EVAL-1000020 Evaluation Board for Demi Brick Converter and Filter Modules Advancing the Power Curve Summary ® SynQor has developed EVAL-1000020, an evaluation board to facilitate testing of our Demi brick DC-DC converters and filter modules. Introduction This application note is a guide to the features, schematic, component placement, and BOM for this evaluation board. The applicable series of modules include the Demi brick single and dual converters and Demi brick filters. 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 – Input and Output Connections Section 2 – Switches, Trim Resistors, and BNC Connectors Section 3 – Schematic Section 4 – Component Placement Section 5 – 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. Also note that the 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#065-0000048 | Rev. A | 02/06/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000020 Section 1 – Input and Output Connections Input power is applied through connector J1 as VIN+ and VIN-. Output power is applied through connector J2 as VOUT+ and VOUT RTRN. Control signals are available through connectors J1 and J2. See Tables 1 and 2 below for input power, output power, and control signals. Table 1: Input Signals (connector J1) Terminal # of Connector Signal Name 1 VIN- 2 VIN- 3 VIN- 4 SYNC-IN 5 SINC-OUT 6 ON/OFF 7 No Connection (N/C) 8 VIN+ 9 VIN+ 10 VIN+ 11 No Connection (N/C) Table 2: Output Signals (connector J2) Terminal # of Connector Signal Name 1 VOUT+ 2 VOUT+ 3 No Connection (N/C) 4 TRIM 5 SENSE- 6 SENSE+ 7 VOUT- 8 VOUT- 9 No Connection (N/C) 10 VOUT RTRN 11 VOUT RTRN Note: Please refer to the appropriate SynQor converter datasheet for descriptions of these features. Page 2 www.synqor.com | QMS#065-0000048 | Rev. A | 02/06/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000020 Section 2 – Switches, Trim Resistors, and BNC Connectors Description of Switches ON/OFF Switch ON/OFF switch SW1 provides manual on and off enable control of the converter. Toggling this switch to the “ON” position enables the converter. Toggling this switch to the “OFF” position disables the converter. Trim Switch Toggling switch SW2 to the “UP” or “DOWN” position connects the converter trim pin to the OUTPUT_RTN or OUTPUT+ pin through the trim resistors. This allows for trimming the output voltage up or down. Leaving the switch in the middle position will disable the output voltage trim function. Description of Trim Resistors Voltage Trim Fixed resistor R2 or R21 and potentiometer R4 are connected to OUTPUT_RTN and are used to adjust up the output voltage set-point of the converter. Fixed resistor R3 or R31 and potentiometer R5 are connected to OUTPUT+ and are used to adjust down the output voltage set-point of the converter. BNC Monitoring Point Descriptions VIN-FILTER Filter module positive input voltage, referenced to filter module input return VIN-CONVERTER Converter module positive input voltage, referenced to converter module input return SYNC-IN SYNC_IN synchronization input signal, referenced to converter module input return SYNC-OUT SYNC_OUT synchronization output signal, referenced to converter module input return VOUT+ Converter module positive output voltage, referenced to converter module output return VOUTConverter module negative output voltage, referenced to converter module output return Page 3 www.synqor.com | QMS#065-0000048 | Rev. A | 02/06/15 | Advancing the Power Curve Advancing the Power Curve ® | 02/06/15 | FLTR1-L FLTR1-K FLTR1-J FLTR1-I FLTR1-H FLTR1-G FLTR1-F FLTR1-E FLTR1-D FLTR1-C FLTR1-B FLTR1-A J12 J11 J10 J9 J8 J7 J6 J5 J4 J3 J2 J1 ON/OFF VOUT- CON_MOLEX_11P_300V_TB J1 11 10 9 8 7 6 5 4 3 2 1 VOUT+ VOUT- VIN- VIN+ SW1 ON/OFF C5 OPEN 6 7 8 1 9 2 VOUT- 10A F1 2 3 4 5 VIN+ 6 7 8 1 9 VOUT- VIN+ OUTPUT_RTN C4 OPEN VIN- ON/OFF SYNC_OUT SYNC_IN OPEN C9 VOUT- D21 49.9 2 3 4 5 49.9 BNC2 2 R12 1 R11 1 VIN+ VIN-CONVERTER VOUT+ OUTPUT_RTN VOUT+ PS2-L PS2-K PS2-J PS2-I PS2-H PS2-G PS2-F PS2-E PS2-D PS2-C PS2-B PS2-A PS1-J PS1-K PS1-L PS1-I PS1-H PS1-F PS1-G PS1-E PS1-D PS1-C PS1-B J1 J12 J11 J10 J9 J8 J7 J6 J5 J4 J3 J2 J1 J12 J11 J10 TRIM SNSSNS+ OUTPUT- OUTPUT+ TP2-1 TP3-1 TP1-1 TP_RTN-1 OUTPUT+ OUTPUT- OUTPUT+ OUTPUT_RTN OUTPUT- C7 OUTPUT_RTN 1.0uF C3 2 3 4 5 VOUT- 6 7 8 1 9 BNC6 C8 R31 Open 2 1 2 2 2 1 2 2 R5 R4 3 CW 3 CW 2 TRIM SW2 JP6 1 VOUT- VOUT+ C16 OPEN Input Cap OPEN C14 C15 10uF 1 1 1 JP1 2 JP3 2 JP5 2 JP6 for high output voltage Trim C17 OPEN C13 OPEN Output Cap Blue Jumper Connectors TRIM OUTPUT- OUTPUT_RTN OUTPUT+ OPEN C12 JP2 and JP3 for single output Trim/Sense Connections TRIM DOWN 1 R3 Open R2 R21 1 1 1 TRIM UP/TRIM SENSE J2 CON_MOLEX_11P_300V_TB 1 2 3 4 5 6 7 8 9 10 11 OUTPUT+ OUTPUT- 1.0uF C2 OUTPUT_RTN 6 7 8 1 9 OUTPUT+ C6 Test Points TRIM OUTPUT- OUTPUT_RTN OUTPUT+ SYNC_IN SYNC_OUT 2 3 4 5 BNC5 VOUT+ OUTPUT_RTN SNS+ JP4 2 SNS- 1 ON/OFF VOUT- VOUT+ TRIM OUTPUT_RTN J8 JP2 2 OUTPUT+ J7 6 7 8 1 9 1 SYNC_IN J6 J9 SYNC_OUT J5 VOUT- VOUT+ ON/OFF VOUT- 2 3 4 5 BNC4 SYNC-OUT J4 J3 J2 6 7 8 1 9 PS1-A 2 3 4 5 BNC3 SYNC-IN SYNC_IN BNC1 SYNC_OUT VIN- 3 2 Rev. A 1 | OUTPUT+ QMS#065-0000048 OUTPUT_RTN VOUT+ 2 R6 1 2 R9 1 2 R7 2 R8 1 | 1 www.synqor.com 1 Page 4 3 2 VIN-FILTER Application Note EVAL-1000020 Section 3 – Schematic Advancing the Power Curve - Advancing the Power Curve ® Application Note EVAL-1000020 Section 4 – Component Placement Page 5 www.synqor.com | QMS#065-0000048 | Rev. A | 02/06/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000020 Section 5 – Bill of Materials (BOM) Table 3: EVAL-1000020 Ref Des Value Tolerance Package C2 1 uF 10 % 1206 Description Capacitor, X7R, 50 V C3 1 uF 10 % 1206 Capacitor, X7R, 50 V C4 OPEN 10 % 1812 Capacitor, X7R, 2000 V C5 OPEN 10 % 1210 Capacitor, X7R, 100 V C6 4.7 uF 10 % 1206 Capacitor, X7R, 50 V C7 4.7 uF 10 % 1206 Capacitor, X7R, 50 V C8 4.7 uF 10 % 1206 Capacitor, X7R, 50 V 10 % 1210 Capacitor, X7R, 100 V 20 % 1210 Capacitor, X7R, 25 V C9 OPEN C12 OPEN C13 OPEN C14 OPEN C15 10 uF 20 % 1210 Capacitor, X7R, 25 V C16 OPEN 20 % 1210 Capacitor, X7R, 25 V C17 OPEN D21 OPEN SMC Diode, TVS, bidirectional, 1.5SMC130CA F1 10 A 2410 Fuse, R451 010. MR R2 OPEN Through-hole Resistor R3 OPEN Through-hole Resistor R4 20K 10 % R5 20K 10 % R6 OPEN Axial Zero Ohm jumper R7 OPEN Axial Zero Ohm jumper R8 0 5% 1206 Resistor R9 0 5% 1206 Resistor Capacitor, aluminum electrolytic Resistor, Trim Potentiometer, 3299Y-1-203 LF Resistor, Trim Potentiometer, 3299Y-1-203 LF R11 49.9 1% 0805 Resistor R12 49.9 1% 0805 Resistor R21 OPEN 5% 1206 Resistor R31 OPEN 5% 1206 Resistor Page 6 www.synqor.com | QMS#065-0000048 | Rev. A | 02/06/15 | Advancing the Power Curve Advancing the Power Curve ®