PD-94532O M3G-SERIES 70V Input, Single/Dual Output HYBRID - HIGH RELIABILITY RADIATION HARDENED DC-DC CONVERTER Description The M3G-Series of DC-DC converters are radiation hardened, high reliability converters designed for extended operation in hostile environments. Their small size and low weight make them ideal for applications such as geostationary earth orbit satellites and deep space probes. They exhibit a high tolerance to total ionizing dose, single event effects and environmental stresses such as temperature extremes, mechanical shock, and vibration. The converters incorporate a fixed frequency single ended forward topology with magnetic feedback and an internal EMI filter that utilizes multilayer ceramic capacitors that are subjected to extensive lot screening for optimum reliability. By using two stage filtering these converters produce low input and output noise. External inhibit and synchronization input and output allow these converters to be easily incorporated into larger power systems. They are enclosed in a hermetic 3" x 2" x 0.475" package constructed of an Aluminum-Silicon-Carbide (AlSiC) base and an Alloy 48 ring frame and they weigh less than 110 grams. The package utilizes rugged ceramic feed-through copper core pins and is sealed using parallel seam welding. Manufactured in a facility fully qualified to MIL-PRF38534, these converters are fabricated utlizing DLA Land and Maritime qualified processes. For available screening options, refer to device screening table in the data sheet. Non-flight versions of the M3G-Series converters are available for system development purposes. Variations in electrical specifications and screening to meet custom requirements can be accommodated. www.irf.com M3G Features n Total Dose > 200KRad(Si), typically usable to > 300KRad(Si) n SEE Hardened to LET up to 82 MeV.cm2/mg n Low Weight, < 110 grams n Low Input & Output Noise n Magnetically Coupled Feedback n 60V to 120V DC Input Range n Up to 40W Output Power n Single and Dual Output Models Include 3.3, 5, 12, 15, ±5, ±12 and ±15V n High Efficiency - to 82% n -55°C to +125°C Operating Temperature Range n 100MΩ @ 500V DC Isolation n Under-Voltage Lockout n Short Circuit and Overload Protection n Output Over Voltage Limiter n Remote Sense on Single Output Models n Adjustable Output Voltage for Duals n Synchronization Input and Output n External Inhibit n > 5,000,000 Hour MTBF Applications n n n Geostationary Earth Orbit Satellites (GEO) Deep Space Satellites / Probes Strategic Weapons and Communication Systems 1 09/12/12 M3G-SERIES (70V Input, Single/Dual Output) Circuit Description The M3G-Series converters utilize a single-ended forward topology with resonant reset. The nominal switching frequency is 500kHz. Electrical isolation and tight output regulation are achieved through the use of a magnetically coupled feedback. Voltage feed-forward with duty factor limiting provides high line rejection and protection against output over voltage in the event of an internal control loop failure. This mechanism limits the maximum output voltage to approximately 20% over the nominal regardless of the line voltage. An internal EMI filter reduces the conducted emissions to less than 5mA rms on the input power leads. A two-stage output filter reduces the typical output ripple to less than 20mV peak-to-peak. Output current is limited under any load fault condition to approximately 125% of rated. An overload condition causes the converter output to behave like a constant current source with the output voltage dropping below nominal. The converter will resume normal operation when the load current is reduced below the current limit point. This protects the converter from both overload and short circuit conditions. The current limit point exhibits a slightly negative temperature coefficient to reduce the possibility of thermal runaway. An under-voltage lockout circuit prohibits the converter from operating when the line voltage is too low to maintain the output voltage. The converter will not start until the line voltage rises to approximately 58 volts and will shut down when the input voltage drops below 54 volts. The four volts of hysteresis reduces the possibility of line noise interfering with the converter’s start-up and shut down. 2 An external inhibit port is provided to control converter operation. The nominal threshold relative to the input return (pin 2) is 1.4V. If 2.0 volts or greater are applied to the Inhibit pin (pin 3) then the converter will operate normally. A voltage of 0.8V or less will cause the converter to shut-down. The pin may be left open for normal operation and has a nominal open circuit voltage of 4.0V. Synchronization input and output allow multiple converters to operate at a common switching frequency. Converters can be synchronized to one another or to an externally provided clock. This can be used to eliminate beat frequency noise or to avoid creating noise at certain frequencies for sensitive systems. Remote sense is provided on the single output models to compensate for voltage drops in the interconnects between the converter and the load. The output voltage of dual output models can be adjusted by a single external resistor. Design Methodology The M3G-Series was developed using a proven conservative design methodology which includes selecting radiation tolerant and established reliability components and fully derating to the requirements of MIL-STD-975 and MIL-STD-1547 except for the CDR type ceramic capacitors, a capacitor with 50V rating is used for in-circuit voltage stress of less than 10V. Careful sizing of decoupling capacitors and current limiting resistors minimizes the possibility of photo-current burn-out. Heavy derating of the radiation hardened power MOSFET virtually eliminates the possibility of SEGR and SEB. A magnetic feedback circuit is utilized instead of optocouplers to minimize temperature, radiation and aging sensitivity. PSPICE and RadSPICE were used extensively to predict and optimize circuit performance for both beginning and end-of-life. Thorough design analyses include Radiation Susceptibility (TREE ), Worst Case, Stress, Thermal, Failure Modes and Effects (FMEA) and Reliability (MTBF). www.irf.com M3G-SERIES (70V Input, Single/Dual Output) Specifications Absolute Maximum Ratings Recommended Operating Conditions Input voltage range Output power Lead temperature Operating temperature Storage temperature Input voltage range -0.5Vdc to +150Vdc Internally limited +300°C for 10 seconds -55°C to +135°C -55°C to +135°C +60Vdc to +120Vdc +60Vdc to +100Vdc 0 to Max. Rated -55°C to +125°C -55°C to +70°C 1 Input voltage range Output power 2 Operating temperature 1 Operating temperature 1 Meets derating per MIL-STD-975 For operation at +125°C see table note 13 2 Electrical Performance Characteristics Parameter Group A Subgroup Conditions -55°C ≤ TC ≤ +85°C VIN = 70V DC ± 5%, CL = 0 unless otherwise specified Input Voltage Output Voltage (Vout) M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D Output power ( POUT ) M3G7003R3S All Others Output current ( IOUT ) M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D Line regulation ( VRLINE ) Limits Min Nom Max Unit 60 70 100 V 3.30 5.00 12.00 15.00 ±5.00 ±12.00 ±15.00 3.32 5.02 12.05 15.06 ±5.02 ±12.05 ±15.06 1 1 1 1 1 1 1 IOUT = 100% rated load Note 4 3.28 4.98 11.95 14.94 ±4.98 ±11.95 ±14.94 2,3 2,3 2,3 2,3 2,3 2,3 2,3 IOUT = 100% rated load Note 4 3.24 4.93 11.84 14.80 ±4.93 ±11.84 ±14.80 3.36 5.07 12.16 15.20 ±5.07 ±12.16 ±15.20 1,2,3 VIN = 60, 70, 100 Volts, Note 2 0 0 30 40 1,2,3 VIN = 60, 70, 100 Volts, Note 2 Either Output, Note 3 Either Output, Note 3 Either Output, Note 3 0 0 0 0 0 0 0 9.1 8.0 3.34 2.67 6.4 2.67 2.14 A VIN = 60, 70, 100 Volts -10 10 mV -0.5 0.5 % -5.0 -3.0 -3.0 5.0 3.0 3.0 % 1,2,3 V W IOUT = 0, 50%, 100% rated, Note 4 Load regulation ( VRLOAD ) 1,2,3 IOUT = 0, 50%, 100% rated, Note 4 VIN = 60, 70, 100 Volts Cross regulation ( VRCROSS ) M3G7005D M3G7012D M3G7015D 1,2,3 Duals only, Note 5 VIN = 60, 70, 100 Volts For Notes to Specifications, refer to page 5 www.irf.com 3 M3G-SERIES (70V Input, Single/Dual Output) Electrical Performance Characteristics Parameter Input current (IIN) Output ripple ( VRIP ) M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D Switching frequency ( FS ) Efficiency ( EFF ) M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D Group A Subgroup ( continued ) Conditions -55°C ≤ TC ≤ +85°C VIN = 70V DC ± 5%, CL = 0 unless otherwise specified 1,2,3 1,2,3 Limits Min Nom mA IOUT = 0, Pin 3 open 30 50 2.0 5.0 VIN = 60, 70, 100 Volts IOUT = 100% rated load Notes 4, 6 15 20 25 25 20 30 30 35 50 60 80 50 60 60 mV p-p 550 KHz Sync. Input (Pin 4) open 450 500 1,2,3 IOUT = 100% rated load Note 4 70 77 78 79 77 78 79 75 81 82 83 81 82 83 Note 1 3.0 -0.5 Synchronization Input frequency range pulse high level pulse low level pulse transition time pulse duty cycle Unit Pin 3 shorted to pin 2 1,2,3 Inhibit Input open circuit voltage drive current ( sink ) voltage range Max Ext. Clock on Sync. Input (Pin 4) Note 1 450 4.0 -0.5 40 20 % 5.0 100 50 V µA V 600 10.0 0.5 80 KHz V V V/µs % Current Limit Point Expressed as a percentage of full rated load current 1,2,3 V out = 90% of Nominal, Note 4 145 % Power dissipation, load fault (PD) 1,2,3 Short Circuit, Overload, Note 8 20 W Output response to step load changes (VTLD) 4,5,6 Half Load to/from Full Load, Notes 4,9 300 mV pk 200 µs -300 300 mV pk 1.0 10 5.0 % ms Recovery time, step line changes (TTLN) 60V to/from 100V IOUT = 100% rated load, Notes 1,4,10,11 Output response to step line changes (VTLN) 60V to/from 100V IOUT = 100% rated load, Notes 1, 4,11 Turn-on Response Overshoot (VOS) Turn-on Delay (TDLY) 4,5,6 No Load, Full Load Notes 4,12 -300 50 For Notes to Specifications, refer to page 5 4 www.irf.com M3G-SERIES (70V Input, Single/Dual Output) Electrical Performance Characteristics Parameter Group A Subgroup Capacitive Load (CL) M3G7003R3S M3G7005S M3G7012S M3G7015S M3G7005D M3G7012D M3G7015D Conditions -55°C ≤ TC ≤ +85°C VIN = 70V DC ± 5%, CL = 0 unless otherwise specified Limits Min Each output on duals 1 IOUT = 100% rated load DC to 50KHz, Notes 1, 4 40 Input to Output or Any Pin to Case except pin 6, test @ 500VDC 100 Device Weight MTBF Nom IOUT = 100% rated load No effect on DC performance Notes 1, 4, 7 Line Rejection Isolation ( continued ) Max Unit 2200 1000 180 120 500 90 60 µF 60 dB MΩ 110 MIL-HDBK-217F2, SF, 35°C 5 x 106 g Hrs Notes: Electrical Performance Characteristics 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Parameter is tested as part of design characterization or after design changes. Thereafter, parameter shall be guaranteed to the limits specified. Parameter verified during line and load regulation tests. Output load current must be distributed such that at least 20% of the total load current is being provided by one of the outputs. Load current split equally between outputs on dual output models. Cross regulation is measured with 20% rated load on output under test while changing the load on the other output from 20% to 80% of rated. Guaranteed for a D.C. to 20MHz bandwidth. Tested using a 20KHz to 10MHz bandwidth. Capacitive load may be any value from 0 to the maximum limit without compromising dc performance. A capacitive load in excess of the maximum limit may interfere with the proper operation of the converter’s overload protection, causing erratic behavior during turn-on. Overload power dissipation is defined as the device power dissipation with the load set such that V OUT = 90% of nominal. Load step transition time ³ 10 µs. Recovery time is measured from the initiation of the transient to where VOUT has returned to within ±1% of its steady state value. Line step transition time ³ 100 µs. Turn-on delay time from either a step application of input power or a logic low to a logic high transition on the inhibit pin (pin 3) to the point where V OUT = 90% of nominal. Although operation at temperatures between +85°C and +125°C is guaranteed, no parametric limits are specified. www.irf.com 5 M3G-SERIES (70V Input, Single/Dual Output) Figure 1. Block Diagram - Single Output Vin 1 EMI FILTER UNDER VOLTAGE LOCKOUT & INHIBIT INHIBIT 3 +10.5V BIAS SUPPLY +5V 13 +OUTPUT 12 RETURN SHORT CIRCUIT & OVERLOAD LEVEL TRANSLATOR & FET DRIVE RETURN 2 10 +SENSE 9 -SENSE 6 CASE GROUND 13 +OUTPUT 12 RETURN 11 -OUTPUT 8 ADJUST + +5V + +5V RS - EA - SYNC. 4 INPUT + OSCILLATOR RAMP GENERATOR SAMPLE & HOLD PWM SYNC. 5 OUTPUT - FEEDBACK TRIGGER Figure 2. Block Diagram - Dual Output Vin 1 INHIBIT 3 EMI FILTER UNDER VOLTAGE LOCKOUT & INHIBIT +10.5V BIAS SUPPLY +5V SHORT CIRCUIT & OVERLOAD LEVEL TRANSLATOR & FET DRIVE RETURN 2 +5V + +5V - EA - + SYNC. 4 INPUT OSCILLATOR SYNC. 5 OUTPUT + PWM - RAMP GENERATOR SAMPLE & HOLD 6 FEEDBACK TRIGGER 6 CASE GROUND www.irf.com M3G-SERIES (70V Input, Single/Dual Output) Radiation Performance Characteristics Test Inspection Method Total Ionizing Dose (Gamma) Operating bias applied during exposure, Min Typ Unit 200 300 Krads(Si) MIL-PRF-883, Method 1019 Full Rated Load, VIN = 70V Dose Rate (Gamma Dot) Temporary Saturation Survival Neutron Fluence MIL-STD-883, Method 1023 Operating bias applied during exposure, Full Rated Load, VIN = 70V 4E10 1E8 1E11 Rads(Si)/sec MIL-STD-883, Method 1017 8E12 1E13 Neutrons/cm2 Heavy Ions (LET) Single Event Effects SEU, SEL, SEGR, SEB Operating bias applied during exposure, Full Rated Load, VIN = 70V 82 2 MeVxcm /mg Test lab: Brookhaven National Laboratory, Tandem Van de Graaff Generator International Rectifier currently does not have a DLA Land and Maritime certified Radiation Hardness Assurance Program. www.irf.com 7 M3G-SERIES (70V Input, Single/Dual Output) Application Notes: A) Attachment of the Converter The following procedure is recommended for mounting the converter for optimum cooling and to circumvent any potential damage to the converter. Ensure that flatness of the plate where M3G converter to be mounted is no greater than 0.003” per linear inch. It is recommended that a thermally conductive gasket is used to promote the thermal transfer and to fill any voids existing between the two surfaces. IR recommends Sil-Pad 2000 with the thickness of 0.010". The shape of the gasket should match the footprint of the converter including the mounting flanges. The gasket is available from IR. The M3G-series converter requires either M3 or 4-40 size screws for attachment purposes. The procedure for mounting the converter is as follows: 1. Check all mounting surfaces and remove foreign material, burrs, if any or anything that may interfere with the attachment of the converter. Place the gasket on the surface reserved for the converter and line it up with the mounting holes. Place the converter on the gasket and line both up with mounting holes. Install screws using appropriate washers and tighten by hand (~ 4 in·oz) in the sequence shown below. 2. 3. 4. 5. Tighten the screws with an appropriate torque driver. Torque the screws up to 6 in·lb in the sequence shown above. 8 www.irf.com M3G-SERIES (70V Input, Single/Dual Output) B) Output Voltage Adjustment. Single Output: Adjustment of the output voltage requires the +Sense pin be connected in one of two ways as shown in Figures 3 and 4 below. Use the equations and circuit configurations provided to calculate the required resistance ( RADJ ) for the applicable voltage adjust range. The output adjustment is limited to 0 to +10% range for reliable operation. Fig 3. Configuration for Adjusting Single Output Voltage from +0.25V to +10% +Out 13 Out 12 Return M3G (single output) +Sense 10 -Sense Radj 9 Fig 4. Configuration for Adjusting Single Output Voltage from 0 to +0.25V +Out 13 Out 12 Return M3G (single output) Radj +Sense 10 -Sense www.irf.com 9 9 M3G-SERIES (70V Input, Single/Dual Output) For M3GXX03R3S: Using the configuration of Fig 8 and where RADJ is in Ohms and 3.513 < VOUT < 3.630 RADJ = 495 VOUT − 3.513 Using the configuration of Fig 9 and where RADJ is in Ohms and 3.300 < VOUT < 3.513 (VOUT − 3.300) (3.513 − VOUT ) RADJ = 150 For M3GXX05S: Using the configuration of Fig 8 and where RADJ is in Ohms and 5.250 < VOUT < 5.500 R ADJ = 750 VOUT − 5.25 Using the configuration of Fig 9 and where RADJ is in Ohms and 5.500 < VOUT < 5.250 R ADJ = 150 (V O U T − 5 .000 ) (5 .250 − V O UT ) For M3GXX12S: Using the configuration of Fig 8 and where RADJ is in Ohms and 12.312 RADJ = 1800 VOUT − 12.312 Using the configuration of Fig 9 and where RADJ is in Ohms and 12.000 RADJ = 150 < VOUT < 16.500 2250 VOUT − 15.315 Using the configuration of Fig 9 and where RADJ is in Ohms and 15.000 RADJ = 150 10 < VOUT < 12.312 (VOUT −12.000) (12.312 −VOUT ) For M3GXX15S: Using the configuration of Fig 8 and where RADJ is in Ohms and 15.315 RADJ = < VOUT < 13.200 < VOUT < 15.315 (VOUT −15.000) (15.315 −VOUT ) www.irf.com M3G-SERIES (70V Input, Single/Dual Output) Dual Output: The dual output models have an Adjust Pin which can be connected through a resistor ( RADJ ) to either output. This allows the outputs to be reliably adjusted by approximately +10% to -25% of the nominal output voltage. Refer to Figure 5 and use equations provided to calculate the required resistance ( RADJ ). Fig 5. Configuration for Adjusting Dual Output Voltage +Out 13 Note 1 Out 12 Return M3G (Dual Output) -Out 11 Notes: 1. For Vout < Vnom 2. For Vout > Vnom Note 2 Radj Adjust 8 For all Dual Output Models, to adjust the output voltage higher: R ADJ = 3.48 (1.64VNOM − 1) − 51 VOUT − VNOM where: RADJ is in KOhms RADJ is connected to -Out pin and VNOM < VOUT < 1.1VNOM (Fig. 5, Note 2) VNOM is the nominal output voltage with the Adjust pin left open VOUT is the desired output voltage For all Dual Output Models, to adjust the output voltage lower: R ADJ = 3.48 (1.64VNOM − 1)(1.64VOUT − 1) − 51 V NOM − VOUT where: RADJ is in KOhms RADJ is connected to +Out pin and 0.75VNOM < VOUT < VNOM (Fig. 5, Note 1) VNOM is the nominal output voltage with the Adjust pin left open VOUT is the desired output voltage www.irf.com 11 M3G-SERIES (70V Input, Single/Dual Output) Mechanical Diagram 3.055 MAX. 0.500 0.080 Max. 2.00 R0.0625 4 places 0.30 0.50 0.20 13 1 12 2 11 10 0.60 9 3 8 4 7 5 6 2.055 MAX. 2.30 0.200 Typ. Noncum. 1.400 Ref. 2.500 Pin Ø0.040 0.45 1.10 0.260 FLANGE DETAIL 3.50 Ref. . R0 0.25 0.25 2 06 5 0.14 0.475 MAX. 0.40 Tolerance : .XX .XXX ±0.01 ±0.005 Pin Designation (Single/Dual) Pin # 12 Designation Pin # Designation 1 + Input 8 NC / Adjust 2 Input Return 9 - Sense / NC 3 Inhibit 10 + Sense / NC 4 Sync. Input 11 NC / - Output 5 Sync. Output 12 Output Return 6 7 Case Ground NC 13 + Output www.irf.com M3G-SERIES (70V Input, Single/Dual Output) Device Screening Requirement MIL-STD-883 Method Temperature Range Element Evaluation No Suffix d CK d EM -55°C to +85°C -55°C to +85°C -55°C to +85°C Class K Class K N/A N/A MIL-PRF-38534 Non-Destructive Bond Pull 2023 Yes Yes Internal Visual 2017 Yes Yes c Temperature Cycle 1010 Cond C Cond C Cond C Constant Acceleration 2001, Y1 Axis 3000 Gs 3000 Gs 3000 Gs PIND 2020 Cond A Cond A N/A Burn-In 1015 320 hrs @ 125°C 320 hrs @ 125°C 48 hrs @ 125°C ( 2 x 160 hrs ) ( 2 x 160 hrs ) Final Electrical MIL-PRF-38534 -55°C, +25°C, -55°C, +25°C, -55°C, +25°C, ( Group A ) & Specification +85°C +85°C +85°C PDA MIL-PRF-38534 2% 2% N/A Seal, Fine and Gross 1014 Cond A, C Cond A, C Cond A Radiographic 2012 Yes Yes N/A External Visual 2009 Yes Yes c Notes: c d Best commercial practice. CK is a DLA Land and Maritime (formerly DSCC) part marking used to designate a Class K compliant hybrid. The CK marking does not indicate the hybrid is radiation certified. No Suffix is a radiation rated device but not available as a DLA Land and Maritime qualified SMD per MIL-PRF-38534. International Rectifier currently does not have a DLA Land and Maritime certified Radiation Hardness Assurance Program. Part Numbering M3G 70 05 S /XX X Model Nominal Input Voltage 70 = 70V Output Voltage 03R3 = 3.3V, 05 = 5V 12 = 12V, 15 = 15V Lead Finish for CK only C = Gold Plated A = Solder Dipped Blank for No Suffix and EM Lead Finish for No Suffix = Gold Plated Lead Finish for EM is Gold Plated or Solder Dipped depending on availability Screening Level (Please refer to Screening Table) No Suffix, CK, EM Output S = Single D = Dual WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105 IR SAN JOSE: 2520 Junction Avenue, San Jose, California 95134, Tel: (408) 434-5000 Visit us at www.irf.com for sales contact information. Data and specifications subject to change without notice. 09/2012 www.irf.com 13