Industrial DC/DC CONVERTER MGDI-25 Standard Input : 25W POWER Industrial Grade 2:1 Standard Input Single Output Metallic case - 1 500 VDC Isolation * Wide input range * Nominal power up to 25/30 W * Wide temperature range : -40C/+ 95C case * High efficiency (up to 89%) * Soft start * Galvanic isolation 1.500 VDC according to EN 60950 * Integrated LC EMI filter * Permanent short circuit protection * No optocoupler for high reliability * RoHS process 1-General The MGDI-25 series is a complete line of DC/DC power modules designed for use in distributed power architecture and are particularly suitable for mobile or ground fixed applications in transportation, industrial and telecommunication areas. These modules use a high frequency fixed swiching technic at 250KHz providing excellent reliability, low noise characteristics and high power density. Standard models are available with wide input voltage range of 45-100 volts. The series include single output voltage choices of 5, 12, 15, 24 volts. No external heatsink is required for the MGDI25 series to supply 25W to 30W output power over the full temperature range. The MGDI-25 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, a permanent short circuit protection and an output overvoltage protection to ensure efficient module protections. 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 with a GAIA Converter automated test equipment. 2-Product Selection Single output model : MGDSI - 25 - input output Input Voltage Range Output Permanent C : 5 VDC E : 12 VDC F : 15 VDC I : 24 VDC K : 45-100 VDC REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC99-043.01/10 Revision G For locations, phone, fax, E-Mail see back cover 5 Industrial Grade MGDI-25 Standard Input Series 2- Product Selection (continued) Input range Output Current Reference Options 45-100 45-100 45-100 45-100 5 VDC 12 VDC 15 VDC 24 VDC 5A 2,5 A 2A 1,25 A MGDSI-25-K-C MGDSI-25-K-E MGDSI-25-K-F MGDSI-25-K-I / / / / VDC VDC VDC VDC Converter Selection Chart M G D S I - 25 - K - C Number of Outputs : S : single output Input voltage range : K : 45-100 VDC 5 Output voltage : See table page 1 (c) Gaia Converter FC99-043.01/10 Revision G 2 For locations, phone, fax, E-Mail see back cover MGDI-25 Standard Input Series Industrial Grade 3- Electrical Specifications Data are valid at +25C, 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 Single Output Conditions Limit or typical Units Full temperature range Nominal VDC 72 Full temperature range Min. - Max. VDC 45-100 Maximum ms 20 Typical mApp 300 Typical mA 40 Maximum mA 60 Nominal Nominal Nominal Nominal VDC VDC VDC VDC 5 12 15 24 Maximum % +/- 2 Maximum W 20/30 Full temperature range Ui min. to max. Maximum Maximum Maximum Maximum A A A A 5 2,5 2 1,25 Ui nominal Full load BW = 20MHz Maximum Maximum Maximum mVpp mVpp mVpp 50 100 150 Typical % +/- 1 Typical % +/- 2,5 Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Ui nominal Short-circuit Ui nominal No load MGDSI-25- K Output Output voltage Set Point accuracy Output power Output current 5V output 12V output 15V output 24V output Ripple output voltage * 5V output 12V output 15V and 24V output Line regulation Load regulation ** 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 Efficiency 5V output 12V and 15V output 24V output Ui nominal Full load Typical Typical Typical % % % 86 88 89 Maximum admissible Capacitive load Ui nominal Full load Per output Maximum F 1 000 5 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 FC99-043.01/10 Revision G 3 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-25 Standard Input Series 4- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load Nominal, fixed 250 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 Output short circuit protection (SCP) Hiccup circuitry with auto-recovery Automatic recovery Permanent See section 10 Output overvoltage protection (OVP) Zener clamp / Maximum Maximum Maximum Maximum For 3.3v : 4.6v For 5v : 6v For 12v : 14v For 15v : 17v 5 7- Reliability Data Characteristics Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 70C 925 000 Hrs 350 000 Hrs Ground mobile (Gm) Case at 40C Case at 70C 445 000 Hrs 148 000 Hrs Telecom switchers Ambient at 25C 100% time on 1 300 000 Hrs Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR (c) Gaia Converter FC99-043.01/10 Revision G 4 For locations, phone, fax, E-Mail see back cover MGDI-25 Standard Input Series Industrial Grade 8- Thermal Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load 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 7C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 95C. The MGDI-25 series operating case temperature at full load 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 at full load (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 : 71C Maximum case temperature : 95C Maximum storage temperature : 105C (c) Gaia Converter FC99-043.01/10 Revision G 5 For locations, phone, fax, E-Mail see back cover MGDI-25 Standard Input Series Industrial Grade 9- 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 (c) Gaia Converter FC99-043.01/10 Revision G 6 For locations, phone, fax, E-Mail see back cover MGDI-25 Standard Input Series Industrial Grade 10- Description of Protections 10-1 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 1s 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 10-2 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 (c) Gaia Converter FC99-043.01/10 Revision G 7 For locations, phone, fax, E-Mail see back cover MGDI-25 Standard Input Series Industrial Grade 11- Application Notes 11-1 Connection of Outputs in Series Any of the bi output converters can be configured to produce an 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. VI +Vo Go GI -Vo VI Vo GI Go 2 x Vo 11-2 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. 2 x Vo VI Vo GI Go 5 11-3 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. (c) Gaia Converter FC99-043.01/10 Revision G VI Vo Vo GI Go VI Vo GI Go 8 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDI-25 Standard Input Series 12- Dimensions Dimensions are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 80 grams (2.8 Ozs) max. 12,70 (0.50") 2,54 (0.10") 12,70 5,08 5,08 5,08 45,72 (1.80") 10,16 (0.40") (2.00") 10,16 (0.40") 50,80 10,16 (0.40") +/-0.8 4 (0.15") (0.50") (0.20")(0.20")(0.20") 50,80 (2.00") Pin dimensions : 0,91 mm (0.036 ") 13- Materials Case : Metallic black painted coating. Pins : Plated with pure matte tin over nickel underplate. 5 14- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 15- Connections 5 6 7 1 2 8 3 4 Pin Single 1 + Input (Vi) 2 - Input (Gi) 3 Case 4 Do not connect 5 Do not connect 6 Output (Vo) 7 Common (Go) 8 Do not connect Bottom view (c) Gaia Converter FC99-043.01/10 Revision G 9 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 FC99-043.01/10 Revision G Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :