MGDDI-20-R-C

Industrial DC/DC CONVERTER MGDDI-20 Ultra Wide Input : 20W POWER Industrial Grade 12:1 Ultra Wide Input Dual Outputs Metallic Case - 2 250 VDC Isolation • Ultra wide input range • Nominal power up to 20 W • Nominal dual output voltage from 5V to 48V • High efficiency over the entire range • Soft start • Galvanic isolation 2 250 VDC • Integrated LC input filter • Permanent short circuit protection • External trim adjustment : -20/+10% • No optocoupler for high reliability • RoHS process 1-General The MGDDI-20 ultra wide input series designates a full family of DC/DC power modules designed for use in distributed power architecture where variable input voltage for multiple battery and transient are prevalent making them ideal particularly for transportation/mass transit, railways or high-end industrial applications. These modules use a high frequency fixed swiching topology at 270KHz providing excellent reliability, low noise characteristics and very high efficiency over the entire input voltage range. Standard models are available with a permanent ultra wide input voltage range of 12-160 volts fully compatible with 24V/36V/72V/110V/125V battery applications. The serie includes dual output voltage choices individually isolated of 2 x 5 volts , 2 x 12 volts, 2 x 15 volts and 2 x 24 volts with easy configurability. The MGDDI-20 serie is designed in conformity with safety standards EN60950. All the modules are designed with LC network filters to minimize reflected input current ripple according to ease EN55022 standard. The modules include a soft-start, an input undervoltage lock-out, a permanent short circuit protection and an output overvoltage limitation 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. 2-Product Selection Dual output model : MGDDI - 20 - input output Input Voltage Range Permanent R : 12-16O VDC Output C E F I : : : : 2 x 5 VDC 2 x 12 VDC 2 x 15 VDC 2 x 24 VDC REDEFINING THE SOURCE OF POWER © Gaia Converter FC14-076.06/22 Revision D For locations, phone, fax, E-Mail see back cover 5 Industrial Grade MGDDI-20 Ultra Wide Input Series 2- Product Selection (continued) Input range 12-160 12-160 12-160 12-160 VDC VDC VDC VDC Output Current per Output Reference Options 2 x 5 VDC 2 x 12 VDC 2 x 15 VDC 2 x 24 VDC 2A 0,825 A 0,65 A 0,425 A MGDDI-20-R-C MGDDI-20-R-E MGDDI-20-R-F MGDDI-20-R-I / / / / / Using various parallel or series connections of outputs, and the 80/110% trim capability, allows to cover almost the complete range of output voltages from 4V to 52V as shown in the table below. Reference Parallel Connection Series Connection MGDDI-20-R-C MGDDI-20-R-E MGDDI-20-R-F MGDDI-20-R-I 4 - 5,5 VDC 9,6 - 13,2 VDC 12 - 16,5 VDC 19,2 - 26,4 VDC 8 - 11 VDC 19,2 - 26,4 VDC 24 - 33 VDC 38,4 - 52,8 VDC 5 Converter Selection Chart M G D D I - 20 - R - C / Number of Outputs : D : dual output Input voltage range : R : 12-160 VDC Output voltage : See table page 1 Option : / © Gaia Converter FC14-076.06/22 Revision D 2 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide 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) Transient Input Voltage Undervoltage lock-out (UVLO) Start up time Reflected ripple current No load input power Standby input power Dual Output Limit or typical Units Full temperature range Full temperature range Full load Full temperature range Full load Turn-on voltage (pin Uvlo open) Turn-off voltage (pin Uvlo open) Ui nominal within 3 ms Nominal output Full load : resistive Ui nominal, full load at switching freq. BW = 20MHz Ui nominal No load Nominal VDC 48 Min. - Max. VDC 12-160 Maximum VDC/ms Maximum Maximum VDC VDC 165/1000 176/100 11,8 10,8 Maximum ms 30 Maximum % Inom. 10 Maximum W 1 Ui nominal Maximum W 1 Full temperature range Ui min. to max. 75% load Nominal Nominal Nominal Nominal VDC VDC VDC VDC 2x 5 2 x 12 2 x 15 2 x 24 Maximum % +/- 2 Maximum W 20 Nominal Nominal Nominal Nominal A A A A 2,0 0,825 0,65 0,425 Typical W 2 Maximum Maximum Maximum Maximum mVpp mVpp mVpp mVpp Maximum % +/- 1,5 Maximum % +10/-2 Minimum Maximum % % 80 110 Maximum Maximum Maximum Maximum µF µF µF µF 2 200 820 680 470 Typical % up to 90 Conditions MGDDI-20 - R Output Output voltage Set Point accuracy Total output power with both outputs Output current per output 5V output 12V output 15V output 24V output Unbalanced output Ripple output voltage ** 5V output 12V output 15V output 24V output Output regulation * (Line + load + thermal) Cross load output regulation Ambient temperature : +25°c Ui nominal, 75% load Full temperature range Ui min. to max. Full temperature range Full load Ui min. to max. Minimum load on V01 for VO2 proper operation Ui nominal Full load BW = 20MHz Ui min. to max. 0% to full load Ui min. to max. V01 at nominal load V02 from 25% to full load Output voltage trim As a function of output voltage Maximum admissible capacitive load 5V output 12V output 15V output 24V output Ui nominal Full load Per output Efficiency Ui nominal Full load 5 180 240 300 520 Note * : Regulation is measured with both outputs in parallel configuration. 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 1 external decoupling capacitor connected between Gin and Gout. These capacitance should be layed-out as close as possible from the converter. The ripple output voltage is measured by connecting a ceramic chip capacitor Co accross Vo and Go pins (C=100µF if Vo5Vdc) © Gaia Converter FC14-076.06/22 Revision D 3 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDDI-20 Ultra Wide 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 270 KHz 5- Isolation Parameter Electric strength voltage * (Case not connected) Isolation resistance Conditions Limit or typical Specifications Input to output Functional 2 250 VDC Between outputs Functional 300 VDC Input to case 500 VDC Output to case 500 VDC Minimum Minimum 100 MOhm 100 MOhm *DC-DC converters are defined as component power supplies. As components they cannot comply with the provisions of any safety requirements without global conditions of acceptability (mechanical, conductors, ..... ). GAIA Converter DC/DC converter provides functional input-ouput insulation and functional insulation between outputs. The customer will be responsible to sustain all relevant end-user safety standards and regulations (IEC/EN/UL 60950-1). 6- Protection Functions Characteristics Protection Device Recovery Limit or typical Specifications Input undervoltage lock-out (UVLO) Turn-on, turn-off circuit with hysteresis cycle Automatic recovery Turn-on nominal Turn-off nominal See section 3 Output current limitation protection (OCP) Straight line current limitation Automatic recovery Typical 130% Output overvoltage protection (OVP) Overvoltage protection limitation Automatic recovery Nominal 130% of output voltage 5 7- Reliability Data Characteristics Conditions Temperature Specifications Ground fixed (Gf) Case at 40°C Case at 70°C 535 000 Hrs 205 000 Hrs Ground mobile (Gm) Case at 40°C Case at 70°C 265 000 Hrs 105 000 Hrs Railway, Payphone Ambient at 25°C 100% time on 325 000 Hrs Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR © Gaia Converter FC14-076.06/22 Revision D 4 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 8- Electromagnetic Interference Electromagnetic interference requirements according to EN55022 class A and class B can be easily achieved as indicated in the following table and following schematics : Electromagnetic Interference according to EN55022 Conducted noise Models emission Radiated noise emission Configuration With a common mode capacitor C c = 10nF and external filter All models Configuration Models Class B With a common mode capacitor C c = 10 nF and external filter All models Class B 8-1 Module Compliance with EN55022 class B Standard Electromagnetic interference requirements according to EN55022 class B or EN50121 can be easily achieved using the following schematics : 5 Please consult EN50155 Transient/EMI Filter design note for further details on components. © Gaia Converter FC14-076.06/22 Revision D 5 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra 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 : • an input limitor filter : see following 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 µs, impedance 2 Ohm EN 50155 Level 1 800 V waveform 50 µs, impedance 100 and 5 Ohm Level 8 400 V waveform 0.1 µs, impedance 100 Ohm EN 61000-4-5 Level 4 with 4 000 V waveform 50 µs, impedance 12 Ohm EN 50155 Level 1 800 V waveform 50 µs, impedance 100 and 5 Ohm Level 8 400 V waveform 0.1 µs, impedance 100 Ohm 5 Please consult EN50155 Transient/EMI Filter design note for further details on components. © Gaia Converter FC14-076.06/22 Revision D 6 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 10- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range Ambient temperature Minimum Maximum - 40°C see below Operating case temperature range at full load Case temperature Minimum Maximum - 40°C see curves herafter Storage temperature range Non functionning Minimum Maximum - 40°C + 115°C Thermal resistance Rth case to ambient in free air natural convection Typical 15°C /W The following discussion will help designer to determine the thermal characteristics and the operating temperature. To calculate the maximum admissible ambient temperature the following method can be used. Heat can be removed from the baseplate via three basic mechanisms : Knowing the power used Pout and the efficiency η: • determine the power dissipated by the module Pdiss that should be evacuated : η - 1) (A) Pdiss = Pout(1/η • Radiation transfert : radiation is counting for less than 5% of total heat transfert in majority of case, for this reason the presence of radient cooling is used as a safety margin and is not considered. • Conduction transfert : in most of the applications, heat will be conducted from the baseplate into an attached heatsink or heat conducting member; heat is conducted thru the interface. • Convection transfert : convecting heat t r a n s f e r into air refers to still air or forced air cooling. In majority of the applications, we will consider that heat will be removed from the baseplate either with : • heatsink, • forced air cooling, • both heatsink and forced air cooling. • then determine the thermal dissipation : Tdiss = Rth(b-a) x Pdiss (B) where Rth(b-a) is the thermal resistance from the baseplate to ambient. This thermal Rth(b-a) resistance is the summ of : • the thermal resistance of baseplate to heatsink (Rth(b-h)). The interface between baseplate and heatsink can be nothing or a conducting member, a thermal compound, a thermal pad.... The value of Rth(b-h) can range from 0.4°C/W for no interface down to 0.1°C/W for a thermal conductive member interface. • the thermal resistance of heatsink to ambient air (Rth(h-a)), which is depending of air flow and given by heatsink supplier. 5 The table hereafter gives some example of thermal resistance for different heat transfert configurations. Heat transfert Free air cooling only Forced air cooling 400 LFM © Gaia Converter FC14-076.06/22 Revision D Thermal resistance heatsink to air Rth(h-a) Thermal resistance baseplate to heatsink Rth(b-h) Global resistance No Heatsink baseplate only : 15°C/W No need of thermal pad 15°C/W BGA-STD-090 ABL Heatsink 10mm height 10°C/W Including conductive adhesive pad 10°C/W SK551 Fischer Elektronik 12,3 mm height 11°C/W Pad value to be added BGA-STD-090 ABL Heatsink 10 mm width 5°C/W Including conductive adhesive pad 11,5-12°C/W 5,2°C/W 7 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 10- Thermal Characteristics (continued) conduct to determine the maximum ambient temperature admissible as a function of the maximum baseplate temperature of the module. The two formulas (A) and (B) described in previous page : • Pdiss = Pout(1/η η - 1) (A) • Tdiss = Rth(b-a) x Pdiss (B) Knowing the maximum baseplate temparature Tmaxbaseplate the maximum ambient temperature is given by the following formula : Ta = Tmaxbaseplate - Tdiss (C) MGDDI-20-R-x Series Maximum Baseplate Temperature Versus % of Maximum Output Power 130 120 Maximum Baseplate Temperature (°C) 110 100 90 80 70 60 50 40 30 20 5 10 0 0 25 50 75 100 % of Maximum Output Power (%) © Gaia Converter FC14-076.06/22 Revision D 8 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra 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 95°C case unit operating IEC 68-2-2 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40°C 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 -40°C / +71°C 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 -40°C / +105°C 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 µs 2 Ohm 4 kV : with transient protection (see section surge) EN61000-4-5 EN50155 Surge Susceptibility © Gaia Converter FC14-076.06/22 Revision D 9 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDDI-20 Ultra Wide Input Series 12- Description of Protections The MGDDI-20 series includes 3 types of protection devices. 