Industrial DC/DC CONVERTER CGDI Standard Input TETHYS : 30W POWER Industrial Grade 2:1 Standard Input Configurable Multiple Outputs Metallic case - 1 500 VDC Isolation * Highly configurable DC/DC converter * Up to 6 outputs and 3 independants line regulations * Low profile : 0,33 " ( 8.5mm) * Nominal Power of 30 W without derating * Wide temperature range : -40C/+95C case * Galvanic isolation 1.500 VDC * Integrated LC EMI filter * Permanent short circuit protection * External trim and sense adjustment : +/-5% * Inhibit function * RoHS process 1-General The TETHYS 30W series is a full family of highly configurable DC/DC low profile power module designed for direct implementation on high density printed circuit boards in distributed power architecture and are particularly suitable for mobile or ground fixed application in transportation, industrial and telecommunication areas. This module uses a high frequency fixed swiching technic at 480 KHz providing excellent reliability, low noise characteristics and low profile package. This model is available with nominal input voltages as 24 volts in range of 18-36 volts. The serie includes thousands of output configuration from single, bi up to six possible output voltages in choices of 3,3, 5, 12, 15, 24 volts with trim and sense functions for output voltage adjustment. No external heatsink is required for the for CGDI series to supply 30W output power over the full temperature range. All the modules are designed with LC network filters to minimize reflected input current ripple and output voltage ripple . The modules include a soft-start, an input undervoltage lock-out, a permanent short circuit protection an output overvoltage protection and a thermal 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 module against short-circuits of any duration by a shut-down and restores to normal when the overload is removed. The thermal protection is adjusted to 110C and protects the module against overheat. The inhibit function is commanded with a low logic level and disables the module for applications requiring on/off operations. The design has been carried out with surface mount components and is manufactured in a fully automated process to guarantee high quality. Each modules are tested with a GAIA Converter automated test equipment. 2-Product Selection Multiple output model : CGDI - input output output output Input Voltage Range Output Permanent 3 : 3.3 VDC 5 : 5 VDC 5B : +/-5VDC 12 : 12 VDC 12B : +/-12VDC 15 : 15 VDC 15B : +/-15VDC 24 : 24 VDC 24B : +/-24VDC I : 18-36 VDC REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC97-020.01/10 Revision L For locations, phone, fax, E-Mail see back cover 5 Industrial Grade CGDI Standard Input TETHYS Series 2- Product Selection (continued) Single line model : CGDI- Dual line model : CGDI- Triple line model : CGDI- O O O > 30 W first line output : primary output > > 20 W first line output : primary output 10 W second line output : secondary output > 10 W on each line output : primary and secondary outputs First line output functions : Trim function at +/- 5% Sense function at +/- 5% Tight regulation below 1% Indefinite short circuit protection Secondary line output functions : Independant regulation from primary output Indefinite short circuit protection Input Voltage Range Designation I Output Voltage Permanent Designation Output Voltage 3 5 5B 12 12B 15 15B 24 3.3 VDC 5 VDC +/-5VDC 12 VDC +/-12VDC 15 VDC +/-15VDC 24 VDC 18-36 VDC 5 Converter Selection Chart C G D I - F - 5 - 0 - 12B Input voltage range : F : 9-18 Vdc I : 18-36 Vdc Output voltage : 5 : 5 Vdc, 20W First line 12B : +/-12 Vdc, 10W second line See table page 1 for complete possibilities (c) Gaia Converter FC97-020.01/10 Revision L 2 For locations, phone, fax, E-Mail see back cover CGDI Standard Input TETHYS Series Industrial Grade 3- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Input Nominal input voltage Permanent input voltage range (Ui) Undervoltage lock-out (UVLO) 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 VDC 24 Full temperature range Min. - Max. VDC 18- 36 Threshold Minimum Maximum VDC VDC 16 17,5 Maximum ms 40 Maximum mApp 50 Maximum mA 60 Maximum mA 60 VDC 3,3V , 5V , 12V , 15V or 24V Consult factory for other outputs Ui nominal Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Ui nominal Short-circuit Ui nominal No load CGDI-I Primary Output Ui min. to max. Nominal 75% load Ambient temperature : +25c Ui min. to max. Maximum 25% to full load Full temperature range Maximum Ui min. to max. % Ripple output voltage ** 3,3V and 5V output 12V output 15V and 24V output Ui nominal Full load BW = 20MHz Maximum Maximum Maximum mVpp mVpp mVpp 40 50 60 Trim function Ui nominal Sense function Ui nominal Maximum Minimum Maximum Minimum % % % % +5 -5 +5 -5 Nominal VDC Output voltage * Set Point accuracy + Line regulation + Load regulation Output power +/- 1 10, 20 or 30 W (limited to respectively 2A, 4A or 6A max) 5 Secondary Output Output voltage * Set point accuracy Output power Ripple output voltage ** 3,3V, 5V and +/-5V output 12V and +/-12V output 15V and +/-15V output 24V and +/-24V output Line regulation Load regulation *** Ui min. to max. 75% load Ambient temperature : +25c Maximum Ui nominal, 75% load Full temperature range Maximum Ui min. to max. Ui nominal Full load BW = 20MHz Ui min. to max. Full load Ui nominal 25% to full load 3,3V , 5V , 12V , 15V or 24V +/- 5V , +/- 12V , +/- 15V or +/- 24V Consult factory for other outputs % W +/- 2 10 or 20 (limited to respectively 2A or 4A max) Maximum Maximum Maximum Maximum mVpp mVpp mVpp mVpp 50 100 150 150 Maximum % +/- 1 Maximum % +/- 2,5 Note * : For proper operation the CGDI module requires to install a 22F 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 capacitor (typically 10nF/rated voltage depending on isolation requirement) connected between the pin Gi and the pin Go 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 FC97-020.01/10 Revision L For locations, phone, fax, E-Mail see back cover 3 Industrial Grade CGDI Standard Input TETHYS 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 18-36 VDC input : 480 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 outputs of the same line of regulation) Output to output Minimum No isolation Electric strength test voltage between outputs (for outputs of different line of regulation) Output to output Minimum 500 VDC/ / 1 min. 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 11 Output overvoltage protection (OVP) Zener clamp / Maximum Maximum Maximum Maximum For 3.3v : 4v For 5v : 6v For 12v : 14v For 15v : 17v over temperature protection (OTP) Thermal device with hysteresis cycle Automatic recovery Nominal 115C 5 7- Reliability Data Characteristics Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 70C 480 000 Hrs 190 000 Hrs Ground mobile (Gm) Case at 40C Case at 70C Consult factory Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR (c) Gaia Converter FC97-020.01/10 Revision L Telecom switchers Ambient at 25C 100% time on 800 000 Hrs 4 For locations, phone, fax, E-Mail see back cover Industrial Grade CGDI Standard Input TETHYS 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 Conducted noise emission With common mode capacitor C c = 10nF and input capacitor C Models 18-36V input models With common mode capacitor C C = 10nF and external filter Class A, C i =4.7F / 50 V tantalum Configuration Radiated noise emission i Class B With common mode capacitor C c = 10 nF Models All models Class B 8-1 Module Compliance with EN 55022 Class B Standard To meet EN55022 Class B requirements, Gaia Converter recommends the use of an external front filter (see EN55022 ClassB EMI Filter Design Note) together with a common mode noise capacitance Cc (10nF/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. The typical schematic hereafter describes the Tethys used in a 4 outputs configuration (exemple 5V/2A, 3.3V/ 2A and +/15V) with front filter, common mode noise Cc and output capacitance to reduce output ripple voltage. Input Filter KG9502 L1 5 C3 L2 + Input + Vo1 Vi C1 22F C2 - Input Gi C4 + Vo1 Case - Vo1 0V + Vo2 + Vo2 22F TETHYS - Vo2 + Vo3 0V 22F Common 3 On/Off + Vo3 0V 22F - Vo3 - Vo3 Command 100K Gin Common mode noise capacitance C c = 10nF (c) Gaia Converter FC97-020.01/10 Revision L 5 For locations, phone, fax, E-Mail see back cover CGDI Standard Input TETHYS Series Industrial Grade 9- 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 4C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 95C. The CGDI 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 : 71C Maximum case temperature : 95C Maximum storage temperature : 105C (c) Gaia Converter FC97-020.01/10 Revision L 6 For locations, phone, fax, E-Mail see back cover CGDI Standard Input TETHYS Series Industrial Grade 10- 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 FC97-020.01/10 Revision L 7 For locations, phone, fax, E-Mail see back cover Industrial Grade CGDI Standard Input TETHYS Series 11- Description of Protections 11-1 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. On Off Vin UVLO Turn-on/Turn-off 11-2 Output Short Circuit Protection (SCP) Vo (%) The short circuit protection device protects the module against short circuits 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. 100 detection time x time recovery time recovery time 11-3 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 11-4 Over Temperature Protection (OTP) On A thermal protection device adjusted at 115C (+/-5%) internal temperature with 10C hysteresis cycle will inhibit the module as long as the overheat is present and restores to normal operation automatically when overheat is removed. The efficiency of the OTP function is warranty with the module mounted on a heatsink. Off 10c 115c (c) Gaia Converter FC97-020.01/10 Revision L Baseplate Temperature 8 For locations, phone, fax, E-Mail see back cover Industrial Grade CGDI Standard Input TETHYS Series 12- Description of Functions 12-1 On/Off Function The control pin 16 (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) : On/Off Command * A logic pulled low (<0.2V@1mA, referenced to Gi) on pin 16 disables the converter * No connection or high impedance on pin 16 enables the converter. 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. 12-2 Trim Function The primary output voltage Vo1 may be trimmed at +/-5% via a single external trimpot or fixed resistor. The trimpot should be connected as shown in figure hereafter. Value of the trim resistance is given in the following table : Vo1 Sense+ 1 2 Trim 3 R1 Vo1 R1 Value Vo1 R1 Value 2,5 V 0 Ohm 12 V 12 KOhm 3,3 V 0 Ohm 15 V 22 KOhm 5V 0 Ohm 24 V 36 KOhm SenseGo1 5 6 Load 10K 5 12-3 Sense Function If the load is seperated from the output by any line lenght, some of these performance characteristics will be degraded at the load terminals by an amount proportional to the impedance of the load leads. With the sense function, the voltage at the power supply output shifts by up to the maximum allowed voltage per load line to compensate the voltage drop in the load leads, there by maintaining a constant voltage at the load terminals. Both Trim and Sense function can be combined but the compensation voltage must not exceed 0.5V max or +/5% of the output voltage. (c) Gaia Converter FC97-020.01/10 Revision L Vo1 Sense+ 1 2 Trim 3 SenseGo1 Load 5 6 9 For locations, phone, fax, E-Mail see back cover CGDI Standard Input TETHYS Series Industrial Grade 13- Application Notes 13-1 Parallel operations Tethys series can be used in parallel to increase output power. Up to 3 Tethys can be used to add power up to a maximum of 90W. Contact factory for further details. 5 (c) Gaia Converter FC97-020.01/10 Revision L 10 For locations, phone, fax, E-Mail see back cover Industrial Grade CGDI Standard Input TETHYS Series 14- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 85 grams (2.9 Ozs) max. 8,6 (0.33") 4 holes M3 40,64 (1.6") 48,26 (1.9") 1x5,08 (1x0.2") 49,9 (1.96") 2x5,08 (2x0.2") 5x2,54 (5x0.1") 2x5,08 (2x0.2") 1,45 +/-0,4 (0.06") 56.00 (2.2") 1x5,08 (1x0.2") 10 (0.39") 0,3 min (0.001") 27,94 (1.1") 7,2 +/-0,4 50,80 (2") (0.28") 76,30 (3") 5 +/-1 (0.19")* 82,40 (3.25") 15- Materials Pin dimensions : O 0,83mm (0.032") * Except pin 15 : 6 mm (0.23") long Case : Matallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 5 16- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 17- Connections Single line Dual line 1 Output 2 Outputs Pin CGDI - - -0-0 CGDI - - -0- CGDI - Triple line 3 Outputs - - -0 CGDI - - -0- CGDI - 4 Outputs - - - CGDI - - - - 5 Outputs CGDI - - - - 1 Ouput 1 + (+Vo1) Output 1 + (+Vo1) Output 1 + (+Vo1) Output 1 + (+Vo1) Output 1 + (+Vo1) Output 1 + (+Vo1) Output 1 + (+Vo1) 6 Outputs CGDI - - - - Output 1 + (+Vo1) 2 Sense + Sense + Sense + Sense + Sense + Sense + Sense + Do not connect 3 Trim Trim Trim Trim Trim Trim Trim Do not connect 4 Do not connect Do not connect Do not connect Do not connect Do not connect Do not connect Do not connect Return 1 (Go1) 5 Sense - Sense - Sense - Sense - Sense - Sense - Sense - Do not connect 6 Return 1 (Go1) Return 1 (Go1) Return 1 (Go1) Return 1- (Go1) Return 1 (Go1) Return 1 (Go1) Return 1 (Go1) Output 1 - (-Vo1) 7 Do not connect Do not connect Output 2+ (+Vo2) Do not connect Output 2 + (+Vo2) Output 2 + (+Vo2) Output 2 + (+Vo2) Output 2 + (+Vo2) 8 Do not connect Do not connect Do not connect Do not connect Do not connect Do not connect Return 2 (Go2) Return 2 (Go2) 9 Do not connect Do not connect Return 2 (Go2) Do not connect Return 2 (Go2) Return 2 (Go2) Output 2 - (-Vo2) Output 2 - (-Vo2) 10 Do not connect Output 2+ (+Vo2) Do not connect Output 2+ (+Vo2) Output 3 + (+Vo3) Output 3 + (+Vo3) Output 3 + (+Vo3) Output 3 + (+Vo3) 11 Do not connect Do not connect Do not connect Return 2 (Go2) Do not connect Return 3 (Go3) Return 3 (Go3) Return 3 (Go3) 12 Do not connect Return 2 (Go2) Do not connect Output 2- (-Vo2) Return 3 (Go3) Output 3 - (-Vo3) Output 3 - (-Vo3) Output 3 - (-Vo3) 13 - Input (Gi) - Input (Gi) - Input (Gi) - Input (Gi) - Input (Gi) - Input (Gi) - Input (Gi) - Input (Gi) 14 + Input (Vi) + Input (Vi) + Input (Vi) + Input (Vi) + Input (Vi) + Input (Vi) + Input (Vi) + Input (Vi) 15 Case Case Case Case Case Case Case Case 16 On/Off On/Off On/Off On/Off On/Off On/Off On/Off On/Off (c) Gaia Converter FC97-020.01/10 Revision L 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 FC97-020.01/10 Revision L Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :