10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THE HIGH-BOOST HARMONIC ATTENUATOR MODULE COMPATIBLE WITH V375, VI-26x AND VI-J6x FAMILIES The HAMD version does not contain an internal bridge rectifier and is intended for configuring higher power arrays with Booster versions, referred to as the VI-BAMD (Figure 10–5). Rectifier AC Line ZCS Boost Converter Inrush & Short Circuit Protection Current Sense Voltage Waveform High Frequency Control Output Voltage Control Module Enable & Housekeeping Power OK Circuitry Gate In Gate Out + DC Out – Note: Non-Isolated Output Aux. Supply Figure 10–1 — HAM block diagram (HAMD version has the rectifier block deleted.) Page 48 of 88 700 400 650 375 350 600 550 derate output power 11 W/V for Vin <110 Vac 325 500 300 450 275 400 85 95 105 115 125 135 145 155 165 175 185 195 205 215 225 235 245 255 265 110 Input Voltage VRMS 250 Rated Output Power Output Voltage Figure 10–3 — Output voltage and power rating vs. input voltage L1 and L2/N (HAM) Pin. An appropriate line filter is required to limit conducted emissions and ensure reliable operation of the HAM, see page 51. Connect single phase AC mains to the input of the line filter via a 10 A, 250 V fuse. Connect the output of the filter to L1 and L2/N of the HAM. Do not put an X-capacitor across the input of the HAM or use a line filter with an X-capacitor on its output as power factor correction may be impacted. +IN, –IN (HAMD, BAMD) Pin. These pins are connected to the output of the external bridge rectifier in HAMD / BAMD configurations (Figure 10–5). GATE IN (HAM) Pin. The user should not make any connection to this pin. NOTE: No input to output isolation. Maxi, Mini, Micro Design Guide 425 Output Voltage (Vdc) The output voltage of the HAM is a function of incoming AC line voltage (Figure 10–3). On a nominal 115 Vac line, the output voltage of the HAM is 280 Vdc — well within the input operating voltage range of Vicor V375 DC-DC converters. Above 180 V input, the output voltage linearly increases with input voltage. At 230 Vac the delivered voltage will be approximately 365 V. For any given input line voltage, the HAM maintains enough headroom between the output voltage and peak input voltage to ensure high quality active power factor correction without sacrificing operating efficiency. Figure 10–2 — Input voltage and current wave forms, without and with power factor correction. Output Power (W) The High-Boost Harmonic Attenuation Module (HAM) consists of a full-wave rectifier, a high-frequency zerocurrent-switching (ZCS) boost converter, active inrush current limiting, short-circuit protection, control, and housekeeping circuitry (Figure 10–1). The incoming AC line is rectified and fed to the boost converter. The control circuitry varies the operating frequency of the boost converter to regulate and maintain the output voltage of the HAM above the peak of the incoming line, while forcing the input current to follow the waveshape and phase of the line voltage. A power factor better than 0.99 is achieved (Figure 10–2). Operating efficiency of the boost converter is optimized at any incoming line voltage by an adaptive output voltage control scheme. GATE IN (HAMD) Pin. This pin provides line voltage envelope and phase information for power factor correction. This connection must be made through the synchronization diodes between the line filter and bridge rectifier (Figure 10–5). Rev 4.9 Apps. Eng. 800 927.9474 vicorpower.com 800 735.6200 10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies GATE IN (BAMD) Pin. The Gate In pin is an interface pin to the Gate Out pin of a HAMD or BAMD depending on configuration. The user should not make any other connection to this pin. GATE OUT Pin. The Gate Out pin is a synchronization pin for HAMD/BAMD arrays; the user should not make any other connection to this pin. +OUT and -OUT Pin. Connect the +OUT of the HAM to the +IN of the respective Vicor DC-DC converters with the recommended fuse. Connect the -OUT of the HAM to the -IN of the converters. In addition, an external hold-up capacitor of 1,000 µF with a minimum voltage rating of 450 Vdc, is required (across the output of the HAM) for 16 ms ride through time at full power (500 µF for half power, etc). This capacitor must be in close proximity to the HAM. Do not exceed 3,000 µF of total output capacitance. Lower values of capacitance may be used for reduced hold up requirements, but not less than 500 µF. Lower capacitance values may degrade power factor specifications. Auxiliary Supply (A/S) Pin. The HAM provides a low voltage non isolated output Auxiliary Supply (A/S) that may be used to power primary side control and monitoring circuitry. This output is 19 – 23 Vdc, referenced to -OUT, at 3 mA max. Do not overload or short this output as the HAM will fail. A typical use for A/S is to power an optical coupler that isolates the Power OK signal (Figure 10-6). Enable Output (E/O) Pin. The Enable Output (E/O) is used to inhibit the DC-DC converters at start up until the hold up capacitors are charged, at which time Enable is asserted high (open state, Figure 10–8). If the AC line fails, E/O goes low when the DC output of the HAM drops below 250 Vdc. E/O must be connected to the Gate Input of all VI-26x and VI-J6x drivers and/or the PC pin of the V375 DC-DC converters (Figure 10-4); failure to do so may cause the converters to toggle on and off. If an external load is connected directly to the output of the HAM, do not apply the load until the output hold up capacitor(s) are fully charged. In applications using VI-26x drivers and VI-26x boosters, the E/O pin should be connected to the Gate In pin of the driver module only, it is not necessary to connect this pin to boosters as they are controlled by their respective driver. The E/O pin ancillary circuitry illustrated in Figures 10–4 and 10–5 provides transient immunity. The illustrated circuitry is the minimum required, see Figures 10–4 and 10–5. Power OK (P/OK) Pin. Power OK is a monitor signal that indicates the status of the AC mains and the DC output voltage of the HAM. P/OK is asserted (active low) when Maxi, Mini, Micro Design Guide Page 49 of 88 the output bus voltage is within normal operating range (>270 Vdc) and 20 – 25 ms after DC-DC converters are enabled by the E/O signal of the HAM. This provides sufficient time for the converters to turn on and their output(s) to stabilize prior to P/OK being asserted, (Figure 10–9). For momentary interruptions of AC power, the HAM will provide at least 16 ms of ride through or hold up time (with 1,000 µF output capacitor). On loss of power or brownout, (when the HAM output voltage drops below 270 Vdc) the P/OK signal will go to an open circuit state (Figure 10–7), signaling an impending loss of input power to the converter modules. P/OK will provide power fail warning at least 1 ms prior to converter shut down. When the HAM output voltage drops below 250 Vdc the converters are disabled via Enable Output (E/O). NOTE: Acoustic Noise. Audible noise may be emitted from the module under no load, light load, or dynamic loading conditions. This is considered normal operation of the module. SAFETY NOTES Each HAM, HAMD or BAMD module must be preceded by a safety agency recognized fast-blow 10A 3AG fuse. The HAM is not isolated from the line – either input or output; a line isolation transformer must be used when making scope measurements. HAMs do not provide input to output isolation. Differential probes should be used when probing the input and output simultaneously to avoid destructive ground loops. PROTECTIVE FEATURES Over Temperature Shut Down. The HAM is designed to shut down when the temperature of the baseplate exceeds 90 °C. Do not operate the HAM above its maximum operating temperature of 85°C. Short Circuit Protection. The HAM contains output short circuit protection. Operation of this function does not clear the input fuse and the output will resume normal operation after removal of the fault. A short period of time may be required to allow for cooling of an internal temperature sensor. Output Over Voltage Protection. The HAM contains output over voltage protection. In the event the output voltage exceeds approximately 420 Vdc, the boost will decrease to maintain 420 Vdc on the output. When the peak of the AC line exceeds 420 V (approximately 293 Vac) the boost will have been reduced to zero and the E/O line will be pulled low shutting down the converters. Beyond this the protection circuit will be enabled and the output voltage will decrease. Rev 4.9 Apps. Eng. 800 927.9474 vicorpower.com 800 735.6200 10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies F3 C5 V1 F1 L1 L1 GND GATE IN R1 R2 R3* D1 D2, D3 D4, D5 V1 C5–C8 F1, F2 F3 L2/N +IN P/OK E/O A/S VI-HAM-xL GATE OUT L2/N D2 R2 R1 C1 PR C2 D1 Description V375 DC-DC Converters PC D4 -IN – OUT C6 LOAD LINE Component Designation C1 C2, C3 C4 L1 Vicor Line Filter P/N 30205 6.3 A L2/N + OUT Y-Capacitor Vicor Part Number 0.1 µF ceramic, 50 V 0.01 µF ceramic, 50 V Hold up capacitor, 500 to 3,000 µF C7 F2 Available as a HUB from Vicor (see adjoining table) 50 KΩ 250 Ω, 0.25 W 100 KΩ, 2 W 1N4691 zener, 6.2 V 1N4006 diode, 800 V 00670 1N5817 schottky diode, 20V 26108 275 V MOV 30076 4,700 pF Y2 cap. 01000 Use recommended fusing for specific DC-DC Converters 10 A, 250 V +IN D3 G ATE IN D5 C4 R3* C3 G ATE OUT VI-26x or VI-J6x DC-DC Converters -IN C8 Y-Capacitor Hold up Box (HUB) µF µF µF Figure 10–4 — Connection diagram HAM / DC-DC converter V375 DC-DC Converters C5 10 A F1 +IN F3 JMK Filter Input V1 P/OK E/O VI-HAMD-xL GATE OUT A/S L1 L1 GND 1N4006 P/N 1319-13 12.6 A* 1N4006 L2/N L2/N -IN Z1 Z2 +IN +OUT GATE IN Bridge Rectifier Vicor P/N 30660 R2 D2 R1 C1 C9 C2 D1 D4 C6 C7 Z3 10 A F2 +IN +OUT C10 R3 D3 PC GATE IN C5–C8 C9,C10 D1 D2, D3 D4, D5 F1, F2 F3 R1 R2, R3 R4** V1 Z1, Z2 Z3 Description 0.1 µF ceramic, 50 V 0.01 µF ceramic, 50 V Hold up capacitor, 1000 to 6000 µF VI-BAMD-xL Vicor Part Number C4 GATE OUT -IN ** C3 D5 R4 -OUT Available as a HUB from Vicor (see adjoining table) 01000 Film or Ceramic 4,700 pF Y2 cap. 0.2 µF, 500 V 1N4691 zener, 6.2 V 1N4006 diode, 800 V 00670 1N5817 schottky diode, 20 V 26108 Use recommended fusing for specific DC-DC Converters 20 A, 250 V 50 KΩ 250 Ω, 0.25 W 100 KΩ, 2 W 275 V MOV 30076 130 V Transorb 1.5KE130CA 150 V Transorb 1.5KE150CA Page 50 of 88 PR -IN C8 * Consult Vicor's Applications Engineering for specific HAMD / BAMD filtering information. ** A 100 KΩ, 2 W resistor is used for every 1,000 µF of hold up capacitance. Hold up Box (HUB) 2000 µF HUB1000-P 1350 W Figure 10–5 — Connection diagram, HAMD / BAMD / V375 DC-DC converters HAMD-CL Driver HAM: No internal bridge rectifier or synchronization diodes. BAMD-CL Booster HAM: Companion module to HAMD-CM used for additional output power. No internal bridge rectifier. Maxi, Mini, Micro Design Guide PR -IN -OUT +IN Component Designation C1 C2, C3 C4 PC Rev 4.9 Apps. Eng. 800 927.9474 vicorpower.com 800 735.6200 10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies +OUT P/OK E/O + A/S – –OUT DO NOT OVERLOAD or directly connect a capacitor to the A/S terminal. IAS ≤ 3 mA +OUT 19 – 23 V D "Power OK" Status Low = OK P/OK E/O G LOGIC S +OUT A/S –OUT P/OK 18 kΩ, 1/4 W E/O A/S –OUT Figure 10–6 — Auxiliary Supply (A/S) Figure 10–7 — Power OK (P/OK) AC Mains 120 Vrms DC Output of HAM +OUT G 270 Vdc 250 Vdc Off at 250 Vdc Enable Output (E/O) E/O D S Boost Voltage Rectified Line P/OK LOGIC 280 Vdc A/S 25 ms Off at 270 Vdc Power OK (P/OK) –OUT 10 ms Outputs DC-DC Converter(s) Figure 10–8 — Enable Output (E/O) Off below 250 Vdc Figure 10–9 — Start-up / shut-down timing diagram For applications using HAMD + BAMD or where the user desires to construct a custom HAM filter, the filter should be designed following Figure 10–10, the schematic of Vicor’s P/N 30205 filter. The current carrying capability of the inductors must be scaled proportionally to the number of HAM modules used. Inductance values must be selected according to Table 10–1. These limits are to ensure proper operation of the HAM and do not guarantee a system will meet conducted emissions specifications. For applications requiring magnetic field shielding, do not place a ferrous EMI shield over the plastic cover of the HAM module. This can cause thermal problems due to induction heating effects. Maxi, Mini, Micro Design Guide Page 51 of 88 MOV* P/N 30076 R Cx CM DM Cy D1 Cy D3 D2 LOAD A line filter is required to provide attenuation of conducted emissions generated by the HAM module and to protect it from line transients. It also presents a well defined high frequency AC line impedance to the input of the HAM. To meet the listed specifications, Vicor’s P/N 30205 line filter/transient suppressor or equivalent must be used, see Figure 10–10. The addition of a MOV external to this filter is required to meet normal mode transient surge requirements. LINE LINE FILTER FOR HIGH BOOST HAM HAM Filter P/N 30205 Cx = 1.5 uF(x2)SH Cy = 0.01 uF, Y2 type LC = 6.9 mH LD = 0.72 mH R = 235 KΩ D1,2 = 1.5KE130CA D3 = 1.5KE150CA *MOV required external to filter to meet normal mode transient surge requirements Figure 10–10 — Recommended HAM filter Parameter Min Typ Max Unit 0.2 0.35 0.75 mH 3 6 Differential Mode Inductance (LD) Common Mode Inductance (LC) Table 10-1 — HAM filter inductance range Rev 4.9 Apps. Eng. 800 927.9474 vicorpower.com 800 735.6200 mH 10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies RATED CURRENT VS AMBIENT TEMPERATURE 90 4.60 ±0.02 2.50 ø0.080 PIN 6 PLACES LINE LOAD 1.200 2.40±0.02 2.00 0.100 OPERATING TEMP (DEG C) 4-40 INSERT 0.25 DP 4 PL 0.060 FACE MAY BE BOWED 0.04 MAX 1.800 0.900 0.30 ±0.02 0.13 ±0.02 0.500 1.45 ±0.02 1.00 MAX 0.500 2.800 80 70 60 50 40 1.0 INSERTION LOSS (db) .060 SEE NOTE 1 2.260 2.000 2 PL 1.900 2 PL 90 A 4.410 4.000 2 PL 3.500 .700 1.200 2 PL .310 Figure 10–11 — HAM filter mechanical diagram 2.500 2 PL '0' 2.0 3.0 4.0 CURRENT (AMPS) 5.0 6.0 7.0 Figure 10–12 — HAM filter’s current rating vs. temperature A ø.102 TPH 6 PL 1.000 2 PL 80 70 NOTES DM 1. TOP OF INSERTS TO BE FLUSH TO .010 ABOVE TOP OF PLASTIC WASHER. 2. FILTER MUST HAVE VICOR AGENCY LABEL (PART # 08094-01 CSA, TUV, UL). '0' .100 2 PL .260 60 50 40 A '0' A '0' ø.136 4 PL MKED 'A' REPRESENTS WORST CASE LOCATION FOR EDGE OF FILTER RECOMMENDED CUSTOMER MOUNTING CM 30 20 10 0 0.01 0.04 0.1 0.4 1 4 10 0.02 0.07 0.2 0.7 2 7 20 FREQUENCY (MEGAHERTZ) 40 70 100 Figure 10–13 — HAM filter insertion loss vs. frequency Parameter Operating voltage Operating temperature (See Fig.10-12) Min Typ Max Unit 250 50 Vac °C 1.2 mA 6.3 1500 34 60 A Vac V Hz 85 –20 Leakage current at 264 Vac, 63 Hz (Either line to earth) Operating current Dielectric withstand (line – case) Residual voltage after 1 sec. Operating frequency Agency Approvals 50 UL, CSA, TÜV Table 10-2 — HAM filter part #30205 specifications Maxi, Mini, Micro Design Guide Page 52 of 88 Rev 4.9 Apps. Eng. 800 927.9474 vicorpower.com 800 735.6200