PD-94533P M3G-SERIES 70V Input, Triple 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 AluminumSilicon-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-PRF-38534, 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. 1 M3G Features Total Dose > 200 kRads(Si) typically usable to > 300 kRads(Si) SEE Hardened to LET up to 82 MeV.cm2/mg Low Input & Output Noise Low Weight < 110 grams Magnetically Coupled Feedback 60V to 120V 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 82% -55°C to +125°C Operating Temperature Range 100M @ 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 Geostationary Earth Orbit Satellites (GEO) Deep Space Satellites / Probes Strategic Weapons and Communication System 2016-06-30 M3G-SERIES (70V Input, Triple Output) Circuit Description The M3G-Series converters utilize a single-ended forward topology with resonant reset. The nominal switching frequency is 500 kHz.. 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. An internal EMI filter reduces the conducted emissions to less than 5mArms 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 58 volts and will shut down when the input voltage drops 54 volts. The four volt of hysteresis reduces the possibility of line noise interfering with the converter’s start-up and shut down. 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 de-rating to the requirements of MIL-STD-975 and MILSTD-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 de-rating of the radiation hardened power MOSFET virtually eliminates the possibility of SEGR and SEB. A magnetic feedback circuit is utilized instead of opto-couplers to minimize temperature, radiation and aging sensitivity. PSPICE and Rad SPICE 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). . 2 2016-06-30 M3G-SERIES (70V Input, Triple Output) Specifications Absolute Maximum Ratings Input voltage range Recommended Operating Conditions -0.5VDC to +150VDC Output power Internally limited Lead temperature Operating temperature Storage temperature Input voltage range +60VDC to +120VDC 1 +60VDC to +100VDC Input voltage range +300°C for 10 seconds -55°C to +135°C -55°C to +135°C 0 to Max. Rated Output power Operating temperature Operating temperature1 1 2 2 -55°C to +125°C -55°C to +70°C Meets de-rating per MIL-STD-975 For operation at +125°C see table note 15 Electrical Performance Characteristics Parameter Input voltage Group A Subgroup Conditions -55°C TC +85°C VIN = 70V DC ± 5%, CL = 0 unless otherwise specified 1,2,3 Note 2 Output voltage (VOUT) (main) M3G700512T (aux.) M3G700515T (aux.) (main) M3G700512T (aux.) M3G700515T (aux.) Output power (POUT) 1 IOUT = 100% rated load, Note 5 Output current (IOUT) (main) M3G700512T (aux.) M3G700515T (aux.) Line regulation (VRLINE ) (main) M3G700512T (aux.) M3G700515T (aux.) Load regulation (VRLOAD ) (main) M3G700512T (aux.) M3G700515T (aux.) 1,2,3 Min Nom Max 60 70 100 4.98 5.00 5.02 ±11.50 ±11.80 ±12.10 ±14.60 ±14.90 ±15.20 Unit V V 4.93 ±11.30 ±14.40 5.07 ±12.30 ±15.40 VIN = 60, 70, 100 Volts, Note 2 0 40 W VIN = 60, 70, 100 Volts, Notes 2,3,4,5 400 83 67 4000 ±833 ±667 mA -10 -120 -150 10 120 150 -50 -400 -500 50 400 500 -3.5 -3.0 2,3 1,2,3 Limits 1,2,3 VIN = 60, 70, 100 Volts IOUT =10%, 50%, 100% rated Note 5, 14 1,2,3 IOUT = 10%, 50%, 100% rated VIN = 60, 70, 100 Volts Notes 5,13 Cross regulation (VRCROSS) M3G700512T (aux.) M3G700515T (aux.) 1,2,3 VIN = 60, 70, 100 Volts IOUT = 2.5A to 1A and 2.5A to 4A on main and ±half rated on aux. outputs Input current (IIN) 1,2,3 IOUT = 0, Pin 3 open Pin 3 shorted to pin 2 35 2.0 3.5 3.0 50 5.0 1,2,3 VIN = 60, 70, 100 Volts 25 30 30 50 60 75 mVp-p 1,2,3 Sync. Input (Pin 4) open 500 550 kHz Output ripple (VRIP) (main) 700512T (aux.) 700515T (aux.) Switching frequency (FS) 450 mV mV % mA For Notes to Electrical Performance Characteristics, refer to page 5 3 2016-06-30 M3G-SERIES (70V Input, Triple Output) Electrical Performance Characteristics (continued) Parameter Efficiency (EFF) Group A Subgroup 1,2,3 Inhibit input open circuit voltage drive current (sink) voltage range Power dissipation, load fault (PD) Output response to step load changes (VTLD) Recovery time, step load changes (TTLD) Nom 78 82 -0.5 Ext. Clock on Sync. Input (Pin 4) Note 1 450 4.0 -0.5 40 20 Unit % 5.0 100 50 V A V 600 10.0 0.5 80 kHz V V V/s % VOUT = 90% of Nominal, Note 5 135 % 1,2,3 Short Circuit, Overload, Note 8 18 W 4,5,6 Half Load to/from Full Load, Notes 5,9 300 mVpk 4,5,6 Half Load to/from Full Load, Note 5,9,10 200 s 300 mVpk 200 s 500 750 5.0 mV mV ms 1000 200 µF Recovery time, step line changes (TTLN) Turn-on response Overshoot (VOS) 60V to/from 100V IOUT = 100% rated load, Notes 1. 5,10,11 4,5,6 -300 50 -300 50 No Load, Full Load Notes 5,12 1.0 Capacitive load (CL) IOUT = 100% rated load, No effect on DC performance, Notes 1, 5, 7 (main) (Each aux. output) Line rejection 1 DC to 50 kHz, Notes 1, 5 IOUT = 100% rated load 40 Input to Output or Any Pin to Case except pin 10, test @ 500VDC 100 Device weight MTBF Max 1,2,3 60V to/from 100V IOUT = 100% rated load, Notes1, 5,11 Isolation Min 3.0 Output response to step line changes (VTLN) (main) (aux.) Turn-on delay (TDLY) Limits Note 1 Synchronization input frequency range pulse high level pulse low level pulse transition time pulse duty cycle Current limit point Expressed as a percentage of full rated output power Conditions -55°C TC +85°C VIN = 70V DC ± 5%, CL = 0 unless otherwise specified IOUT = 100% rated load Note 5 60 dB M 110 MIL-HDBK-217F2, SF, 35°C 5 x 106 g Hrs For Notes to Electrical Performance Characteristics, refer to page 5 4 2016-06-30 M3G-SERIES (70V Input, Triple Output) Notes: Electrical Performance Characteristics Table 1. Parameter is tested as part of design characterization or after design changes. Thereafter, parameter shall be guaranteed to the limits specified.. 2. Parameter verified during line and load regulation tests. 3. 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 out put power, whichever Is greater, be taken from the main (+5 volt) output. 4. 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. 5. 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. 6. Guaranteed for a D.C. to 20 MHz bandwidth. Tested using a 20 kHz to 10 MHz bandwidth. 7. 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. 8. Overload power dissipation is defined as the device power dissipation with the load set such that VOUT = 90% of nominal. 9. Load step transition time 10 s. 10. Recovery time is measured from the initiation of the transient to where VOUT has returned to within ±1% of its steady state value. 11. Line step transition time 100 s. 12. 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 VOUT = 90% of nominal. 13. Load Regulation relative to output voltage at 50% rated load. 14. Line Regulation relative to output voltage at 70Vdc input. 15. Although operation at temperatures between +85°C and +125°C is guaranteed, no parametric limits are specified. Radiation Performance Characteristics Test Conditions Min Typ Unit Total Ionizing Dose (Gamma) MIL-STD-883, Method 1019 Operating bias applied during exposure, Full Rated Load, VIN = 70V 200 300 kRads (Si) Dose Rate (Gamma Dot) Temporary Saturation Survival MIL-STD-883, Method 1023 Operating bias applied during exposure, Full Rated Load, VIN = 70V 1E8 4E10 1E11 MIL-STD-883, Method 1017 8E12 1E13 Neutron Fluence Single Event Effects SEU, SEL, SEGR, SEB Heavy ions (LET) Operating bias applied during exposure, Full Rated Load, VIN = 70V Test lab: Brookhaven National Laboratory, Tandem Van de Graaff Generator 82 Rads (Si)/sec Neutrons/cm2 MeVcm2 /mg IR HiRel currently does not have a DLA Land and Maritime certified Radiation Hardness Assurance Program. 5 2016-06-30 M3G-SERIES (70V Input, Triple Output) Fig 1. Block Diagram - Triple Output Vin EMI FILTER 1 +10.5V UNDER VOLTAGE LOCKOUT & INHIBIT INHIBIT 3 BIAS SUPPLY +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 13 2 +5V + +5V EA - SYNC. INPUT 4 + OSCILLATOR SYNC. OUTPUT PWM 5 - RAMP GENERATOR REF SAMPLE & HOLD FEEDBACK TRIGGER Fig 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 6 0.1 0.2 0.3 0.4 0.5 0.6 ±12V Load Current ( Amps each ) 0.7 0.8 0.9 1 2016-06-30 M3G-SERIES (70V Input, Triple Output) Fig 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 0.1 0.2 0.3 0.4 0.5 0.6 ±15V Load Current ( Amps each ) 0.7 0.8 0.9 1 Fig 4. Line Rejection, Main Output 0 -10 -20 -30 dB -40 -50 -60 -70 -80 -90 -100 1E2 1E3 1E4 1E5 Frequency ( Hz ) 7 2016-06-30 M3G-SERIES (70V Input, Triple Output) Fig 5. Line Rejection, Aux. Outputs 0 -10 -20 -30 dB -40 -50 -60 -70 -80 -90 -100 1E2 1E3 1E4 1E5 Frequency ( Hz ) Fig 6. Conducted Emissions, Normal Mode 100 90 80 70 MIL-STD-461C CE03 LIMIT dB-uA 60 50 40 30 20 10 0 1E3 1E4 1E5 1E6 1E7 1E8 Frequency ( Hz ) 8 2016-06-30 M3G-SERIES (70V Input, Triple Output) Fig 7. Conducted Emissions, Common Mode 100 90 80 70 MIL-STD-461C CE03 LIMIT dB-uA 60 50 40 30 20 10 0 1E3 1E4 1E5 1E6 1E7 1E8 Frequency ( Hz ) 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 HiRel 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 HiRel. 