Hi-Rel HOLD-UP MODULE HUGD-50 : 50W POWER Hi-Rel Grade Hold-Up Solution 16-40V & 9-36V DC/DC Converter Compatible Metallic Case * Unique Product for Hold-Up Solution * Reduce Capacitance by 80% * High efficiency (98%) * Power range : from 4W to 50W * Compatible with 9-36 or 16-40VDC Converter * Include monitoring signals * Programmable inrush current limitation 1-General The GAIA Converter Hold up device HUGD-50 provides a state-of-the-art solution to the problem of maintaining electronic system in operation during input bus drop-out with enough time. Usually this approach uses very large capacitors because they are only charged at the voltage at which power fail. The Gaia Converter HUGD-50 module provides an alternative solution to reduce the amount of capacitance needed by charging the hold up capacitor at a high voltage (typically 38V) while limiting the input current. The HUGD-50 needs to be connected between the line source and DC/DC modules (if an EMI filter and /or a pre-regulator are used, the HUGD-50 is connected between them and the converters). Basically the HUGD-50 charges the external capacitor to 38V while powering the DC/DC converters. If the power fails, the HUGD-50 generates a signal and the converters are powered from the external capacitor. The HUGD-50 can be used either with 16-40V or 936V input voltage DC/DC converters since the power fail voltage is externally adjustable between 8.8V and 15.3V by the user. The HUGD-50 features 3 modes of operations: * Charging operation mode : when the input voltage ramps-up and reaches the startup charge threshold (which is set at 1Vdc above the power fail voltage), the HUGD-50 begins to charge the external capacitor at 38 VDC while powering the dc/dc converter. the charging current is controled and externally adjustable between 100mA and 2A by a resistance. The capacitor charging time depends on the charging current. When the capacitor voltage reaches 34V, (representing 90% of charge) the signal (active, floating output collector) capacitor charged is activated and the HUGD-50 enters in the normal operation mode. * Normal operation mode : in normal operation mode with the capacitor charged and the input bus is between the output power fail and 40VDC, the HUGD-50 consumes only power to keep the capacitor charged (i.e.less than 1W. The voltage drop between input and output is lower than 150mV in the worth case (50W power and 9 VDC input voltage) The HUGD-50 will operate indefinitely until the input voltage drops below the power fail voltage threshold. * Power fail mode : when the input voltage drops below the power fail voltage threshold a power fail signal is activated and the HUGD-50 disconnects input and output and connects the hold-up capacitor to the output. At this point the DC/DC converters are powered by the capacitor. When 90% of the usable stored energy in the capacitor is activated and operation will stop as the energy reaches zero. 2-Product Selection HUGD - 50 (/T) and/or (/S) (/T) : option for -55C start up operating temperature. (/S) : option for screening and serialization REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC97-027.01/06 Revision H For locations, phone, fax, E-Mail see back cover 4 HUGD-50 Series Hi-Rel Grade 3- Block Diagram The HUGD-50 module includes 3 main circuits : * An input monitoring circuit * An hold-up charger circuit * A hold-up monitoring circuit * Input monitoring Circuit : The input monitoring circuit monitors the value of the input bus voltage and compares it to the power fail threshold voltage (Vth) set externally through a resistor. Depending on this comparison, the circuit allows the activation of the hold-up switch and the hold-up charger and generates an isolated power fail flag (PF). * Hold-up Charger : The hold-up charger is used to feed the hold-up capacitor with a constant Vc=38V voltage. The design of this charger has been optimized to minimize the input inrush current which can be set externally through the Vcl input by a resistor. * Hold-up monitoring Circuit : The hold-up monitoring circuit monitors the charging status of the hold-up capacitor. The circuit generates 2 isolated flags : the capacitor charged flag (CC) and the capacitor discharged flag (CD). These flags can be used at system level for management of power interruption (VME system, PCI, ...) The HUGD-50 features 3 modes of operations : * Charging operation mode * Normal operation mode * power fail mode The following figure represents the HUGD-50 series block diagram. HUGD-50 Block Diagram Vi Vth Vo 4 Input Monitoring Hold-up Charger Vc Vcl PF CC Hold-up Monitoring Gi (c) Gaia Converter FC97-027.01/06 Revision H CD Go 2 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HUGD-50 Series 4- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Input Conditions Limit or typical Units HUGD-50 Permanent input voltage range (Ui) Full temperature load Full load Minimum Maximum VDC VDC Transient input voltage Full temperature load Full load Maximum VDC/ms Power fail voltage threshold (Vfail) with the setting Vth unconnected Minimum Typical Maximum VDC VDC VDC 15 15,3 15,6 Power fail voltage threshold (Vfail) with the setting Vth connected to ground Minimum Typical Maximum VDC VDC VDC 8,6 8,8 9 Input current consumption during charging at 28V min: Vcl unconnected max: Vcl connected to ground Minimum Maximum A A 0,1 1,5 Input current consumption during charging at 16V min: Vcl unconnected max: Vcl connected to ground Minimum Maximum A A 0,1 2,2 Output admissible power Full temperature load Full load Maximum W 50 Dissipated power Vin @ 9V, full power Maximum W 1 Voltage drop input/ouput Vin @ 9V, full power Maximum mV 160 Minimum Maximum VDC VDC 33,8 34,8 9 40 50/100 Output Capacitor charged signal threshold Capacitor discharged signal threshold with setting Vth unconnected Minimum Maximum VDC VDC 15,9 16,7 Capacitor discharged signal threshold with setting Vth connected to ground Minimum Maximum VDC VDC 9,4 10,2 Minimum Maximum F F 470 30.000 Maximum admissible hold-up capacitor Hold-up time at full load Vth unconnected Vth connected to ground Minimum Minimum s/F s/F 11,2 12,8 Hold-up time at 10W load Vth unconnected Vth connected to ground Minimum Minimum s/F s/F 55,6 64,4 (c) Gaia Converter FC97-027.01/06 Revision H 4 3 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 5- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load Nominal, fixed 200 KHz Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output 6- Isolation / No isolation 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 FC97-027.01/06 Revision H Conditions Temperature Specifications Ground fixed (Gf) Case at 40C Case at 85C 1.500.000 Hrs 590.000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40C Case at 85C 730.000 Hrs 300.000 Hrs Avionics Military Cargo / Consult factory 4 For locations, phone, fax, E-Mail see back cover HUGD-50 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 HUGD-50 series operating case temperature 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 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 90 100 110 Temperature (C) Full load ambient temperature without derating : 85C Maximum case temperature : 105C Maximum storage temperature : 125C (c) Gaia Converter FC97-027.01/06 Revision H 5 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 9- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Duration Temperature / status of unit Test D : 1.000 Hrs @ 105C case, unit operating @ 125C ambient, unit not operating 40.000 ft@-55C 30 min. 1.000 ft/min to 70.000 f@-55C, 30 min. unit operating 10 Cycle I : 24 Hrs 60 % to 88 % 31C to 41C unit not operating 93 % relative humidity 40C 56 days unit not operating 35C 5% 48 Hrs unit not operating 200 -40C / +85C 40 min. 20 min. unit operating 100 -55C / +105C 10 sec. 20 min. unit not operating Test procedure Climatic Qualifications Life at high temperature Altitude Humidity cyclic Humidity steady Salt atmosphere Temperature cycling Temperature shock Altitude level C Duration Climb up Stabilization Status of unit Number of cycle Cycle duration Relative humidity variation Temperature variation Status of unit Damp heat Temperature Duration Status of unit Temperature Concentration NaCl Duration Status of unit Number of cycles Temperature change Transfert time Steady state time Status of unit Number of shocks Temperature change Transfert time Steady state time Status of unit MIL-STD-202G Method 108A MIL-STD-810E Method 500.3 MIL-STD-810E Method 507.3 MIL-STD-202G Method 103B MIL-STD-810E Method 509.3 MIL-STD-202A Method 102A 4 MIL-STD-202G Method 107G Mechanical Qualifications Vibration (Sinusoidal) Shock (Half sinus) Bump (Half sinus) Number of cycles Frequency / amplitude Frequency / acceleration Duration Status of unit Number of shocks Peak acceleration Duration Shock form Status of unit Number of bumps Peak acceleration Duration Status of unit (c) Gaia Converter FC97-027.01/06 Revision H 10 cycles in each axis 10 to 60 Hz / 0.7 mm 60 to 2000 Hz / 10 g 2h 30 min. per axis unit not operating 3 shocks in each axis 100 g 6 ms 1/2 sinusoidal unit not operating 2000 Bumps in each axis 40 g 6 ms unit not operating MIL-STD-810D Method 514.3 MIL-STD-810D Method 516.3 MIL-STD-810D Method 516.3 6 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 10- Application Notes 10-1 General on Input Bus ShutDown Requirements During bus power drop-out, avionics and military systems require a maintain of operation for saving data and controlling the shut-down. The duration of this shut-down operation is defined in different standards and can last up to 7 secondes. 10-1-1 Capacitor Stand-Alone Solution 10-1-2 Capacitor with Hold Up Module Solution To maintain operation during this power drop-out, the traditional approach is the use of a bulk capacitor connected at the input of the converters to power them when power drops-out. The capacitor needed depends on the system specifications, the load and the efficiency of the DC/DC converters and the amount of capacitor for a given hold-up time. The value of the capacitance is determined by the following formula : To reduce drastically the size of this capacitor, GAIA Converter proposes the hold up module HUGD-50 that will charge the capacitor at a much higher voltage (typically 38V). C1 = Moroever this module allows a selection of the minimum threshold voltage at which the capacitance will begin to power the converters. In this case the amount of capacitance needed for a given hold up time is determined by the following formula : ( 2 x P x Dt ) { h x ( V12 - V22 )} C2 = 2 x P x (Dt + 0.01) { h x ( 382 - V22 )} where : C : is the required capacitor (in farads) P : is the power at the load (output of converter) (in watts) h : is the efficiency of the converter at rated load Dt : is the required hold up time (in seconds) V1 : is the initial charged capacitor voltage (in volts) V2 : is the low line voltage of DC/DC converter where C : P : h : Dt : V2 : For a typical hold-up time of 50 ms with 50W power (at the input of the DC/DC converter with 80% efficiency) plugged on a MIL-STD-704D 28V bus that can range down to 22V and considering the minimum permanent input voltage of GAIA Converter module at 16V, the required capacitance is a huge with value of 18.000 F/40V rated. For a typical hold-up time of 50 ms with 50W power (at the input of the DC/DC converter with 80% efficiency) plugged on a MIL-STD-704D 28V bus and using the hold up module the capacitance required will decrease down to value of 5.000 F/40V rated. (c) Gaia Converter FC97-027.01/06 Revision H 4 : is the required capacitor (in farads) is the power to the load (output of converter) (in watts) is the efficiency of the converter at rated load is the required hold up time (in seconds) is the low line voltage of DC/DC converter (in volts). 7 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 10- Application Notes (continued) 10-2 Hold-up Capacitor Selection with HUGD-50 Solution The external capacitor supplies the energy for the DC/DC converters operation during failure. The capacitance should not exceed 30.000F, and should be higher than 470F. The amount of capacitance for a given hold up time is given by the formula : C= where C P Dt VL : : : : is is is is 2 x P (Dt + 0.01 ) 382 -VL2 the required capacitance (in Farads) the power consumed by the DC/DC converters (in Watts) the required hold-up time (in seconds) the lower admissible voltage of DC/DC converters (in volts) The following curve gives the capacitor value as a function of the required hold up time. Gaia Converter recommends a high CV low ESR and extended temperature capacitor. 4 1000 50W 900 40W Hold-up time (ms) 800 30W 20W 700 600 500 400 300 200 100 0 0 5 000 10 000 15 000 20 000 25 000 30 000 Hold-up capacitance ( F) (c) Gaia Converter FC97-027.01/06 Revision H 8 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 10- Application Notes (continued) 10-3 Power Fail Voltage Threshold : Vth The power fail voltage threshold determines the operation mode of the HUGD-50. This threshold has to be set up in conjunction with the type of modules used (i.e. 9-36 VDC or 16-40 VDC input voltage type of modules) and can be adjusted between 8,8VDC and 15,3VDC by external resistance Rth connected between the Vth pin and Gout pin. Vth unconnected will set up the threshold at 15,3VDC valid for 16-40Vdc input modules, Vth connected to ground will set up the threshold at 8,8VDC valid for 9-36Vdc input modules. If the HUGD-50 is used with the PGDS-50-N-K, Vth has to remain unconnected; with the PGDS-50-O-K, Vth has to be connected to Go. The following curve determines the function of Vth threshold as a function of the resitor Rth. Power fil voltage threshold (Vdc) Power fail voltage threshold versus Rth 15,5 15 14,5 14 13,5 13 12,5 12 11,5 11 10,5 10 9,5 9 8,5 1,00E+00 1,00E+01 1,00E+02 1,00E+03 1,00E+04 1,00E+05 4 1,00E+06 Rth (ohms) 10-4 Charging Current Setting : VCL knowing that the capacitor is charged at 38VDC. The following curve gives the resistance Rcl value as a function of current & charging time. The HUGD-50 controls the inrush current (charging current) to remain between 100 mA to 2A by an external resistance Rcl connected between the Vcl pin and the Gout pin. This charging current is a direct function of the charging time 2,5 900 700 1,5 Vi=16V Vi=28V Vi=40V 1 Charging rate in s/F Input reflected charging current (A) 800 2 600 500 Vi=16V Vi=28V Vi=40V 400 300 200 0,5 100 0 0 0 500 1000 1500 2000 2500 0 500 Rcl (c) Gaia Converter FC97-027.01/06 Revision H 1000 1500 2000 2500 Rcl 9 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HUGD-50 Series 10- Application Notes (continued) 10-5 Power Fail Signal : PF 10-6 Capacitor Charged Signal : CC The power fail output signal is activated when the voltage drops below the power fail voltage threshold. the PF signal is an open collector output active low. The capacitor charged signal is actived when the voltage at the capacitor pins reaches 34 VDC corresponding to an energy stored of about 90% of it's full charge. The CC signal is an open collector output actived low. 10-7 Capacitor Discharged Signal : CD 10-8 Transition Capacitor The capacitor discharged signal is activated when the voltage at the capacitor pins reaches 16.3 VDC (or 9.8 VDC) corresponding to a remaining energy of about 20% of it's full charge. The CD signal is an open collector output active low. To help transitionning the system in the different operating mode, GAIA Converter recommends the use of a transition capacitor. This capacitor is used to maintain output voltage during the HUGD-50 commutation from input line to hold up capacitor. A 100F electrolytic capacitor is enough for a 50W load, and this value can be reduced for lower loads. The table below gives the minimum required values versus output power : Output power (W) Capacitance value (F) 10 20 30 40 50 22 47 68 82 100 10-9 Typical Schematics This typical application schematics includes an EMI filter, a PGDS-50 pre-regulator, the hold-up module and an assembly of standard DC/DC converters. Additionnal details are given in the EMI filters application notes and PGDS-50 datasheet. 4 Power fail signal Capacitor charged signal Capacitor discharged signal VI R* C* L1 LMC1 1 VI + Input R1 C1 C3 +Vo 6 PF CC CD 1 +Vo 6 VI PGDS50 C5 C2 MGDM-series 2 Vimes C6 C4 +Vo GI Go VI +Vo Vc 7 HUGD50 C7 4 GI - Input Go 5 4 GI On/Off L2 Vth 3 EMI input filter Go 5 Vcl 2 Rth** MGDM-series GI Go VI +Vo 3 Rcl On/Off MGDM-series GI Go Note * : Due to possible oscillations caused by surges or fast transients at the input voltage level, it is recommended to implement a RC filter on the VIMES signal; several implementations as shown in the above figure can be tested to optimize the design. Typical values for the resistor R is 470 Ohm and for for the capacitance C is 1F. Note ** : When used in conjunction with PGDS-50 series, the resistance Rth of HUGD module has to be left unconnected. (c) Gaia Converter FC97-027.01/06 Revision H 10 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 10- Application Notes (continued) 10-10 Timming Diagram The following diagram describes the HUGD-50 output signals through the different operation modes : * Input voltage (Vi) * Output voltage to DC/DC converter (Vo) * Power Fail signal (PF) * Capacitor voltage (Vc) * Capacitor charged signal (CC) * Capacitor discharge signals (CD) 4 (c) Gaia Converter FC97-027.01/06 Revision H 11 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade HUGD-50 Series 11- Dimensions Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 20 grams (0.7 Ozs) max. 40 26 (1.58") (1.03") 7,60 8 (0.30") (0.32") 5 min (0.20") 26,20 5,08 7,62 (1.03") (0.20") (0.30") 35,56 20,32 (1.40") (0.80") Pin dimensions : O 0,73 mm (0.03 ") Metallic case black anodized coating solder plated pin 10,16 7,62 (0.40") (0.30") 2,54 (0.10") 2,54 (0.10") 3 x 2,54 (3 x 0.10") 4 12- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 13- Connections 6 1 7 8 9 10 2 3 5 4 Pin HUGD-50 1 + Input (Vi) 2 Power Fail Threshold (Vth) 3 Voltage Current Level (Vcl) 4 - Input (Gi) 5 Common (Go) 6 Output (Vo) 7 Voltage Capacitor (Vc) 8 Power Fail Signal (PF) 9 Capacitor charged signal (CC) 10 Capacitor discharged signal (CD) Bottom view (c) Gaia Converter FC97-027.01/06 Revision H 12 For locations, phone, fax, E-Mail see back cover International Headquarters Marketing and Sales department GAIA Converter - France Address : B.P. 26 - 33186 LE HAILLAN - FRANCE Tel. : + (33)-5-57-92-12-80 Fax : + (33)-5-57-92-12-89 North American Headquarters GAIA Converter Canada, Inc Address : 6611 Thimens ST-LAURENT, QUEBEC - CANADA H4S 1W2 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 FC97-027.01/06 Revision H. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :