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 1- General • 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 2- Product Selection PGDS - 50 - 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 20µs 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 Gaïa 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. (/T) and/or (/S) (/T) : option for -55°C start up operating temperature. (/S) : option for screening and serialization Input Voltage Range Output Brown-out - Transient N : 10V/15s - 80V/100ms O : 6V/1s - 100V/50ms REDEFINING THE SOURCE OF POWER © Gaia Converter FC97-012.10/05 Revision H For locations, phone, fax, E-Mail see back cover K 4 Hi-Rel Grade PGDS-50 Series 3- Block Diagram The PGDS-50 module includes 3 main circuits : • A Boost Circuit • An Active clamping Circuit • A Control Circuit • 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. • 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. 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. • 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. PGDS-50 Block Diagram 6µH Vin Active Clamping Vo Vimes 4 19µF 2µF Boost Function Control Circuit On/Off Gin Go PGDS-50 Modes of Operation Modes of Operation Power Fail Operation Low Line Operation Normal Operation Transient & Surge Operation © Gaia Converter FC97-012.10/05 Revision H Control Circuit Boost Circuit Active Clamping Circuitt Off Off Off On On Off On Off Off On Off On 2 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade PGDS-50 Series 4- Modes of Operation 4-1 PGDS-50-N-K Modes of Operation • Power fail operation : An undervoltage lock-out stops operation for voltage below this low line operation threshold. 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 : • Normal operation : Normal operation occurs between the permanent input voltage of DC/DC converter; The module is then operating in steady transparency state. • 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.. • 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 20µs with 50 ohms impedance . PGDS-50-N-K Transfert Function 40 37,5 35 32,5 output voltage (Vdc) 30 Normal operation Power fail Low line operation operation 27,5 Transient and spike operation 4 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 Input voltage (Vdc) Parameter Unit Min. Typ. Max. Notes, conditions Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Off Vdc Vdc 11,25 8,80 / / 12 9,50 / / Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation Off Maximum output power at 10V@30sec Vdc Vdc W 16,30 16,40 / / / / 17 17,2 36 / / see page 6 Normal operation : Maximum output power W / / 50 see page 6 Transient & Surge Operation : Maximum output power at 80V/100ms W / / 50 see page 6 © Gaia Converter FC97-012.10/05 Revision H 3 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade PGDS-50 Series 4- Modes of Operation (continued) 4-2 PGDS-50-O-K Modes of Operation • Power fail operation : An undervoltage lock-out stops operation for voltage below this low line operation threshold. 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: • Normal operation : Normal operation occurs between the permanent input voltage of DC/DC converter; The module is then operating in steady transparency state. • 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. • 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 20µs with 50 ohms impedance . PGDS-50-O-K Transfert Function 37,5 35 32,5 30 output voltage (Vdc) 27,5 Power fail 25 operation 4 Transient and spike operation Normal operation Low line operation 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 Unit Min. Typ. Max. Notes, conditions Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Off Vdc Vdc 5,35 4,12 / / 5,65 4,38 / / Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation Off Maximum output power 6V@1s Vdc Vdc W 11,40 11,70 / / / / 11,80 12,00 30 / / see page 6 Normal Operation : Maximum output power W / / 50 see page 6 Transient & Surge Operation : Maximum output power at 100V/50ms W / / 30 see page 6 © Gaia Converter FC97-012.10/05 Revision H 4 For locations, phone, fax, E-Mail see back cover PGDS-50 Series Hi-Rel Grade 5- Electrical Specifications Data are valid at +25°C, unless otherwise specified. Parameter Limit or typical Conditions Units PGDS-50-N-K PGDS-50-O-K J series H series Input 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 16-40Vdc 9-36Vdc Typical Typical VDC VDC 12 9 6 5,65 Maximum ms 15 15 Minimum Maximum VDC VDC 17 37 12 37 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 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 10V/15s Compliant Compliant Compliant Compliant Not compliant 80V/100ms 47V/1s Compliant Compliant Compliant Compliant Not compliant 6V/1s Compliant Compliant Compliant Compliant Compliant 100V/50ms 47V/1s Compliant Compliant Compliant Compliant Compliant Maximum MIL-STD-704A AECMA EN2282 AIR2021E DO160D cat A/Z MIL-STD-1275A/B VDC/µs 600V/10µs 400V/100µs 600V/10µs 600V/10µs 250V/70µs 600V/20µs Compliant Compliant Compliant Compliant / 600V/20µs Compliant Compliant Compliant Compliant Compliant with EMI front filter Maximum mA 25 25 Minimum Maximum VDC VDC 16 40 9 36 Nominal VDC Ui - 0,6 Ui - 0,6 In low line Input voltage Nominal Minimum VDC VDC see page 6 figure 1 see page 6 figure 2 In transient Input voltage Nominal VDC see page 6 figure 3 see page 4 figure 4 Ui = 28VDC Full load Minimum % 96 96 Minimum Maximum Maximum W W W see page 6 figure 5 see page 6 figure 6 Compatible module Voltage drop-out limit in low line operation Voltage transient limit in transient operation Voltage spike limit in transient operation 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 Full temperature range Full temperature range 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 50 Ohms impedance 15 mJ energy content Ui min. to max. Full load Full temperature range Output power range In low line operation In transient operation © Gaia Converter FC97-012.10/05 Revision H 4 5 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade PGDS-50 Series 5- Electrical Characteristics (continued) Figure 1 : PGDS-50-N-K Brown-Out Response at 10Vdc 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 6 : PGDS-50-O-K Output Power versus Input Voltage 50 50 45 45 40 40 35 35 30 Pout max Pout min 25 20 Pout (W) Pout (W) Figure 5 : PGDS-50-N-K Output Power versus Input Voltage 30 20 15 15 10 10 5 5 0 Pout max Pout min 25 0 0 10 20 30 40 50 60 70 80 0 10 20 30 Vin (Vdc) © Gaia Converter FC97-012.10/05 Revision H 40 50 60 70 80 90 100 Vin (Vdc) 6 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade PGDS-50 Series 6- Switching Frequency Parameter Conditions Limit or typical Specifications Switching frequency Full temperature range Ui min. to max. No load to full load Nominal, fixed in low line operation 500 KHz Parameter Conditions Limit or typical Specifications Electric strength test voltage Input to output Input to case Output to case / Minimum Minimum No isolation 1.500 VDC / 1 min 1.500 VDC / 1 min Isolation resistance 500 VDC Minimum 100 MOhm Characteristics Protection Device Recovery Limit or typical Specifications Input undervoltage lock-out (UVLO) Turn-on, turn-off circuit with hysteresis Automatic recovery Typical see section 5 Conditions Temperature Specifications Ground fixed (Gf) Case at 40°C Case at 85°C 1.700.000 Hrs 710.000 Hrs Airborne, Inhabited, Cargo (AIC) Case at 40°C Case at 85°C 850.000 Hrs 360.000 Hrs 7- Isolation 8- Protection Functions 4 9- 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 FC97-012.10/05 Revision H Avionics Military Cargo / Consult factory 7 For locations, phone, fax, E-Mail see back cover PGDS-50 Series Hi-Rel Grade 10- Thermal Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Characteristics 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 MGDM-04 series operating case temperature at full load 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 at full load (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 FC97-012.10/05 Revision H 8 For locations, phone, fax, E-Mail see back cover PGDS-50 Series Hi-Rel Grade 11- 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 FC97-012.10/05 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 9 For locations, phone, fax, E-Mail see back cover Hi-Rel Grade PGDS-50 Series 12- Application Notes 12-1 Reverse Polarity Compatibility 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 On/Off Command 100K 4 Gi 12-3 EMI Compatibility with MIL-STD-461C and MIL-STD-461D/E The PGDS-50 series includes a π 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* C* L1 LMC1 1 VI + Input R1 C1 C3 +Vo 6 PGDS50 C5 GI Go VI +Vo C6 C4 C2 MGDM-series 2 Vimes +Vo C7 4 GI - Input Go 5 On/Off L2 MGDM-series GI Go VI +Vo 3 EMI input filter On/Off MGDM-series Please consult EMI filters design notes for further details on EMI. © Gaia Converter FC97-012.10/05 Revision H GI Go 10 For locations, phone, fax, E-Mail see back cover PGDS-50 Series Hi-Rel Grade 13- 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") 7,90 8 (0.30") (0.32") 5 min (0.20") 26,20 8,89 8,89 (1.03") (0.35") (0.35") 35,56 20,32 (0.80") (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 PGDS-50 1 + Input (Vi) 2 Input measure (VIMES) 3 On / Off 4 - Input (Gi) 5 Common (Go) 6 Output (Vo) Bottom view © Gaia Converter FC97-012.10/05 Revision H 11 For locations, phone, fax, E-Mail see back cover 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 FC97-012.08/05 Revision G. Graphisme : Philippe Clicq For more detailed specifications and applications information, contact :