Hi-Rel AC/DC PFC MODULE
HGMM-35 : 35W POWER
• AC/DC Isolated Power Factor Corrected Module
• 115 VAC single phase
• Input range : 95 - 140 VAC
• Variable frequency : 360 - 800 Hz
• MIL-STD-704, ABD100 compliant
• Low input current harmonic distorsion < 10%
• Output Power : 35W
• Active inrush current limitation
• Isolation : 1 500 Vrms
• Inhibition function
• RoHS or Leaded process option
Gaia Converter FC05-049.01/10 Revision D
©
REDEFINING THE SOURCE OF POWER
1- General
Hi-Rel
Grade
For locations, phone, fax, E-Mail see back cover
2- Product Selection
Input Voltage Range
17 : 2 x 17 VDC
Output
The GAIA Converter HGMM-35 series designates
a family of active power factor corrected AC/DC
isolated modules designed to be compatible with
the latest airborne input bus with single phase
115VAC/400Hz variable frequency.
This module accepts a variable frequency input
from 360 to 800 Hz in the range of 95 to 140Vac
and an active power factor that enables a very
low level of current and voltage harmonic
distorsion over the entire frequency excursion.
The HGMM-35 series is compliant with numereous
avionics/military standards among them with :
• the latest Airbus standards ABD100 :
- permanent input range : 108-122Vac
- transient : 71Vac/15ms - 180Vac/100ms
- variable frequency : 360 - 800 Hz
- power factor : > 0,95
• the international standard DO-160D :
- permanent input range : 100-122Vac
- transient : up to 180Vac/100ms
• the US military standard MIL-STD-704E :
- permanent input range : 108-118Vac
- transient : 80Vac/10ms - 180Vac/100ms
W : 95-140 VAC/400 Hz
4
115 VAC/400Hz Active Power Factor Corrected
Variable Frequency 360-800Hz
Dual Isolated Output
Metallic Case
The HGMM-35 series includes a soft start, a per-
manent short circuit protection and an inhibit
fuction.
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 HGMM-35 series includes a model available
with dual 2 x 17 Vdc outputs serialisable/
parallable 17 or 34 Vdc to optimize the use of
hold-up capacitance.
The HGMM-35 series has to be used as front-end
in conjunction with a capacitance for hold-up
and DC/DC modules at the output.
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 Gaïa
Converter automated test equipment. The mo-
dules are potted with a bi-component thermal
conductive compound and packaged in a metalic
case to ensure the module’s integrity under high
environmental conditions.
Options : Suffix :
/T : option for -55°C start up operating temperature nothing : RoHS process
/S : option for screening and serialization -L : leaded process (available in N. America)
HGMB - 35 - option
/suffix
input output
For locations, phone, fax, E-Mail see back cover
2
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
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4
Hi-Rel
Grade
3- Electrical Specifications
Data are valid at +25°C, unless otherwise specified.
Parameter Conditions Limit or
typical Units HGMB-35-W-17
Input
Nominal input voltage Full temperature range
between phase and neutral Nominal VAC 115
Permanent input voltage
range (Ui)
Full temperature range
between phase and neutral Min. - Max. VAC 95 - 140
Transient input voltage Full temperature range
between phase and neutral Min. - Max. VAC/ms 71 / 15
180 / 100
Frequency range
permanent
Full temperature range
Ui min. to max. Min. Max. Hz 360 - 800
Frequency range
transient
Full temperature range
Ui min. to max.
Transient compliant with
ABD100 Hz/s 320 / 0,3
Power Factor (PF) Ui nominal
at 400Hz
At full load
At half load
At quarter load
/
0,99
0,98
0,90
Total Harmonic
Distorsion (THD) Ui min. to max. from 50% to full load
from 400Hz to 800Hz % < 10
Individual current
harmonic distorsion
Ui min. to max.
from 360Hz to 800Hz on all harmonics / see page 3
Start up input voltage Full load with nominal output Minimum VAC TBD
Start up time Ui min. to max., 400Hz
at full load with resistive load Maximum ms 60
Inrush current Ui nominal, 400Hz Nominal A 1
Input current in short
circuit mode (Average)
Ui nominal, 400Hz
Short-circuit Maximum mA TBD
No load input current Ui nominal, 400Hz
No load Maximum mA 45
Current in inhibit mode Ui nominal, 400Hz
Inhibit Maximum mA 30
Output
Output voltage
Full temperature range
Ui min. to max.,
Full load
Dual output
Nominal
Isolated
VDC 2 x 17 VDC
Set point accuracy Ambient temperature : +25°C
Ui nominal, 75% load, 400Hz % +/-4
Output power Full temperature range
Ui min. to max. Maximum W 35
Output current Full temperature range
Ui min. to max. Maximum A 1,05
Ripple output voltage
Ui nominal, 400Hz
Full load
with 4.400µF output capacitor
per output BW=20MHz
Maximum mVpp 200
Line regulation Ui min. to max., 400Hz
Full load Maximum % +/-1
Load regulation Ui nominal, 400Hz
25% to full load Maximum % +/-4
Efficiency Ui nominal, 400Hz
Full load Typical % 84
Maximum admissible
capacitive load
Ui nominal, 400Hz
Full load Maximum per output µF 14 000
For locations, phone, fax, E-Mail see back cover
3
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
3- Electrical Characteristics (continued)
3-3 Individual Current Harmonic Distorsion Characteristics
The individual current harmonic distorsion requirement is
a very specific requirement defining for each harmonic
row, the maximum admissible current in all functionning
conditions.
This requirement induced the Total Harmonic Distorsion
Factor (THD) defined above.
These requirements are defined by the aircraft
manufacturers in proprietary (and confidential) standards.
GAIA Converter HGMM series comply with individual current
harmonic distorsion requirements of :
• AIRBUS ABD100 section 1.8 with specific limits on :
odd non triplen and odd triplen harmonics
even 2 & 4 and other even harmonics
• BOEING D6-44588 with specific limits on
odd non triplen and odd triplen harmonics
even harmonics
0 5 10 15 20 25 30 35
2,5
5,0
7,5
10,0
12,5
15,0
17,5
20,0
22,5
25,0
27,5
30,0
32,5
35,0
37,5
40,0
Total Harmonic Distorsion Factor (THD) versus Load at 115Vac
F=400Hz
F=800Hz
Load
THD
3-2 Total Harmonic Distorsion Factor (THD) Characteristics
The Total Harmonic Distorsion (THD) is the ratio between
the total energy contained in all row harmonic (except
fundamental harmonic) by the fundamental harmonic wave.
The following curves represent the HGMM-35 Total Harmonic
Distorsion Factor at frequency of 400 Hz and at frequency
of 800 Hz.
3-1 Power Factor (PF) Characteristics
The Power Factor (PF) is the ratio of the «real» power to
the apparent power.
The apparent power is the product of the rms volts measured
with one meter and the rms amps measured with another
meter (value in VA).
The «real» power is the time average of the instant product
of voltage and current (value in Watts).
0 5 10 15 20 25 30 35
0,400
0,450
0,500
0,550
0,600
0,650
0,700
0,750
0,800
0,850
0,900
0,950
1,000
Power Factor (PF) versus Load at 115Vac
F=400Hz
F=800Hz
Load
Power Factor
The «real» power cannot be measured directly with 2 meters
as it has to integrate the phase shift between voltage and
current. This phase shift between voltage and current
reduces the effective power delivered.
The Power Factor (PF) is a measure of the effectiveness
with which an AC load can extract the usable power from
an AC source.
For locations, phone, fax, E-Mail see back cover
4
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
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Hi-Rel
Grade
3- Electrical Characteristics (continued)
3-5 Efficiency
3-4 Anharmonic Input Current
The anharmonic input current of the HGMM-35 series is given hereafter for 400 Hz and 800 Hz at 35W power.
