Hi-Rel AC/DC PFC MODULE HGMM-35 : 35W POWER Hi-Rel Grade 115 VAC/400Hz Active Power Factor Corrected Variable Frequency 360-800Hz Dual Isolated Output Metallic Case * 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 1- General 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 The HGMM-35 series includes a soft start, a permanent 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 Gaia Converter automated test equipment. The modules 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. 2- Product Selection HGMB - 35 - input output / option suffix Input Voltage Range W : 95-140 VAC/400 Hz Options : /T : option for -55C start up operating temperature /S : option for screening and serialization Output 17 : 2 x 17 VDC Suffix : nothing : RoHS process -L : leaded process (available in N. America) REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC05-049.01/10 Revision D For locations, phone, fax, E-Mail see back cover 4 HGMM-35 Series Hi-Rel Grade 3- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Conditions Limit or typical Units Nominal VAC 115 Min. - Max. VAC 95 - 140 Min. - Max. VAC/ms 71 / 15 180 / 100 Min. Max. Hz 360 - 800 HGMB-35-W-17 Input Full temperature range between phase and neutral Permanent input voltage Full temperature range range (Ui) between phase and neutral Full temperature range Transient input voltage between phase and neutral Frequency range Full temperature range permanent Ui min. to max. Frequency range Full temperature range transient Ui min. to max. Nominal input voltage Power Factor (PF) Total Harmonic Distorsion (THD) Individual current harmonic distorsion Start up input voltage Start up time Inrush current Input current in short circuit mode (Average) No load input current Current in inhibit mode Ui nominal at 400Hz Ui min. to max. Transient compliant with Hz/s ABD100 At full load At half load / At quarter load from 50% to full load % from 400Hz to 800Hz 320 / 0,3 0,99 0,98 0,90 < 10 Ui min. to max. from 360Hz to 800Hz on all harmonics / Full load with nominal output Minimum VAC TBD Maximum ms 60 Nominal A 1 Maximum mA TBD Maximum mA 45 Maximum mA 30 Dual output Nominal Isolated VDC 2 x 17 VDC Ui min. to max., 400Hz at full load with resistive load Ui nominal, 400Hz Ui nominal, 400Hz Short-circuit Ui nominal, 400Hz No load Ui nominal, 400Hz Inhibit see page 3 4 Output Output voltage Set point accuracy Output power Output current Ripple output voltage Line regulation Load regulation Efficiency Maximum admissible capacitive load (c) Gaia Converter FC05-049.01/10 Revision D Full temperature range Ui min. to max., Full load Ambient temperature : +25C Ui nominal, 75% load, 400Hz Full temperature range Ui min. to max. Full temperature range Ui min. to max. Ui nominal, 400Hz Full load with 4.400F output capacitor per output BW=20MHz Ui min. to max., 400Hz Full load Ui nominal, 400Hz 25% to full load Ui nominal, 400Hz Full load Ui nominal, 400Hz Full load % +/-4 Maximum W 35 Maximum A 1,05 Maximum mVpp 200 Maximum % +/-1 Maximum % +/-4 Typical % 84 Maximum per output F 14 000 2 For locations, phone, fax, E-Mail see back cover HGMM-35 Series Hi-Rel Grade 3- Electrical Characteristics (continued) 3-1 Power Factor (PF) Characteristics 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. 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). Power Factor (PF) versus Load at 115Vac 1,000 0,950 0,900 Power Factor 0,850 0,800 0,750 F=400Hz F=800Hz 0,700 0,650 0,600 0,550 0,500 0,450 0,400 0 5 10 15 20 25 30 35 Load 4 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. THD Total Harmonic Distorsion Factor (THD) versus Load at 115Vac 40,0 37,5 35,0 32,5 30,0 27,5 25,0 22,5 20,0 17,5 15,0 12,5 10,0 7,5 5,0 2,5 F=400Hz F=800Hz 0 5 10 15 20 25 30 35 Load 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. (c) Gaia Converter FC05-049.01/10 Revision D 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 3 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HGMM-35 Series 3- Electrical Characteristics (continued) 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. 4 3-5 Efficiency The efficiency of the HGMM-35 series is given hereafter for 400 Hz and 800 Hz at various load conditions. 87,00% 86,50% 86,00% 85,50% 85,00% Efficiency 84,50% 84,00% 400Hz 83,50% 800Hz 83,00% 82,50% 82,00% 81,50% 81,00% 80,50% 80,00% 7,5 10 12,5 15 17,5 20 22,5 25 27,5 30 32,5 35 Load (c) Gaia Converter FC05-049.01/10 Revision D 4 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HGMM-35 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 160 KHz 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 5- Isolation 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 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 FC05-049.01/10 Revision D Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 85C 730 000 Hrs 230 000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40C Case at 85C 415 000 Hrs 145 000 Hrs Civilian avionics, calculators Ambient at 55C 100% time on 640 000 Hrs 5 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HGMM-35 Series 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. 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 L1 L2 C2 (*) Case 1 Phase Vo2 Neutral Go2 8 C1 2 L3 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) 4 HGMB-35 3 Recommended list of components : 7 C3 (*) 4 On/Off Vo1 On/Off_ref Go1 6 5 Case Fig : D0-160D Conducted Noise Emission (c) Gaia Converter FC05-049.01/10 Revision D 6 For locations, phone, fax, E-Mail see back cover HGMM-35 Series Hi-Rel Grade 9- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range Ambient temperature * Minimum Maximum - 40C + 85C Operating case temperature range Case temperature Minimum Maximum - 40C + 105C Storage temperature range Non functionning Minimum Maximum - 55C + 125C Thermal resistance Rth case to ambiant in free air natural converction Typical 6C/W Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105C. The HGMM-35 series operating case temperature must not exceed 105C. The maximum ambient temperature admissible for the 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 this following graph), * an area with cooling features (air flow or heatsink) ensuring a maximum case temperature below the maximum operating case temperature of 105C (white area in the following graph). Power (W) 100% Additionnal cooling operation area 75% 50% Natural convection operation area 25% 10 20 30 40 50 60 70 80 90 100 Temperature (C) Full load ambient temperature without derating : 65C Maximum case temperature : 105C Maximum storage temperature : 125C (c) Gaia Converter FC05-049.01/10 Revision D 7 For locations, phone, fax, E-Mail see back cover HGMM-35 Series Hi-Rel Grade 10- 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 FC05-049.01/10 Revision D 8 For locations, phone, fax, E-Mail see back cover HGMM-35 Series Hi-Rel Grade 11- Description of Protections 11-1 Output Short Circuit Protection (SCP) Vo (%) The short circuit protection device protects the module against short circuit 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 1s 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 11-2 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 module itself. 4 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 Vcc R Unit Min. Typ. Max. On/Off module enable current A / / 200 On/Off module disable current mA 2.5 / 20 On/Off module enable delay Vdc / / / On/Off module disable delay s / / 100 (c) Gaia Converter FC05-049.01/10 Revision D Notes, conditions 3 430 VF=1.15V 4 See start-up time I Vin, full load 9 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HGMM-35 Series 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 2.200F (minimum value to optimize output voltage ripple) up to 6.800 F to obtain 50 ms transparency time. 1 Vo2 Phase 8 115Vac / 400Hz 2 Neutral Go2 7 HGMB-35 3 On/Off 4 On/Off_ref Vo1 Go1 6 34V 5 4 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 8.800F (minimum value to optimize output voltage ripple) up to 27.000 F to obtain 50 ms transparency time. (c) Gaia Converter FC05-049.01/10 Revision D 1 Vo2 Phase 8 115Vac / 400Hz 17V 2 Go2 Neutral 7 HGMB-35 3 On/Off 4 On/Off_ref Vo1 Go1 6 5 10 For locations, phone, fax, E-Mail see back cover HGMM-35 Series 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 holdup capacitance is ranging from 2 200F (minimum value to optimize output voltage ripple) up to 6 800 F to obtain 50 ms transparency time. The EMI filter is described in section 8. VI +Vo MGDM-series EMI Input Filter C2 (*) L2 L1 115V / 400Hz Input Bus 1 Case Phase Vo2 Neutral Go2 8 GI Go VI +Vo C1 2 L3 7 HGMB-35 3 On/Off 4 C3 (*) Vo1 On/Off_ref Go1 6 34Vdc / 35W Intermediate Bus MGDM-series GI Go VI +Vo 5 Case MGDM-series GI Go 13-3-2 Connection to achieve 70W power 4 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 L1 C2 (*) L2 115V / 400Hz Input Bus Case 1 Vo2 Phase 8 VI +Vo C1 MGDM-series Go2 7 2 Neutral L3 HGMB-35 3 On/Off 4 C3 (*) GI Vo1 On/Off_ref Go1 Go 6 5 Case 34Vdc / 70W Intermediate Bus VI +Vo MGDM-series C2 (*) Case 1 2 Phase Vo2 Neutral Go2 Go VI +Vo 8 7 HGMB-35 3 On/Off GI Vo1 6 MGDM-series C3 (*) (c) Gaia Converter FC05-049.01/10 Revision D 4 On/Off_ref Go1 5 GI Go Case 11 For locations, phone, fax, E-Mail see back cover HGMM-35 Series Hi-Rel Grade 14- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 80 grams (2.80 Ozs) max. 76,90 (3.02") R2 10,28 +/-0,4 (0.40") 7,62 (0.3") 2 3 6 (0.23") 4 20 (0.79") 10,5 42,90 (1.68") 6 5 16,63 (0.65") 82,50 (3.25") (0.41") 12,50 (0.50") 18,20 (0.71") 7 40,23 (1.58") 4,42 +/-0,4 (0.17") 3,80 (0.15") 8 5,75 48.50 22,86 (1.91") (0.9") 3,3 (0.23") 1 4 holes 3,20 (0.13") 73,66 (2.90") Pin dimensions : 4 0,91 mm (0.036") 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. 17- Connections Pin 1 1 Phase 8 2 Neutral 3 On/Off 7 4 On/Off ref. 5 Common 1 (GO1) 2 3 6 4 5 (c) Gaia Converter FC05-049.01/10 Revision D Bi-output 6 Output 1 (VO1) 7 Common 2 (GO2) 8 Output 2 (VO2) 12 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 FC05-049.01/106 Revision D. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :