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CBAMTM HUL-28 Module
Features
· High energy density
· User programmable hold-up trip voltage
· Trip status indicator
· Designed for use with Calex DC/DC Converters
· Small package design (1.45" x 2.28" x 0.50")
· Excellent MTBF
· Aluminum substrate technology
· All applicable materials used are a minimum of
UL94V-0 rated. Designed to meet UL60950.
· Five year warranty
· Available with RoHS compliant construction,
simply add "(RoHS)" after the part number:
HUL-28 (RoHS)
Description
The HUL-28 is a hold-up module designed for use with
Calex DC/DC converters to protect against brown-out
and temporary power loss conditions and provide a
clean, uninterrupted source of power for downstream
circuitry. The HUL-28 is built in a small package with a
user programmable hold-up trip voltage.
Figure 1. Recommended Application
CompuMess Elektronik GmbH · Lise-Meitner-Str. 1 · D-85716 Unterschleißheim
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CBAMTM HUL-28 Module
Principles of Operation Thermal Considerations
The HUL-28 has two modes of operation: "stand-by" and In stand-by mode, the HUL-28 does not dissipate much
"tripped". During stand-by, the HUL-28 charges the hold- heat and the baseplate temperature will typically be 5ºC
up capacitor to 45V and maintains that voltage. When higher than ambient temperature in a still air environment.
tripped, the HUL-28 stops charging the hold-up capacitor When the HUL-28 transitions from tripped to stand-
and connects it to the VOUT pins. by mode and vice versa, a large amount of power is
dissipated in the HUL-28. If frequent transitions are
The mode of operation is determined by the value of the expected, care should be taken to ensure the baseplate
input voltage (+INPUT) in relation to the "trip voltage". temperature does not exceed 100ºC.
Tripped mode is entered when the input voltage drops
below a preset trip voltage. Stand-by mode is entered Caution
when the input voltage rises 2.1V above the trip voltage. After shutting off power to the HUL-28, do not handle
The trip voltage is set by the user via the VPROG pin. the circuit until the hold-up capacitor is discharged. With
no load on the output, voltages in excess of 45V may
be present on the VCAP and VOUT pins for a prolonged
period of time.
Figure 2. Internal Block Diagram
Hold-up Time
Hold-up time is dened as the maximum time that the
downstream circuitry can be powered solely from the
hold-up capacitor. In this data sheet, hold-up time is
dened as the time when the downstream circuitry is
powered solely from the hold-up capacitor and the hold-
up capacitor is charged to at least 10V. The following table
illustrates the maximum hold-up time (ms) achievable
with different capacitor congurations.
Power (W)
60 120 180
10 160ms 80ms 53ms
Capacitance
20 321ms 160ms 107ms
(mF)
30 481ms 241ms 160ms
40 642ms 321ms 214ms
50 802ms 401ms 267ms
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CBAMTM HUL-28 Module
Notes:
Input Parameters (1) All parameters measured at Tc=25ºC, Vin=28VDC,
Input Voltage MIN (3) 15.5 unless otherwise noted. Refer to the CALEX Application
TYP 28 VDC Notes for the denition of terms, measurement circuits,
MAX 36 and other information.
(2) Refer to the CALEX Application Notes for information
Input Current, hold-up capacitor
TYP 25 mARMS on fusing.
charged
(3) Minimum operating voltage is affected by the value of
Input Current while charging hold-up MIN 20 the trip voltage.
mA
capacitor MAX 350 (4) The response time is dened as the time from when the
Input Overvoltage, 100ms MAX 50 VDC input voltage drops to the trip voltage to the moment
when the output voltage "VOUT" starts rising.
Switching Frequency TYP 310 kHz (5) This capacitance includes all input capacitance on the
Reected Ripple TYP 40 mA P-P downstream circuitry: internal capacitance and Co.
(6) Isolation is measured by applying a DC voltage
Recommended Input Fuse Note (2) between pins and baseplate.
Output Parameters (7) The case thermal impedance is dened as the case
temperature rise over ambient per package watt
Hold-up Cap voltage (pin 6 and pin 7) MIN 44
dissipated.
TYP 45 VDC
(8) Thermal impedance is tested with the module mounted
MAX 46
vertically and facing another printed circuit board 1/2
Hold-up Cap Charge Rate (0-45V) s inch away.
TYP 278
F (9) Torque fasteners into threaded mounting inserts at 12
in. oz. or less. Greater torque may result in damage to
Hold-up Capacitor (Ch) MAX 50,000 µF
unit and void the warranty.
Response Time (4) TYP 5 µs (10) Calex CBAMTM modules are designed to withstand
VCAP to VOUT Voltage Drop MIN 0.6 VDC most solder/wash processes. Careful attention
should be used when assessing the applicability in
Hold-up Output Power MAX 200 W your specic manufacturing process. The CBAMTM
VOUT Voltage MIN 9.0 modules are not hermetically sealed.
VDC (11) MTBF is calculated based on MIL-HDBK-217F under
MAX 45.5
the following conditions:
Output Capacitance (5) TC 80ºC MAX 350 Reliability prediction method = Part Stress Analysis
µF
TC 100ºC MAX 170 Baseplate temperature = 40ºC
Environment = Ground, Benign
Control Parameters (12) Available with RoHS and Non-RoHS construction,
Trip Voltage VPROG = 0V MIN 21.4 contact factory for details.
VDC
TYP 22 RoHS Compliance means conformity to EU Directive
MAX 22.5 2002/95/EC of 27 January 2003, on the restriction of
the use of certain hazardous substances in electrical
VPROG Open MIN 17.5
VDC and electronic equipment, lead, cadmium, mercury,
TYP 18
hexavalent chromium, polybrominated biphenyls,
MAX 18.5
and polybrominated diphenyl ethers are not present
VPROG = 5V MIN 13 in quantities exceeding the following maximum
TYP 13.5 VDC concentrations in any homogeneous material, except
MAX 14 for applicable exemptions.
Trip Voltage Hysteresis TYP 2.1 VDC 0.1% (by weight of homogeneous material) lead,
mercury, hexavalent chromium, polybrominated
VPROG Voltage MIN 0 biphenyls, polybrominated diphenyl ethers, or 0.01%
VDC
MAX 5 (by weight of homogeneous material) cadmium.
Input Impedance TYP 24 k The RoHS marking is as follows.
Status Pin Voltage MAX 50 VDC
Status Pin Current MAX 2 mA
CompuMess Elektronik GmbH · Lise-Meitner-Str. 1 · D-85716 Unterschleißheim
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CBAMTM HUL-28 Module
Isolation
Baseplate to Input (6) MIN 700 VDC
Enviromental
Baseplate Operating Temp Range MIN -40
ºC
MAX 100
Storage Temperature Range MIN -40
ºC
MAX 120
Case Thermal Impedance (7), (8) TYP 13 ºC/Watt
MTBF MIL-STD-217F (11) TYP 365,308 h
General
Unit Weight TYP 55 g
Case Dimension 1.45" x 2.28" x 0.50"
Torque on Mounting Inserts (9) MAX 12 in. oz
Mechanical tolerances unless otherwise noted:
Pin Diameter Name X.XX dimensions: ±0.020 inches
1 0.040" GND X.XXX dimensions: ± 0.005 inches
2 0.040" STATUS
3 0.060" VPROG
4 0.060" +INPUT
5 0.060" GND
6 0.040" VCAP
7 0.040" VCAP
8 0.040" VOUT
9 0.060" VOUT
CompuMess Elektronik GmbH · Lise-Meitner-Str. 1 · D-85716 Unterschleißheim
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CBAMTM HUL-28 Module
HUL-28 Application Section
Advantages of the HUL-28 in attaining
Hold-up Time the desired hold-up time
Hold-up time, as dened earlier, depends on downstream The "bulk capacitance" method (gure A2) can be used
circuitry power draw, power loss in the HUL-28, the size to provide hold-up without using the HUL-28. However,
of the hold-up capacitor, and the initial voltage of the for any desired hold-up time, less capacitance will be
hold-up capacitor. required with the HUL-28. Furthermore, for the same
Generally, for a C farad capacitor charged to V volts, the hold-up time, the HUL-28 draws signicantly lower inrush
amount of energy available to provide hold-up is: current.
1 2 1 2
E= · C ·V · C·10
2 2
Therefore, a load drawing P watts will be supplied for t
seconds:
t = E = 1 · C · (V2-102)
P 2 P
Assuming full 45V charge in the hold-up capacitor, Figure A2.
constant power draw, and no loss in the HUL-28, the
hold-up time can be estimated by: For any given combination of capacitance and power
draw, gure A3 shows how the HUL-28 improves hold-
th = 1 · C · (452-102) up time over the bulk capacitor solution. Equivalently,
2 P for any desired hold-up time at a given load, gure A3
where th is the hold-up time in seconds. Figure A1 allows shows how many times more hold-up capacitance is
for a quick estimate of hold-up time based on hold-up required without the HUL-28.
capacitance at three levels of power draw. In the case
of a 84% efcient converter delivering 100W, the power
drawn from the HUL-28 would be 119W.
Improvement
Hold-up time (s)
Line Voltage (V)
Figure A3. Improvement in hold-up time for a given
Hold-up capacitor, Ch (mF)
combination of capacitance and power draw
Consider a Calex 24S15.10HEW converter operating
Figure A1. Hold-up time as a function of capacitance and
power draw
from a 28V bus. 100ms hold-up time is desired. The
converter is supplying a 7A, 15V load. at 86% efciency,
Note that this hold-up time can only be achieved after the the converter is drawing 122W. From gure A1, it is
hold-up capacitor has been fully charged. Therefore the estimated that 12.5mF of capacitance is required if
hold-up time is reduced or non-existent whenever the using the HUL-28. If hold-up is provided by the circuit
hold-up capacitor is not charged to 45V. This condition shown in gure A2, the hold-up capacitor only charges
is present immediately after start-up and immediately to the line voltage (28V). From gure A3, 2.8 times more
after recovering from a brown-out. Power loss due to capacitance, that is 35mF, would be required. If during
the voltage drop from VCAP to VOUT will slightly reduce normal operation, the line voltage is allowed to drop
this theoretical hold-up time. to 16V, 12 times more capacitance (150mF) would be
required. With the HUL-28, hold-up time is not affected
by line voltage.
CompuMess Elektronik GmbH · Lise-Meitner-Str. 1 · D-85716 Unterschleißheim
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CBAMTM HUL-28 Module
Trip Voltage Set-point
There are three ways to set the trip voltage for the
HUL-28.
Trip Voltage (V)
I. Connect a voltage source (0 to 5V) to VPROG to obtain
any trip voltage between 13.5V and 22V. The trip
voltage may be computed as:
VTRIP = 21.9 - 1.69VPROG
Alternately it can be estimated from gure A4.
Resistance (k)
Figure A6. Trip voltage as a function or resistance
connected between VPROG and +INPUT
Trip Voltage (V)
Figure A7. External resistor method for obtaining a trip
VPROG (V)
voltage greater than 18V
Figure A4. Trip voltage as a function of VPROG
II. For 18V trip voltage, leave VPROG open. Hysteresis
is reduced to 1.6V.
Trip Voltage (V)
III. External resistor method. This method allows the trip
voltage to be set to any value between 13.5V and 22V,
without using a separate voltage source. However,
using this method, the hysteresis is reduced to as
low as 1V, therefore stand-by mode may be entered
whenever the line voltage rises as low as 1V above
the trip voltage. Resistance (k)
a. For a trip voltage smaller than 18V, connect a resistor
Figure A8. Trip voltage as a function of resistance
between VPROG and +INPUT as shown in gure A5. connected between VPROG and GND
The trip voltage can be estimated from gure A6.
b. For a trip voltage greater than 18V, connect a resistor Follow these steps to pick a trip voltage:
between VPROG and GND as shown in gure A7. The 1. Decide on the lowest acceptable voltage for the
trip voltage can be estimated from gure A8. downstream circuitry.
2. Compute or measure the change in voltage on the
positive input of the downstream circuitry during
the 5µs HUL-28 response time. This depends on
downstream circuitry input capacitance (both internal
and external), power draw, and trip voltage.
3. To obtain the trip voltage, add the two values above
and the forward voltage drop of the input diode DI.
Figure A5. External resistor method for obtaining a trip
voltage smaller than 18V
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CBAMTM HUL-28 Module
Status Pin
Pin 2, STATUS, allows external circuitry to monitor the
state of the HUL-28 as shown in the table below. This
pin is connected to the open drain of a FET, therefore a
pull-up resistor to the logic high voltage is required for
normal operation.
Status Pin HUL-28 Status
logic low Tripped Figure A11. HUL-28 properly congured to avoid high
logic high Stand-by currents through the module
Figure A9 shows an arrangement where a TTL compatible
signal is generated at the STATUS pin. VPROG is open,
therefore the trip voltage is 18V. The voltage on +INPUT
is ramped down then up. Figure A10 shows the behavior
of the STATUS pin. Note that the HUL-28 returns to
stand-by mode only after +INPUT rises about 2V above
the trip voltage.
Figure A12a. Incorrect conguration: Hold-up current
through HUL-28
Figure A9. STATUS pin congured for TTL operation Figure A12b. Incorrect conguration: Converter current
through HUL-28
Hysteresis and Lack of Brown-out
Protection
Once the HUL-28 trips, the hold-up capacitor will not
be recharged until the input voltage rises 2.1V above
the trip voltage. If, after the HUL-28 is tripped, the input
voltage recovers but does not rise at least 2.1V over the
trip voltage, the HUL-28 will not provide any protection
from any subsequent brown-out.
Consider the following scenario: The trip voltage is
18V. The line voltage (28V) drops out for 500ms.
Uninterrupted power is provided by the HUL-28. The
Figure A10. STATUS pin operation. ch1: +INPUT voltage,
line recovers, but only to 19V. The HUL-28 remains in
ch2: STATUS voltage tripped mode, as the line voltage does not rise above
20V. Another 400ms brown-out occurs after which the
line voltage fully recovers to 28V. Since the hold-up
Ground Connection capacitor is only partially charged the HUL-28 can not
keep the load running. This is illustrated in gure A13.
There are two GND pins (1 and 5) on the HUL-28. Avoid The same experiment is repeated after setting VPROG to
running current through the module from one pin to the 3.5V for a trip voltage of 16V. The results are shown in
other. The correct conguration is shown in gure A11. gure A14.
Some incorrect congurations are presented in gures
A12a and A12b. To avoid this problem, set the trip voltage 2.1V lower
than the lowest permissible value for the line voltage.
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CBAMTM HUL-28 Module
HUL-28 Input Capacitance
Ci and Co shown in gure 1 are optional and are not
required for the proper operation of the HUL-28. Co
may be used if downstream circuitry requires external
capacitance. If the required input capacitance is greater
than the limit set by the HUL-28 output capacitance, Ci
may be used in parallel with Co to attain the desired
capacitance. When the HUL-28 is used with Calex
HEW series converters, 220µF for Ci and 40µF for Co
are recommended. Depending on operating conditions
and converter model, other values may be required.
Measurements
Figure A13. HUL-28 does not provide protection due to
high trip voltage.
Figure A15. Brown-out event
Figure A14. Lower trip voltage allows the HUL-28 to
provide protection.
Layout Issues
+INPUT connection.
Connect +INPUT directly to the anode of the input diode,
DI. This will provide the best measurement of the input
voltage.
Stray Inductance on Output.
Care must be taken to reduce stray inductance that may
be present between the hold-up capacitors, the HUL-28,
and the downstream circuitry. When HUL-28 trips, the
voltage on VOUT will suffer a step rise as large as 35V.
This will be accompanied by a 35A inrush current into
the output capacitance. Inductance present in the path Figure A16. Start of brown-out event in gure A15
of this current will cause a large voltage spike and/or
ringing on VOUT.
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CBAMTM HUL-28 Module
Figure A20. HUL-28 input current (ch4) with respect to
Figure A17. End of brown-out event in gure A15 hold-up capacitor voltage (ch1) at +INPUT = 36V
Figure A21. Typical input current ripple (ch4) while
Figure A18. HUL-28 input current (ch4) with respect to hold-up capacitor is charging (ch1)
hold-up capacitor voltage (ch1) at +INPUT = 15.5V
Figure A19. HUL-28 input current (ch4) with respect to Figure A22. Typical input ripple when HUL-28 is in stand-
hold-up capacitor voltage (ch1) at +INPUT = 28V by mode
CompuMess Elektronik GmbH · Lise-Meitner-Str. 1 · D-85716 Unterschleißheim
2401 Stanwell Drive, Concord Ca. 94520 Ph: 925-687-4411 Fax: 925-687-3333 www.calex.com Email: sales@calex.com
Telefon (089) 32 15 01 - 0 · Telefax (089) 32 15 01 - 11
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