Hi-Rel LIMITOR MODULE LGDS-100 : up to 100W POWER Hi-Rel Grade 100V and 200V Transient Protection Module DEF-STAN 61-5 Part 6 & MIL-STD-1275 Metallic Case * Ultra compact limitor module * Transient suppressor module 202V * DEF-STAN-61-5 Part 6 Issue 6, * Transient suppressor module 100V * MIL-STD-1275A/B/C/D, * Transient suppressor module 80V 1- General * MIL-STD-704A/D/E/F, EN2282, AIR2021E * DO160E cat A, B and Z * Power range : up to 90W/100W * Inrush current limitation * RoHS process The GAIA Converter limitor LGDS-100 is an ultra compact power adaptator module designed to allow operation during voltage transients and spikes, occuring in avionics or military systems. The LGDS-100 delivers an output voltage adapted to GAIA Converter DC/DC modules. This module is optimized to provide high power efficiency up to 98%. The LGDS-100 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-100 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-100. * Transient operation : The LGDS-100 clamps input transient up to 202V/350ms, or 101V/400ms. The LGDS-100 series is compliant with the international input bus standards : - DEF-STAN-61-5 Part 6 Issue 6 - MIL-STD-1275A/B/C/D - MIL-STD-704A/D/E/F - AECMA EN2282 - GAM-EG13B/AIR2021E - DO160E cat A, B and Z 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 - 100 - input output / option Input Voltage Range Output Transient P : 202V/350ms Options : /T : option for -55C start up operating temperature /S : option for screening and serialization REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC12-045.02/12 Revision A For locations, phone, fax, E-Mail see back cover K 4 Hi-Rel Grade LGDS-100 Series 3- Modes of Operation 3-1 LGDS-100 Modes of Operation The LGDS-100-P-K operates with H input family of GAIA Converter DC/DC Converters. The LGDS-100-P-K features 3 modes of operations as described 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-100 turns to power fail mode and stops operation until the failure is removed. The LGDS-100 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-100 turns to transient mode operation. It clamps input transient up to 202V as long as 350ms and 101V during 400ms . 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-100 Transfer Function 45 35 output voltage (Vdc) 30 Normal operation area Power fail operation area 40 Transient operation area 25 20 15 10 5 0 0 20 40 60 80 100 120 140 160 180 200 Input voltage (Vdc) (c) Gaia Converter FC12-045.02/12 Revision A 2 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-100 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 filter (see 8) ** with companion filter FGDS series Under voltage lock- out (UVLO) Start up time Full temperature range 50 Ohms impedance 15 mJ energy content 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 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 10A (c) Gaia Converter FC12-045.02/12 Revision A Limit or typical Units Minimum Maximum VDC VDC Maximum Maximum DEF-STAN-61-5-6-6 DEF-STAN-61-5-6-6 MIL-STD-1275A/D MIL-STD-704A/F AECMA EN2282 AIR2021E DO160E cat A/Z DEF-STAN-61-5-6-6 MIL-STD-1275A/D MIL-STD-704A/F AECMA EN2282 AIR2021E DO160E cat A/Z Minimum Maximum VDC/ms VDC/s 202V/350ms 101V/400ms 100V/50ms 80V/75ms 60V/50ms 60V/100ms 80V/100ms 228V/0,2s 250V/70s 600V/10s 400V/100s 600V/10s 600V/10s 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 10 (or 100W) Maximum W see page 4 figure 3 Maximum W 1,55 LGDS-100 9 42 202V/350ms 48V/1s Compliant Compliant Compliant 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-100 Series Hi-Rel Grade 4- Electrical Characteristics (continued) Figure 1 : LGDS-100-P-K Transient Response at 202Vdc (according to DEF-STAN-61-5 Part 6 Issue 6) Figure 2 : LGDS-100-P-K Transient Response at 100Vdc (according to MIL-STD-1275D) 4 Figure 3 : LGDS-100-P-K Output Power versus Input Voltage @ Tcase max. for DEF-STAN 61-5 part 6 Issue 6 Figure 4 : LGDS-100-P-K Start-up Timing 100 90 80 Pout (W) 70 60 Permanent operation area 50 40 Transient Operation area 30 20 10 0 0 9 20 42 40 60 80 100 120 140 160 180 200 Vin (Vdc) (c) Gaia Converter FC12-045.02/12 Revision A 4 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-100 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 FC12-045.02/12 Revision A 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 5 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade LGDS-100 Series 8- Electromagnetic Interference Electromagnetic interference requirements for an architecture using LGDS-100 and GAIA Converter DC/DC module according to DEF STAN 59-411 or MIL-STD-461D/E/F or D0-160D/E/F can be easily achieved as indicated in the following table with the use of an additionnal external filter as suggested hereafter. Standards DEF STAN 59-411 DO-160D MIL-STD-461E DCE01 Section 21 CE 101 CE 102 compliant module stand alone compliant with additionnal filter Conducted susceptibility (CS) : Low frequency High frequency DCS01 DCS02 Section 20 CS 101 CS 114 compliant with additionnal filter compliant with additionnal filter Radiated emission (RE) : Magnetic fireld Electrical field DRE02 DRE01 Section 21 RE 101 RE 102 compliant module stand alone compliant module stand alone Radiated susceptibility (RS) : Magnetic field Electrical field DRS01 DRS02 Section 20 RS 101 RS 013 Conducted emission (CE) : Low frequency High frequency Vi 1 2 3 Vo EMI input filter Gi Vo 7 Vi LGDS-100 Drive Go Compliance compliant module stand alone compliant module stand alone Vo Vi 8 9 4 MGDMxx C* 4 Go Vo Gi Note on C* : for stability purpose recommends the use of a 220F/50V capacitor after the LGDS-100. EMI Input Filter The LGDS-100 is compliant with : - GAIA converter ready-to-use EMI filter LGDS series for any MIL-STD-461D/E/F, DO-160D/E/F requirements, (see FGDS datasheet for details). - specific component design EMI filter for compliance with DEF STAN 59-411 requirements and DEF-STAN 61-5 transient levels (see figure hereafter). EMI Filter Suggested Schematic L1 L2 Vi Vo C6 C2 C1 C3 C4 C5 Gi C7 C8 C9 Go Recommended list of components : L1, L2 ............... : Common mode choke 590H current 5,6A (type Pulse PO353 or other common mode choke with higher value than 250H and rated according to maximum current) C1...................... : Ceramic chip capacitors 2 x 2.2F/100V 1210 (example Murata GRM32ER71H475KA88 or other ceramic chip capacitors connected in parallel with an equivalent total value) C2, C3, C6, C7..... : Film chip capacitor 10 nF/500V (example AVX : 1206 7 C 103 M) C4 ,C8 ................ : Ceramic chip capacitors 10 x 2.2F/100V 1210 (example Murata GRM32ER71H475KA88 or other ceramic chip capacitors connected in parallel with an equivalent total value) C5, C9 ............... : Tantalum or aluminium electrolytic capacitor 47 to 100F/250V (with low ESR) (c) Gaia Converter FC12-045.02/12 Revision A 6 For locations, phone, fax, E-Mail see back cover LGDS-100 Series Hi-Rel Grade 9- 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-100 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 FC12-045.02/12 Revision A 7 For locations, phone, fax, E-Mail see back cover LGDS-100 Series Hi-Rel Grade 10- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Test D : 1 000 Hrs @ 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-810G Method 500.5 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-810G Method 507.5 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-810G Method 509.5 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-810G Method 514.6 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-810G Method 516.6 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-810G Method 516.6 Climatic Qualifications Life at high temperature Duration Temperature / status of unit 4 Mechanical Qualifications (c) Gaia Converter FC12-045.02/12 Revision A 8 For locations, phone, fax, E-Mail see back cover LGDS-100 Series Hi-Rel Grade 11- Description of Protections The LGDS-100 includes 3 types of protection devices. 11-1 Output Over Current Protection (OCP) The LGDS-100 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-100 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 19A with a detection time lower than 5ms. Vo (%) 100 detection time x time recovery time recovery time 11-2 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 1 VI +Vo 7 2 8 3 LGDS-100 9 where : 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 11-3 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 FC12-045.02/12 Revision A 9 For locations, phone, fax, E-Mail see back cover LGDS-100 Series Hi-Rel Grade 12- Application Notes 12-1 Reverse Polarity Compatibility The LGDS-100 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-100 9 1 VI +Vo 7 2 8 3 LGDS-100 9 Drive 4 Drive Gi 4 Gi 5 5 12-2 Drive Function The LGDS-100 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 -1 000 / / 100 0 Notes, conditions 4 Drive current source sink Must be externally limited 12-3 Typical Architecture Schematics Using LGDS-100 with Multiple Modules The LGDS-100 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-100. 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-100 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-100. (c) Gaia Converter FC12-045.02/12 Revision A For locations, phone, fax, E-Mail see back cover 10 LGDS-100 Series Hi-Rel Grade 13- Dimensions Dimension are given in mm. Tolerance : +/- 0,2 mm unless otherwise indicated. Weight : 35 grams (1.22 Ozs) max. 14- Materials 4 Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 15- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing. 16- Connections 4 5 6 Pin LGDS-100 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 FC12-045.02/12 Revision A 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 FC12-045.02/12 Revision A. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :