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 500 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, 9-18 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, and a permanent short circuit protection to ensure efficient module protection. 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 F : 9-18 VDC I : 18-36 VDC REDEFINING THE SOURCE OF POWER © Gaia Converter FC97-006.08/05 Revision J 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 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 / / / / / / / 9-18 9-18 9-18 9-18 9-18 9-18 9-18 VDC VDC VDC VDC VDC VDC VDC 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-F-B MGDSI-10-F-C MGDSI-10-F-E MGDSI-10-F-F MGDBI-10-F-C MGDBI-10-F-E MGDBI-10-F-F / / / / / / / 18-36 18-36 18-36 18-36 18-36 18-36 18-36 VDC VDC VDC VDC VDC VDC VDC 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 - F - C Number of Outputs : S : single output B : bi output Input voltage range : C : 4.5-5.5 VDC F : 9-18 VDC I : 18-36VDC Output voltage : See table page 1 © Gaia Converter FC97-006.08/05 Revision J 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) 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 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 Single Output MGDSI- 10 10 - C 10 - F 10 - I VDC 5 15 24 Min. - Max. VDC 4,5- 5,5 9- 18 18- 36 Maximum ms 30 30 30 Maximum mApp 50 50 30 Maximum mA 50 30 30 Maximum mA 50 30 30 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 3,3 5 12 15 3,3 5 12 15 3,3 5 12 15 Maximum % +/- 2 +/- 2 +/- 2 Maximum W 10 10 10 Maximum Maximum Maximum Maximum mA mA mA mA 2.000 2.000 800 650 2.000 2.000 800 650 2.000 2.000 800 650 Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 50 100 150 50 100 150 Maximum % +/- 1 +/- 1 +/- 1 Maximum % +/- 2,5 +/- 2,5 +/- 2,5 Typical % 77 82 83 Maximum Maximum µF µF 1.000 330 1.000 330 1.000 330 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. Full temperature range Ui min. to max. Ui nominal Full load BW = 20MHz 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 capacitance (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. © Gaia Converter FC97-006.08/05 Revision J 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) 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 Bi Output MGDBI- 10 10 - C 10 - F 10 - I VDC 5 15 24 Min. - Max. VDC 4,5- 5,5 9- 18 18- 36 Maximum ms 30 30 30 Maximum mApp 50 50 30 Maximum mA 50 30 30 Maximum mA 50 30 30 Full temperature range Ui min. to max. 75% load Ambient temperature : +25°c Ui nominal, 75% load Full temperature range Ui min. to max. Nominal Nominal Nominal VDC VDC VDC +/- 5 +/- 12 +/- 15 +/- 5 +/- 12 +/- 15 +/- 5 +/- 12 +/- 15 Maximum % +/- 2 +/- 2 +/- 2 Maximum W +/- 5 +/- 5 +/- 5 Full temperature range Ui min. to max. Maximum Maximum Maximum mA mA mA +/- 1.000 +/- 400 +/- 330 +/- 1.000 +/- 400 +/- 330 +/- 1.000 +/- 400 +/- 330 Ui nominal Full load BW = 20MHz 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 Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 50 100 150 50 100 150 Maximum % +/- 1 +/- 1 +/- 1 Maximum % +/- 2,5 +/- 2,5 +/- 2,5 Maximum % +/- 0,5 +/- 0,5 +/- 0,5 Typical % 77 82 83 Maximum Maximum µF µF 470 100 470 100 470 100 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 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 capacitance (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. © Gaia Converter FC97-006.08/05 Revision J 4 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-10 Standard Input Series 4- Functional Characteristics Characteristics Conditions Limit or typical Performances Electric strength test voltage Input to output Minimum 1.500 VDC / 1 min Isolation resistance 500 VDC Minimum 100 Mohm Short circuit protection Short circuit Auto restart Permanent Switching frequency No load to full load Nominal 480 KHz 5- 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 * TNote * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 95°C (See Application Notes : Ambient versus case temperature). 6- Reliability Characteristics Characteristics Conditions Temperature Performances Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Ground fixed (Gf) Case at 40°C Case at 70°C 950.000 Hrs 380.000 Hrs 7- Environmental Qualifications Characteristics Conditions Severity Test procedure Humidity Damp heat Temperature 93 % H.R 56 Days 40°C IEC 68-2-3 Temperature cycling Number of cycles Temperature change Transfert time / Steady state time 200 -40°C / +71°C 40 min. / 20 min. IEC 68-2-14 Vibration (Sinusoidal) Number of cycles Frequency Amplitude /acceleration 10 cycles in each axis 10 to 60 Hz/ 60 to 2000 Hz 0.7 mm/10 g IEC 68-2-6 Shock (Half sinus) Number of shocks Peak acceleration Duration 3 shocks in each axis 100 g 6 ms IEC 68-2-27 Bump (Half sinus) Number of bumps Duration Peak acceleration 2000 Bumps in each axis 6 ms 25 g IEC 68-2-29 Electrical discharge susceptibility Air discharge level 4 kV Contact discharge level 2kV Air discharge level 8 kV Contact discharge level 4 kV sanction A sanction A sanction B sanction B EN55082-2 with : EN61000-4-2 IEC 801-2 Electrical field susceptibility Antenna at 1 m Wave form : AM modulated 80 %, 1KHz Test : 26 MHz to 1 GHz Value 10 V/m EN55082-2 with : EN61000-4-3 IEC801-3 Electrical fast transient susceptibility Level 1 : 0.5 kV Level 3 : 2 kV sanction A sanction B EN55082-2 with : EN61000-4-4 IEC801-4 © Gaia Converter FC97-006.08/05 Revision J 5 5 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 8- Electromagnetic Interference Qualifications 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 Radiated noise emission With common mode capacitor C c = 10nF and input capacitor C Models i 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 with KG9502 9-18V input models Class A, C i =10µF/ 35 V tantalum Class B with KG9502 18-36V input models Class A, C i =4.7µF / 50 V tantalum Class B with KG9502 Configuration With common mode capacitor C c = 10 nF Models All models Class B 8-1 Basic Configuration : Module Stand Alone with Input & Common Mode Noise Capacitance : EN55022 class A 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 Configuration with Module and Front filter KG9502 and Common Mode Noise Capacitance : EN 55022 Class B mode inductance, together with a common mode noise capacitance (10 nF/rated voltage depending on isolation requirement) connected between Gin and Gout. Please consult KG9502 datasheet for further details. Electromagnetic interference requirements according to EN55022 class B can be easily achieved by adding an external input filter KG9502 consisting of 4 capacitances, a common mode choke, and a differential L1 L2 C3 Vi + Input C1 C2 - Input Vo MGDI - Series Gi Go C4 Common mode noise capacitance C c = 10nF © Gaia Converter FC97-006.08/05 Revision J 6 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 9- Application Notes 9-1 Short Circuit Protection The short circuit protection device protects the modules against short circuits of any duration and restores the module to normal operation when the short circuit is removed. 9-2 Custom Output Any of the bi output converters can be configured to produce 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. 9-3 Safety The MGDI-10 series is recognized according to UL1950, EN60950 and EN41003. The isolation voltage is an operational insulation in accordance with EN60950 and the DC/DC module shall be installed in an end-use equipement. 9-4 Ambient versus Case Temperature The MGDI-10 series operating case temperature at full load must not exceed 95°C. The maximum ambient temperature admissible for the DC/DC converter corresponding to the maximum operating case temperature depends on the ambient airflow, the unit mounting/orientation, the cooling features and the power dissipated. Thermal calculation shows two areas of operation : • a normal operation area in a free natural ambient convection (grey area in the following graph), • an area with cooling features (air flow or heatsink ) ensuring a maximum case temperature below 95°C at full load (white area in the following graph). 5 Power (W) 100% 75% 50% Natural convection Max. case temperature 25% 10 20 30 40 50 60 70 71˚C © Gaia Converter FC97-006.08/05 Revision J 80 90 100 110 Temperature (˚C) 95˚C 7 For locations, phone, fax, E-Mail see back cover MGDI-10 Standard Input Series Industrial Grade 10- 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 solder plated pin 11- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 5 12- 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 FC97-006.08/05 Revision J 8 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 FC97-004.08/04 Revision I Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :