Industrial DC/DC CONVERTER MGDI-10 Standard Input : 10W POWER Industrial Grade 2:1 Standard Input Single & Bi Outputs Metallic case - 1.500 VDC Isolation • Low profile : 0,33 “ ( 8.5mm) • Nominal power of 10 W without derating • Wide temperature range : -40°C/+95°C case • High efficiency up to 83 % • Soft start • Galvanic isolation 1.500 VDC • Integrated LC EMI filter • Permanent short circuit protection • No optocoupler for high reliability 1-General The MGDI-10 series is a full family of DC/DC power modules designed for use in distributed power architecture and are particularly suitable for mobile or ground fixed applications in transportation, industry and télécommunication areas. These modules use a high frequency fixed switching technic at 480 KHz providing excellent reliability, low noise characteristics, high power density and a low profile package. Standard models are available with nominal input voltages as 5, 12, or 24 volts in range of 4,5-5,5 or 18-36 volts. The series include single and bi output voltage choices of 3,3, 5, 12, 15, +/-5, +/-12 or +/-15 volts. No external heatsink is required for the MGDI10 series to supply 10W output power over the case temperature range of -40°C up to 95°C. The MGDI-10 series is designed in conformity with safety standards EN60950 and UL1950. All the modules are designed with LC network filters to minimize reflected input current ripple and output voltage ripple according to EN55022 and FCC Part 15J standard. The modules include a soft-start, an input undervoltage lock-out, a permanent short circuit protection and an output overvoltage 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. Each module is tested and burned in with a GAIA Converter automated test equipment. 2-Product Selection Single output model : MGDSI-10- Bi output model : MGDBI-10- Input Voltage Range Output Permanent B : 3.3 VDC C : 5 VDC or +/-5VDC E : 12 VDC or +/-12VDC F : 15 VDC or +/-15VDC C : 4,5-5,5 VDC I : 18-36 VDC REDEFINING THE SOURCE OF POWER © Gaia Converter FC97-006.03/06 Revision M For locations, phone, fax, E-Mail see back cover 5 Industrial Grade MGDI-10 Standard Input Series 2- Product Selection (continued) Input range 4.5-5.5 4.5-5.5 4.5-5.5 4.5-5.5 4.5-5.5 4.5-5.5 4.5-5.5 18-36 18-36 18-36 18-36 18-36 18-36 18-36 VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC Output Current Reference Options 3,3 VDC 5 VDC 12 VDC 15 VDC +/- 5 VDC +/- 12 VDC +/- 15 VDC 2A 2A 0,80 A 0,65 A +/- 1 A +/- 0,40 A +/- 0,33 A MGDSI-10-C-B MGDSI-10-C-C MGDSI-10-C-E MGDSI-10-C-F MGDBI-10-C-C MGDBI-10-C-E MGDBI-10-C-F / / / / / / / 3,3 VDC 5 VDC 12 VDC 15 VDC +/- 5 VDC +/- 12 VDC +/- 15 VDC 2A 2A 0.80 A 0.65 A +/- 1 A +/- 0.40 A +/- 0.33 A MGDSI-10-I-B MGDSI-10-I-C MGDSI-10-I-E MGDSI-10-I-F MGDBI-10-I-C MGDBI-10-I-E MGDBI-10-I-F / / / / / / / Converter Selection Chart 5 M G D S I - 10 - I - C Number of Outputs : S : single output B : bi output Input voltage range : C : 4.5-5.5 VDC I : 18-36VDC Output voltage : See table page 1 © Gaia Converter FC97-006.03/06 Revision M 2 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 3- Electrical Specifications Data are valid at +25°C, unless otherwise specified. Parameter Input Nominal input voltage Permanent input voltage range (Ui) Undervoltage lock-out (UVLO) Start up time Reflected ripple current Input current in short circuit mode (Average) No load input current Conditions Limit or typical Units Full temperature range Nominal Full temperature range turn-on/turn-off threshold Single Output MGDSI- 10 10 - C 10 - I VDC 5 24 Min. - Max. VDC 4,5- 5,5 18- 36 Minimum Maximum VDC VDC 4 4,5 16 17,5 Maximum ms 30 30 Maximum mApp 50 30 Maximum mA 50 30 Maximum mA 50 30 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 3,3 5 12 15 3,3 5 12 15 Maximum % +/- 2 +/- 2 Maximum W 10 10 Full temperature range Ui min. to max. Maximum Maximum Maximum Maximum A A A A 2 2 0,80 0,65 2 2 0,80 0,65 Ui nominal Full load BW = 20MHz Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 50 100 150 Maximum % +/- 1 +/- 1 Maximum % +/- 2,5 +/- 2,5 Typical % 77 83 Maximum Maximum µF µF 1.000 330 1.000 330 Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Decoupling capacitor 10µF Ui nominal Short-circuit Ui nominal No load 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 *** Efficiency Maximum admissible Capacity load 3,3V and 5V output 12V and 15V output Full temperature range Ui min. to max. 75% load Ambient temperature : +25°c Ui nominal, 75% load Full temperature range Ui min. to max. Ui min. to max. Full load Ui nominal 25% to full load Ui nominal Full load Ui nominal Full load Per output 5 Note * : For proper operation the MGDI-10 module requires to install a 22µF chemical or tantalum capacitance accross output terminals. 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 capacitor (typically 10nF/rated voltage depending on isolation requirement) connected between the pin Gin and the pin Gout of the converter. This capacitor should be layed-out as close as possible from the converter. Note *** : For load regulation characteristics from 0% to full load, please contact factory. © Gaia Converter FC97-006.03/06 Revision M 3 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 3- Electrical Specifications (continued) Data are valid at +25°C, unless otherwise specified. Parameter Input Nominal input voltage Permanent input voltage range (Ui) Undervoltage lock-out (UVLO) Start up time Reflected ripple current Input current in short circuit mode (Average) No load input current Conditions Limit or typical Units Full temperature range Nominal Full temperature range turn-on/turn-off threshold Bi Output MGDBI- 10 10 - C 10 - I VDC 5 24 Min. - Max. VDC 4,5- 5,5 18- 36 Minimum Maximum VDC VDC 4 4,5 16 17,5 Maximum ms 30 30 Maximum mApp 50 30 Maximum mA 50 30 Maximum mA 50 30 Nominal Nominal Nominal VDC VDC VDC +/- 5 +/- 12 +/- 15 +/- 5 +/- 12 +/- 15 Maximum % +/- 2 +/- 2 Maximum W +/- 5 +/- 5 Full temperature range Ui min. to max. Maximum Maximum Maximum A A A +/- 1 +/- 0,40 +/- 0,33 +/- 1 +/- 0,40 +/- 0,33 Ui nominal Full load BW = 20MHz Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 50 100 150 Maximum % +/- 1 +/- 1 Maximum % +/- 2,5 +/- 2,5 Maximum % +/- 0,5 +/- 0,5 Typical % 77 83 Maximum Maximum µF µF 470 100 470 100 Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Decoupling capacitor 10µF Ui nominal Short-circuit Ui nominal No load Output Output voltage * Set Point accuracy Output power Output current +/- 5V output +/- 12V output +/- 15V output Ripple output voltage ** 5V output 12V output 15V output Line regulation Load regulation *** Cross load output regulation Efficiency Maximum admissible Capacity load 3,3V and 5V output 12V and 15V output Full temperature range Ui min. to max. 75% load Ambient temperature : +25°c Ui nominal, 75% load Full temperature range Ui min. to max. Ui min. to max. Full load Ui nominal 25% to full load Ui nominal + Vout nominal load - Vout from 25% to full load Ui nominal Full load Ui nominal Full load Per output 5 Note * : For proper operation the MGDI-10 module requires to install a 22µF chemical or tantalum capacitance accross output terminals. 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 capacitor (typically 10nF/rated voltage depending on isolation requirement) connected between the pin Gin and the pin Gout of the converter. This capacitance should be layed-out as close as possible from the converter. Note *** : For load regulation characteristics from 0% to full load, please contact factory. © Gaia Converter FC97-006.03/06 Revision M 4 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-10 Standard Input 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 480 KHz Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output Minimum 1.500 VDC / 1 min Electric strength test voltage between outputs (for dual and triple outputs) Output to output Minimum No isolation 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 no hysteresis Automatic recovery Threshold See section 3 Output short circuit protection (SCP) Hiccup circuitry with auto-recovery Automatic recovery Permanent See section 11 / Maximum Maximum Maximum Maximum For 3.3v : 4v For 5v : 6v For 12v : 14v For 15v : 17v Output overvoltage protection (OVP) Zener clamp 5 7- Reliability Data Characteristics Conditions Temperature Specifications Ground fixed (Gf) Case at 40°C Case at 70°C 950.000 Hrs 380.000 Hrs Ground mobile (Gm) Case at 40°C Case at 70°C 240.000 Hrs 105.000 Hrs Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR © Gaia Converter FC97-006.03/06 Revision M Telecom switchers / Consult factory 5 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-10 Standard Input Series 8- Electromagnetic Interference Electromagnetic interference requirements according to EN55022 class A and class B can be easily achieved as indicated in the following table : Electromagnetic Interference according to EN55022 Configuration Conducted noise emission With common mode capacitor C c = 10nF and input capacitor C Models With common mode capacitor C C = 10nF and external filter 4,5-5,5V input models Class A, C i =10µF/ 35 V tantalum Class B 18-36V input models Class A, C i =4.7µF / 50 V tantalum Class B Configuration Radiated noise emission i With common mode capacitor C c = 10 nF Models All models Class B 8-1 Module Compliance with EN55022 class A Standard Electromagnetic interference requirements according to EN55022 class A can be easily achieved by adding an external input capacitance (CI Value explained in previous table) and a common mode noise capacitance Cc (10 nF/rated voltage depending on isolation requirement) connected between Gin and Gout. This common mode noise capacitance Cc should be layedout as close as possible from the DC/DC converter. + Input Vi Input capacitance C i Vo MGDI - Series 5 Go Gi - Input Common mode noise capacitance C c = 10nF 8-2 Module Compliance with EN 55022 Class B Standard Electromagnetic interference requirements according to EN55022 class B can be easily achieved by adding an external input filter consisting of 4 capacitances, a common mode choke, and a differential L1 L2 mode inductance, together with a common mode noise capacitance (10 nF/rated voltage depending on isolation requirement) connected between Gin and Gout. Please consult EN55022 Class B EMI Filter design dote for further details. C3 Vi + Input C1 C2 - Input Vo MGDI - Series Gi Go C4 Common mode noise capacitance C c = 10nF © Gaia Converter FC97-006.03/06 Revision M 6 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 9- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Ambient temperature * Minimum Maximum - 40°C + 71°C Operating case temperature range at full load Case temperature Minimum Maximum - 40°C +95°C Storage temperature range Non functionning Minimum Maximum - 40°C + 105°C Thermal resistance Rth case to ambient in free air natural convection Typical 12°C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 95°C. The MGDI-10 series operating case temperature must not exceed 95°C. The maximum ambient temperature admissible for the DC/DC converter corresponding to the maximum operating case temperature of 95°C 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 = 95°C of the module, the power used Pout and the efficiency η : • determine the power dissipated by the module Pdiss that should be evacuated : η - 1) Pdiss = Pout(1/η • determine the maximum ambient temperature : Ta = 95°C - Rth x Pdiss where Rth is the thermal resistance from the case to ambient. 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 95°C (white area in the following graph). 5 Power (W) 100% Additionnal cooling operation area 75% Natural convection operation area 50% 25% 10 20 30 40 50 60 70 80 90 100 Temperature (˚C) Full load ambient temperature without derating : 71˚C Maximum case temperature : 95˚C Maximum storage temperature : 105˚C © Gaia Converter FC97-006.03/06 Revision M 7 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 10- 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 1.000 Hrs 95°C case unit operating IEC 68-2-2 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40°C 56 days unit not operating IEC 68-2-3 Test Ca Temperature cycling Number of cycles Temperature change Transfert time Steady state time Status of unit 200 -40°C / +71°C 40 min. 20 min. unit not operating IEC 68-2-14 Test N Temperature shock Number of shocks Temperature change Transfert time Steady state time Status of unit 50 -40°C / +105°C 10 sec. 20 min. unit not operating IEC 68-2-14 Test Na Mechanical Qualifications Vibration (Sinusoidal) Number of cycles Frequency : amplitude Frequency : acceleration Amplitude /acceleration Duration Status of unit 10 cycles in each axis 10 to 60 Hz / 0.7 mm 60 to 2000 Hz / 10 g 0.7 mm/10 g 2h 30 min. per axis unit not operating 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 IEC 68-2-27 Test Ea Bump (Half sinus) Number of bumps Peak acceleration Duration Status of unit 2000 bumps in each axis 25 g 6 ms unit not operating IEC 68-2-29 Test Eb IEC 68-2-6 Test Fc 5 Electrical Immunity Qualifications Electrical discharge susceptibility Number of discharges Air discharge level Contact discharge level Air discharge level Contact discharge level 10 positive & 10 negative discharges 4 kV : sanction A 2 Kk : sanction A 8 Kk : sanction B 4 kV : sanction B EN55082-2 with : EN61000-4-2 IEC 801-2 Electrical field susceptibility Antenna position Electromagnetic field Wave form signal Frequency range at 1 m 10 V/m AM 80%, 1 kHz 26 MHz to 1 GHz EN55082-2 with : EN61000-4-3 IEC801-3 Electrical fast transient susceptibility Burst form Wave form signal Impedance Level 1 Level 3 5/50 ns 5 kHz with 15 ms burst duration period 300 ms 50 Ohm 0,5 kV : sanction A 2 kV : sanction B EN55082-2 with : EN61000-4-4 IEC801-4 © Gaia Converter FC97-006.03/06 Revision M 8 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-10 Standard Input Series 11- Description of Protections 11-1 Input Undervoltage Lock-out (UVLO) The input undervoltage lock-out protection device turnson and turns-off the output voltage when the input bus voltage reaches the undervoltage lock-out threshold. There is no hysteresis cycle at turn-on and turn-off. On Off UVLO Turn-on/Turn-off 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 200ms 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 11-3 Output Overvoltage Protection (OVP) The output overvoltage protection device protects external components against high voltage or possible overvoltages which can be supplied by the module (i.e in case of internal failure). It consists of a zener diode clamping the output voltage; under worst case conditions this zener diode will short-circuit. The output voltage protection is not designed to withstand externally applied output overvoltages to protect the module itself. © Gaia Converter FC97-006.03/06 Revision M 5 9 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 12- Application Notes 12-1 Connection of Outputs in Series Any of the bi output converters can be configured to produce an output of 10V (+/-5 output models), 24V (+/-12V output models), or 30V (+/-15V output models) by connecting the load across the output (+) and the output (-) with either output grounded, and leaving the common pin floating. VI +Vo Go GI -Vo VI Vo GI Go 2 x Vo 12-2 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. 2 x Vo VI Vo GI Go 5 12-3 Connection of Modules in Parallel Several converters with equal output voltage can be connected in parallel to increase power. Nevertheless some cares have to be taken in particular as the output voltage of each converter is slightly different, when paralleling, the converter with the highest output voltage will source the most current. However the GAIA Converter modules are designed with a “soft’’ output voltage versus current characteristic. This causes the output voltage of each converter to automatically adjust downward as its current increases so each converter very approximately shares the total output current. It is important that each converter has approximately the same impedance between their output and the common load. © Gaia Converter FC97-006.03/06 Revision M VI Vo Vo GI Go VI Vo GI Go 10 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 13- Dimensions Dimensions are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated. Weight : 20 grams (0.7 Ozs) max. 40 26 (1.58") (1.03") 7,60 8 (0.30") (0.32") 5 min (0.20") 26,20 10,16 (1.03") (0.40") 20,32 35.56 (0.80") (1,40") Pin dimensions : O 0,73 mm (0.03 ”) Metallic case black anodized coating Matte tin plating finished pin 14- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 5 15- Connections 4 5 1 2 6 Pin Bi Output Single Output 1 + Input (Vi) + Input (Vi) 2 No pin No pin 3 - Input (Gi) - Input (Gi) 4 Output + (+Vo) Output (Vo) 5 Common (Go) No pin 6 Output - (-Vo) Common (Go) 3 Bottom view © Gaia Converter FC97-006.03/06 Revision M 11 For locations, phone, fax, E-Mail see back cover International Headquarters Marketing and Sales department GAÏA Converter - France Address : B.P. 14 - MERIGNAC - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAÏA Converter Canada, Inc Address : 6611 Thimens ST-LAURENT, QUEBEC - CANADA H4S 1W2 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 FC97-004.03/06 Revision M Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :