Hi-Rel LIMITOR MODULE LGDS-300 : up to 300W POWER Hi-Rel Grade 80V or 100V Transient Protection Module MIL-STD-704A & MIL-STD-1275 Metallic Case * Ultra compact limitor module * Transient suppressor module 80V * MIL-STD-704A/D/E/F, EN2282, AIR2021E * DO160E cat A, B and Z * Transient suppressor module 100V * MIL-STD-1275A/B/C/D, 1- General * Power range : up to 300W * Inrush current limitation * RoHS process The GAIA Converter limitor LGDS-300 is an ultra compact power adaptator module designed to allow operation during voltage transients and spikes, occuring in avionics or military systems. The LGDS-300 delivers an output voltage adapted to GAIA Converter DC/DC modules. This module is optimized to provide high power efficiency up to 99% over the whole power range up to 300W. The LGDS-300 features 3 modes of operations as follow: * Normal operation : Normal operation occurs in between the permanent input voltage of the DC/DC converter; The LGDS-300 is then operating in steady transparency state. * Power fail operation : The power fail operation occurs when the input bus drops below 9 Vdc low voltage limit ; an undervoltage lock-out stops the LGDS-300. * Transient operation : The LGDS-300 clamps input transient up to 80V/100ms or 100V/50ms. The LGDS-300 series is compliant with the international input bus standards : - MIL-STD-704A/D/E/F - AECMA EN2282 - GAM-EG13B/AIR2021E - DO160E cat A, B and Z - MIL-STD-1275A/B/C/D The design has been carried out with surface mount components and is manufactured in a fully automated process to guarranty high quality. Every module is tested with a Gaia Converter automated test equipment. The modules are potted with a bi-component thermal conductive compound and packaged in a metallic case to ensure the module's integrity under severe environmental conditions. 2- Product Selection LGDS - 300 - input output / option Input Voltage Range Output Transient O : 100V/50ms Options : /T : option for -55C start up operating temperature /S : option for screening and serialization REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC08-059.01/10 Revision D For locations, phone, fax, E-Mail see back cover K 4 Hi-Rel Grade LGDS-300 Series 3- Modes of Operation 3-1 LGDS-300 Modes of Operation The LGDS-300-O-K operates with H input family of GAIA Converter DC/DC Converters. The LGDS-300-O-K features 3 modes of operations as describes in the following state diagram : Normal Mode OCP (Vout=Vin-Vdrop) * Normal operation : Normal operation occurs in between 9V and 42V input voltage; the module is then operating in steady transparency state. OTP Start-up Vin>Vst Surge UVLO Power fail Mode (output disabled) End of Surge * Power fail operation : When a failure occurs such as an undervoltage, an over current or an over temperature, the LGDS-300 turns to power fail mode and stops operation until the failure is removed. The LGDS-300 features 3 protection functions : input undervoltage lockout (UVLO), output over current protection (OCP) and over temperature protection (OTP). Transient Mode (Vout=Vlim) * Transient operation : When a surge occurs, the LGDS-300 turns to transient mode operation. It clamps input transient up to 100V as long as 50ms. During this transient mode, the over current protection (OCP) is activated in order to prevent applications failure. OTP OCP : Over Temperature Protection : Over Current Protection 4 LGDS-300 Transfer Function 45 Power fail operation area 40 35 output voltage (Vdc) 30 Normal operation Area Transient operation Area 25 20 15 10 5 0 0 (c) Gaia Converter FC08-059.01/10 Revision D 10 20 30 40 50 Input voltage (Vdc) 60 70 80 90 100 2 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-300 Series 4- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Conditions Input Permanent input Full temperature range voltage range (Ui) Full load in normal operation Compliance with standards voltage transient limit Compliance with standards voltage spike limit *with companion filter FGDS series Under voltage lock- out (UVLO) Start up time Full temperature range 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 15 mJ energy content Turn-on/Turn-off threshold Ui nominal 28V Full load Full temperature range C=1000F Ui nominal 28V No load Inrush current limitation No load input current Output Nominal voltage in Ui < 42V normal operation Full load Nominal voltage in In transient transient Input voltage range protection mode Output voltage During start-up time slew rate Full temperature range Output current Ui min. to max. Full temperature range Output Power Ui min. to max. Ui nominal 28V Power dissipation Output current 20A (c) Gaia Converter FC08-059.01/10 Revision D Limit or typical Units Minimum Maximum VDC VDC Maximum Maximum MIL-STD-704A/F AECMA EN2282 AIR2021E DO160E cat A/Z MIL-STD-1275A/D MIL-STD-704A/F AECMA EN2282 AIR2021E DO160E cat A/Z MIL-STD-1275A/D Minimum Maximum VDC/ms VDC/s 80V/75ms 60V/50ms 60V/100ms 80V/100ms 100V/50ms 600V/10s 400V/100s 600V/10s 600V/10s 250V/70s VDC VDC Maximum ms 6 Typical A 5 Maximum mA 10 Minimum / Minimum Nominal Maximum VDC VDC VDC 40 42 44 Typical VDC/ms 5 Maximum A 20 Maximum W see page 4 figure 5 Maximum W 3 LGDS-300 9 42 100V/50ms 48V/1s Compliant Compliant Compliant Compliant Compliant Compliant* Compliant* Compliant* Compliant* Compliant* 7 9 4 Ui - 125mV 3 For locations, phone, fax, E-Mail see back cover LGDS-300 Series Hi-Rel Grade 4- Electrical Characteristics (continued) Figure 1 : LGDS-300-O-K Transient Response at 80Vdc (according to DO-160D/E/F) Figure 2 : LGDS-300-O-K Transient Response at 100Vdc (according to MIL-STD-1275D) 4 Figure 3 : LGDS-300-O-K Output Power versus Input Voltage Figure 4 : LGDS-300-O-K Start-up Timing 350 300W max 300 Pout (W) 250 200 20A max 150 Permanent operation Area Transient operation Area 100 50 0 0 10 20 30 (c) Gaia Converter FC08-059.01/10 Revision D 40 50 60 Vin (Vdc) 70 80 90 100 4 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-300 Series 4- Electrical Characteristics (continued) The following figures describe the LGDS-300-O-K maximum admissible energy in compliance with standard requirements for single pulse and repetitive surge conditions. LGDS-300-O-K Maximum Admissible Energy in Single Pulse Condition 75.00 DO-160E/CATZ worst case 60V / 510ms 70.00 65.00 MIL-STD-1275D worst case 75V / 240ms 60.00 Limitor Dissipated Energy (J) 55.00 50.00 45.00 40.00 MIL-STD-1275C worst case 68V / 170ms 35.00 30.00 MIL-STD-1275A/B worst case 85V / 70ms 25.00 20.00 LGDS300 VIN 42V 300W MIL-STD1275C MIL-STD1275D DO160E-CATZ MILSTD1275A/B 15.00 MIL-STD-1275A/B/C/D (100V/50ms) 10.00 5.00 4 1. 6 1. 65 1. 5 1. 55 1. 4 1. 45 1. 3 1. 35 1. 2 1. 25 1. 1 1. 15 1 1. 05 0. 9 0. 95 0. 8 0. 85 0. 7 0. 75 0. 6 0. 65 0. 5 0. 55 0. 4 0. 45 0. 3 0. 35 0. 2 0. 25 0. 1 0. 15 0. 05 0.00 time (s) LGDS-300-O-K Maximum Admissible Energy in Repetitive Surge Condition 300.00 275.00 250.00 LGDS-300-O-K MIL-STD-1275C/D Repetitive surge at worst case energy operation Limitor dissipated energy (J) 225.00 100V/50ms pulses 7 pulses at 1sec interval according MIL-STD-1275C standard testing 200.00 175.00 150.00 125.00 100.00 100V/50ms pulses 5 pulses at 1sec interval according MIL-STD1275A/B/D 75.00 80V/100ms pulses 3 pulses at 10 sec interval according DO-160E standard testing 50.00 25.00 0.00 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 time (s) (c) Gaia Converter FC08-059.01/10 Revision D For locations, phone, fax, E-Mail see back cover 5 5.5 6 6.5 7 5 Hi-Rel Grade LGDS-300 Series 5- Isolation Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output All pins to case / Minimum No isolation 500 VDC / 1 min Isolation resistance 50 VDC, all pins to case Minimum 100 MOhm 6- Protection Functions Characteristics Protection Device Recovery Limit or typical Specifications Output over current protection (OCP) Hiccup circuitry with auto-recovery Automatic recovery Permanent See section 10 Over temperature protection (OTP) Thermal device with hysteresis cycle Automatic recovery Nominal 120C 4 7- Reliability Data Characteristics Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Mean Time Between Failure (MTBF) According to IEC-62380-TR (c) Gaia Converter FC08-059.01/10 Revision D Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 85C 1 300 000 Hrs 425 000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40C Case at 85C 675 000 Hrs 250 000 Hrs Civilian avionics, calculators Ambient at 55C 100% time on 1 800 000 Hrs 6 For locations, phone, fax, E-Mail see back cover LGDS-300 Series Hi-Rel Grade 8- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Ambient temperature * Minimum Maximum - 40C + 85C Operating case temperature range at full load Case temperature Minimum Maximum - 40C +105C Storage temperature range Non functionning Minimum Maximum - 55C + 125C Thermal resistance Rth case to ambient in free air natural convection Typical 12C /W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105C. The LGDS-300 series operating case temperature at full load must not exceed 105C. The maximum ambient temperature admissible for the DC/DC converter corresponding to the maximum operating case temperature of 105C 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 = 105C 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 = 105C - Rth x Pdiss where Rth is the thermal resistance from the case to ambient. 4 The previous thermal calculation shows two areas of operation : * a normal operation area in a free natural ambient convection (grey area in the following graph), * an area with cooling features (air flow or heatsink) ensuring a maximum case temperature below the maximum operating case temperature of 105C at full load (white area in the following graph). Power (W) 100% Additionnal cooling operation area 75% Natural convection operation area 50% 25% 10 20 30 40 50 60 70 80 90 Temperature (C) Full load ambient temperature without derating : 75C Maximum case temperature : 105C Maximum storage temperature : 125C (c) Gaia Converter FC08-059.01/10 Revision D 7 For locations, phone, fax, E-Mail see back cover LGDS-300 Series Hi-Rel Grade 9- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Duration Temperature / status of unit Test D : 1 000 Hrs @ 105C case, unit operating @ 125C ambient, unit not operating MIL-STD-202G Method 108A Altitude Altitude level C Duration Climb up Stabilization Status of unit 40 000 ft@-55C 30 min. 1 000 ft/min to 70 000 ft@-55C, 30 min. unit operating MIL-STD-810E Method 500.3 Humidity cyclic Number of cycle Cycle duration Relative humidity variation Temperature variation Status of unit 10 Cycle I : 24 Hrs 60 % to 88 % 31C to 41C unit not operating MIL-STD-810E Method 507.3 Humidity steady Damp heat Temperature Duration Status of unit 93 % relative humidity 40C 56 days unit not operating MIL-STD-202G Method 103B Salt atmosphere Temperature Concentration NaCl Duration Status of unit 35C 5% 48 Hrs unit not operating MIL-STD-810E Method 509.3 Temperature cycling Number of cycles Temperature change Transfert time Steady state time Status of unit 200 -40C / +85C 40 min. 20 min. unit operating MIL-STD-202A Method 102A Temperature shock Number of shocks Temperature change Transfert time Steady state time Status of unit 100 -55C / +105C 10 sec. 20 min. unit not operating MIL-STD-202G Method 107G Vibration (Sinusoidal) Number of cycles Frequency / amplitude Frequency / acceleration Duration Status of unit 10 cycles in each axis 10 to 60 Hz / 0.7 mm 60 to 2 000 Hz / 10 g 2h 30 min. per axis unit not operating MIL-STD-810D Method 514.3 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 MIL-STD-810D Method 516.3 Bump (Half sinus) Number of bumps Peak acceleration Duration Status of unit 2 000 Bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 516.3 Climatic Qualifications Life at high temperature 4 Mechanical Qualifications (c) Gaia Converter FC08-059.01/10 Revision D 8 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-300 Series 10- Description of Protections The LGDS-300 includes 3 types of protection devices. 10-1 Output Over Current Protection (OCP) The LGDS-300 provides a circuit breaker function that latches the output off if the load current exceeds the current limit threshold for a duration. The circuit breaker function automatically attempts to restart power after a load current fault at a low duty cycle to prevent the LGDS-300 from overheating. The over current protection function protects the module against over load of any duration and restores the module to normal operation when the over load 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 30A with a detection time lower than 5ms. Vo (%) 100 detection time x time recovery time recovery time 10-2 Inrush Current Limitation The inrush current limitation function operates by limiting the output voltage ramp up. It is internally set at 5V/ms typically. The inrush current is calculated as follow. I inrush= C outx dV out dt where : 1 VI +Vo 7 2 8 3 LGDS-300 9 Drive * Cout is the capacitor value connected to the output * dV out dt 4 4 COUT = 5V/ms By adding a capacitor connected across the pins Drive & Gi, and in order to reduce the inrush current the value dV out can be adjusted as follow : CDRIVE Gi VOUT 5 dt dVout = dt 50 10 + C V/ms C is given in nF DRIVE DRIVE 10-3 Over Temperature Protection (OTP) A thermal protection device adjusted at 120C (+/-5%) internal temperature with a 10C hysteresis cycle will inhibit the module as long as the overheat is present and restores to normal operation automatically when overheat is removed. On Off 10c Temperature 120c (c) Gaia Converter FC08-059.01/10 Revision D 9 For locations, phone, fax, E-Mail see back cover LGDS-300 Series Hi-Rel Grade 11- Application Notes 11-1 Reverse Polarity Compatibility The LGDS-300 has been designed to be compliant with reverse polarity requirements. The reverse polarity protection can be externally achieved either by a standard solution using a schottky diode or either a low losses solution using a N channel power MOSFET. The following figures are showing both solutions. 1 VI +Vo 7 2 8 3 LGDS-300 9 1 VI +Vo 7 2 8 3 LGDS-300 9 Drive 4 Drive Gi 4 Gi 5 5 11-2 Drive Function The LGDS-300 features a drive function used to adjust the inrush current limit during start-up phase and to achieve a low loss reverse polarity protection. Parameter Unit Min. Typ. Max. Drive voltage Vdc Vo-0.6 / Vo+12 A A 50 -1000 / / 100 0 Notes, conditions 4 Drive current source sink Must be externally limited 11-5 Typical Architecture Schematics Using LGDS-300 with Multiple Modules The LGDS-300 is compliant for use with several DC/DC GAIA converter modules in various configurations. To meet MIL-STD-461D/E/F, DO-160D/E/F requirements, GAIA Converter recommends the use of ready-to-use EMI filter together with it's R*C* cell (see EMI filter datasheet for details). For stability purpose GAIA Converter recommends the use of a 220F/50V capacitor after the LGDS-300. VI +Vo MGDM-series Vi Vo EMI input filter FGDS-10A-50V Vi Vo EMI input filter FGDS-10A-50V R* 1 2 3 Gnd Go Gi Go Gnd Go VI +Vo Vo 7 Vi 8 9 LGDS-300 220F/50V C* Gi GI 5 MGDM-series GI Go VI +Vo Gi MGDM-series GI Go Note : such design with joint EMI filter is incompatible with reverse polarity compatibility. In such case place the second EMI filter after LGDS-300. (c) Gaia Converter FC08-059.01/10 Revision D For locations, phone, fax, E-Mail see back cover 10 LGDS-300 Series Hi-Rel Grade 12- Dimensions Dimension are given in mm. Tolerance : +/- 0,2 mm unless otherwise indicated. Weight : 35 grams (1.22 Ozs) max. 13- Materials 4 Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 14- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 15- Connections 4 5 6 Pin LGDS-300 1,2,3 +Input (Vin) 4 Drive 5 Common (Gin) 6 Not connected 7,8,9 Output (Vo) 7 3 8 2 9 1 Bottom view (c) Gaia Converter FC08-059.01/10 Revision D 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 Gaia Converter FC08-059.01/10 Revision D. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :