PD-94533I 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. All components are fully derated to meet the requirements of MIL-STD-975, MIL-STD1547 and GSFC PPL-21 Appendix B. 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 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 DSCC 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 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% -55C to +125C 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 n n n Geostationary Earth Orbit Satellites (GEO) Deep Space Satellites / Probes Strategic Weapons and Communication Systems 1 05/07/10 M3G-SERIES 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 power 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 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. 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 opto-couplers 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). 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. 2 www.irf.com M3G-SERIES Specifications Absolute Maximum Ratings Recommended Operating Conditions Input voltage range -0.5Vdc to +150Vdc Input voltage range Output power Internally limited Lead temperature +300C for 10 seconds Input voltage range Output power +60Vdc to +120Vdc 1 +60Vdc to +100Vdc 0 to Max. Rated Operating temperature -55C to +135C Operating temperature 2 Storage temperature -55C to +135C Operating temperature 1 1 -55C to +125C -55C to +70C Meets derating per MIL-STD-975 For operation at +125C see table note 15 2 Electrical Performance Characteristics Parameter Input Voltage Output Voltage ( Vout ) (main) M3G700512T (aux.) M3G700515T (aux.) (main) M3G700512T (aux.) M3G700515T (aux.) Output power ( POUT ) Output current ( IOUT ) (main) M3G700512T (aux.) M3G700515T (aux.) Line regulation ( VRLINE ) (main) M3G700512T (aux.) M3G700515T (aux.) Load regulation ( VRLOAD ) (main) M3G700512T (aux.) M3G700515T (aux.) Cross regulation ( VRCROSS ) M3G700512T (aux.) M3G700515T (aux.) Input current ( IIN ) Limits Group A Subgroup Conditions -55C TC +85C V IN = 70V DC 5%, CL = 0 unless otherwise specified Min Nom Max Unit 1,2,3 Note 2 60 70 100 V 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 2,3 4.93 11.30 14.40 5.07 12.30 15.40 V 1,2,3 VIN = 60, 70, 100 Volts, Note 2 0 40 W 1,2,3 VIN = 60, 70, 100 Volts, Notes 2,3,4,5 400 83 67 4000 833 667 mA 1,2,3 VIN = 60, 70, 100 Volts IOUT =10%, 50%, 100% rated Note 5, 14 -10 -120 -150 10 120 150 mV IOUT = 10%, 50%, 100% rated VIN = 60, 70, 100 Volts Notes 5,13 -50 -400 -500 50 400 500 mV VIN = 60, 70, 100 Volts IOUT = 2.5A to 1A and 2.5A to 4A on main and half rated on aux. outputs -3.5 -3.0 3.5 3.0 % mA 1,2,3 1,2,3 1,2,3 IOUT = 0, Pin 3 open 35 50 Pin 3 shorted to pin 2 2.0 5.0 For Notes to Specifications, refer to page 5 www.irf.com 3 M3G-SERIES Electrical Performance Characteristics Parameter Output ripple ( VRIP ) (main) 700512T (aux.) 700515T (aux.) ( continued ) Conditions -55C TC +85C VIN = 70V DC 5%, CL = 0 unless otherwise specified Group A Subgroup Limits Min VIN = 60, 70, 100 Volts IOUT = 100% rated load, Notes 5, 6 1,2,3 Nom Max Unit 25 30 30 50 60 75 mV p-p 550 KHz Switching frequency ( FS ) 1,2,3 Sync. Input (Pin 4) open 450 500 Efficiency ( EFF ) 1,2,3 IOUT = 100% rated load Note 5 78 82 Note 1 3.0 Inhibit Input open circuit voltage drive current ( sink ) voltage range -0.5 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 Ext. Clock on Sync. Input (Pin 4) Note 1 Vout = 90% of Nominal, Note 5 1,2,3 Power dissipation, load fault (PD) 1,2,3 Short Circuit, Overload, Note 8 Output response to step load changes (VTLD) 4,5,6 Half Load to/from Full Load, Notes 5,9 Recovery time, step load changes (TTLD) 4,5,6 Half Load to/from Full Load, Note 5,9,10 Output response to step line changes (VTLN) 60V to/from 100V IOUT = 100% rated load, Notes1, 5,11 Recovery time, step line changes (TTLN) 60V to/from 100V IOUT = 100% rated load, Notes 1. 5,10,11 Turn-on Response Overshoot (VOS) ( main ) ( aux. ) Turn-on Delay (TDLY) 4,5,6 -300 50 -300 50 No Load, Full Load Notes 5,12 1.0 Capacitive Load (CL) (main) (Each aux. output) IOUT = 100% rated load, No effect on DC performance, Notes 1, 5, 7 DC to 50KHz, Notes 1, 5 IOUT = 100% rated load Line Rejection Isolation 450 4.0 -0.5 40 20 1 40 5.0 100 50 V A V 600 10.0 0.5 80 KHz V V V/s % 135 % 18 W 300 mV pk 200 s 300 mV pk 200 s 500 750 mV mV 5.0 ms 1000 200 F 60 Input to Output or Any Pin to Case except pin 10, test @ 500VDC 100 MIL-HDBK-217F2, SF, 35C 5 x 10 dB M Device Weight MTBF % 110 6 g Hrs For Notes to Specifications, refer to page 5 4 www.irf.com M3G-SERIES 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 VOUT = 90% of nominal. Load step transition time 10 s. Recovery time is measured from the initiation of the transient to where V OUT has returned to within 1% of its steady state value. Line step transition time 100 s. 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 (pin 3) to the point where V OUT = 90% of nominal. Load Regulation relative to output voltage at 50% rated load. Line Regulation relative to output voltage at 70Vdc input. Although operation at temperatures between +85C and +125C is guaranteed, no parametric limits are specified. www.irf.com 5 M3G-SERIES 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 100 300 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 Heavy ions (LET) Operating bias applied during exposure, Full Rated Load, VIN = 70V 82 Neutron Fluence Single Event Effects SEU, SEL, SEGR, SEB Rads (Si)/sec Neutrons 2 /cm 2 MeV*cm /mg International Rectifier currently does not have a DSCC certified Radiation Hardness Assurance Program. Figure 1. Block Diagram - Triple Output 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 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 Figure 4. Line Rejection, Main Output 0 -10 -20 -30 dB -40 -50 -60 -70 -80 -90 -100 1E2 1E3 Frequency ( Hz ) 1E4 1E5 Figure 5. Line Rejection, Aux. Outputs 0 -10 -20 -30 dB -40 -50 -60 -70 -80 -90 -100 1E2 8 1E3 Frequency ( Hz ) 1E4 1E5 www.irf.com M3G-SERIES Figure 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 Frequency ( Hz ) 1E6 1E7 1E8 Figure 7. Conducted Emissions, Common Mode 100 90 80 70 MIL-STD-461C CE03 LIMIT dB-uA 60 50 40 30 20 10 0 1E3 www.irf.com 1E4 1E5 1E6 Frequency ( Hz ) 1E7 1E8 9 M3G-SERIES 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. 2. 3. 4. 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. 5. Tighten the screws with an appropriate torque driver. Torque the screws up to 6 in*lb in the sequence shown above. 10 www.irf.com M3G-SERIES 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 O0.040 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 Output) Pin # www.irf.com 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 11 M3G-SERIES Device Screening Requirement MIL-STD-883 Method Temperature Range No Suffix d CK d EM -55C to +85C -55C to +85C -55C to +85C 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 @ 125C 320 hrs @ 125C 48 hrs @ 125C ( 2 x 160 hrs ) ( 2 x 160 hrs ) Final Electrical MIL-PRF-38534 -55C, +25C, -55C, +25C, -55C, +25C, ( Group A ) & Specification +85C +85C +85C 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 DSCC class K compliant without radiation performance. No Suffix is a radiation rated device but not available as a DSCC qualified SMD per MIL-PRF-38534. International Rectifier currently does not have a DSCC certified Radiation Hardness Assurance Program. Part Numbering M3G 70 05 15 T /EM Model Nominal Input Voltage 70 = 70V Main Output Voltage 03R3 = 3.3V 05 = 5V 12 = 12V 15 = 15V 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: 2520Junction 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. 05/2010 12 www.irf.com