PDF 10. High Boost HAM

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