7,5 10 12,5 15 17,5 20 22,5 25 27,5 30 32,5 35
80,00%
80,50%
81,00%
81,50%
82,00%
82,50%
83,00%
83,50%
84,00%
84,50%
85,00%
85,50%
86,00%
86,50%
87,00%
400Hz
800Hz
Load
Efficiency
The efficiency of the HGMM-35 series is given hereafter for 400 Hz and 800 Hz at various load conditions.
For locations, phone, fax, E-Mail see back cover
5
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
4- Switching Frequency
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 20 VDC
7- Reliability Data
Parameter Conditions Limit or typical Specifications
Switching frequency
Full temperature range
Ui min. to max.
No load to full load
Nominal, fixed 160 KHz
5- Isolation
Characteristics Conditions Temperature Specifications
Mean Time Between Failure (MTBF)
According to MIL-HDBK-217F
Ground fixed (Gf) Case at 40°C
Case at 85°C
730 000 Hrs
230 000 Hrs
Airborne, Inhabited,
Cargo (AIC)
Case at 40°C
Case at 85°C
415 000 Hrs
145 000 Hrs
Mean Time Between Failure (MTBF)
According to IEC-62380-TR
Civilian avionics,
calculators
Ambient at 55°C
100% time on 640 000 Hrs
Parameter Conditions Limit or typical Specifications
Electric strength test voltage
Input to output
Input to case
Output to case
Minimum
Minimum
Minimum
1 500 VAC / 1 min
1 500 VAC / 1 min
1 500 VAC / 1 min
Isolation resistance 500 VDC Minimum 100 MOhm
For locations, phone, fax, E-Mail see back cover
6
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
C2
(*)
C3
(*)
L2
L1 Case
Case
C1
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
L3
8- Electromagnetic Interference
Electromagnetic interference requirements according to DO-160D or MIL-STD-461D/E can be easily achieved as
indicated in the following table with the use of an additionnal external filter as described hereafter.
Recommended list of components :
L1 ......... : Common mode chole 4.4mH (Epcos B82720S2601N040)
(or API Delevan CM6460-505)
L2, L3 ... : Inductance 1mH (Wurth 74477030)
C1 ......... : Ceramic 1206 33NF/630V capacitors (TDK C3216JB2J333M)
C2, C3 ... : Ceramic 1206 4.7nF/500V capacitors (AVX 1206 7 C 472 M)
Standards DO-160D MIL-STD-461E Compliance
Conducted emission (CE) :
Low frequency
High frequency
Section 21 CE 101
CE 102
compliant module stand alone
compliant with additionnal filter
Conducted susceptibility (CS) :
low frequency
High frequency
Section 20 CS 101
CS114
compliant with additionnal filter
compliant with additionnal filter
Radiated emission (RE) :
Magnetic fireld
Electrical field
Section 21 RE 101
RE 102
compliant module stand alone
compliant module stand alone
Radiated susceptibility (RS) :
Magnetic field
Electrical field
Section 20 RS 101
RS 013
compliant module stand alone
compliant module stand alone
Fig : D0-160D Conducted Noise Emission
For locations, phone, fax, E-Mail see back cover
7
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
9- Thermal Characteristics
Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105°C.
10 10030 807060 9020 40 50
25%
75%
50%
100%
Power (W)
Temperature (˚C)
Full load ambient temperature without derating : 65˚C
Maximum case temperature : 105˚C
Natural convection operation area
Additionnal cooling operation area
Maximum storage temperature : 125˚C
The HGMM-35 series operating case temperature must not exceed 105°C. The maximum ambient temperature admissible
for the converter corresponding to the maximum operating case temperature of 105°C 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 = 105°C of the module, the power used Pout and the efficiency η :
• determine the power dissipated by the module Pdiss that should be evacuated :
Pdiss = Pout(1/ηη
ηη
η - 1)
• determine the maximum ambient temperature :
Ta = 105°C - 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 105°C (white area in the following graph).
For locations, phone, fax, E-Mail see back cover
8
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
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
Test D : 1 000 Hrs
@ 105°C case, unit operating
@ 125°C ambient, unit not operating
MIL-STD-202G
Method 108A
Altitude
Altitude level C
Duration
Climb up
Stabilization
Status of unit
40 000 ft@-55°C
30 min.
1 000 ft/min to 70 000 ft@-55°C,
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 %
31°C to 41°C
unit not operating
MIL-STD-810E
Method 507.3
Humidity steady
Damp heat
Temperature
Duration
Status of unit
93 % relative humidity
40°C
56 days
unit not operating
MIL-STD-202G
Method 103B
Salt atmosphere
Temperature
Concentration NaCl
Duration
Status of unit
35°C
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
-40°C / +85°C
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
-55°C / +105°C
10 sec.
20 min.
unit not operating
MIL-STD-202G
Method 107G
Mechanical Qualifications
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
For locations, phone, fax, E-Mail see back cover
9
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
11- Description of Protections
11-1 Output Short Circuit Protection (SCP)
The short circuit protection device protects the module
against short circuit of any duration and restores the mo-
dule to normal operation when the short circuit 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 200% of maxi-
mum current with a detection time lower than 5ms.
11-2 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 mo-
dule itself.
12- Description of Functions
12-1 On/Off Function
The On/Off function is performed with an internal
optocoupler.
It is driven through pins 3 and 4 :
• When the switch is open, the module is turned on
• When the switch is closed the module is turned off.
Parameter Unit Min. Typ. Max. Notes, conditions
On/Off module enable current µA / / 200
On/Off module disable current mA 2.5 / 20
On/Off module enable delay Vdc / / / See start-up time
On/Off module disable delay µs / / 100 Vin, full load
Vcc
3
4
430
R
V
F
=1.15V
I
time
recovery time
detection time
recovery time
x
100
Vo (%)
For locations, phone, fax, E-Mail see back cover
10
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
13- Application Notes
The HGMM-35 series can be connected in two ways :
• connection in parallel
• connection in series
In addition, the HGMM-35 series has to be used in
conjunction with an external hold-up capacitance accross
the outputs to keep a good power factor and to limit the
output voltage ripple. This hold-up capacitance is also
used to achieve a transparency time > 50ms.
13-1 Connection of Outputs in Series to
Achieve 34Vdc Output Voltage
The connection in series of both 17 Vdc outputs provides
34Vdc output voltage (at 35W power).
With a connection in series, the HGMM-35 has to be used
with any of GAIA Converter J inputs 16-40 Vdc to get an
optimum voltage variation between 16 Vdc and 34 Vdc to
minimize the size of the hold-up capacitance.
Typical value of the hold-up capacitance
is ranging from 2.200µF (minimum value to optimize out-
put voltage ripple) up to 6.800 µF to obtain 50 ms
transparency time.
13-2 Connection of Outputs in Parallel to
Achieve 17Vdc Output Voltage
The connection in parallel of both 17 Vdc outputs provides
17Vdc output voltage (at 35W power).
With a connection in parallel, the HGMM-35 has to be used
with any of GAIA Converter H inputs 9-36 Vdc to get an
optimum voltage variation between 9 Vdc and 17 Vdc to
minimize the size of the hold-up capacitance.
Typical value of the hold-up capacitance
is ranging from 8.800µF (minimum value to optimize out-
put voltage ripple) up to 27.000 µF to obtain 50 ms
transparency time.
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
115Vac / 400Hz 17V
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
115Vac / 400Hz
34V
For locations, phone, fax, E-Mail see back cover
11
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
13- Application Notes (continued)
13-3 Using HGMM-35 Series for up to 70W Power Requiring Anharmonic Input Current
The HGMM-35 series can be used in 2 ways :
• single module connection to achieve 35W power
• double module connection to achieve 70W power
13-3-1 Connection to achieve 35W power
The connection in series of both 17 Vdc outputs of a single HGMM-35 allows a 35W power on a 34 Vdc intermediate bus output
voltage. With a connection in series, the HGMM-35 has to be used with any of GAIA Converter J inputs (i.e 16-40 Vdc) to get an
optimum voltage variation between 16 Vdc and 34 Vdc to minimize the size of the hold-up capacitance. Typical value of the hold-
up capacitance is ranging from 2 200µF (minimum value to optimize output voltage ripple) up to 6 800 µF to obtain 50 ms
transparency time. The EMI filter is described in section 8.
13-3-2 Connection to achieve 70W power
The connection in series of both 17 Vdc outputs of a each HGMM-35 module allows a 70W power on a 34 Vdc intermediate bus
output voltage. With a connection in series, the HGMM-35 has to be used with any of GAIA Converter J inputs (i.e 16-40 Vdc) to get
an optimum voltage variation between 16 Vdc and 34 Vdc to minimize the size of the hold-up capacitances. Typical value of the 2
hold-up capacitances have to be determined according to section 13-2 paragraph «Connection in Parallel to achieve 17Vdc output
voltage». The EMI filter structure is the same as for a single module connection (see section 8), the three inductances have to be
rated twice the current value as for a single module solution, the capacitor C1 is doubled, C2 and C3 remain the same.
EMI Input Filter
115V / 400Hz
Input Bus
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
34Vdc / 70W
Intermediate Bus
C2
(*)
C3
(*)
Case
Case
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
L2
L1
C1
L3
C2
(*)
C3
(*)
Case
Case
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
EMI Input Filter
115V / 400Hz
Input Bus
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
34Vdc / 35W
Intermediate Bus
L2
L1
C1
L3
C2
(*)
C3
(*)
Case
Case
HGMB-35
Vo1
Vo2
On/Off_ref
Phase
Go1
Go2
On/Off
Neutral
6
7
8
4
3
2
1
5
For locations, phone, fax, E-Mail see back cover
12
HGMM-35 Series
Gaia Converter FC05-049.01/10 Revision D
©
4
Hi-Rel
Grade
14- Dimensions
17- Connections
Pin dimensions : 0,91 mm (0.036")
5,75
(0.23")
73,66 (2.90")
10,5
(0.41")
12,50
(0.50")
20
(0.79")
6
(0.23")
R2
82,50 (3.25")
76,90 (3.02") 4 holes 3,3
42,90
(1.68")
22,86
(0.9")
48.50
(1.91")
16,63 (0.65")40,23 (1.58")
10,28 +/-0,4
(0.40")
1
2
3
4
7
6
8
7,62
(0.3")
4,42 +/-0,4
(0.17")
3,20
(0.13")
5
18,20
(0.71")
3,80
(0.15")
1
2
3
4
7
6
8
5
Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated.
Weight : 80 grams (2.80 Ozs) max.
Pin Bi-output
1 Phase
2 Neutral
3 On/Off
4 On/Off ref.
5 Common 1 (GO1)
6 Output 1 (VO1)
7 Common 2 (GO2)
8 Output 2 (VO2)
15- Materials
Case : Metallic black anodized coating.
Pins : Plated with pure matte tin over nickel underplate.
16- Product Marking
Upper face : Company logo, location of manufacturing.
Side face : Module reference : HGMx-35-»X»-»Y».
Date code : year and week of manufacturing, suffix, /option.
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 FC05-049.01/106 Revision D. Graphisme : Philippe Clicq
Represented by :
For more detailed specifications and applications information, contact :
International Headquarters
GAÏA Converter - France
ZI de la Morandière
33185 LE HAILLAN - FRANCE
Tel. : + (33)-5-57-92-12-80
Fax : + (33)-5-57-92-12-89
North American Headquarters
GAÏA Converter Canada, Inc
4038 Le Corbusier Blvd
LAVAL, QUEBEC - CANADA H7L 5R2
Tel. : (514)-333-3169
Fax : (514)-333-4519