Industrial DC/DC CONVERTER MGDI-18 Wide Input : 18W POWER Industrial Grade 3:1 & 4:1 Wide Input Single Output Metallic Case - 1 500 VDC Isolation * Wide input range and high transient compliance * Ultra compact 18/20W DC/DC converter * Wide temperature range : -40C/+95C case * High efficiency (typ. 85%) * Soft start * Permanent short circuit protection * No optocoupler for high reliability * RoHS process 1-General The MGDI-18 series is a full family of DC/DC power modules designed for use in distributed power architecture where variable input voltage and transient are prevalent making them ideal particularly for transportation, railways or highend industrial applications. These modules use a high frequency fixed swiching technic at 480KHz providing excellent reliability, low noise characteristics, high power density and low profile package. Standard models are available with wide input voltage range of 4,7-16, 9-36, 16-40 and 36-140 volts, with high transient levels. The series include single voltage choices of 3,3, 5, 12 or 15 volts. The MGDI-18 series is able to supply up to 18/20W output power. The MGDI-18 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 softstart allows current limitation and eliminates inrush current during start-up. The short circuit protection completely protects the module 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 - 18 - input output / option Input Voltage Range D H J Q Permanent : 4,7-16 VDC : 9-36 VDC : 16-40 VDC* : 36-140 VDC** * for 45 Vdc consult ** for 154 Vdc consult Transient n/a 40 VDC/100 ms 45 VDC/100 ms 175 VDC/100 ms Output B : 3.3 VDC C : 5 VDC E : 12 VDC F : 15 VDC factory factory Options : /M : option for On/Off function REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC01-037.01/11 Revision J For locations, phone, fax, E-Mail see back cover 5 Industrial Grade MGDI-18 Wide Input Series 2- Product Selection (continued) Input range Output Current Reference Options 4,7-16 4,7-16 4,7-16 4,7-16 3,3 VDC 5 VDC 12 VDC 15 VDC 4A 4A 1,50 A 1,20 A MGDSI-18-D-B MGDSI-18-D-C MGDSI-18-D-E MGDSI-18-D-F /M /M /M /M VDC VDC VDC VDC 9-36 9-36 9-36 9-36 VDC VDC VDC VDC 3,3 VDC 5 VDC 12 VDC 15 VDC 4A 4A 1,50 A 1,20 A MGDSI-18-H-B MGDSI-18-H-C MGDSI-18-H-E MGDSI-18-H-F /M /M /M /M 16-40 16-40 16-40 16-40 VDC VDC VDC VDC 3,3 VDC 5 VDC 12 VDC 15 VDC 4A 4A 1,50 A 1,20 A MGDSI-18-J-B MGDSI-18-J-C MGDSI-18-J-E MGDSI-18-J-F /M /M /M /M 36-140 36-140 36-140 36-140 VDC VDC VDC VDC 3,3 VDC 5 VDC 12 VDC 15 VDC 4A 4A 1,50 A 1,20 A MGDSI-18-Q-B MGDSI-18-Q-C MGDSI-18-Q-E MGDSI-18-Q-F /M /M /M /M 5 Converter Selection Chart M G D S I - 18 - Q - C / M Number of Outputs : S : single output Input voltage range : D : 4,7-16 VDC H : 9-36 VDC J : 16-40 VDC* Q : 36-140 VDC** Output voltage : See table page 1 Option : /M : On/Off function * for 45 Vdc consult factory ** for 154 Vdc consult factory (c) Gaia Converter FC01-037.01/11 Revision J 2 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-18 Wide Input Series 3- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Conditions Limit or typical Units Single Output MGDSI-18 18-D 18 - H 18 - J 18 - Q Input Nominal input voltage Permanent input voltage range (Ui) Extended permanent input voltage range Full temperature range Nominal VDC 9 20 24 72 Full temperature range Min. - Max. VDC 4,7-16 9-36 16-40 36-140 Full temperature range (Consult factory) Min. - Max. VDC / / 16-45 36-154 Transient input voltage Full load Start up input voltage Undervoltage lock-out No undervoltage lock-out turn-on/turn-off threshold Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Ui nominal Short-circuit Ui nominal No load Maximum Maximum Minimum Min. - Max. VDC/S VDC/S VDC VDC / / / 4-4,5 40/0,1 / / 7-8,5 45/0,1 / / 12-15 175/0,1 165/1 33 / Maximum ms 40 40 40 40 Typical mApp 50 50 50 50 Maximum mA 100 60 60 40 Maximum mA 100 60 60 40 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 3,3 5 12 15 3,3 5 12 15 3,3 5 12 15 3,3 5 12 15 Maximum % +/- 2 +/- 2 +/- 2 +/- 2 Maximum W 20 20 20 20 Full temperature range Ui min. to max. Maximum Maximum Maximum Maximum A A A A 4 4 1,5 1,2 4 4 1,5 1,2 4 4 1,5 1,2 4 4 1,5 1,2 Ui nominal Full load BW = 20MHz Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 50 100 150 50 100 150 50 100 150 Typical % +/- 1 +/- 1 +/- 1 +/- 1 Typical % +/- 2,5 +/- 2,5 +/- 2,5 +/- 2,5 Typical % 81 82 83 83 Maximum Maximum F F 2 000 680 2 000 680 2 000 680 2 000 680 Start up time Reflected ripple current Input current in short circuit mode (Average) No load input current 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 Capacitive load 3,3V and 5V output 12V and 15V output Full temperature range Ui min. to max. 75% load Ambient temperature : +25c 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-18 module requires to install a 22F chemical or tantalum capacitance accross output terminals. Note ** : For 9-36V input range, the current is derated at 80% at 9V and increases linearly to full current at 12V. 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. (c) Gaia Converter FC01-037.01/11 Revision J 3 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-18 Wide Input Series 4- Switching Frequency Parameter Conditions Full temperature range Ui min. to max. No load to full load Switching frequency Limit or typical Specifications Nominal, fixed 4.7-16 VDC input : 480 KHz 9-36 VDC input : 480 KHz 16-40 VDC input : 480 KHz 36-140 VDC input : 430 KHz 5- Isolation Parameter Conditions Limit or typical Specifications Electric strength test voltage (basic version) 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 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 12 / 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 40C Case at 70C 475 000 Hrs 190 000 Hrs Ground mobile (Gm) Case at 40C Case at 70C 120 000 Hrs 55 000 Hrs Railway, Payphone Ambient at 25C 100% time on 202 000 Hrs Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR (c) Gaia Converter FC01-037.01/11 Revision J 4 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-18 Wide 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 With common mode capacitor C c = 10nF and input capacitor C Models Conducted noise emission Radiated noise emission 4,7-16V input models With common mode capacitor C c = 10nF and external filter i Class A, C i =10F/ 35 V tantalum + inductance 4,7mH Class B 9-36V input models Class A, C i =4,7F/ 50 V tantalum Class B 16-40V input models Class A, C i =4,7F/ 50 V tantalum Class B 36-140V input models Class A, C i =47F / 200 V chemical / Configuration 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 common mode noise capacitance (C = 10nF/rated voltage depending on isolation requirement) and an input capacitance (CI Value explained in previous table). This common mode noise capacitance C should be layed-out as close as possible from the DC/ DC converter. C C + 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, a differential mode inductance L1 L2 and the common mode noise capacitance (C = 10nF/rated voltage depending on isolation requirement). Please consult EN55022 Class B EMI Filter design note for further details. C C3 Vi + Input C1 C2 - Input Vo MGDI - Series Gi Go C4 Common mode noise capacitance C c = 10nF * Note : Value of common mode noise capacitance depends on isolation requirements (typically 10nF/1500V or 10nF/3000V ). In case of dielectric strengh test in AC mode, adapt the capacitance value in order to be compatible with maximum admissible leakage current. (c) Gaia Converter FC01-037.01/11 Revision J 5 For locations, phone, fax, E-Mail see back cover MGDI-18 Wide Input Series Industrial Grade 9- Surge Susceptibility EN61000-4-5 & EN50155 Surge susceptibility requirements according to EN50155, EN61000-4-5 and electromagnetic interference requirements of EN55022 class A can easily be achieved using either : * a limitor module LGDS-50 series : ready-to-use single module solution, * an input limitor filter KG9503 : schematics of discret components, to sustain the following surge levels : Characteristics Spikes Line to line Spikes Line to earth Standards Levels EN 61000-4-5 Level 4 with 4 000 V waveform 50 s, impedance 2 Ohm EN 50155 Level 1 800 V waveform 50 s, impedance 100 and 5 Ohm Level 8 400 V waveform 0.1 s, impedance 100 Ohm EN 61000-4-5 Level 4 with 4 000 V waveform 50 s, impedance 12 Ohm EN 50155 Level 1 800 V waveform 50 s, impedance 100 and 5 Ohm Level 8 400 V waveform 0.1 s, impedance 100 Ohm 9-1 Surge Protection with Off-the-Shelf Solution : LGDS-50 Limitor Module To sustain surge requirements of EN61000-4-5, and EN50155 together with EN55022 class A, GAIA Converter proposes a ready-to-use single product. Depending on bus input range two references of limitor module are existing with references as follow : Input types DC/DC converter family Limitor module reference 9-36 VDC Input 16-40 VDC Input 36-140 VDC Input MGDI-18-H series MGDI-18-J series MGDI-18-Q series LGDS-50-J-K LGDS-50-J-K LGDS-50-Q-K These modules designated LGDS-50 series are designed up to 50W power and will protect MGDI-18 series with 9-36, 16-40 or 36-140 VDC input against surges. The implantation of LGDS-50 with modules can be undertook as follow : Vi + Input Vo 5 MGDI - Series LGDS-50 - Input Gi Go Vi Vo MGDI - Series Go Gi Please consult LGDS-50 datasheet for further details. 9-2 Surge Protection with Discrete Components To sustain surge requirements of EN61000-4-5 and EN50155 together with EN55022 class A, GAIA Converter proposes the following front protection filter. F1 D1 L1 Vi + Input C1 - Input C2 D2 D4 D3 D5 Vo MGDI - Series Gi Go * Common mode noise capacitance Cc = 10nF Please consult EN50155 Transient/EMI filter design note for further details. * Note : Value of common mode noise capacitance rated voltage depends on isolation requirements. (c) Gaia Converter FC01-037.01/11 Revision J 6 For locations, phone, fax, E-Mail see back cover MGDI-18 Wide Input Series Industrial Grade 10- Thermal Characteristics Conditions Limit or typical Performances Operating ambient temperature range Characteristics Ambient temperature * Minimum Maximum - 40C + 71C Operating case temperature range at full load Case temperature Minimum Maximum - 40C +95C Storage temperature range Non functionning Minimum Maximum - 40C + 105C Thermal resistance Rth case to ambient in free air natural convection Typical 12C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 95C. The MGDI-18 series operating case temperature must not exceed 95C. The maximum ambient temperature admissible for the DC/DC converter corresponding to the maximum operating case temperature of 95C 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 = 95C of the module, the power used Pout and the efficiency : * determine the power dissipated by the module Pdiss that should be evacuated : - 1) Pdiss = Pout(1/ * determine the maximum ambient temperature : Ta = 95C - 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 95C (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 : 60C Maximum case temperature : 95C Maximum storage temperature : 105C (c) Gaia Converter FC01-037.01/11 Revision J 7 For locations, phone, fax, E-Mail see back cover MGDI-18 Wide Input Series Industrial Grade 11- 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 95C case unit operating IEC 68-2-2 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40C 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 -40C / +71C 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 -40C / +105C 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 2 000 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 Surge form Impedance Level 4 1,2/50 s 2 Ohm 4 kV : with transient protection or LGDS-50 limitor module (see section surge) EN61000-4-5 EN50155 Surge Susceptibility (c) Gaia Converter FC01-037.01/11 Revision J 8 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-18 Wide Input Series 12- Description of Protections 12-1 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. For Q input range models, the UVLO protection is not implemented. On Off Vin UVLO Turn-on/Turn-off 12-2 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. Vo (%) 100 detection time x time recovery time recovery time 12-3 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. 5 13- Description of Functions 13-1 Option (/M) : On/Off Function The optionnal control pin A (On/Off) can be used for applications requiring On/Off operation. By using an open collector command with a transistor Q referenced to the common terminal (Gi) : * A logic pulled low (<0.2V@1mA, referenced to Gi) on pin A disables the converter * No connection or high impedance on pin A enables the converter. On/Off Command GI By releasing the On/Off function, the converter will restart within the start-up time specifications given in table page 3. For further details please consult `'Logic On/Off'' application note. (c) Gaia Converter FC01-037.01/11 Revision J 9 For locations, phone, fax, E-Mail see back cover MGDI-18 Wide Input Series Industrial Grade 14- Application Notes 14-1 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. VI Vo GI Go 2 x Vo VI Vo GI Go VI Vo 14-2 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. Vo GI Go VI Vo GI Go 5 14-3 Safety Consideration For safety agency approval of the system in which the power module is used, the power module must be installed in compliance with requirements of the UL1950, CSA22.2-950, EN60950 standards : i.e if the output circuit operator accessible, it shall be a SELV circuit. A SELV (Safety Extra Low Voltage) output for a converter is a secondary circuit that under normal operation or a single fault condition cannot reach hazardous voltage (i.e Voltage above 60 VDC) between any two accessible parts or an accessible part and protective each. In the event of a single fault condition (insulation or component failure), the voltage in accessible parts of SELV circuits shall not exceed 60 VDC for longer than 0.2 sec. and an absolute limit of 120 VDC SELV circuits must be separated from hazardous voltages (e.g primary circuits) by two levels of protection which may be double or reinforced insulation or basic insulation combined with an earthed conductive barrier. Generally DC/DC Converters are power by an input bus that comes from a front end which can be an AC/DC powered supply, a transformer, a charger or a battery. It is the sole responsability of the user to ensure compliance of the frontend with the relevant safety requiements. The following table resumes some possible installation configuration using Gaia Converter wide input series. Bus voltage at the input of DC/DC converter Safety status of the input bus DC/DC converter requirements Resulting safety at the DC/DC converter output Voltage : < 60 VDC Basic isolation with ELV circuit Basic isolation with earthed SELV circuit Operationnal insulation Operationnal insulation Earthed SELV circuit SELV circuit Hazardous voltage : > 60VDC Basic isolation with hazardous voltage Double or reinforced insulation with hazadous voltage Operationnal insulation Operationnal insulation Earthed SELV circuit Earthed SELV circuit (c) Gaia Converter FC01-037.01/11 Revision J 10 For locations, phone, fax, E-Mail see back cover MGDI-18 Wide Input Series Industrial Grade 15- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 35 grams (1.22 Ozs) max. 5 min (0.20") 2 (0.078") 40,80 26,80 (1.61") (1.06") 16 16,5 (0.63") (0.65") 27,40 10,16 (1.08") (0.40") 35,56 20,32 (1.40") (0.80") Pin dimensions : O 0,73 mm (0.03 ") 16- Materials Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 17- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 5 18- Connections 4 5 6 2 Single 1 + Input (Vi) 2 Do not connect 3 - Input (Gi) 4 Output (Vo) 5 No pin 6 Common (Go) A No pin * * Option /M : Pin A existing for On/Off function. Please add /M to module reference. A 1 Pin 3 Bottom view (c) Gaia Converter FC01-037.01/11 Revision J 11 For locations, phone, fax, E-Mail see back cover International Headquarters GAIA Converter - France ZI de la Morandiere 33185 LE HAILLAN - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAIA Converter Canada, Inc 4038 Le Corbusier Blvd LAVAL, QUEBEC - CANADA H7L 5R2 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 Gaia Converter FC97-005.01/11 Revision J. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :