EVAL-1000005 Evaluation Board for High Current High Voltage Isolated Converters, Full and Half Brick Advancing the Power Curve Summary ® SynQor has developed EVAL-1000005, an evaluation board to facilitate testing of our high current isolated full and half brick DC-DC converters rated for voltages up to 450 Vdc, 475 V surge 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-270, MCOTS-C-150 and the InQor (IQ), RailQor (RQ), and half brick BusQor (BQ) that are rated for voltages up to 450 Vdc, 475 V surge. 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#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000005 Section 1 – Input and Output Connections Input power is applied through connector Syn_IN9, Vin+ and Vin-. Output power is applied through connectors Syn_IN3 and Term1 Vout+, and SynIN6 and Term2 Vout-. Control signals are available through connectors SynIN2, SynIN7, and SynIN8. See Tables 1, 2 and 3 below for descriptions Table 1: Input Signal Connector (SynIN8) Terminal # of Connector Signal Name 1 SYN_IN 2 SYN_OU 3 HB_SHARE 4 +ON/OFF 5 -ON/OFF Table 2: Output Signal Connector (SynIN7) Terminal # of Connector Signal Name 1 Sense- 2 Trim 3 Sense+ Table 3: Monitor and Control Signal Connector (SynIN2) Terminal # of Connector Signal Name 1 START_SYNC 2 VO- 3 No Connection 4 VAUX 5 VO- 6 No Connection 7 PAR 8 VO- 9 No Connection 10 No Connection 11 No Connection Note: Please refer to the appropriate SynQor converter datasheet for descriptions of these features. Page 2 www.synqor.com | QMS#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000005 Section 2 – Switches, Trim Resistors, and BNC Connectors Description of Switches FB_Enable Switch This switch provides manual On/Off control of the full-brick converters. Toggling this switch to the position closest to the output power connectors will connect +ONOFF to –ONOFF and to VO-. Toggling this switch to the position closest to the input connectors will connect +ONOFF to VAUX through diode D1. HB_Enable Switch This switch provides manual On/Off control of the half-brick converters. Toggling this switch to the position closest to the output power connectors will disconnect ENABLE and allow it to float. Toggling this switch to the position closest to the input connectors will connect ENABLE to VIN-. Trim Switch Toggling this switch connects the converter trim pin to the Sense+ or Sense- pin through the trim resistors, R5 (fixed) / R11 (trim pot) or R6 (fixed) / R12 (trim pot). 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 R5 and potentiometer R11 are connected to SENSE+ and are used to adjust the output voltage set-point of the converter. Fixed resistor R6 and potentiometer R12 are connected to SENSE- are used to adjust the output voltage setpoint of the converter. The trim pot resistors R11 and R12 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 BNC1 – Test Point 6, UVLO Control Signal, full-brick jumper to TP8, half-brick jumper to TP7 VOUT – Converter Output Voltage SYN_IN1 – Sync Input SYN_IN SYN_OU1 – Sync Output SYN_OU Page 3 www.synqor.com | QMS#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000005 Section 3 – Schematic Page 4 www.synqor.com | QMS#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000005 Section 4 – Component Placement Page 5 www.synqor.com | QMS#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000005 Section 5 – Bill of Materials (BOM) Table 4: EVAL-1000005 Ref Des Value Tolerance Package Description C1 10 uF 20 % 16X25MM Cap, Alum Elec, 450 V C2 0.022 uF 10 % 1210 C3 100 uF 20 % 12.5X20MM Cap, Alum Elec, 100 V C4 100 uF 20 % 12.5X20MM Cap, Alum Elec, 100 V C5 1 uF 20 % 0805 Cap, ceramic, X7R, 50 V C6 Open 10 % 0805 Cap, ceramic, COG, 250 V, 22 pF C7 Open 10% 0805 Cap, ceramic, COG, 250 V, 22 pF C8 1 uF 10 % 0812 Cap, ceramic, X7R, 100 V C9 1 uF 10 % 0812 Cap, ceramic, X7R, 100 V C10 0.022 uF 10 % 1210 Cap, ceramic, X7R, 1000 V Cap, ceramic, X7R, 1000 V Cap, ceramic, X7R, 1000V C11 0.022 uF 10 % 1210 C12 10 uF 20 % 16X25MM C13 0.022 uF 10 % 1210 Cap, ceramic, X7R, 1000 V C14 1000 pF 10 % 1812 Cap, ceramic, 1000 V, X1/Y2 Safety Cap, 1500 VAC Withstand, 5000 V Impulse C15 1000 pF 10 % 1812 Cap, ceramic, 1000 V, X1/Y2 Safety Cap, 1500 VAC Withstand, 5000 V Impulse C16 0.022 uF 10 % 1210 Cap, ceramic, X7R, 1000V C17 1000 pF 10 % 1812 Cap, ceramic, 1000 V, X1/Y2 Safety Cap, 1500 VAC Withstand, 5000 V Impulse C18 1000 pF 10 % 1812 Cap, ceramic, 1000 V, X1/Y2 Safety Cap, 1500 VAC Withstand, 5000 V Impulse D1 600 V SMB Diode, STTH2L06U F2 5A F3 Open Fuse, Littelfuse, Maxi Blade, 80V L1 10 uH Inductor, Coiltronics, DR127-100-R L2 10 uH Inductor, Coiltronics, DR127-100-R LED1 Orange R1 49.9 1% 0805 Resistor R2 3.3K 5% 2010 Resistor R3 1.8 10 % 2010 Resistor, surge R5 Open 1% 0805 Resistor, 300 V, 200K R6 Open 1% 0805 Resistor R7 1.8 10 % 2010 Resistor, surge R8 1.8 10 % 2010 Resistor, surge R9 1.8 10 % 2010 Resistor, surge R10 1.8 10 % 2010 Resistor, surge R11 Open R12 Open R14 1.8 10 % 2010 Resistor, surge R18 3.3K 5% 2010 Resistor Page 6 www.synqor.com Cap, Alum Elec, 450 V Fuse, through-hole, radial, subminiture LED, LED0603 Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) Resistor, Trim Potentiometer, 3299Y-1-xxx LF (xxx = value) | QMS#065-0000036 | Rev. A | 02/18/15 | Advancing the Power Curve Advancing the Power Curve ®