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. 2. Place the gasket on the surface reserved for the converter and line it up with the mounting holes. 3. Place the converter on the gasket and line both up with mounting holes. 4. Install screws using appropriate washers and tighten by hand (~ 4 in·oz) in the sequence shown below. 5. Tighten the screws with an appropriate torque driver. Torque the screws up to 6 in·lb in the sequence shown above. 9 2016-06-30 M3G-SERIES (70V Input, Triple Output) Mechanical Outline 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. 5 62 .0 R0 0.25 0.25 0.14 0.475 MAX. 0.40 Tolerance : .XX .XXX ±0.01 ±0.005 Pin Designation 10 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 2016-06-30 M3G-SERIES (70V Input, Triple Output) Device Screening Requirement MIL-STD-883 Method No Suffix CK EM Temperature Range — -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 Temperature Cycle 1010 Cond C Cond C Cond C Constant Acceleration PIND 2001, Y1 Axis 2020 1015 Final Electrical (Group A) PDA MIL-PRF-38534 & Specification MIL-PRF-38534 3000 Gs Cond A 320 hrs @ 125°C (2 x 160 hrs) -55°C, +25°C, +85°C 2% 3000 Gs N/A Burn-In 3000 Gs Cond A 320 hrs @ 125°C (2 x 160 hrs) -55°C, +25°C, +85°C 2% Seal, Fine and Gross 1014 Cond A, C Cond A, C Cond A Radiographic 2012 Yes Yes N/A External Visual 2009 Yes Yes 48 hrs @ 125°C -55°C, +25°C, +85°C N/A Notes: 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. Any Engineering Model (EM) build with the “EM” Suffix shall only be form, fit and functional equivalent to its Flight Model (FM) counterpart, and it may not meet the radiation performance. The EM Model shall not be expected comply with MIL-PRF-38534 flight quality/workmanship standards, and configuration control. An EM build may use electrical equivalent commercial grade components. IR HiRel will provide a list of non-compliance items upon request. Part Numbering M3G 70 05 15 T /XX X Model Nominal Input Voltage 70 = 70V 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 IR HiRel Headquarters: 101 N. Sepulveda Blvd., El Segundo, California 90245, USA Tel: (310) 252-7105 IR HiRel Leominster: 205 Crawford St., Leominster, Massachusetts 01453, USA Tel: (978) 534-5776 IR HiRel San Jose: 2520 Junction Avenue, San Jose, California 95134, USA Tel: (408) 434-5000 Data and specifications subject to change without notice. 11 2016-06-30 M3G-SERIES (70V Input, Triple Output) IMPORTANT NOTICE The information given in this document shall be in no event regarded as guarantee of conditions or characteristic. The data contained herein is a characterization of the component based on internal standards and is intended to demonstrate and provide guidance for typical part performance. It will require further evaluation, qualification and analysis to determine suitability in the application environment to confirm compliance to your system requirements. With respect to any example hints or any typical values stated herein and/or any information regarding the application of the product, Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind including without limitation warranties on non- infringement of intellectual property rights and any third party. In addition, any information given in this document is subject to customer’s compliance with its obligations stated in this document and any applicable legal requirements, norms and standards concerning customer’s product and any use of the product of Infineon Technologies in customer’s applications. The data contained in this document is exclusively intended for technically trained staff. It is the responsibility of any customer’s technical departments to evaluate the suitability of the product for the intended applications and the completeness of the product information given in this document with respect to applications. For further information on the product, technology, delivery terms and conditions and prices, please contact your local sales representative or go to (www.infineon.com/hirel). WARNING Due to technical requirements products may contain dangerous substances. For information on the types in question, please contact your nearest Infineon Technologies office. 12 2016-06-30