 Keep out areas 8,76 +-0, (0.34") 47,90 (.88") 0 (0.79"),6 (0.0") R 9,8 (0.39") (0.9"),08 (0."),08 (0."),08 (0."),4 (0."),4 (0."),08 (0."),4 (0."),4 (0.") 4,6 +-0 ( ") 7,80 +- (0.70"),0 (0.49") 0,7 (0.4") 7,0 (0.9''),0 (0.49'') 6, +-0, (.03") 63,0 (.0") 4,4 (0.7") 7 (0.67") 3,0 +-0, (0.9") 7- Materials Pin dimensions : 0,9 mm (0.036") Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 8- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 9- Connections Pin Single On Off Synchro (Sync) 3 UVLO 4,, 6 - Input (Gi) + Input (Vi) 0,, Output () 3, 4, Common () 6 Sense + 7 Trim 8 Sense - Bottom view

16 For more detailed specifications and applications information, contact : International Headquarters GAÏA Converter - France ZI de la Morandière 338 LE HAILLAN - FRANCE Tel. : + (33) Fax : + (33) Represented by : North American Headquarters GAÏA Converter Canada, Inc 4038 Le Corbusier Blvd LAVAL, QUEBEC - CANADA H7L R Tel. : (4) Fax : (4) 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 Gaia Converter FC Revision D. Graphisme : Philippe Clicq