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Hi-Rel PREGULATOR MODULE PGDS-50 : up to 50W POWER
Hi-Rel Grade
10-80V or 6-100V Brown-out / Transient 600V Spike Suppression Module Metallic Case
* Transient suppressor module 80V * MIL-STD-704A/D/E/F, EN2282, AIR2021E * DO160D cat A, B and Z * Transient suppressor module 100V * MIL-STD-1275A/B, * Spike suppressor module 600V * MIL-STD-704A/D/E/F, EN2282, AIR2021E * DO160D cat A, B and Z * Extended operation for voltage drop out and cranking down to 6V * Power range : from 4W to 50W * Inhibition function The GAIA Converter pre-regulator PGDS-50 series designates a low profile power adaptator module designed to extend input bus voltage to meet system operation during voltage transients, spikes, cranking and drop out occuring in avionics or military systems. The PGDS-50 delivers an output voltage adapted to GAIA Converter DC/DC modules. This line of module is optimized to provide high power efficiency up to 96% over the whole power range between 4W and 50W. The PGDS-50 features 4 modes of operations as follow: * Low line operation : Low line operation occurs when the input bus voltage drops down below the permanent input voltage range of the DC/DC converter ; then the PGDS-50 operates in boost mode to provide an output voltage compatible with DC/DC converter. The PGDS-50 series can sustain low line operation down to 6V. * Power fail operation : An undervoltage lock-out stops operation and disables the boost mode for voltage below this low line operation. * Normal operation : Normal operation occurs between the permanent input voltage of DC/DC converter; The module is then operating in steady transparency state. * Transient and spike operation : The PGDS-50 can sustain input transient up to 80V/100ms or 100V/50ms and spike up to 600V during 20s with 50 ohms impedance . The PGDS-50 series is compliant with the international input bus standards : - MIL-STD-704A/D/E/F - AECMA EN2282 - GAM-EG13B/AIR2021E - DO160D cat A, B and Z - MIL-STD-1275A/B 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 high environmental conditions.
1- General
4
2- Product Selection
PGDS - 50 -
(/T) and/or (/S)
(/T) : option for -55C start up operating temperature. (/S) : option for screening and serialization Input Voltage Range Brown-out - Transient N : 10V/15s - 80V/100ms O : 6V/1s - 100V/50ms K Output
REDEFINING THE SOURCE OF POWER
(c) Gaia Converter FC97-012.10/05 Revision H
For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 3- Block Diagram
The PGDS-50 module includes 3 main circuits : * A Boost Circuit * An Active clamping Circuit * A Control Circuit * Boost Circuitry : The boost circuit operates when the input bus voltage drops-down (low line operation) and boost the input voltage to a higher output value. * Active Clamping : The active clamping circuit operates when the input bus voltage increases (transient & spike operation). The circuitry clamps the input voltage to typically 38Vdc.
Hi-Rel Grade
* Control Circuit : The control circuit monitors the different modes of operation thrugh the VIMES signal and allows the functionning of the active clamping circuit or the boost circuit. The PGDS-50 series features 4 modes of operations : * Power fail operation * Low line operation * Normal operation * Transient & surge operation The following figure represents the PGDS-50 series block diagram while the table hereafter describes the circuitry activation depending on the 4 modes of operations.
PGDS-50 Block Diagram
6H
Vin
Active Clamping
Vo
Vimes
2F 19F
4
Control Circuit On/Off
Boost Function
Gin
Go
PGDS-50 Modes of Operation
Modes of Operation Power Fail Operation Low Line Operation Normal Operation Transient & Surge Operation Control Circuit Off On On On Boost Circuit Off On Off Off Active Clamping Circuitt Off Off Off On
(c) Gaia Converter FC97-012.10/05 Revision H
2 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 4- Modes of Operation
4-1 PGDS-50-N-K Modes of Operation
The PGDS-50-N-K operates with J input (i.e 16-40Vdc) family of GAIA Converter DC/DC Converters. The PGDS-50-N-K features 4 modes of operations as follow : * Low line operation : Low line operation occurs when the input bus voltage drops down below the permanent input voltage range of the DC/DC converter i.e 16 Vdc. The PGDS-50-N-K then operates in boost mode to provide an output voltage compatible with the DC/ DC converter. The PGDS-50-N-K series can sustain low line operation down to 10V during 30 sec..
Hi-Rel Grade
* Power fail operation : An undervoltage lock-out stops operation for voltage below this low line operation threshold. * Normal operation : Normal operation occurs between the permanent input voltage of DC/DC converter; The module is then operating in steady transparency state. * Transient and spike operation : The PGDS-50-N-K can sustain input transient up to 80V as long as 100ms and spike up to 600V during 20s with 50 ohms impedance .
PGDS-50-N-K Transfert Function
40 37,5 35 32,5 30 27,5 25 22,5 20 17,5 15 12,5 10 7,5 5 2,5 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 Power fail Low line operation operation Normal operation Transient and spike operation
output voltage (Vdc)
4
Input voltage (Vdc)
Parameter Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Off Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation Off Maximum output power at 10V@30sec Normal operation : Maximum output power Transient & Surge Operation : Maximum output power at 80V/100ms Unit Vdc Vdc Vdc Vdc W W W Min. 11,25 8,80 16,30 16,40 / / / Typ. / / / / / / / Max. 12 9,50 17 17,2 36 50 50 Notes, conditions / / / / see page 6 see page 6 see page 6
(c) Gaia Converter FC97-012.10/05 Revision H
3 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 4- Modes of Operation (continued)
4-2 PGDS-50-O-K Modes of Operation
The PGDS-50-O-K operates with H input (i.e 9-36Vdc) family of GAIA Converter DC/DC Converters. The PGDS-50-O-K features 4 modes of operations as follow: * Low line operation : Low line operation occurs when the input bus voltage drops down below the permanent input voltage range of the DC/DC converter i.e 9 Vdc. The PGDS-50-O-K then operates in boost mode to provide an output voltage compatible with the DC/ DC converter. The PGDS-50-O-K series can sustain low line operation down to 6V during 1 sec.
Hi-Rel Grade
* Power fail operation : An undervoltage lock-out stops operation for voltage below this low line operation threshold. * Normal operation : Normal operation occurs between the permanent input voltage of DC/DC converter; The module is then operating in steady transparency state. * Transient and spike operation : The PGDS-50-O-K can sustain input transient up to 100V as long as 50ms and spike up to 600V during 20s with 50 ohms impedance .
PGDS-50-O-K Transfert Function
37,5 35 32,5 30 27,5
output voltage (Vdc)
Power fail 25 operation Low line operation
Normal operation
Transient and spike operation
4
22,5 20 17,5 15 12,5 10 7,5 5 2,5 0 0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95 100
Input voltage (Vdc)
Parameter Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Off Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation Off Maximum output power 6V@1s Normal Operation : Maximum output power Transient & Surge Operation : Maximum output power at 100V/50ms Unit Vdc Vdc Vdc Vdc W W W Min. 5,35 4,12 11,40 11,70 / / / Typ. / / / / / / / Max. 5,65 4,38 11,80 12,00 30 50 30 Notes, conditions / / / / see page 6 see page 6 see page 6
(c) Gaia Converter FC97-012.10/05 Revision H
4 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 5- Electrical Specifications
Data are valid at +25C, unless otherwise specified.
Hi-Rel Grade
Parameter Input
Conditions
Limit or typical 16-40Vdc 9-36Vdc Typical Typical Maximum Minimum Maximum Minimum MIL-STD-704A AECMA EN2282 AIR2021E DO160D cat A/B/Z MIL-STD-1275A/B Maximum Maximum MIL-STD-704A AECMA EN2282 AIR2021E DO160D cat A/Z MIL-STD-1275A/B Maximum MIL-STD-704A AECMA EN2282 AIR2021E DO160D cat A/Z MIL-STD-1275A/B Maximum
Units
PGDS-50-N-K
PGDS-50-O-K
J series of DC/DC module H series of DC/DC module Under voltage lock- Turn-on voltage out (UVLO) Turn-off voltage Ui min. to max. Start up time No load to full load Permanent input Full temperature range voltage range (Ui) Full load in normal operation Compatible module Voltage drop-out limit in low line operation
J series VDC VDC ms VDC VDC VDC/s 10V/50ms 12V/30ms 12V/50ms 10V/15s 6V/1s VDC/ms VDC/s 80V/75ms 60V/50ms 60V/100ms 80V/100ms 100V/50ms VDC/s 600V/10s 400V/100s 600V/10s 600V/10s 250V/70s mA 12 9 15 17 37 10V/15s Compliant Compliant Compliant Compliant Not compliant 80V/100ms 47V/1s Compliant Compliant Compliant Compliant Not compliant 600V/20s Compliant Compliant Compliant Compliant / 25
H series 6 5,65 15 12 37 6V/1s Compliant Compliant Compliant Compliant Compliant 100V/50ms 47V/1s Compliant Compliant Compliant Compliant Compliant 600V/20s Compliant Compliant Compliant Compliant Compliant with EMI front filter 25
Full temperature range
Voltage transient limit in transient operation
Full temperature range
4
Voltage spike limit in transient operation
50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 15 mJ energy content
Current in inhibit mode Output Output voltage range Nominal voltage in normal operation Nominal voltage in low line operation Nominal voltage in transient protection mode Efficiency
Ui min. to max. Full load
Minimum Maximum Nominal
VDC VDC VDC VDC VDC VDC % W W W
16 40 Ui - 0,6 see page 6 figure 1 see page 6 figure 3 96 see page 6 figure 5
9 36 Ui - 0,6 see page 6 figure 2 see page 4 figure 4 96 see page 6 figure 6
In low line Input voltage In transient Input voltage Ui = 28VDC Full load
Nominal Minimum Nominal Minimum Minimum Maximum Maximum
Full temperature range Output power range In low line operation In transient operation
(c) Gaia Converter FC97-012.10/05 Revision H
5 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 5- Electrical Characteristics (continued)
Figure 1 : PGDS-50-N-K Brown-Out Response at 10Vdc
Hi-Rel Grade
Figure 2 : PGDS-50-O-K Brown-Out Response at 6Vdc
Figure 3 : PGDS-50-N-K Transient Response at 80Vdc
Figure 4 : PGDS-50-O-K Transient Response at 100Vdc
4
Figure 5 : PGDS-50-N-K Output Power versus Input Voltage
50 45 40 35
Figure 6 : PGDS-50-O-K Output Power versus Input Voltage
50 45 40 35
Pout (W)
25 20 15 10 5 0 0 10 20 30 40 50 60 70 80
Pout max Pout min
Pout (W)
30
30 25 20 15 10 5 0 0 10 20 30 40 50 60 70 80 90 100 Pout max Pout min
Vin (Vdc)
Vin (Vdc)
(c) Gaia Converter FC97-012.10/05 Revision H
6 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 6- Switching Frequency
Parameter Switching frequency Conditions Full temperature range Ui min. to max. No load to full load Limit or typical Nominal, fixed in low line operation Specifications 500 KHz
Hi-Rel Grade
7- Isolation
Parameter Electric strength test voltage Isolation resistance Conditions Input to output Input to case Output to case 500 VDC Limit or typical / Minimum Minimum Minimum Specifications No isolation 1.500 VDC / 1 min 1.500 VDC / 1 min 100 MOhm
8- Protection Functions
Characteristics Input undervoltage lock-out (UVLO) Protection Device Turn-on, turn-off circuit with hysteresis Recovery Automatic recovery Limit or typical Typical Specifications see section 5
4
9- 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 1.700.000 Hrs 710.000 Hrs 850.000 Hrs 360.000 Hrs Consult factory
Mean Time Between Failure (MTBF) According to IEC-62380-TR
(c) Gaia Converter FC97-012.10/05 Revision H
7 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 10- 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 MGDM-04 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 : 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 at full load (white area in the following graph).
4
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 FC97-012.10/05 Revision H
8 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 11- 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
4
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 FC97-012.10/05 Revision H
9 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 12- Application Notes
12-1 Reverse Polarity Compatibility
Hi-Rel Grade
The PGDS-50 is compatible with an external reverse input polarity protection connected directly on Vin (pin 1). GAIA Converter recommends a diode with a minimum current rating of 7 A and a voltage breakdown rating greater than 100V.
12-2 On/Off Function
The control pin 3 (On/Off) can be used for applications requiring On/Off operations. By using an open collector command with a transistor Q referenced to the terminal Gi : * A logic pulled low (<0.2V@1mA, referenced to Gi) on pin 3 disables the converter. * No connection or high impedance on pin 3 enables the converter.
3 Command 100K 4 Gi On/Off
12-3 EMI Compatibility with MIL-STD-461C and MIL-STD-461D/E
The PGDS-50 series includes a EMI filter to attenuate ripple and noise. To meet MIL-STD-461C and MIL-STD-461D/E requirements, GAIA Converter recommends the use of an external filter (see section 12-5 Typical Schematics and EMI filters design notes for details).
12-4 VIMES Signal
The VIMES signal is used to sense the bus input voltage and depending on the achieved level to drive the operation mode of the PGDS-50. Due to possible oscillation caused by surge or fast transients on the bus line, it is recommended to implement an RC filter on this signal as described in the following schematics. The connection of VIMES trough the resistance R could be done before or after the EMI input filter (see section 12-5 Typical Schematics). If no RC filter is used, connect pin VIMES to pin Vi.
4
12-5 Typical Schematics
The PGDS-50 series is suitable to be used with several DC/DC GAIA converter modules in various configurations as follow :
VI R* LMC1 + Input C1 C3 C2 - Input
L2
+Vo
C* L1 R1 C4 C5 C7
4 GI 1 VI
2
MGDM-series +Vo 6 GI Go
Vimes
C6
PGDS50
VI
+Vo
Go 5 On/Off
3
MGDM-series GI Go
EMI input filter
On/Off
VI
+Vo
MGDM-series
Please consult EMI filters design notes for further details on EMI.
GI
Go
(c) Gaia Converter FC97-012.10/05 Revision H
10 For locations, phone, fax, E-Mail see back cover
PGDS-50 Series 13- Dimensions
Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 ") unless otherwise indicated. Weight : 20 grams (0.7 Ozs) max.
Hi-Rel Grade
40
(1.58")
26
(1.03")
7,90
(0.30")
8
(0.32")
5 min
(0.20")
26,20
(1.03")
8,89
(0.35")
8,89 20,32
(0.80") (0.35")
35,56
(1.40")
Pin dimensions : O 0,73 mm (0.03 ")
Metallic case black anodized coating solder plated pin
14- Product Marking
Upper face : Company logo, location of manufacturing. Side face : Module reference, option, date code : year and week of manufacturing.
4
15- Connections
6 5
Pin 1 2 3 4 5
1 2 3 4
PGDS-50 + Input (Vi) Input measure (VIMES) On / Off - Input (Gi) Common (Go) Output (Vo)
6
Bottom view
(c) Gaia Converter FC97-012.10/05 Revision H
11 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 FC97-012.08/05 Revision G. 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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