Hi-Rel PRE-REGULATOR MODULE PGDS-50 : up to 50W POWER

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John Norton
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PRE-REGULATOR MODULE PGDS-0 : up to 0W POWER Brown-outTransient 10-80V or 6-100V Protection Module DO-160, MIL-STD-70, MIL-STD-127 Metallic Case Transient suppressor module 80V MIL-STD-70ADEF,

1 PRE-REGULATOR MODULE PGDS-0 : up to 0W POWER Brown-outTransient 10-80V or 6-100V Protection Module DO-160, MIL-STD-70, MIL-STD-127 Metallic Case Transient suppressor module 80V MIL-STD-70ADEF, EN2282, AIR2021E DO160D cat A, B and Z Transient suppressor module 100V MIL-STD-127AB, Extended operation for voltage drop out and cranking down to 6V Power range : from W to 0W Inhibition function RoHS or Leaded process 1- General The GAIA Converter pre-regulator PGDS-0 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-0 delivers an output voltage adapted to GAIA Converter DCDC modules. This line of module is optimized to provide high power efficiency up to 96% over the whole power range between W and 0W. The PGDS-0 features 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 DCDC converter ; then the PGDS-0 operates in «boost» mode to provide an output voltage compatible with DCDC converter. The PGDS-0 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. 2- Product Selection Normal operation : Normal operation occurs between the permanent input voltage of DCDC converter; The module is then operating in steady transparency state. Transient operation : The PGDS-0 series clamps input transient up to 80V100ms or 100V0ms. The PGDS-0 series is compliant with the international input bus standards : - MIL-STD-70ADEF - AECMA EN GAM-EG13BAIR2021E - DO160D cat A, B and Z - MIL-STD-127AB 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. PGDS input output option suffix Input Voltage Range Output Brown-out - Transient N : 10V30s - 80V100ms O : 6V1s - 100V0ms K Options : Suffix : T : option for - C start up operating temperature nothing : RoHS process S : option for screening and serialization -L : leaded process (available in N. America) REDEFINING THE SOURCE OF POWER Gaia Converter FC Revision J

2 3- Block Diagram The PGDS-0 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 38. 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-0 series features modes of operations : Power fail operation Low line operation Normal operation Transient & surge operation The following figure represents the PGDS-0 series block diagram while the table hereafter describes the circuitry activation depending on the modes of operations. PGDS-0 Block Diagram 6µH Vin Active Clamping Vo Vimes 2µF 19µF On Control Circuit Boost Function Gin Go PGDS-0 Modes of Operation Modes of Operation Control Circuit Boost Circuit Active Clamping Circuitt Power Fail Operation Low Line Operation On On Normal Operation On Transient & Surge Operation On On Gaia Converter FC Revision J 2

3 - Modes of Operation -1 PGDS-0-N-K Modes of Operation The PGDS-0-N-K operates with J input (i.e 16-0) family of GAIA Converter DCDC Converters. The PGDS-0-N-K features 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 DCDC converter i.e 16. The PGDS-0-N-K then operates in boost mode to provide an output voltage compatible with the DC DC converter. The PGDS-0-N-K series can sustain low line operation down to 10V during 30 sec. 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 DCDC converter; The module is then operating in steady transparency state. Transient operation : The PGDS-0-N-K clamps input transient up to 80V as long as 100ms. output voltage () 0 37, 3 32, 30 27, 2 22, 20 17, 1 12, 10 7, 2, Power fail Low line operation operation PGDS-0-N-K Transfert Function Normal operation Input voltage () Transient and spike operation Parameter Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation output power at 10V@30sec U nit M in. T yp. Max. W 11,2 8,80 16,30 16,0 12 9, ,2 36 Notes, conditions Normal operation : output power W 0 Transient & Surge Operation : output power at 80V100ms W 0 Gaia Converter FC Revision J 3

4 - Modes of Operation (continued) -2 PGDS-0-O-K Modes of Operation The PGDS-0-O-K operates with H input (i.e 9-36) family of GAIA Converter DCDC Converters. The PGDS-0-O-K features 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 DCDC converter i.e 9. The PGDS-0-O-K then operates in boost mode to provide an output voltage compatible with the DC DC converter. The PGDS-0-O-K series can sustain low line operation down to 6V during 1 sec. 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 DCDC converter; The module is then operating in steady transparency state. Transient and spike operation : The PGDS-0-O-K clamps input transient up to 100V as long as 0ms. PGDS-0-O-K Transfert Function output voltage () 37, 3 32, 30 27, Power fail 2 operation 22, 20 17, 1 12, 10 7, 2, Low line operation Input voltage () Parameter Power Fail Operation : Undervoltage Lockout On Undevoltage Lockout Normal operation Low Line Operation : Voltage Low Line Operation On Voltage Low Line Operation output power 6V@1s U nit M in. T yp. Max. W,3,12 11,0 11,70 Transient and spike operation,6,38 11,80 12,00 30 Notes, conditions Normal Operation : output power W 0 Transient & Surge Operation : output power at 100V0ms W 30 Gaia Converter FC Revision J

5 - Electrical Specifications Data are valid at +2 C, unless otherwise specified. Parameter Input Compatible module Under voltage lockout (UVLO) Start up time Permanent input voltage range (Ui) in normal operation Compliance with standards voltage drop-out limit in low line operation Compliance with standards voltage transient limit Conditions J series of DCDC module H series of DCDC module Turn-on voltage Turn-off voltage Ui min. to max. No load to full load Full temperature range Full load Full temperature range Full temperature range Limit or typical Typical Typical Units PGDS-0-N-K PGDS-0-O-K J series 12 9 H series 6,6 ms 1 1 MIL-STD-70A AECMA EN2282 AIR2021E DO160D cat ABZ MIL-STD-127AB MIL-STD-70A AECMA EN2282 AIR2021E DO160D cat AZ MIL-STD-127AB s 10V0ms 12V30ms 12V0ms 10V1s 6V1s ms s 80V7ms 60V0ms 60V100ms 80V100ms 100V0ms V30s Not compliant 80V100ms 8V1s Not compliant V1s 100V0ms 8V1s Compliance with standards voltage spike limit *with companion filter FGDS series 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 0 Ohms impedance 0 Ohms impedance 0 Ohms impedance 0 Ohms impedance 1 mj energy content Ui min. to max. Full load In low line Input voltage In transient Input voltage Ui = 28 Full load MIL-STD-70A AECMA EN2282 AIR2021E DO160D cat AZ MIL-STD-127AB 600V10µs 00V100µs 600V10µs 600V10µs 20V70µs * * * * Not compliant * * * * * ma Nominal Ui - 0,6 Ui - 0,6 Nominal Nominal figure 1 figure 3 figure 2 see page figure % Output power range Full temperature range In low line operation In transient operation W W W figure figure 6 Gaia Converter FC Revision J

6 - Electrical Characteristics (continued) Figure 1 : PGDS-0-N-K Brown-Out Response at 10 Figure 2 : PGDS-0-O-K Brown-Out Response at 6 Figure 3 : PGDS-0-N-K Transient Response at 80 Figure : PGDS-0-O-K Transient Response at 100 Figure : PGDS-0-N-K Output Power versus Input Voltage Figure 6 : PGDS-0-O-K Output Power versus Input Voltage Pout (W) Pout max Pout min Pout (W) Pout max Pout min Vin () Vin () Gaia Converter FC Revision J 6

7 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 00 KHz 7- Isolation Parameter Electric strength test voltage Conditions Input to output Input to case Output to case Limit or typical Specifications No isolation min min Isolation resistance MOhm 8- Protection Functions Characteristics Protection Device Recovery Input undervoltage lock-out (UVLO) Turn-on, turn-off circuit with hysteresis Automatic recovery Limit or typical Specifications Typical see section 9- Reliability Data Characteristics Conditions Temperature Specifications Mean Time Between Failure (MTBF) According to MIL-HDBK-217F Ground fixed (Gf) Airborne, Inhabited, Cargo (AIC) Case at 0 C Case at 8 C Case at 0 C Case at 8 C Hrs Hrs Hrs Hrs Mean Time Between Failure (MTBF) According to IEC TR Civilian avionics, calculators Ambient at C 100% time on Consult factory Gaia Converter FC Revision J 7

8 10- Thermal Characteristics Characteristics Conditions Limit or typical Performances Operating ambient temperature range at full load Operating case temperature range at full load Storage temperature range Thermal resistance Ambient temperature * Case temperature Non functionning Rth case to ambient in free air natural convection Note * : The upper temperature range depends on configuration, the user must assure a max. case temperature of + 10 C. - 0 C + 8 C - 0 C +10 C - C + 12 C Typical 12 C W The PGDS-0 series operating case temperature at full load must not exceed 10 C. The maximum ambient temperature admissible for the DCDC converter corresponding to the maximum operating case temperature of 10 C depends on the ambient airflow, the mountingorientation, 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 = 10 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(1η - 1) determine the maximum ambient temperature : Ta = 10 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 10 C at full load (white area in the following graph). Power (W) 100% 7% Additionnal cooling operation area 0% 2% Natural convection operation area Temperature ( C) Full load ambient temperature without derating : 8 C case temperature : 10 C storage temperature : 12 C Gaia Converter FC Revision J 8

9 11- Environmental Qualifications The modules have been subjected to the following environmental qualifications. Characteristics Conditions Severity Test procedure Climatic Qualifications Life at high temperature Altitude Humidity cyclic Humidity steady Salt atmosphere Temperature cycling Temperature shock Temperature status of unit Altitude level C Climb up Stabilization Number of cycle Cycle duration Relative humidity variation Temperature variation Damp heat Temperature Temperature Concentration NaCl Number of cycles Temperature change Transfert time Steady state time Number of shocks Temperature change Transfert time Steady state time Test D : C case, unit 12 C ambient, ft@- C 30 min ftmin to ft@- C, 30 min. unit operating 10 Cycle I : 2 Hrs 60 % to 88 % 31 C to 1 C 93 % relative humidity 0 C 6 days 3 C % 8 Hrs C +8 C 0 min. 20 min. unit operating C +10 C 10 sec. 20 min. MIL-STD-202G Method 108A MIL-STD-810E Method 00.3 MIL-STD-810E Method 07.3 MIL-STD-202G Method 103B MIL-STD-810E Method 09.3 MIL-STD-202A Method 102A MIL-STD-202G Method 107G Mechanical Qualifications Vibration (Sinusoidal) Shock (Half sinus) Bump (Half sinus) Number of cycles Frequency amplitude Frequency acceleration Number of shocks Peak acceleration Shock form Number of bumps Peak acceleration 10 cycles in each axis 10 to 60 Hz 0.7 mm 60 to Hz 10 g 2h 30 min. per axis 3 shocks in each axis 100 g 6 ms 12 sinusoidal Bumps in each axis 0 g 6 ms MIL-STD-810D Method 1.3 MIL-STD-810D Method 16.3 MIL-STD-810D Method 16.3 Gaia Converter FC Revision J 9

10 12- Application Notes 12-1 Reverse Polarity Compatibility The PGDS-0 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 On Function The control pin 3 (On) can be used for applications requiring On 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. Command 100K 3 On Gi 12-3 EMI Compatibility with MIL-STD-61C and MIL-STD-61DE The PGDS-0 series includes a π EMI filter to attenuate ripple and noise. To meet MIL-STD-61C and MIL-STD-61DE requirements, GAIA Converter recommends the use of an external filter (see section 12- Typical Schematics and EMI filters design notes for details). 12- VIMES Signal The VIMES signal is used to sense the input bus voltage and depending on the achieved level, to drive the mode of operation of the PGDS-0. Due to possible oscillation caused by surge or fast transients on the bus line, it is recommended to implement an R*C* 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- Typical Schematics). If no RC filter is used, connect pin VIMES to pin Vi. 12- Typical Schematics The PGDS-0 series is suitable to be used with several DCDC GAIA converter modules in various configurations as follow : R* VI +Vo + Input VI Vo C* 1 VI 2 Vimes +Vo 6 MGDM-series GI Go EMI input Filter PGDS0 VI +Vo MGDM-series - Input GI Go GI On 3 Go GI Go VI +Vo MGDM-series On GI Go Note * : Typical value of resistor R* is : 70 Ohm, typical value of capacitor C* is : 1 µf Please consult EMI filters datasheet for further details on EMI. Gaia Converter FC Revision J 10

11 13- Dimensions Dimension are given in mm (inches). Tolerance : +- 0,2 mm ( ) unless otherwise indicated. Weight : 20 grams (0.7 Ozs) max. 0 (1.8") 26 (1.03") 7,90 (0.30") 8 (0.32") min (0.20") 26,20 (1.03") 3,6 (1.0") Pin dimensions : O 0,73 mm (0.03 ) 8,89 (0.3") 20,32 (0.80") 8,89 (0.3") 1- Materials Case : Metallic black anodized coating. Pins : Plated with pure matte tin over nickel underplate. 1- Product Marking Upper face : Company logo, location of manufacturing. Side face : Module reference : PGDS-0-»X»-»Y». Date code : year and week of manufacturing, suffix, option. 16- Connections 6 Pin PGDS Input (Vi) 2 Input measure (VIMES) 3 On - Input (Gi) Common (Go) Output (Vo) Bottom view Gaia Converter FC Revision J 11

For more detailed specifications and applications information, contact : International Headquarters GAÏA Converter - France ZI de la Morandière 3318 LE HAILLAN - FRANCE Tel.

12 For more detailed specifications and applications information, contact : International Headquarters GAÏA Converter - France ZI de la Morandière 3318 LE HAILLAN - FRANCE Tel. : + (33) Fax : + (33) Represented by : North American Headquarters GAÏA Converter Canada, Inc 038 Le Corbusier Blvd LAVAL, QUEBEC - CANADA H7L R2 Tel. : (1) Fax : (1) 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 FC Revision J. Graphisme : Philippe Clicq

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