12-1 Input Undervoltage Lockout (UVLO) An input undervoltage protection will inhibit the module when input voltage drops below the lock-out turn-off threshold (see section 3 for value) and restores to normal operation automatically when the input voltage rises the lock-out turn-on threshold. On Off Without resistor, the turn on voltage is 11.8V and turn off voltage is 10.8V UVLO Turn- off UVLO Turn- on UVLO Turn- off UVLO Turn- on Vin Uvlo Voltage trimming 150 Turn on voltage turn off voltage 130 110 Vuvlo (Vdc) The UVLO voltage can be adjusted using a resistor (Ruvlo) connected between pin 3 and Gi. This value can be ajusted in order to allow converter to stops properly accordingly to the input bus (or battery ) voltage value. The Ruvlo can be determined using the following formula : Ruvlo (KΩ) = 187/[Vuvlo - 11] Ruvlo = trimming resistance Vuvlo = desire turn-on voltage 90 70 50 30 10 100 1000 Ruvlo (Ω) 10000 100000 12-2 Output Over Current Limitation Protection (OCP) The MGDDI-20 Series incorporates a overcurrent protection circuit. The overcurrent protection detects short circuit or over curent and protects the module according to the hiccup graph . The maximum detection current Id is depending on input voltage Vin, temperature, and is higher than 105 % maximum nominal output curent. When OCP is triggered, the converter falls in hiccup mode by testing periodically if the overload is still present. The module restart automatically to normal operation when overcurrent is removed. Td (detection time) and Th (hiccup period) are depending on Vin and temperature. In hiccup mode the average curent is arround 25 % of Inom. 5 12-3 Output Overvoltage Protection (OVP) The MGDDI-20 series has an internal overvoltage limitation protection circuit that monitors the voltage accross the output power terminals. It is designed to limit the converter output voltage to 130% (+/-10%) of nominal output voltage. © Gaia Converter FC14-076.06/22 Revision D 10 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 13- Description of Functions 13-1 Connection of Outputs The outputs of MGDDI-20 can be connected in various configurations such as : - connections in series - connection in parallel - connection in symmetry - connection in independance Please note that regulation is achieved through output V01/G01 referenced as primary output. When connected in symetrie or independant configurations with unbalanced loads, VO1/GO1 has to be loaded at 2W minimum to insure proper operating of the converter. The V02/G02 output referenced as secondary output may stay unloaded, but in that case its regulation may drift up as shown in curve below. There is no minimum load when the two outputs are connected in parallel or balanced serie. 13-1-1 Connection of Outputs in Series 13-1-2 Connection of Outputs in Parallel Outputs connected in series allow to achieve 10V, 24V, 30V or 48V output voltages up to 20W total power. These values can be extended using trim adjustment. Outputs connected in paralell allow to achieve single output 5V, 12V, 15V or 24V up to 20W power. These values can be extended using trim adjustment. 5 13-1-3 Connection of Outputs in Symmetry Outputs connected in symetrie allow to achieve +/-5V, +/-12V, +/-15V or +/-24V voltages (+/-10W each) with possible unbalanced loadup to 17W on primary outout, 3W on secondary output and vice versa. 13-1-4 Connection of Outputs in Independance Outputs connected independantly with floating DC between each other can be achieved for 2x5V, 2x12V, 2x15V or 2x24V voltages (30W each) with possible unbalanced load up to 17W on primary output 3W on secondary output and vice versa. © Gaia Converter FC14-076.06/22 Revision D 11 For locations, phone, fax, E-Mail see back cover Industrial Grade MGDDI-20 Ultra Wide Input Series 13- Description of Functions (continued) 13-2 Trim Function The output voltage Vo1 may be trimmed in a range of 80%/110% of the nominal output voltage via a single external trimpot or fixed resistor. The Vo2 output will automatically follow output Vo1. Trim Up Function Do not attempt to trim the module higher than 110% of nominal output voltage as the overvoltage protection may occur. Also do not exceed the maximum rated output power when the module is trimmed up. The trim up resistance must be calculated with the following formula : Trim Down Function Do not trim down more than -20% of nominal output voltage otherwise the module may be damaged. The available output power is reduced by the same percentage that output voltage is trimmed down. 5 The trim down resistance must be calculated with the following formula : Parameter Unit Min. Typ. Max. Trim reference Vref Vdc 1,2 1,225 1,25 Resistor R1 Ohm / 3,9K / Resistor R2 Ohm / 270 / nF / TBD / Trim capacitor C © Gaia Converter FC14-076.06/22 Revision D 12 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 13- Description of Functions (continued) 13-3 On/Off Function The control pin 1 (On/Off) can be used for applications requiring On/Off operation. This may be done with an open collector transistor, a switch, a relay or an optocoupler. Several converters may be disabled with a single switch by connecting all On/Off pins together. • The converter is disabled by pulling low the pin 1. • No connection or high impedance on pin 1 enables the converter. By releasing the On/Off function, the converter will restart within the start up time specifications given in table section 3 Parameter Unit Min. Typ. Max. Notes, conditions On/Off module enable voltage Vdc 2.5 / 3.0 Open, the switch must not sink more than 50µA On/Off module disable voltage Vdc 0 / 0.5 The switch must be able to sink 0,5mA On/Off module enable delay ms / / 30 The module restarts with the same delay after alarm mode removed On/Off module disable delay µs / / 100 Vi nominal, full load 13-4 Input Filter Compensation (VIF) The «VIF» pin is a direct access to the capacitor of the LC input filter and allows to increase the C value to enhance the converter’s stability and performance and to reduce the input current ripple for improved EMI performance.It is recommended to provide low ESR ceramic capacitors, total value can rate from 2.2µF for high input voltage use to 10µF for low input voltage use.These capacitors should have the proper voltage rating. Because of high current flowing through it, it should be connected between «VIF» and «Gin» as close as possible from the converter, using large copper traces. © Gaia Converter FC14-076.06/22 Revision D 5 13 For locations, phone, fax, E-Mail see back cover MGDDI-20 Ultra Wide Input Series Industrial Grade 14- Dimensions Dimension are given in mm. Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated. Weight : 35 grams (1.25 Ozs) max. 15- Materials Case : Metallic black anodized coating. Pins : Flash gold plating over nickel underplate. 5 16- Product Marking Upper face : Company logo. Side face : Module reference, option, date code : year and week of manufacturing. 17- Connections The MGDI-20 series has been designed for on-board mounting. it is recommended not to lay-out any component under the module. Bottom view © Gaia Converter FC14-076.06/22 Revision D Pin Single 1 On/Off 2 Do not connect 3 UVLO 4, 5 Do not connect 6 - Input (Gi) 7 VIF 8 + Input (Vi) 9 + Output 2 (Vo2) 10 - Output 2 (Go2) 11 Do not connect 12 + Output 1 (Vo1) 13 - Output 1 (Go1) 14 Do not connect 15 Vtrm 16 Do not connect 14 For locations, phone, fax, E-Mail see back cover International Headquarters GAÏA Converter - France 18 Rue Caroline Aigle 33186 LE HAILLAN - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAÏA Converter Canada, Inc 1405 Transcanada Hwy, Suite 520 DORVAL, QUEBEC, H9P 2V9 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 FC14-076. 06/22 Revision D. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :