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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.
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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
HUGD-50 Series 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.
Hi-Rel Grade
* 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
Vo
4
Vth
Input Monitoring Hold-up Charger
Vc PF CC Hold-up Monitoring CD
Vcl
Gi
Go
(c) Gaia Converter FC97-027.01/06 Revision H
2 For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 4- Electrical Specifications
Data are valid at +25C, unless otherwise specified.
Hi-Rel Grade
Parameter Input Permanent input voltage range (Ui)
Conditions
Limit or typical
Units
HUGD-50
Full temperature load Full load Full temperature load Full load with the setting Vth unconnected
Minimum Maximum
VDC VDC
9 40
Transient input voltage
Maximum Minimum Typical Maximum Minimum Typical Maximum Minimum Maximum
VDC/ms VDC VDC VDC VDC VDC VDC A A
50/100 15 15,3 15,6 8,6 8,8 9 0,1 1,5
Power fail voltage threshold (Vfail)
Power fail voltage threshold (Vfail)
with the setting Vth connected to ground
Input current consumption during charging at 28V
min: Vcl unconnected max: Vcl connected to ground
Input current consumption during charging at 16V Output Output admissible power
min: Vcl unconnected max: Vcl connected to ground
Minimum Maximum
A A
0,1 2,2
4
Full temperature load Full load Vin @ 9V, full power
Maximum
W
50
Dissipated power
Maximum
W
1
Voltage drop input/ouput Capacitor charged signal threshold Capacitor discharged signal threshold Capacitor discharged signal threshold Maximum admissible hold-up capacitor
Vin @ 9V, full power
Maximum Minimum Maximum
mV VDC VDC VDC VDC VDC VDC F F s/F s/F s/F s/F
160 33,8 34,8 15,9 16,7 9,4 10,2 470 30.000 11,2 12,8 55,6 64,4
3
with setting Vth unconnected with setting Vth connected to ground
Minimum Maximum Minimum Maximum Minimum Maximum
Hold-up time at full load
Vth unconnected Vth connected to ground Vth unconnected Vth connected to ground
Minimum Minimum Minimum Minimum
Hold-up time at 10W load
(c) Gaia Converter FC97-027.01/06 Revision H
For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 5- Switching Frequency
Parameter Switching frequency Conditions Full temperature range Ui min. to max. No load to full load Limit or typical Nominal, fixed Specifications 200 KHz
Hi-Rel Grade
6- Isolation
Parameter Electric strength test voltage Conditions Input to output Limit or typical / Specifications No isolation
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7- Reliability Data
Characteristics Conditions Ground fixed (Gf) Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Airborne, Inhabited, Cargo (AIC) Avionics Military Cargo Temperature Case at 40C Case at 85C Case at 40C Case at 85C / Specifications 1.500.000 Hrs 590.000 Hrs 730.000 Hrs 300.000 Hrs Consult factory
Mean Time Between Failure (MTBF) According to IEC-62380-TR
(c) Gaia Converter FC97-027.01/06 Revision H
4 For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 8- Thermal Characteristics
Characteristics Operating ambient temperature range at full load Operating case temperature range at full load Storage temperature range Thermal resistance Conditions Ambient temperature * Case temperature Non functionning Rth case to ambient in free air natural convection Limit or typical Minimum Maximum Minimum Maximum Minimum Maximum Typical
Hi-Rel Grade
Performances - 40C + 85C - 40C +105C - 55C + 125C 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 : Pdiss = Pout(1/ - 1) * determine the maximum ambient temperature : Ta = 105C - 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 105C (white area in the following graph).
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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 9- Environmental Qualifications
The modules have been subjected to the following environmental qualifications.
Hi-Rel Grade
Characteristics Climatic Qualifications Life at high temperature
Conditions
Severity
Test procedure
Duration Temperature / status of unit 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
Altitude
Humidity cyclic
Humidity steady
Salt atmosphere
Temperature cycling
Temperature shock
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
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
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MIL-STD-202G Method 107G
Mechanical Qualifications 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 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
Vibration (Sinusoidal)
MIL-STD-810D Method 514.3
Shock (Half sinus)
MIL-STD-810D Method 516.3
Bump (Half sinus)
MIL-STD-810D Method 516.3
(c) Gaia Converter FC97-027.01/06 Revision H
6 For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 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.
Hi-Rel Grade
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
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 :
10-1-2 Capacitor with Hold Up Module Solution
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). 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 :
C1 =
( 2 x P x Dt ) { h x ( V12 - V22 )}
C2 =
2 x P x (Dt + 0.01) { h x ( 382 - V22 )}
4
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 :
: 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 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
7 For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 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 :
Hi-Rel Grade
C=
2 x P (Dt + 0.01 ) 382 -VL2
where C P Dt VL
: : : :
is is is is
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.
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1000 900 800 50W 40W 30W 20W
Hold-up time (ms)
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 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.
Hi-Rel Grade
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 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
Power fil voltage threshold (Vdc)
1,00E+01
1,00E+02
1,00E+03
1,00E+04
1,00E+05
1,00E+06
Rth (ohms)
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10-4 Charging Current Setting : VCL
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 knowing that the capacitor is charged at 38VDC. The following curve gives the resistance Rcl value as a function of current & charging time.
2,5
900
800
Input reflected charging current (A)
2 700
Charging rate in s/F
600
1,5 Vi=16V Vi=28V Vi=40V 1
500
400
Vi=16V Vi=28V Vi=40V
300
0,5
200
100 0 0 500 1000 1500 2000 2500
0 0 500 1000 1500 2000 2500
Rcl
Rcl
(c) Gaia Converter FC97-027.01/06 Revision H
9 For locations, phone, fax, E-Mail see back cover
HUGD-50 Series 10- Application Notes (continued)
10-5 Power Fail Signal : PF
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.
Hi-Rel Grade
10-6 Capacitor Charged Signal : CC
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
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.
10-8 Transition Capacitor
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.
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Power fail signal Capacitor charged signal Capacitor discharged signal VI R* LMC1 + Input C1 C3 C2 - Input
L2
+Vo
C* L1
1 VI
2 Vimes
MGDM-series +Vo
6
PF CC CD 1 +Vo 6 VI Vc 7
GI
Go
R1 C4 C5
C6
PGDS50
C7
4 GI
HUGD50
4
VI
+Vo
Go 5 On/Off
3
GI Vth 2 Vcl
Go 3 Rcl
5
MGDM-series GI Go
EMI input filter
On/Off
Rth**
VI
+Vo
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 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)
Hi-Rel Grade
4
(c) Gaia Converter FC97-027.01/06 Revision H
11 For locations, phone, fax, E-Mail see back cover
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
(1.58")
Hi-Rel Grade
26
(1.03")
7,60
(0.30")
8
(0.32")
5 min
(0.20")
26,20
(1.03")
5,08
(0.20")
7,62
(0.30")
35,56
(1.40")
20,32
(0.80")
Pin dimensions : O 0,73 mm (0.03 ")
Metallic case black anodized coating solder plated pin
10,16
(0.40")
7,62
(0.30")
2,54 2,54 (0.10")
(0.10")
3 x 2,54
(3 x 0.10")
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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 7 8 9 10 5
Pin 1 2 3 4 5 6 7 8
HUGD-50 + Input (Vi) Power Fail Threshold (Vth) Voltage Current Level (Vcl) - Input (Gi) Common (Go) Output (Vo) Voltage Capacitor (Vc) Power Fail Signal (PF) Capacitor charged signal (CC) Capacitor discharged signal (CD)
1
23
4
9 10
Bottom view
(c) Gaia Converter FC97-027.01/06 Revision H
12 For locations, phone, fax, E-Mail see back cover
For more detailed specifications and applications information, contact :
Printed in France by GAIA Converter Gaia Converter FC97-027.01/06 Revision H. Graphisme : Philippe Clicq
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.

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