EVAL-1000018

EVAL-1000018
Evaluation Board for High Current
Non-Isolated Quarter and Eighth Brick
Converters, S-Version
Advancing the
Power Curve
Summary
®
SynQor has developed EVAL-1000018, an evaluation
board to facilitate testing of our high current,
non-isolated standard-version quarter and eighth brick
DC-DC converters.
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 the S-Version NQ20, NQ40 and NQ60 series.
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.
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Rev. A
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Advancing the Power Curve Advancing the
Power Curve
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Application Note
EVAL-1000018
Section 1 – Evaluation Board Configuration
This high current evaluation board EVAL-1000018 is designed to facilitate testing of our standard feature quarter and eighth brick, non-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 EVAL1000008, EVAL-1000014, 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-1000008, EVAL-1000014, 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
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Jumper
J1
Jumper
J2
Open
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Rev. A
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02/06/15
Open
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Advancing the Power Curve Advancing the
Power Curve
®
Application Note
EVAL-1000018
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
High Voltage NiQor
Quarter and Eighth Brick
1
On/Off
2
No Connection
3
No Connection
4
No Connection
5
Vin-
Table 3: Output Signal Connector (C_OUT)
Terminal # of Connector
High Voltage NiQor
C_OUT
Quarter and Eighth Brick
S-Version
1
Sense +
2
Voltage Set
3
Sense -
Note: Please refer to the appropriate SynQor converter datasheet for descriptions of these features.
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Advancing the Power Curve Advancing the
Power Curve
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Application Note
EVAL-1000018
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
Moving this switch to the “Down” position allows the output voltage of the non-isolated converters to be
adjusted by R1 and R2.
Description of Set-Point Adjustment Resistors
Voltage Set-Point Adjustment
Fixed resistor R1 and potentiometer R2 are used to adjust the output voltage set-point of the non-isolated
converter.
BNC Monitoring Point Descriptions
VIN – Converter Input Voltage
VOUT – Converter Output Voltage
VSENSE – Output Sense Voltage
Note: Do not connect to this BNC when evaluating quarter and eighth brick high-voltage NiQors
with adjustable current limit (C-version)
VRIPPLE – Output ripple voltage measurement point. Use this BNC with AC coupling on the oscilloscope.
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Advancing the Power Curve Advancing the
Power Curve
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Application Note
EVAL-1000018
Section 4 – Schematic
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Advancing the Power Curve Advancing the
Power Curve
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Application Note
EVAL-1000018
Section 5 – Component Placement
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Advancing the Power Curve Advancing the
Power Curve
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Application Note
EVAL-1000018
Section 6 – Bill of Materials (BOM)
Table 4: EVAL-1000018
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
270 uF
20%
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, 220V
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
50 A
JP1
SHORT
Fuse, Littelfuse, Maxi Blade, 80V, 166.6885.5501
Jumper
JP2
SHORT
Jumper
JP3
OPEN
Jumper
JP4
OPEN
Jumper
L1
0.3 uH
R1
220
20 %
Inductor, SMT, Coilcraft, SER2010-301ML
R2
200 k
Resistor, Trim Potentiometer, 3299Y-1-204 LF
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)
Resistor, ¼ W, through-hole
1%
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
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Rev. A
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Advancing the Power Curve Advancing the
Power Curve
®