Hi-Rel HOLD-UP MODULE
HUGD-50 : 50W POWER
• 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
Gaia Converter FC97-027.04/12 Revision L
©
REDEFINING THE SOURCE OF POWER
1-General
Hi-Rel
Grade
For locations, phone, fax, E-Mail see back cover
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 Gaïa
Converter HUGD-50 module provides an alterna-
tive 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 HUGD-
50 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 start-
up 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 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 HUGD-
50 will operate indefinitely in this state until
the input voltage drops below the «power fail
voltage» threshold.
• Power fail mode : when the input vol-
tage 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.
4
Hold-Up Solution
9-36V & 16-40V DC/DC Converter Compatible
Metallic Case
2-Product Selection
Options : Suffix :
/T : option for -55°C start up operating temperature nothing : RoHS process
/S : option for screening and serialization -L : leaded process (available in N. America)
HUGD - 50 - option
/suffix
For locations, phone, fax, E-Mail see back cover
2
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
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
enables the activation of the hold-up switch or the
hold-up charger and generates an open-drain «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 de-
sign 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 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
Input
Monitoring
Hold-up
Monitoring
Vi
Vcl
Vth
Vo
Hold-up
Charger
Gi Go
Vc
CC
CD
PF
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3
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
4- Electrical Specifications
Data are valid at +25°C, unless otherwise specified.
Parameter Conditions Limit or typical Units HUGD-50
Input
Permanent input voltage range
(Ui)
Full temperature range
Full load
Minimum
Maximum
VDC
VDC
9
40
Transient input voltage Full temperature range
Full load Maximum VDC/ms 50/100
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
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
Output
Output power Full temperature range
Full load Maximum W 50
Output current Full temperature range
Ui min. to max. Maximum A 5,6
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
µF
µF
470
30 000
Hold-up time at 50W 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
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4
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
5- Switching Frequency
7- Reliability Data
Parameter Conditions Limit or typical Specifications
Switching frequency
Full temperature range
Ui min. to max.
No load to full load
Nominal, fixed 200 KHz
6- Isolation
Characteristics Conditions Temperature Specifications
Mean Time Between Failure (MTBF)
According to MIL-HDBK-217F
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
Mean Time Between Failure (MTBF)
According to IEC-62380-TR
Civilian avionics,
calculators
Ambient at 55°C
100% time on Consult factory
Parameter Conditions Limit or typical Specifications
Electric strength test voltage Input to output / No isolation
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5
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
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
+ 90°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.
10 10030 110807060 9020 40 50
25%
75%
50%
100%
Power (W)
Temperature (˚C)
Full load ambient temperature without derating : 90˚C
Maximum case temperature : 105˚C
Natural convection operation area
Additionnal cooling operation area
Maximum storage temperature : 125˚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 :
Pdiss = Pout(1/ηη
ηη
η - 1)
• determine the maximum ambient temperature :
Ta = 105°C - 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 105°C (white area in the following graph).
For locations, phone, fax, E-Mail see back cover
6
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
9- Environmental Qualifications
The modules have been subjected to the following environmental qualifications.
Characteristics Conditions Severity Test procedure
Climatic Qualifications
Life at high
temperature
Duration
Temperature / status of unit
Test D : 1 000 Hrs
@ 105°C case, unit operating
@ 125°C ambient, unit not operating
MIL-STD-202G
Method 108A
Altitude
Altitude level C
Duration
Climb up
Stabilization
Status of unit
40 000 ft@-55°C
30 min.
1 000 ft/min to 70 000 ft@-55°C,
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 %
31°C to 41°C
unit not operating
MIL-STD-810E
Method 507.3
Humidity steady
Damp heat
Temperature
Duration
Status of unit
93 % relative humidity
40°C
56 days
unit not operating
MIL-STD-202G
Method 103B
Salt atmosphere
Temperature
Concentration NaCl
Duration
Status of unit
35°C
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
-40°C / +85°C
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
-55°C / +105°C
10 sec.
20 min.
unit not operating
MIL-STD-202G
Method 107G
Mechanical Qualifications
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
For locations, phone, fax, E-Mail see back cover
7
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
10- Application Notes
10-1 General on Input Bus Shut-
Down 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
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 :
where :
C : is the required capacitor (in farads)
P : is the power at the load (output of converter)
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
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.
10-1-2 Capacitor with Hold Up Module Solution
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.
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 :
where :
C : is the required capacitor (in farads)
P : is the power to 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)
V2 : 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 per-
manent 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.
2 x P x (Dt + 0.01)
h x ( 382 - V22 )
C2 =
2 x P x Dt
h x ( V12 - V22 )
C1 =
For locations, phone, fax, E-Mail see back cover
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HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
10- Application Notes (continued)
0
100
200
300
400
500
600
700
800
900
1000
0 5 000 10 000 15 000 20 000 25 000 30 000
Hold-up capacitance (F)
50W
40W
30W
20W
The external capacitor supplies the energy for the DC/DC converters operation during power drop-out.
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 :
2 x P (Dt + 0.01 )
382 -VL
2
C =
where
C: is the required capacitance (in Farads)
P: is the power consumed by the DC/DC converters (in Watts)
Dt : is the required hold-up time (in seconds). 10ms are added for design margin
VL: is the 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.
10-2 Hold-up Capacitor Selection with HUGD-50 Solution
Hold up time as a function of hold up capacitance
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9
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
0,1 1 10 100 1000
8
9
10
11
12
13
14
15
16
Power fail voltage threshold versus Rth
Rth (kohms)
Power fail voltage threshold (Vdc)
10- Application Notes (continued)
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 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
0
0.5
1
1.5
2
2.5
0 500 1000 1500 2000 2500
Rcl
Input reflected charging current (A)
Vi=16V
Vi=28V
Vi=40V
0
100
200
300
400
500
600
700
800
900
0 500 1000 1500 2000 2500
Rcl
Charging rate in µs/µF
Vi=16V
Vi=28V
Vi=40V
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.
knowing that the capacitor is charged at 38VDC. The
following curve gives the resistance Rcl value as a function
of current & charging time.
10-4 Charging Current Setting : VCL
10-3 Power Fail Voltage Threshold : Vth
Input charging current as function of external resistor Rcl Input charging rate as function of external resistor Rcl
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10
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Go
+Vo
GI
VI
MGDM-series
Vcl
3
HUGD50
Go
+Vo
GI
CC
5
61
4
Vc 7
Vth
2
Vcl
PF
VI
CD
Rth Rcl
Power fail signal
Capacitor charged signal
Capacitor discharged signal
+ Input
- Input On/Off
3
PGDS50
Go
+Vo
GI
VI
5
6
2
1
4
Vimes
R*
C*
On/Off
EMI input Filter
Go
Vo
GI
VI
To help transitionning the system in the different operating
mode, GAÏA Converter recommends the use of a transi-
tion capacitor. This capacitor is used to maintain output
voltage during the HUGD-50 switching 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 :
The «power fail» output signal is activated when the vol-
tage 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 vol-
tage 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.
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.
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.
10-8 Transition Capacitor10-6 Capacitor Discharged Signal : CD
10-7 Capacitor Charged Signal : CC10-5 Power Fail Signal : PF
Output power (W)
Capacitance value (µF)
10 20 30 40 50
22 47 68 82 100
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.
10- Application Notes (continued)
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11
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
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)
Vstart
Vth
VO
Vstart
Vth
PF
VI
38V
35V
30,5V
VC
CC
CD
Vth+0,9V
Vth+4,9V
10- Application Notes (continued)
For locations, phone, fax, E-Mail see back cover
12
HUGD-50 Series
Gaia Converter FC97-027.04/12 Revision L
©
4
Hi-Rel
Grade
11- Dimensions
Dimension are given in mm (inches). Tolerance : +/- 0,2 mm (+/- 0.01 “) unless otherwise indicated.
Weight : 20 grams (0.7 Ozs) max.
14- Connections
Pin dimensions : O 0,73 mm (0.03 ”)
40
(1.58")
35,56
(1.40")
7,60
(0.30")
5 min
(0.20")
20,32
(0.80")
26
(1.03")
8
(0.32")
26,20
(1.03")
5,08
(0.20")
7,62
(0.30")
3 x 2,54
(3 x 0.10")
2,54 (0.10")
2,54
(0.10")
7,62
(0.30")
10,16
(0.40")
Bottom view
4
12 3
5
68 9
710
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)
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.
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
Represented by :
For more detailed specifications and applications information, contact :
International Headquarters
GAÏA Converter - France
ZI de la Morandière
33185 LE HAILLAN - FRANCE
Tel. : + (33)-5-57-92-12-80
Fax : + (33)-5-57-92-12-89
North American Headquarters
GAÏA Converter Canada, Inc
4038 Le Corbusier Blvd
LAVAL, QUEBEC - CANADA H7L 5R2
Tel. : (514)-333-3169
Fax : (514)-333-4519