EVAL-1000008 Evaluation Board for High Current Isolated Converters; Half, Quarter, and Eighth Brick Advancing the Power Curve Summary ® SynQor has developed EVAL-1000008, an evaluation board to facilitate testing of our high current isolated half-brick, quarter-brick and eighth-brick DC-DC converters rated to 100 V or less. Introduction This application note is a guide to the features, schematic, component placement, and BOM for this evaluation board. The applicable series of DC-DC converter modules include MCOTS-C-28/28V/28VE, MCOTS-C-48, PowerQor (PQ), InQor (IQ), RailQor (RQ), BusQor (BQ), Semi-Regulated BusQor (SQ) and CFQor (CF) rated to 100 V or less. For assistance with testing the performance of our DC-DC power converters, please refer to our application note “Guidelines for Testing SynQor DC-DC Converters”. Contents Section 1 – Evaluation Board Configuration Section 2 – Input and Output Connections Section 3 – Switches, Trim Resistors, and BNC Connectors Section 4 – Schematic Section 5 – Component Placement Section 6 – Bill of Materials (BOM) Shock Warning: There are areas of this evaluation board that have exposed access to high voltage. Exercise caution to avoid contact with those voltages. This evaluation board may retain high voltage temporarily after input power has been removed. Exercise caution when handling. Application of Input Power: Never apply input power to a converter with a switch closure, such as a knife switch or circuit breaker. That type of action applies input voltage with an uncontrolled very high rate of rise (dV/dt) that could be damaging to the converter and to external components before the converter. Instead, apply input voltage with a controlled rate of rise. Also, ensure input voltage is off before inserting or removing a converter module from the evaluation board. Thermal Considerations: When testing converters on an evaluation board, ensure adequate cooling. Apply cooling air with a fan blowing across the converter or across a heatsink attached to the converter. Monitor the converter temperature to ensure it doesn’t exceed the maximum rated per the datasheet specification. Sockets: This evaluation board uses sockets to provide the option of testing multiple converters. These sockets are not rated for continuous high currents. Short-term testing is fine, but be aware of this limitation for longerterm testing. The spring fingers in the sockets will add resistance in the power path, which will cause voltage drops at higher currents that could contribute significant errors in regulation and efficiency measurements. These spring fingers also do not provide the thermal cooling path from the module pins to PCB routing that is enabled by soldered connections. This may contribute to higher converter temperatures and error when performing thermal evaluations. For longer-term testing, thermal testing, and permanent installations use soldered connections. Page 1 www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 1 – Evaluation Board Configuration This high current evaluation board EVAL-1000008 is designed to facilitate testing of multiple types of halfbrick, quarter-brick and eighth-brick isolated DC-DC converters. Other versions of this evaluation board can be configured to facilitate testing of other DC-DC converter modules. The other evaluation board versions include EVAL-1000014, EVAL-1000018, and EVAL-1000019. The configuration of jumpers JP1, JP2, JP3, and JP4, along with some component differences determine the version of the evaluation board and which DC-DC converters are appropriate to test. A comparison of the jumper configurations is shown in Table1 below. The BOM of this evaluation board and a comparison of component differences between this evaluation board and the other versions are shown on Tables 4 and 5, respectively, in Section 6. Caution is advised if changing the jumper configurations as incorrect jumper placement may cause improper converter operation and could potentially damage the converter. Some of the electrical components on this version of the evaluation board are not appropriate for all versions of this family of evaluation boards. If changing the jumper configuration from the original then check the components on the evaluation board to ensure they are suitable for the converter being tested. See the specific application note for EVAL-1000014, EVAL-1000018, and EVAL-1000019 for detailed description of those evaluation boards, and refer to the appropriate product datasheet prior to testing a power converter module. Table 1: Evaluation Board Jumper Configurations Evaluation Board Part Number Converter Type EVAL-1000008 Isolated converters: half, quarter and eighth brick less than 100V EVAL-1000014 Jumper J3 Jumper J4 Short for local sense Short for local sense Open for remote sense Open for remote sense Open Open Non-isolated half brick converters Short for local sense Short for local sense Open for remote sense Open for remote sense Short Open EVAL-1000018 Non-isolated converters S-Version quarter and eighth brick Short for local sense Short for local sense Open for remote sense Open for remote sense Open Open EVAL-1000019 Non-isolated converters C-Version quarter and eighth brick Open Short Page 2 www.synqor.com | QMS#065-0000043 Jumper J1 Jumper J2 Open | Rev. A | 02/25/15 Open | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 2 – Input and Output Connections Input power is applied through connectors P_IN+ and P_IN-. Output power is applied through connectors P_OUT+ / J1 and P_OUT- / J2. Control signals are applied through connectors C_IN and C_OUT. See Tables 2 and 3 below for descriptions. Table 2: Input Signal Connector (C_IN) Terminal # of Connector C_IN Standard Isolated Converter Half, Quarter, Eighth Brick Full-Featured Isolated Converter Half Brick Full-Featured Isolated Converter Half Brick Zeta series (Z) 1 On/Off On/Off On/Off 2 No Connection Clock Sync No Connection 3 No Connection Start Sync Current Share + 4 No Connection Current Share Current Share - 5 Vin- Vin- Vin- Table 3: Output Signal Connector (C_OUT) Terminal # of Connector C_OUT 1 2 3 Standard & Full Featured Isolated Converter Sense + Voltage Trim Sense - Note: Please refer to the appropriate SynQor converter datasheet for descriptions of these features. Page 3 www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 3 – Switches, Trim Resistors, and BNC Connectors Description of Switches Enable On/Off Switch Moving this switch to the ON (N) position enables “N” type negative on/off logic converters. Moving this switch to the ON (P) position enables “P” type positive on/off logic converters. The enable signal is connected to the input control connector (C_IN) for remote access. Voltage Trim Switch For the isolated converters, moving this switch to the “Up” or “Down” position connects the converter trim pin to Vout+ or Vout- pin through the trim resistors, R1-R4. This allows for trimming the output voltage up or down by adjusting the trim resistors. Leaving the switch in the middle position will disable the output voltage trim function. Description of Trim Resistors Voltage Trim Fixed resistor R1 and potentiometer R2 are used to adjust up the output voltage set-point of the non-isolated converter. Fixed resistor R4 and potentiometer R3 are used to adjust down the output voltage set-point of the non-isolated converter. The trim resistors R1 through R4 are not populated in this evaluation board. This is to allow the user to determine and install the needed trim resistance values based on the range of desired output voltage adjustment of the module being evaluated. BNC Monitoring Point Descriptions VIN – Converter Input Voltage VOUT – Converter Output Voltage VSENSE – Output Sense Voltage VRIPPLE – Output ripple voltage measurement point. Use this BNC with AC coupling on the oscilloscope. Page 4 www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 4 – Schematic Page 5 www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 5 – Component Placement Page 6 www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000008 Section 6 – Bill of Materials (BOM) Table 4: EVAL-1000008 Ref Des Value Tolerance Package Description C1 270 uF 20 % 16X35MM Cap, Alum Elec, 220 V C2 1 uF 10 % 1812 Cap, ceramic, X7R, 100V C3 1 uF 10 % 1812 Cap, ceramic, X7R, 100V (on bottom of PCB) C4 1 uF 10 % 1812 Cap, ceramic, X7R, 100V (on bottom of PCB) C5 1 uF 10 % 1812 Cap, ceramic, X7R, 100V (on bottom of PCB) C6 1 uF 10 % 1812 Cap, ceramic, X7R, 100V (on bottom of PCB) C7 OPEN 16X35MM C8 OPEN 1812 Cap, ceramic C9 OPEN 0805 Cap, ceramic (on bottom of PCB) C10 OPEN 0805 Cap, ceramic (on bottom of PCB) Cap, Alum Elec C11 OPEN 0805 Cap, ceramic (on bottom of PCB) C12 OPEN 0805 Cap, ceramic (on bottom of PCB) D1 120 V DO-201 TVS, axial, 1.5KE120A F1 40 A JP1 SHORT Fuse, Littelfuse, Maxi Blade, 80V, 166.6885.5401 Jumper JP2 SHORT Jumper JP3 OPEN Jumper JP4 OPEN Jumper L1 1 uH R1 OPEN 20 % Resistor, ¼ W, through-hole R2 OPEN Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) R3 OPEN Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) R4 OPEN Resistor, ¼ W, through-hole R5 49.9 R6 OPEN Resistor, ¼ W, through-hole R7 OPEN Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) R8 OPEN Resistor, ¼ W, through-hole R9 OPEN Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) 1% Inductor, SMT, Coilcraft, SER2010-102ML 0805 Resistor (on bottom of PCB) Table 5: Component Differences of Evaluation Board Versions Page 7 Ref Des EVAL-1000008 EVAL-1000014 EVAL-1000018 EVAL-1000019 C7 OPEN 270 uF 270 uF 270 uF F1 40 A 50 A 50 A 50 A JP1 SHORT or OPEN SHORT or OPEN SHORT or OPEN OPEN JP2 SHORT or OPEN SHORT or OPEN SHORT or OPEN OPEN JP3 OPEN SHORT OPEN OPEN JP4 OPEN OPEN OPEN SHORT L1 1 uH 0.3 uH 0.3 uH 0.3 uH R1 OPEN 220 220 220 R2 OPEN 200K 200K 200K R6 OPEN 560 OPEN OPEN R7 OPEN 100K OPEN OPEN R8 OPEN OPEN OPEN 560 R9 OPEN OPEN OPEN 100K www.synqor.com | QMS#065-0000043 | Rev. A | 02/25/15 | Advancing the Power Curve Advancing the Power Curve ®