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 Gaïa 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 -55°C start up operating temperature.
(/S) : option for screening and serialization
REDEFINING THE SOURCE OF POWER
© 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
© Gaia Converter FC97-027.01/06 Revision H
CD
Go
2
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Hi-Rel
Grade
HUGD-50 Series
4- Electrical Specifications
Data are valid at +25°C, 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
µF
µF
470
30.000
Maximum admissible
hold-up capacitor
Hold-up time at full load
Vth unconnected
Vth connected to ground
Minimum
Minimum
µs/µF
µs/µF
11,2
12,8
Hold-up time at 10W load
Vth unconnected
Vth connected to ground
Minimum
Minimum
µs/µF
µs/µF
55,6
64,4
© Gaia Converter FC97-027.01/06 Revision H
4
3
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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
© Gaia Converter FC97-027.01/06 Revision H
Conditions
Temperature
Specifications
Ground fixed (Gf)
Case at 40°C
Case at 85°C
1.500.000 Hrs
590.000 Hrs
Airborne, Inhabited,
Cargo (AIC)
Case at 40°C
Case at 85°C
730.000 Hrs
300.000 Hrs
Avionics Military Cargo
/
Consult factory
4
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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
- 40°C
+ 85°C
Operating case temperature
range at full load
Case temperature
Minimum
Maximum
- 40°C
+105°C
Storage temperature range
Non functionning
Minimum
Maximum
- 55°C
+ 125°C
Thermal resistance
Rth case to ambient in free air
natural convection
Typical
12°C /W
Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 105°C.
The HUGD-50 series operating case temperature must not exceed 105°C. The maximum ambient temperature admissible for
the DC/DC converter corresponding to the maximum operating case temperature of 105°C 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 = 105°C of the module, the power used Pout and the efficiency η :
• determine the power dissipated by the module Pdiss that should be evacuated :
η - 1)
Pdiss = Pout(1/η
• determine the maximum ambient temperature :
Ta = 105°C - 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 105°C (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 : 85˚C
Maximum case temperature : 105˚C
Maximum storage temperature : 125˚C
© Gaia Converter FC97-027.01/06 Revision H
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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
@ 105°C case, unit operating
@ 125°C ambient, unit not operating
40.000 ft@-55°C
30 min.
1.000 ft/min to 70.000 f@-55°C,
30 min.
unit operating
10
Cycle I : 24 Hrs
60 % to 88 %
31°C to 41°C
unit not operating
93 % relative humidity
40°C
56 days
unit not operating
35°C
5%
48 Hrs
unit not operating
200
-40°C / +85°C
40 min.
20 min.
unit operating
100
-55°C / +105°C
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
© 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
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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 µF/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 µF/40V rated.
© 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
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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 30.000µF, and should be higher than 470µF.
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 (µ F)
© Gaia Converter FC97-027.01/06 Revision H
8
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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 µs/µF
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
© Gaia Converter FC97-027.01/06 Revision H
1000
1500
2000
2500
Rcl
9
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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, GAÏA 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 100µF 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 (µF)
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 1µF.
Note ** : When used in conjunction with PGDS-50 series, the resistance Rth of HUGD module has to be left unconnected.
© Gaia Converter FC97-027.01/06 Revision H
10
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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
© Gaia Converter FC97-027.01/06 Revision H
11
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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
© Gaia Converter FC97-027.01/06 Revision H
12
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International Headquarters
Marketing and Sales department
GAÏA 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
GAÏA 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 :