Hi-Rel DC/DC CONVERTER MGDM-75 : 75W POWER

Transcription

1 DC/DC CONVERTER MGDM-75 : 75W POWER :1 High Input Voltage : VDC Single Output Metallic case - 00 VDC Isolation Wide input range Vdc 70Vdc input compliant with MIL-STD-70E/F Industry standard quarter brick package Power up to 75 W Wide temperature range : -0/+5 C baseplate High efficiency (up to %) Soft start Galvanic isolation 00 VDC 1-General Integrated input filter hronizable No load to full load operation Fully protected by independant protection Undervoltage lock-out Overvoltage protection Current limitation protection Overtemperature protection No optocoupler for high reliability RoHS process The MGDM-75 high input 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 500 KHz providing wide input range, low noise characteristics and high power density. Standard models are available with wide input voltage range of volts. The series include single output voltage of., 5, 1, 15, 6 volts. The MGDM-75 high input series include synchronization, parallelable with 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 parallelable function allows increased 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 have totally independant security functions including input undervoltage 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, and is manufactured in a fully automated process to guarantee high quality. The modules are potted with a bicomponent thermal conductive compound to ensure optimum power dissipation under harsh environmental conditions. -Product Selection Single output model : MGDS input output / option suffix Input Voltage Range Permanent S : VDC Output B :. VDC C : 5 VDC E : 1 VDC F : 15 VDC 6 : 6 VDC Options : Suffix : /T : option for -55 C start up operating temperature /S : option for screening and serialization nothing : RoHS process REDEFINING THE SOURCE OF POWER Gaia Converter FC-06.01/18 Revision E

2 - Product Selection (continued) Input range Output Current Reference Options Suffix VDC VDC VDC VDC VDC. VDC 5 VDC 1 VDC 15 VDC 6 VDC 15 A 15 A 6,5 A 5 A,85 A MGD75-B MGD75-C MGD75-E MGD75-F MGD75-6 /T, /S /T, /S /T, /S /T, /S /T, /S / / / / / Converter Selection Chart MGDS S - C / T - Number of Outputs : S : single output Input voltage range : S : VDC Output voltage : See table page 1 Option : /T : -55 C start up operation /S : screening & serialization (consult application note «screening grades») Suffix : nothing : RoHS process Gaia Converter FC-06.01/18 Revision E

3 - Electrical Specifications Data are valid at +5 C, unless otherwise specified. Parameter Input 6V output 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 - and - 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 an external decoupling capacitor (typically 0 pf) connected between Gin and ut. This capacitor should be layedout as close as possible from the converter. Note **** : These performances are with input LC filter. Gaia Converter FC-06.01/18 Revision E Conditions Limit or typical Units MGD75 - S Nominal input voltage Full temperature range Nominal VDC 70 Permanent input voltage range (Ui) Full temperature range For MGD75-B For other models Min. - Max. Min. - Max. VDC VDC Undervoltage lock-out (UVLO) Turn-on voltage VDC 155 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 **.V output 5V output 1V output 15V output 6V output Ripple output voltage ***.V, 5V output 1V, 15V output 6V output Output regulation * (Line + load + thermal) Output Voltage Trim Efficiency admissible capacitive load.v and 5V output 1V and 15V output Ui nominal Full load : resistive Ui nominal, full load BW = 0MHz Ui nominal Short-circuit Ui nominal No load Ui nominal Inhibit Ui min. to max. Ambient temperature : +5 c Ui nominal, 75% load At 5 c baseplate 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 function of output voltage Ui nominal Full load Ui nominal Full load ms 0 % of input current Typical ma 5 Typical ma 0 ma Nominal Nominal Nominal Nominal Nominal VDC VDC VDC VDC VDC % +/- W 75 Typical A A A A A mvpp mvpp mvpp ,5 5, % +/- 1 Minimum % % 0 * 1 Typical % 0 µf µf µf

4 - Electrical Characteristics (continued) 0, Typical efficiency MGD75-B 0,5 Typical efficiency MGD75-C 0,85 0, 0,8 0,85 0,75 0,7 0,65 0,6,75 7,15,5 0,8 0,75 0,7 0,65 0,6 7,5 56,5 75 0,55 0,55 0, Input voltage Vin (Vdc) 0, Input voltage Vin (Vdc) 1 0,5 0, 0,85 0,8 0,75 0,7 0,65 0,6 0,55 Typical efficiency MGD75-E 0, Input voltage Vin (Vdc) 7,5 56, ,5 0, 0,85 0,8 0,75 0,7 0,65 0,6 0,55 Typical efficiency MGD75-6 0, Input voltage Vin (Vdc) 7,5 56,5 75 Gaia Converter FC-06.01/18 Revision E

5 - Switching Frequency Parameter Switching frequency Conditions Full temperature range Ui min. to max. No load to full load Limit or typical Nominal, fixed Specifications 500 KHz 5- Isolation Parameter Electric strength test voltage Conditions Input to output Input to case Output to case Limit or typical Minimum Minimum Minimum Specifications 00 VDC / 1 min 00 VDC / 1 min 00 VDC / 1 min Isolation resistance 500 VDC Minimum 0 MOhm 6- Protection Functions Characteristics Protection Device Recovery Limit or typical Specifications Input undervoltage lock-out (UVLO) Output current limitation protection (OCP) Output overvoltage protection (OVP) Over temperature protection (OTP) Turn-on, turn-off circuit with hysteresis cycle Straight line current limitation Overvoltage protection device with latch-up Thermal device with hysteresis cycle Automatic recovery Automatic recovery Automatic recovery Automatic recovery Turn-on nominal Turn-off nominal Nominal Nominal Nominal 10 C see section 10% of output current 10% of output voltage 7- Reliability Data Characteristics Conditions Temperature Specifications Mean Time Between Failure (MTBF) According to MIL-HDBK-17F Ground fixed (Gf) Airborne, Inhabited, Cargo (AIC) Case at 0 C Case at 85 C Case at 0 C Case at 85 C Consult factory Hrs 000 Hrs Mean Time Between Failure (MTBF) According to IEC-680-TR Civilian avionics, calculators Ambient at 55 C 0% time on Consult factory Gaia Converter FC-06.01/18 Revision E 5

6 8- Electromagnetic Interference Electromagnetic Interference requirements according to MIL-STD-61C/D/E standards can be easily achieved as indicated in the following section. The following table resumes the different sections covered by these standards. Standard Requirements MIL-STD-61C Standard MIL-STD-61D/E Standard Compliance with GAIA Converter Module & common mode capacitance Conducted emission (CE) : Low frequency High frequency CE 01 CE 0 CE 1 CE compliant module stand-alone compliant with additionnal filter Conducted susceptibility (CS) : Low frequency High frequency CS 01 CS 0 CS 1 CS11 compliant with additionnal filter compliant with additionnal filter Radiated emission (RE) : Magnetic field Electrical field RE 01 RE 0 RE 1 RE compliant with additionnal filter compliant with additionnal filter Radiated susceptibility (RS) : Magnetic field Electrical field RS 01 RS 0 RS 1 RS compliant with additionnal filter compliant with additionnal filter -1 Module Compliance with MIL-STD-61C Standard To meet MIL-STD-61C requirements and in particular CE0 requirement, Gaïa Converter recommends the use of the following front filter together with external decoupling capacitors connected between inputs and case and between outputs and case. Please consult MIL-STD-61C EMI filter design note for further details. L1,mH L,mH C Vin Vo S+ 6 7 C1 x560nf C x560nf Trim 8 1 Gin C L1... : Common mode choke,mh 0,6A L... : Common mode choke,mh 0,6A C1... : x ceramic capacitors 560nF C... : x ceramic capacitors 560nF C, C, C5*... : Low ESR and ESL ceramic capacitor C5 (*) Must be placed as close as possible to the converter in order to reduce the path length or the connections to the pins and the baseplate. Gaia Converter FC-06.01/18 Revision E 6

7 - Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Ambient temperature * Minimum - 0 C see below Baseplate temperature Base plate temperature Minimum - 0 C see curves herafter Storage temperature range Non functionning Minimum - 55 C + 15 C Thermal resistance Baseplate to ambient Rth(b-a) free air Typical 11 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 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, 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(1/η - 1) (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. C/W for no interface down to 0.1 C/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. 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 00 LFM No Heatsink baseplate only : 11 C/W No need of thermal pad 11 C/W Heatsink Thermaflo 5OOBOOOO : 7,6 C/W Bergquist Silpad* : 0,1 C/W 7,85 C/W Heatsink Thermaflo 8OOBOOOO :,5 C/W Bergquist Silpad* : 0,1 C/W,71 C/W No Heatsink baseplate only : 6, C/W No need of thermal pad 6, C/W Heatsink Radian HS1568EX :,5 C/W Bergquist Silpad* : 0,1 C/W,71 C/W Heatsink Thermaflo 8OOBOOOO :,8 C/W Bergquist Silpad* : 0,1 C/W,01 C/W No Heatsink baseplate only :,8 C/W No need of thermal pad,8 C/W Heatsink Radian HS1568EX : C/W Bergquist Silpad* : 0,1 C/W,1 C/W Heatsink Thermaflo 8OOBOOOO : 1,8 C/W Bergquist Silpad* : 0,1 C/W,01 C/W Forced air cooling 00 LFM Radian and Thermaflo are heasink manufacturers. «Silpad» is a registered trademark of Bergquist. Note* : Silpad performance are for Silpad 00 with pressure conditions of 50 Psi. Surface of MGD75 series is, inch. Gaia Converter FC-06.01/18 Revision E No Heatsink baseplate only :,8 C/W No need of thermal pad,8 C/W Heatsink Thermaflo 8OOBOOOO : 1 C/W Bergquist Silpad* : 0,1 C/W 1,1 C/W 7

8 - Thermal Characteristics (continued) The two formulas (A) and (B) described in previous page : Pdiss = Pout(1/η - 1) (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) MGD75-B T base plate max vs Po MGD75-C T base plate max vs Po T base plate max ( C) T base plate max ( C) Po (W) Po (W) Veminext = 155V Vemin = 170V Venom = 75V Vemax = 0V Veint = 70V Venom = 75V Vemax = 0V MGD75-E T base plate max vs Po MGD75-6 T base plate max vs Po T base plate max ( C) T base plate max ( C) Po (W) Po (W) Veminext = 155V Vemin = 170V Venom = 75V Vemax = 0V Veminext = 155V Vemin = 170V Venom = 75V Vemax = 0V Gaia Converter FC-06.01/18 Revision E 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 Duration Temperature / status of unit Test D : C ambient, unit not operating MIL-STD-0G Method 8A Altitude Humidity cyclic Humidity steady Salt atmosphere Temperature cycling Temperature shock Altitude level C Duration Climb up Stabilization Number of cycle Cycle duration Relative humidity variation Temperature variation Damp heat Temperature Duration Temperature Concentration NaCl Duration Number of cycles Temperature change Transfert time Steady state time Number of shocks Temperature change Transfert time Steady state time ft@-55 C 0 min ft/min to ft@-55 C, 0 min. unit operating Cycle I : Hrs 60 % to 88 % 1 C to 1 C unit not operating % relative humidity 0 C 56 days unit not operating 5 C 5 % 8 Hrs unit not operating 00-0 C / +85 C 0 min. 0 min. unit operating 0-55 C / +5 C sec. 0 min. unit not operating MIL-STD-8G Method MIL-STD-8G Method MIL-STD-0G Method B MIL-STD-8G Method 50.5 MIL-STD-0A Method A MIL-STD-0G Method 7G Mechanical Qualifications Vibration (Sinusoidal) Shock (Half sinus) Bump (Half sinus) Number of cycles Frequency / amplitude Frequency / acceleration Duration Number of shocks Peak acceleration Duration Shock form Number of bumps Peak acceleration Duration cycles in each axis to 60 Hz / 0,7 mm 60 to 000 Hz / g h 0 min. per axis unit not operating shocks in each axis 0 g 6 ms 1/ sinusoidal unit not operating 000 Bumps in each axis 0 g 6 ms unit not operating MIL-STD-8G Method 51.6 MIL-STD-8G Method MIL-STD-8G Method Gaia Converter FC-06.01/18 Revision E

10 11- Description of Protections The MGDM-75 high input series include types of protection devices Input Undervoltage Lockout (UVLO) An undervoltage protection is implemented to switch off the converter as long as the input voltage has not reached the UVLO turn-on threshold (see section for value) which is the minimum input voltage required to operate without damaging the converter. On Off V UVLO Turn-on Vin 11- Output Over Current Protection (OCP) The MGDM-75 high input series incorporates a foldback current limit and protection circuit. When the output current reaches 10% of its full-rated current, the output voltage falls and output current drops along the foldback line as described in the figure herein. The module falls in hiccup mode and automatically resumes to normal operation when the overcurrent is removed. Vout 60% Vout Icurrent limit Iout 1% of full 10% of full rated current rated current 11- Output Overvoltage Protection (OVP) The MGDM-75 high input series has an internal overvoltage protection circuit that monitors the voltage accross the output power terminals. It is designed to limit the converter at 10% (+/-5%) of output voltage. 11- Over Temperature Protection (OTP) A thermal protection device adjusted at 10 C (+/-5%) internal temperature with C hysteresis cycle will inhibit the module as long as the overheat is present and will restore to normal operation automatically once the overheat is removed. The effectiveness of the OTP function is warranty with the module mounted on a heatsink. On Off c 10 c Temperature Gaia Converter FC-06.01/18 Revision E

11 1- Description of Functions 1-1 Trim Function The output voltage Vo may be trimmed in a range of 0% to 1% of the nominal output voltage via an external trimmer or a fixed resistor. Trim Up Function Do not trim the module above 1% of nominal output voltage as the overvoltage protection will trigger. Also do not exceed the maximum rated output power when the module is trimmed up. The trim up resistor must be connected to the S+ pin. The trim up resistor must be calculated with the following formula : Vin Vo S+ Trim Ru Load Ru R1 Vo Vref Vo nom Vo Vo nom Vref R1 R Trim Down Function Do not trim down below 0% of nominal output voltage. The available output power is reduced by the same percentage that output voltage is trimmed down. The trim down resistor must be connected to pin. The trim down resistor must be calculated with the following formula : Vin Vo S+ Trim Rd Load Rd R1 R Vo R Vo nom Vo nom Vo 1 Gin Trim via a voltage The output voltage is given by the following formula : Vo 1 R1 R1 R Vcont Vref 1 Vo nom Vin Vo S+ Trim 6 7 Ru 8 BAT5 Vcontrol 0nF Load Trim resistor values calculated automatically: On-line calculators for trim resistor values are available on the Gaia converter website at : Parameter Unit Min. Typ. Max. Trim reference Vdc,5,5,55 Resistor R1 Ohm / K / Resistor R Ohm / 70 / Gaia Converter FC-06.01/18 Revision E 11

12 1- Description of Functions (continued) 1- 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 +/-% of output voltage. The overvoltage protection will be activated and module will shut down if remote sense tries to boost output voltage above 1% of nominal output voltage. Connection is described in figure herein. Vin Vo 6 S+ 7 Trim 8 Load 1- 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. For further details please consult Logic application note. Vi Gi Vin Vo 6 S+ 7 Trim 8 Load Parameter Unit Min. Typ. Max. Notes, conditions module enable voltage Vdc.5 / 5 Open, the switch must not sink more than 0µA module disable voltage Vdc 0 / 0,5 The switch must be able to sink 1mA alarm level Vdc 0 / 0,5 OTP or OCP faulty module module enable delay ms / / 0 The module restarts with the same delay after alarm mode removed module disable delay µs / / 50 Vi nominal, full load 1- hronization Function An external clock with pulse signals can be used to lock one or more converters (active on rising edge). The external clock signal should have a frequency range from 500KHz to 55KHz, a low level below 0,5V a high level of V (+/-0,5V), a rise time of 50 ns max., a fall time of 50ns max., and a pulse width of 00 ns maximum. Several converters can be synchronized by connecting their pin together. V +/-0,5 V Ext. clock Totem pole output Vin Vo 6 S+ 7 Trim 8 0V 50ns max 00ns max 50ns max Tsync ( 500Khz < F < 55Khz ) Gaia Converter FC-06.01/18 Revision E 1

13 1- Application Notes 1-1 Caution when Hard Plug-In Hard plug-in can cause high input voltage or internal overshoot due to resonance of the input filter or internal module filter. This overshoot can lead to internal component voltage breakdown which may dammage the converter. In order to avoid such concerns, GAIA Converter recommends to use a minimum of µf decoupling capacitor connected across the Vin and Gin lines of the converter. When designing the EMI input filter, the resonant frequency of this input filter has to be lower than 1 KHz so that when hard plug-in occurs, it will not generate overshoot higher than the maximum input voltage specified. If not, it will be necessary to clamp the overshoot with a transorb. 1- Input Capacitor Coupling It is recommended to use a minimum of µf decoupling capacitor connected across the Vin anf Gin lines of the converter to restore a low line impedance and improve stability input filter Vin Vo 6 S+ 7 µf Trim 8 Gaia Converter FC-06.01/18 Revision E 1

14 1- Application Notes (continued) 1- hronization of Modules The MGDM-75 high input series provides a synchronization function trough the pin (hro) 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). µf Vin Vo 6 S+ 7 Trim 8 µf Vin Vo 6 S+ 7 Trim 8 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. GAIA Converter recommends to protect each individual output with a 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 are not synchronous. Special care must be taken to layout properly low level signals. and from high current tracks. They must be shielded with GIA signal to avoid any disturbances by noises and crosstalk. µf µf Vin Vin Vo 6 S+ 7 Trim 8 Vo 6 S+ 7 Trim 8 Gaia Converter FC-06.01/18 Revision E 1

15 11- Dimensions Dimensions are given in mm (inches). Tolerance : +/- 0, mm (+/ ) unless otherwise indicated. Weight : 60 grams (1.67 Ozs) max. 1- Materials Case : Aluminium alodined coating. Pins : Plated with flash gold over nickel underplate. 1- Product Marking Side face : Company logo, location of manufacturing. : Module reference : MGDx-75-»X»-»Y». Date code : year and week of manufacturing, suffix, /option. 1- Connections Gaia Converter FC-06.01/18 Revision E Bottom view Pin Single Output 1 - Input (Gi) hro () + Input (Vi) 5 No pin 6 + Output (Vo) 7 Sense + (S+) 8 Trim (Trim) Sense - () - Output () Pin 5 added with option parallelable referenced /P : «Share» (consult factory) 15

16 For more detailed specifications and applications information, contact : International Headquarters GAÏA Converter - France ZI de la Morandière 185 LE HAILLAN - FRANCE Tel. : + () Fax : + () Represented by : North American Headquarters GAÏA Converter Canada, Inc 08 Le Corbusier Blvd LAVAL, QUEBEC - CANADA H7L 5R Tel. : (51)--16 Fax : (51)--51 Printed in France by Gaia Converter FC-06.01/18 Revision E Graphisme : Philippe Clicq 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.