Board Mountable
DC-DC Converters
G Series
25 Watt DC-DC Converters
Input voltage ranges up to 75 V DC
3 outputs 5...15 V DC
1500 V DC I/O electric strength test voltage
• Very high efficiency, typ. 87%
• Operating case temperature range –25...95°C
• Flex power (flexible load distribution on all outputs)
• Excellent dynamic response (magnetic feedback)
• Active current sharing for operation in parallel
• Outputs overload, no-load and short-circuit proof
• Serial 8 bit status communication interface
• Thermal protection with pre-warning prior to shut-
down
• Very compact (chip and wire technology)
• High reliability
MTBF >700'000 h (Ground benign, 40°C)
G Series
43
1.69"
10.5
0.41"
53
2.1"
Safety according to IEC/EN 60950, UL 1950
Summary
The G series of 25 Watt DC-DC converters represents a
versalite range of board mountable power supplies for use
in advanced electronic systems of centralized or decentral-
ized structure. Features include very high efficiency com-
bined with compact size, high reliability (MTBF), wide input
voltage ranges, transient voltage and surge protection, low
output ripple and noise and excellent dynamic response to
load and line changes.
Available with three outputs electrically isolated from the in-
put the converters deliver 25 Watt output power with flexible
load distribution between all outputs without provoking un-
acceptable voltage deviations.
The G series is designed as a hybrid circuit comprising pro-
prietary control ASICs and chip and wire technology.
The design is based on an advanced zero-voltage switch-
ing topology, optimised circuitry and high grade compo-
nents including the latest integration technologies.
Main application areas are telecom, avionics, industrial and
mobile applications where outstanding electrical perform-
ance and reliability are required.
Optionally the converters are available with an output volt-
age monitor with diagnostic results obtainable via an 8bit
serial interface and reset/shut-down signals for micro con-
troller applications.
Two different aluminium cases are available either for sim-
ple board mounting or with an additional mounting-flange.
Table of Contents
Page
Page
Auxiliary Functions ........................................................... 8
Electromagnetic Compatibility (EMC) ............................ 10
Immunity to Environmental Conditions ........................... 11
Mechanical Data ............................................................ 12
Safety and Installation Instructions ................................ 12
Description of Options .................................................... 14
1/16
Summary .......................................................................... 1
Type Survey and Key Data .............................................. 2
Type Key .......................................................................... 2
Functional Description ...................................................... 3
Electrical Input Data ......................................................... 4
Electrical Output Data ...................................................... 5
Edition 1/06.2002
Board Mountable
Type Survey and Key Data
Table 1: Type survey
DC-DC Converters
G Series
Output 1
Output 2
Output 3
Output
U
o1 nom
I
o1 nom
I
o1 max 1
U
o2 nom
I
o2 nom
I
o2 max 1
U
o3 nom
I
o3 nom
I
o3 max 1
power
[V DC]
[A]
[A]
[V DC]
[A]
[A]
[V DC]
[A]
[A]
P
o nom
[W]
5.05
5.05
5.05
5.05
1
Input voltage Effic.
2
range
[V DC]
h
typ
[%]
14...36
36...75
14...36
36...75
87
86
87
86
Type
designation
BG 3020-9
CG 3020-9
BG 3040-9
CG 3040-9
Opt.
2
2
2
2
5
5
5
5
12.6
12.6
15.4
15.4
0.6
0.6
0.5
0.5
2
2
1.6
1.6
–12.6
–12.6
–15.4
–15.4
–0.6
–0.6
–0.5
–0.5
–2
–2
–1.6
–1.6
25
25
25
25
D
B
2
Flexible load distribution on triple output units. Maximum current available from one output with all other outputs in no-load condition.
The total output power may not exceed the sum of the nominal output power of all outputs.
Efficiency at
U
i nom
and
I
o nom
.
Type Key
Type Key
B G 3 0 40 -9 D B
Input voltage range
U
i
14...36 V DC ................................................ B
36...75 V DC ............................................... C
Series .............................................................................. G
Number of outputs ............................................................ 3
Output 1,
U
o1 nom
5 V .......................................................... 0...1
other voltages ......................................... 7...8
Output 2 and 3,
U
o2 nom
,
U
o3 nom
12 V .................................................... 20...39
15 V .................................................... 40...59
Operational ambient temperature range
T
A
–40…71°C (option) ..................................... -9
Options:
Output voltage monitor, reset sequencer .... D
Case with additional fixing holes .................. B
Edition 1/06.2002
2/16
Board Mountable
Functional Description
DC-DC Converters
G Series
The input voltage is fed via the Vi+ and the Vi– pins and an
input
π-filter
to a zero-voltage switching (ZVS) flyback con-
verter. The controlled resonant switching of the transistors
keeps the EMI noise low.
On the secondary side, depending upon the converter type,
two or three output voltages are available, all referenced to
common ground (Go). Each output has an individual filter
for further noise reduction designed without any restriction
to the dynamic behaviour.
The control circuit on the secondary side senses the main
output voltage
U
o1
and generates a control signal which is
transmitted via a pulse transformer to the primary control
circuit. The primary control circuit transforms this signal with
respect to the maximum admissible output power into a
second control signal for the switching transistors.
The regulation for the second and third output voltages re-
lies on the close magnetic coupling of the transformer
windings and the circuit symmetry. Thanks to the unique
control philosophy of the flyback converter topology no
minimum load is required at any of the outputs and no out-
put voltage will drift under no-load condition.
An optional voltage monitor and signal sequencer on the
secondary side generates shut-down and reset signals dur-
ing the power-up and power-down sequence for a control-
led turn-on and turn-off of a microprocessor or another cir-
cuit. The monitor circuit checks for proper converter func-
tion and monitors all output voltages wether they remain
within an upper and lower limit.
Any failure will be indicated by a /FAIL signal and may be
identified if necessary by an 8 bit diagnostic information.
Efficiency
Thanks to the latest integration methods, optimised zero-
voltage switching topology with synchronous rectifier on all
outputs and a unique control philosophy a very high effi-
ciency over the whole input voltage range is achieved. The
benefits are minimized heat dissipation and increased sys-
tem reliability.
03005
5 Vo3–
Case
1
0
ZVS
Flyback
Converter
Input Filter
and TVS
2
×
22 nF
1000 V
Output Filter
6 Vo2+
7 Go
8 Go
Output Filter
9 Vo1+
Vi– 4
Vi+
3
TMON
2
Primary
Controller
Secondary
Controller
17 Go
18 R
19 T
16 Uo OK or CT2
12 /PDW
U
o1
U
o2
U
o3
Option D
Supervisory
Circuit
13 /SDW
14 /RST
15 CT1
i
1
10
1
Pin not fitted with option B
2
Uo OK without option D, CT2 if with option D
11
/FAIL /SRQ
Fig. 1
Block diagram
Edition 1/06.2002
3/16
Board Mountable
Electrical Input Data
DC-DC Converters
G Series
General conditions:
–
T
A
= 25°C, unless
T
C
is specified.
– Connector pins i (inhibit) and Vi– interconnected unless
U
inh
is specified.
– R input not connected.
Table 2: Input data
Input
Characteristics
Conditions
min
14
24
10
BG
typ
max
36
min
36
48
25
2
16
11
9
3
2
10
W
mA
A
µF
CG
typ
max
75
Unit
V DC
U
i
U
i nom
U
i uv
P
i 0
I
i inh
I
inr p
C
i
f
s
1
2
Input voltage range
Nominal input voltage
Undervoltage lock-out
No-load input power
Input current when
inhibited
Peak inrush current
Input capacitance
Switching frequency
2
T
C min
…
T
C max
I
o
= 0...I
o nom
U
i nom
,
I
o
= 0
U
inh
> 2.4 V
U
i min
...U
i max
U
i nom 1
U
i nom
,
I
o nom
2
Source impedance according to prETS 300132-2 (Ver. 4.3).
The switching frequency varies with input voltage and output load (see:
Typical performance curves).
Input Transient Voltage Protection
A suppressor diode at the input together with the input filter
provides an effective protection against input transients
which may be caused for example by short circuits accross
the input lines where the network inductance may generate
high energy pulses.
Reverse Polarity Protection at Input
The suppressor diode at the input also provides for reverse
polarity protection by conducting current in the reverse di-
rection, thus protecting the unit. An external fuse is required
to limit reverse current:
– for BG units a fast 3 A (F3A) fuse is required.
– for CG units a fast 1.25 A (F1.25A) fuse is required.
Filter recommendations for compliance with
EN 55022, level B
Electromagnetic emission requirements according to
EN 55022, level B can be achieved by adding an external
filter to the input of the converter. (tbd)
Table 3: Built-in transient voltage suppressor
Type
Breakdown
voltage (1 mA)
V
BR min
[V]
43
90
Peak power
at 1 ms
P
P
[W]
600
600
Peak pulse
current
I
P
[A]
8.6
4.1
BG
1
CG
1
1
To achieve higher input transient ratings an additional inductor
and capacitor should be provided externally.
Inrush current
The inrush current has been kept as low as possible by
choosing a small internal input capacitance.
04007
2 A/Div.
Steady state
input current
0
50
µs/Div.
Fig. 2
Typical inrush current at U
i nom
, P
o nom
versus time
(BG 3040) measured according prETS 300132-2 (Ver. 4.3).
Edition 1/06.2002
4/16
Board Mountable
Electrical Output Data
DC-DC Converters
G Series
General conditions:
–
T
A
= 25°C, unless
T
C
is specified.
– Connector pins i (inhibit) and Vi– interconnected
– R input not connected.
Table 4a: Output data for dual output modules BG...CG 3020-7
Output
Output 1
Characteristics
Conditions
min
5.0
5
typ
5.05
max
5.1
5.1
BG...CG 3020-7
Output 2
min
typ
max
min
Output 3
typ
max
Unit
U
o
Output voltage
Static output voltage
U
i nom
,
I
o nom
T
C min
...T
C max
U
i nom
I
o
= 0...I
o max 1
U
i nom
only one output
loaded
12.15 12.6 12.85
11.95
13.25
–12.85 –12.6 –12.15
–13.25
–11.95
I
o nom
Output current
I
o max
u
o
Output
voltage
noise
Switching freq.
Total
2
5
25
50
4.8
5.25
100
60...110
11.35
0.6
2
50
100
13.85
100
60...110
–13.85
–2
–0.6
A
U
i nom
,
I
o nom
IEC/EN 61204
2
BW = 20 MHz
U
i min
...U
i max
I
o nom
↔
1
/
2
I
o nom
IEC/EN 61204
U
o nom
setting
via R input
50
100
–11.35
100
60..100
mV
pp
u
o d
t
d
Dynamic
3
Voltage limits
load
Recovery time
regulation
V
µs
% of
U
o nom
U
o adj
Output voltage
adjustment range
Table 4b: Output data for dual output modules BG...CG 3040-7
Output
Output 1
Characteristics
Conditions
min
5.0
5
typ
5.05
max
5.1
5.1
BG...CG 3040-7
Output 2
min
15.0
14.6
typ
15.4
max
15.7
16.2
min
Output 3
typ
max
–15.0
–14.6
Unit
V
U
o
Output voltage
Static output voltage
U
i nom
,
I
o nom
T
C min
...T
C max
U
i nom
I
o
= 0...I
o max 1
U
i nom
only one output
loaded
–15.7 –15.4
–16.2
I
o nom
Output current
I
o max
u
o
Output
voltage
noise
Switching freq.
Total
2
5
25
50
4.8
5.25
100
60...110
13.8
0.5
1.6
50
100
17.0
100
60...110
–17.0
–1.6
–0.5
A
U
i nom
,
I
o nom
IEC/EN 61204
2
BW = 20 MHz
U
i min
...U
i max
I
o nom
↔
1
/
2
I
o nom
IEC/EN 61204
U
o nom
setting
via R input
50
100
–13.8
100
60..100
mV
pp
u
o d
t
d
Dynamic
3
Voltage limits
load
Recovery time
regulation
V
µs
% of
U
o nom
U
o adj
Output voltage
adjustment range
1
2
3
Power difference between one auxiliary output and main output <12 W. Total output power
≤
P
o nom
.
See:
Technical Information: Measuring and Testing.
Load current change for specific output. Other outputs loaded with
I
o nom
.
Output Current Limitation
The G series modules have a current limitation allowing
free choice of load distribution between all outputs, up to a
total current:
U
o2 nom
U
o3 nom
I
o1
+ ––––––– •
I
o2
+ ––––––– •
I
o3
≤
I
o1 max
U
o1 nom
U
o1 nom
In overload all output voltages are simultaneously reduced.
Output Overvoltage Protection
The outputs of the unit are protected against overvoltages
by a second fully independent control loop which disables
the unit. The unit tries to restart after a short time (5 ms).
The main purpose of this second control loop is to protect
against possible overvoltages which could occur due to a
failure in the normal feedback control loop. The second con-
trol loop does not protect the unit against externally applied
overvoltages.
Edition 1/06.2002
5/16
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