Hi-Rel HOLD-UP MODULE HUGD-50 : 50W POWER Hi-Rel Grade Hold-Up Solution 9-36V & 16-40V 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 * RoHS or Leaded process option 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 for enough time. Usually this approach uses very large capacitors because they are only charged at the voltage at which power fails. 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 must 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 HUGD50 can be used either with 16-40V or 9-36V input voltage DC/DC converters since the power fail voltage is externally adjustable by the user between 8.8V and 15.3V . 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 2-Product Selection HUGD - 50 - / option 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 controlled and externally adjustable between 100mA and 2A by a resistor. The capacitor charging time depends on the charging current. When the capacitor voltage reaches 35V, the signal (active low, open-drain) capacitor charged is activated and the HUGD-50 enters in the normal operation mode. * Normal operation mode : in normal operation mode when the capacitor is charged and the input bus is between the output power fail and 40VDC, the HUGD-50 only consumes power to keep the capacitor charged (i.e.less than 1W). The voltage drop between input and output is lower than 150mV in the worst case (50W power and 9 VDC input voltage) The HUGD50 will operate indefinitely in this state 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 from output and connects the hold-up capacitor to the output. At this point the DC/DC converters are powered by the capacitor. When its voltage finally discharges to a value slightly above the power fail voltage threshold value, a capacitor discharged flag is activated. suffix Options : /T : option for -55C start up operating temperature /S : option for screening and serialization Suffix : nothing : RoHS process -L : leaded process (available in N. America) REDEFINING THE SOURCE OF POWER (c) Gaia Converter FC97-027.04/12 Revision L For locations, phone, fax, E-Mail see back cover 4 HUGD-50 Series Hi-Rel Grade 3- Block Diagram * 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. 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 enables the activation of the hold-up switch or the hold-up charger and generates an open-drain power fail flag (PF). * Hold-up monitoring Circuit : The hold-up monitoring circuit monitors the charging status of the hold-up capacitor. The circuit generates 2 open-drain flags : the capacitor charged flag (CC) and the capacitor discharged flag (CD). These flags can be used at system level for power interruption management (VME system, PCI, ...). The following diagram 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 FC97-027.04/12 Revision L CD Go 2 For locations, phone, fax, E-Mail see back cover HUGD-50 Series Hi-Rel Grade 4- Electrical Specifications Data are valid at +25C, unless otherwise specified. Parameter Conditions Limit or typical Units HUGD-50 Full temperature range Full load Minimum Maximum VDC VDC Transient input voltage Full temperature range Full load Maximum VDC/ms Power fail voltage threshold (Vfail) with the setting Vth unconnected Power fail voltage threshold (Vfail) with the setting Vth connected to ground Minimum Typical Maximum Minimum Typical Maximum VDC VDC VDC VDC VDC VDC 15 15,3 15,6 8,6 8,8 9 Power fail hysteresis / Typical VDC 1 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 Maximum W 50 Maximum A 5,6 Input Permanent input voltage range (Ui) 9 40 50/100 Output Output power Output current Full temperature range Full load Full temperature range Ui min. to max. Dissipated power Vin @ 9V, full power Maximum W 2 Voltage drop input/ouput Vin @ 9V, full power Maximum mV 160 Capacitor charged signal (CC) threshold Turn off threshold Turn on threshold Typical Typical VDC VDC 30,5 35 Capacitor discharged signal (CD) threshold with setting Vth unconnected Minimum Maximum VDC VDC 15,9 16,7 Capacitor discharged signal (CD) threshold with setting Vth connected to ground Minimum Maximum VDC VDC 9,4 10,2 CC, CD, PF sink current / Maximum mA 25 Admissible hold-up capacitor / Minimum Maximum F F 470 30 000 Vth unconnected Vth connected to ground Vth unconnected Vth connected to ground Minimum Minimum Minimum Minimum s/F s/F s/F s/F Hold-up time at 50W load Hold-up time at 10W load (c) Gaia Converter FC97-027.04/12 Revision L 4 11,2 12,8 55,6 64,4 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 Electric strength test voltage Input to output 6- Isolation / Specifications 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 FC97-027.04/12 Revision L 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 Civilian avionics, calculators Ambient at 55C 100% time on 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 + 90C 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 : 90C Maximum case temperature : 105C Maximum storage temperature : 125C (c) Gaia Converter FC97-027.04/12 Revision L 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 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 FC97-027.04/12 Revision L 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 data saving and shut-down control. 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 power drop-out, the traditional approach is to use a bulk capacitor connected at the input of the converters to power them when power drops-out. This capacitor depends on the system specifications, the load, the efficiency of the DC/DC converter and the hold-up time requirement. The value of the capacitance is determined by the following formula : To reduce drastically the size of this capacitor, GAIA Converter proposes the HUGD-50 hold up module that will charge the capacitor at a higher voltage, typically 38V. C1 = where C : P : h : Dt : V1 : V2 : Moroever this module also allows to select the minimum threshold voltage at which the capacitance will 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 = : is the required capacitor (in farads) is the power at the load (output of converter) is the efficiency of the converter at rated load is the required hold up time (in seconds) is the initial charged capacitor voltage (in volts) is the low line voltage of DC/DC converter For a typical 50ms hold-up time with 50W output power, considering a GAIA Converter module with a minimum permanent input voltage at 16V and 80% efficiency connected on a MIL-STD-704 28V bus that can range down to 22V, the resulting capacitor is a large 27 400uF/40V. (c) Gaia Converter FC97-027.04/12 Revision L where C : P : h : Dt : V2 : 2 x P x (Dt + 0.01) h x ( 382 - V22 ) 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). For a typical 50ms hold-up time with 50W output power, considering a GAIA Converter module with a minimum permanent input voltage at 16V and 80% efficiency connected on a MIL-STD-704 28V bus, using the HUGD50 will reduce the capacitor value down to 6 300uF/40V. 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 power drop-out. 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 the the the the 2 x P (Dt + 0.01 ) 382 -VL2 required capacitance (in Farads) power consumed by the DC/DC converters (in Watts) required hold-up time (in seconds). 10ms are added for design margin lowest admissible voltage of DC/DC converters (in volts) The following curve gives the hold up time as a function of the capacitor value. Gaia Converter recommends a low ESR extended temperature range electrolytic capacitor. 4 Hold up time as a function of hold up capacitance 1000 50W 900 40W 800 30W 20W Hold-up time (ms) 700 600 500 400 300 200 100 0 0 5 000 10 000 1 5 000 20 0 00 25 000 30 0 00 Hold-up c apac itanc e ( F) (c) Gaia Converter FC97-027.04/12 Revision L 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 an external resistor Rth connected between the Vth pin and Gout pin. Vth unconnected will set the threshold at 15,3VDC valid for 16-40Vdc input modules whereas Vth connected to ground will set 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 shows the Vth function threshold as a function of the resitor Rth. The hysteresis on the undervoltage detection is typically 1V. Once an undervoltage has been detected and the input bus has been disconnected to switch on the hold-up capacitor energy reservoir, the HUGD-50 will reconnect the input bus when it is 1V above the value set with the Vth pin. Therefore, it is recommended to minimize the series resistance of elements in front of the HUGD-50 to prevent false triggerings when the input current becomes 0A as the Vth threshold is reached and the bus is disconnected, because the voltage at the input of the HUGD-50 will then slightly increase. The resulting unwanted bounces may lead to a loss of stored energy and internal switch overstress. The series resistance should be kept below 0,75 x Vth / Pout. Power fail voltage threshold versus Rth 16 Power fail voltage threshold (Vdc) 15 14 13 4 12 11 10 9 8 0,1 1 10 100 1000 Rth (kohms) 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 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 Input charging current as function of external resistor Rcl Input charging rate as function of external resistor Rcl 900 2.5 Vi=16V Vi=28V Vi=40V 700 Vi=16V Vi=28V Vi=40V Charging rate in s/F Input reflected charging current (A) 800 2 1.5 1 600 500 400 300 200 0.5 100 0 0 0 500 1000 1500 2000 2500 0 500 Rcl (c) Gaia Converter FC97-027.04/12 Revision L 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 10-7 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 active low open-drain output. The capacitor charged signal is actived when the voltage at the capacitor pins reaches 35 VDC corresponding to an energy stored of about 90% of it's full charge. The CC signal is an active low open-drain output. 10-6 Capacitor Discharged Signal : CD 10-8 Transition Capacitor The Capacitor discharged signal is activated when the voltage at the hold-up capacitor pin reaches the value programmed with the Vth pin + 0.9V to inform the system that the energy storage capacitor voltage is closed to the value which is considered a power fail event. It can be used as a last warning before system shut-off. With the Vth pin unconnected, the corresponding value will be Vc = 16.2V, whereas with the Vth pin grounded, the corresponding value will be Vc = 9.7V. The CD signal is an open drain active low output. 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 switching 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. Although the HUGD50 has been designed for up to 50W operation, it is possible to use it in higher power applications with some additional external parts. Please consult factory for details and specific application note. 4 Power fail signal Capacitor charged signal Capacitor discharged signal R* VI C* + Input Vo VI 1 VI - Input GI Go MGDM-series 2 Vimes +Vo 6 PF CC CD 1 +Vo 6 VI PGDS50 EMI input Filter 4 GI +Vo HUGD50 Go 5 4 GI On/Off 2 Rth Go VI +Vo Vc 7 Go Vth 3 GI 5 Vcl 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. (c) Gaia Converter FC97-027.04/12 Revision L 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) VI Vstart Vth VO Vstart Vth 4 PF VC 38V 35V 30,5V Vth+4,9V Vth+0,9V CC CD (c) Gaia Converter FC97-027.04/12 Revision L 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 ") 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- Materials Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 13- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference : HUGD-50. Date code : year and week of manufacturing, suffix, /option. 14- 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 FC97-027.04/12 Revision L 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 FC97-027.04/12 Revision L. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :