PD-94559M M3G-SERIES HYBRID-HIGH RELIABILITY RADIATION HARDENED DC-DC CONVERTER 50V Input, Triple Output 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. These converters are capable of meeting the conducted emissions and conducted susceptibility requirements of MIL-STD-461C without additional components. 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 utilizing 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 > 200 krad(Si), typically usable to > 300 krad(Si) n n n n n n n n n n n n n n n n n SEE Hardened up to 82 MeV.cm2/mg Low Weight, < 110 grams Low Input & Output Noise Magnetically Coupled Feedback 38V to 60V DC Input Range Up to 40W Output Power Triple Output Models Include +5V and ±12V or ±15V Main Output Isolated from Dual Outputs High Efficiency - to 80% -55°C to +125°C Operating Temperature Range 100MΩ @ 500VDC Isolation Under-Voltage Lockout Synchronization Input and Output Short Circuit and Overload Protection Output Over Voltage Limiter External Inhibit 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 (50V Input, Triple 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. The main (+5 volt) output is regulated by the control loop and typically exhibits better than 1% regulation. The auxiliary (±12 volt or ±15 volt) outputs are maintained through tight coupling in the power transformer and main output filter inductor and typically exhibit better than 5% regulation. The main output and auxiliary outputs are isolated from each other. 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 36 volts and will shut down when the input voltage drops below 34 volts. This two 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. 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 (50V Input, Triple Output) Specifications Absolute Maximum Ratings Recommended Operating Conditions Input voltage range Input voltage range -0.5Vdc to +80Vdc +38Vdc to +60Vdc Output power Internally limited Output power 0 to Max. Rated Lead temperature 300°C for 10 seconds Operating case temperature 1 -55°C to +125°C Operating temperature -55°C to +135°C Storage temperature -55°C to +135°C 1 Electrical Performance Characteristics Parameter Input Voltage Group A Subgroup For operation at +125°C see table note 15 Conditions -55°C ≤ TC ≤ +85°C VIN = 28V DC ± 5%, CL = 0 unless otherwise specified Limits Unit Min Nom Max 1, 2, 3 Note 2 38 50 60 V (main) M3G500512T (aux.) M3G500515T (aux.) 1 IOUT = 100% rated load, Note 5 4.98 ±11.50 ±14.60 5.00 ±11.80 ±14.90 5.02 ±12.10 ±15.20 (main) M3G500512T (aux.) M3G500515T (aux.) 2, 3 IOUT = 100% rated load, Note 5 4.93 ±11.30 ±14.40 5.07 ±12.30 ±15.40 1, 2, 3 VIN = 38, 50, 60 Volts, Note 2 0 40 W 1, 2, 3 VIN = 38, 50, 60 Volts, Notes 2,3,4,5 400 ±83 ±67 4000 ±833 ±667 mA 1, 2, 3 IOUT = 10%, 50%, 100% rated VIN = 38, 50, 60 Volts Note 5 -10 -120 -150 10 120 150 mV 1, 2, 3 IOUT = 10%, 50%, 100% rated VIN = 38, 50, 60 Volts Notes 5,13 -50 -400 -500 50 400 500 mV 1, 2, 3 VIN = 38, 50, 60 Volts IOUT = 2.5A to 1A and 2.5 to 4A on main output and ±half rated on aux. outputs -3.5 -3.0 3.5 3.0 Output Voltage ( Vout ) V Output power ( POUT ) Output current ( IOUT ) (main) M3G500512T (aux.) M3G500515T (aux.) Line regulation ( VRLINE ) (main) M3G500512T (aux.) M3G500515T (aux.) Load regulation ( VRLOAD ) (main) M3G500512T (aux.) M3G500515T (aux.) Cross regulation ( VRCROSS ) (main) M3G500512T (aux.) M3G500515T (aux.) % For Notes to Electrical Performance Characterstics Table, refer to page 5 www.irf.com 3 M3G-SERIES (50V Input, Triple Output) Electrical Performance Characteristics Parameter Input current ( IIN ) ( continued ) Group A Subgroup Conditions -55°C ≤ TC ≤ +85°C VIN = 28V DC ± 5%, CL = 0 unless otherwise specified 1, 2, 3 IOUT = 0, Pin 3 open 80 Pin 3 shorted to pin 2 5.0 Limits Min Nom Max Unit mA Output ripple ( VRIP ) 1, 2, 3 VIN = 38, 50, 60 Volts I OUT = 100% rated load, Notes 5, 6 Switching frequency ( FS ) 1, 2, 3 Sync. Input (Pin 4) open Efficiency ( Eff ) 1, 2, 3 (main) M3G500512T (aux.) M3G500515T (aux.) Inhibit Input open circuit voltage drive current ( sink ) voltage range 25 30 30 50 60 75 mV p-p 450 500 550 KHz IOUT = 100% rated load Note 5 75 79 Note 1 3.0 -0.5 Synchronization Input frequency range pulse high level pulse low level pulse transition time pulse duty cycle 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 0.5 80 KHz V V V/µs % Current Limit Point Expressed as a percentage of full rated output power 1, 2, 3 Vout = 90% of Nominal, Note 5 135 % 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 5,9 300 mV pk 4, 5, 6 Half Load to/from Full Load, Note 5,9,10 Recovery time, step load changes (TTLD) Output response to step line changes (VTLN) 18V to/from 50V IOUT = 100% rated load, Notes 1,5,11 Recovery time, step line changes (TTLN) 18V to/from 50V IOUT = 100% rated load, Notes 1,5,10,11 -300 -300 100 µs 300 mV pk 100 µs For Notes to Electrical Performance Characterstics Table, refer to page 5 4 www.irf.com M3G-SERIES (50V Input, Triple Output) Electrical Performance Characteristics Parameter Turn-on Response Overshoot (VOS) (main) M3G500512T (aux.) M3G500515T (aux.) Group A Subgroup ( continued ) Conditions -55°C ≤ TC ≤ +85°C VIN = 28V DC ± 5%, CL = 0 unless otherwise specified 4, 5, 6 Limits Min Nom No Load, Full Load Notes 5,12 Turn-on Delay (TDLY) 1.0 Max Unit 500 750 1000 mV 5.0 ms 1000 200 µF Capacitive Load (CL) IOUT = 100% rated load, No effect on DC performance, Notes 1, 5, 7 (main) (Each aux. output) Line Rejection Isolation 1 IOUT = 100% rated load DC to 50KHz, Notes 1, 5 40 Input to Output or Any Pin to Case except pin 10, test @ 500VDC 100 MΩ Device Weight MTBF dB 60 110 MIL-HDBK-217F2, SF, 35ºC 6 5 x 10 g Hrs Notes: Electrical Performance Characteristics 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 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. Although operation with no load is permissible, light loading on the main (+5 volt) output may cause the output voltage of the auxiliary outputs(±12 volt or ±15 volt) to drop out of regulation. It is therefore recommended that at least 200 mA or 20 percent of the total output power, whichever is greater, be taken from the main (+5 volt) output. Although operation with no load is permissible, heavy loading on the main (+5 volt) output may cause the output voltage of the auxiliary outputs(±12 volt or ±15 volt) to rise out of regulation. It is therefore recommended that at least 50 mA or 20 percent of the total output power, whichever is greater, be taken from the auxiliary (±12 volt or ±15 volt) outputs. Unless otherwise specified, “Rated” load is 20W on the main (+5 volt) output and 10 watts each on the auxiliary (±12 volt or ±15 volt) outputs. Load currents of up to 5A and ±1A on the main and auxiliary outputs respectively are acceptable as long as the total output power does not to exceed 40 watts. 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(pin3 to the point where V OUT = 90% of nominal. Load is varied for output under test while the remaining outputs are loaded at 50% of rated. Regulation relative to output voltage at 50% rated load. Although operation at temperatures between +85°C and +125°C is guaranteed, no parametric limits are specified. www.irf.com 5 M3G-SERIES (50V Input, Triple 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 = 50V Dose Rate (Gamma Dot) Temporary Saturation Survival MIL-STD-883, Method 1023 Operating bias applied during exposure, Full Rated Load, VIN = 50V 4E10 1E11 MIL-STD-883, Method 1017 8E12 1E13 Neutron Fluence 1E8 Rads(Si)/sec Neutrons/cm2 Heavy Ions (LET) Single Event Effects Operating bias applied during exposure, Full Rated Load, VIN = 50V SEU, SEL, SEGR, SEB 2 82 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. Figure 1. Block Diagram Vin 1 EMI FILTER +10.5V INHIBIT 3 UNDER VOLTAGE LOCKOUT & INHIBIT BIAS SUPPLY 13 +AUX. OUTPUT 12 AUX. RETURN 11 -AUX. OUTPUT 7 +MAIN 6 MAIN RETURN 10 CASE GROUND +5V SHORT CIRCUIT & OVERLOAD LEVEL TRANSLATOR & FET DRIVE RETURN 2 +5V + +5V EA - SYNC. 4 INPUT OSCILLATOR SYNC. 5 OUTPUT + PWM - RAMP GENERATOR REF SAMPLE & HOLD FEEDBACK TRIGGER 6 www.irf.com M3G-SERIES (50V Input, Triple Output) Figure 2. ±12V Load Regulation vs 5V Load 14 ±12V Magnitudes ( Volts ) 13.5 13 12.5 12 5V load = 4A 5V load = 2A 11.5 5V load = 0.4A 11 10.5 10 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 ±12V Load Current ( Amps each ) 0.8 0.9 1 Figure 3. ±15V Load Regulation vs 5V Load 18 17.5 ±15V Magnitudes ( Volts ) 17 16.5 16 15.5 15 5V load = 4A 14.5 5V load = 2A 14 5V load = 0.4A 13.5 13 0 www.irf.com 0.1 0.2 0.3 0.4 0.5 0.6 0.7 ±15V Load Current ( Amps each ) 0.8 0.9 1 7 M3G-SERIES (50V Input, Triple Output) Application Note: 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 the 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 (50V Input, Triple 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 2.500 0.200 Typ. Noncum. 1.400 Ref. Pin Ø0.040 0.45 1.10 0.260 FLANGE DETAIL 3.50 Ref. 2 .06 R0 0.25 0.25 5 0.14 0.475 MAX. 0.40 Tolerance : .XX .XXX ±0.01 ±0.005 Pin Designation (Triple) www.irf.com Pin # Designation Pin # Designation 1 + Input 8 NC 2 Input Return 9 NC 3 Inhibit 10 Case Ground 4 Sync. Input 11 - Aux. Output 5 Sync. Output 12 Aux. Output Return 6 Main Return 13 +Aux. Output 7 + Main Output 9 M3G-SERIES (50V Input, Triple Output) Device Screening Requirement MIL-STD-883 Method Temperature Range No Suffix d CK d EM -55°C to +85°C -55°C to +85°C -55°C to +85°C Element Evaluation MIL-PRF-38534 Class K Class K N/A Non-Destructive Bond Pull 2023 Yes Yes N/A 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 50 05 15 T /XX X Model Nominal Input Voltage 50 = 50V Main 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 T = Triple Auxiliary Output Voltage 05 = ± 5V, 12 = ± 12V 15 = ± 15V 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 10 www.irf.com