13. AC Input Harmonic Attenuator Module (HAM)

13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
THE HARMONIC ATTENUATOR MODULE
COMPATIBLE WITH 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 13–5).
Rectifier
AC
Line
ZCS
Boost
Converter
Current
Sense
Voltage
Waveform
+
Inrush
& Short
Circuit
Protection
DC
Out
–
High Frequency
Control
Output Voltage
Control
Module Enable
& Housekeeping
Power OK
Circuitry
Gate In
Gate Out
Note:
Non-Isolated
Output
Aux. Supply
Figure 13–1 — HAM block diagram (HAMD version has the rectifier
block deleted.)
Page 37 of 98
435
600
365
650
550
500
400
330
derate output power 8 W/V for Vin <110 Vac
295
450
400
350
85
260
225
190
95 105 115 125 135 145 155 165 175 185 195 205 215 225 235 245 255 265
110 Vac
Input Voltage
VRMS
Rated Output Power
Output Voltage
Figure 13–3 — 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 40. 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 13–5).
GATE IN (HAM) Pin. The user should not make any
connection to this pin.
NOTE: No input to output isolation.
VI-200 and VI-J00 Family Design Guide
700
Output Voltage (Vdc)
The output voltage of the HAM varies as a function of
incoming AC line voltage (Figure 13-3). On a nominal 120
Vac line the output voltage of the HAM is 260 Vdc — well
within the input operating voltage range of Vicor VI-26x
and VI-J6x converters. As input line increases, so does the
HAM output voltage; at 220 Vac the delivered voltage will
be about 350 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 unnecessarily sacrificing
operating efficiency.
Figure 13–2 — Input voltage and current wave forms, without and
with power factor correction.
Output Power (W)
The Harmonic Attenuation Module (HAM) consists of a
full-wave rectifier, a high-frequency zero-current-switching
(ZCS) boost converter, active inrush current limiting, shortcircuit protection, control, and housekeeping circuitry
(Figure 13–1). 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 13–2).
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 13–5).
Rev 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200
13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 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 13–6).
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 13–8). If the AC line
fails, E/O goes low when the DC output of the HAM
drops below 195 Vdc.
E/O must be connected to the Gate Input of all VI-26x and
VI-J6x drivers (Figure 13–4); failure to do so may cause the
converters to toggle on and off. It is not necessary to
connect this pin to boosters as they are controlled by their
respective driver. 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.
The E/O pin ancillary circuitry illustrated in Figures 13–4 and
13–5 provides transient immunity. The illustrated circuitry is
the minimum required, see Figures 13–4 and 13–5.
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
the output bus voltage is within normal operating range
20 – 25 ms after DC-DC converters are enabled by the
VI-200 and VI-J00 Family Design Guide
Page 38 of 98
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 13–9). 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 230 Vdc) the P/OK
signal will go to an open circuit state (see Figure 13–7),
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 195 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 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200
13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
VI-26x or VI-J6x DC-DC Converters
F3
Input
V1
C5
F1
L1
L1
GND
GATE IN
R1
C9, C10
R4*
D1
D2, D3
D4, D5
V1
C5–C8
F1, F2
L2/N
L2/N
+IN
D2
R1
C1
D1
G ATE IN
Driver
G ATE OUT
C2
D4
C9
– OUT
-IN
LOAD
Description
C6
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
0.2 µF to 500 V
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
F3
P/OK
E/O
A/S
VI-HAM-xM
GATE OUT
LINE
Component
Designation
C1
C2, C3
C4
L1
Vicor
Line Filter
P/N 30205
6.3 A
L2/N
+ OUT
+IN
D3
G ATE IN
C4
D5
R4*
Driver
G ATE OUT
C3
C10
-IN
Y-Capacitor
C8
Hold up Box (HUB)
µ
µ
µ
Figure 13–4 — Connection diagram HAM / DC-DC converter
VI-26x or VI-J6x DC-DC Converters
C5
10 A
F1
+IN
F3
JMK Filter
Input
V1
P/OK
VI-HAMD-xM E/O
GATE OUT
A/S
L1
L1
GND
1N4006
P/N 1319-13
12.6 A*
1N4006
L2/N
-IN
Z1
Z2
+IN
+OUT
GATE IN
Bridge
Rectifier
Vicor P/N 30660
D2
R1
C1
C9
C2
D1
D4
C6
C7
Z3
L2/N
10 A
F2
+IN
+OUT
GATE IN
GATE IN
C5–C8
C9,C10
D1
D2, D3
D4, D5
F1, F2
F3
R1
R4**
V1
Z1, Z2
Z3
Description
0.1 µF ceramic, 50 V
0.01 µF ceramic, 50 V
Hold up capacitor,
1000 to 6,000 µF
VI-BAMD-xM
Vicor
Part Number
C4
GATE OUT
-IN
**
R4
C10
-OUT
GATE OUT
-IN
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
100 KΩ, 2 W
275 V MOV
30076
130 V Transorb
1.5KE130CA
150 V Transorb
1.5KE150CA
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 1200 W
Figure 13–5 — Connection Diagram, HAMD / BAMD / VI-26x or VI-J6x DC-DC Converters
HAMD-CM Driver HAM: No internal bridge rectifier or synchronization diodes.
BAMD-CM Booster HAM: Companion module to HAMD-CM used for additional output power. No internal bridge rectifier.
VI-200 and VI-J00 Family Design Guide
Page 39 of 98
Driver
GATE OUT
-IN
-OUT
+IN
Component
Designation
C1
C2, C3
C4
GATE IN
Rev 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200
Booster (N)
13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 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 13–6 — Auxiliary Supply (A/S)
Figure 13–7 — Power OK (P/OK)
AC Mains
120 Vrms
DC Output
of HAM
+OUT
G
230 Vdc
195 Vdc
Off at 195 Vdc
Enable Output (E/O)
E/O
D
S
Boost Voltage
Rectified Line
P/OK
LOGIC
240 Vdc
A/S
25 ms
Off at 230 Vdc
Power OK (P/OK)
–OUT
10 ms
Outputs
DC-DC Converter(s)
Figure 13–8 — Enable Output (E/O)
Off below 195 Vdc
Figure 13–9 — 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 13–10, 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 13–1. 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.
VI-200 and VI-J00 Family Design Guide
Page 40 of 98
MOV*
P/N 30076
R
Cx
CM
DM
Cy
D1
Cy
D3
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 (Figure 13–10). 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
D2
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 13–10 — Recommended HAM filter
Parameter
Differential Mode
Inductance (LD)
Common Mode
Inductance (LC)
Min
Typ
Max
Unit
0.2
0.35
0.75
mH
3
6
Table 13-1 — HAM filter inductance range
Rev 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200
mH
13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 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
1.00
MAX
0.500
1.45
±0.02
2.800
PL
PL
PL
'0'
80
70
60
50
40
1.0
2.0 3.0 4.0
CURRENT (AMPS)
5.0
6.0
7.0
Figure 13–12 — HAM filter’s current rating vs. temperature
Figure 13–11 — HAM filter mechanical diagram
90
INSERTION LOSS (db)
80
N
70
DM
60
50
M
40
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 13–13 — HAM filter insertion loss vs. frequency
Parameter
Operating voltage
Operating temperature (See Fig.13-12)
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
50
Table 13-2 — HAM filter part #30205 specifications
VI-200 and VI-J00 Family Design Guide
Page 41 of 98
Rev 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200
13. AC Input Harmonic Attenuator Module (HAM)
Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
HAM DO’S AND DON’TS
The following cautions should be observed before applying
power to the HAM.
• It is important that the output of the HAM not be
loaded until the input voltage has exceeded 85 Vac and
the output has begun to boost to 260 Vdc. This means
that if the load on the HAM is a Vicor converter, the
ENABLE Output of the HAM must be connected to the
GATE IN of all Driver modules. The HAM will then disable
the module output until the input exceeds 85 Vac and
the output has been boosted to 260 Vdc. If an external
load is connected directly to the output of the HAM, do
not apply the load until the output of the HAM is
stabilized in boost mode.
• Although the efficiency of the HAM is quite high, it still
dissipates significantly more power than a VI-26x
DC-DC converter. Care should be taken to cool it. Do
not rely on the internal overtemperature shut down to
take the place of adequate planning relative to the
cooling of the HAM. Thermal compound should be
used between the heat sink and baseplate of the HAM,
HAMD and BAMD.
VI-200 and VI-J00 Family Design Guide
Page 42 of 98
• Power factor is 0.997 at 120 Vac and 0.995 at 240 Vac.
Harmonic content at 240 Vac is therefore somewhat
higher than at 120 Vac. Remember that harmonic
content measured cannot be any lower than the
harmonic content of the AC mains. A precision AC
source is required for accurate power factor measurements.
• The input voltage range of the HAM is 85 – 264 Vac;
however it may not start boosting until the AC mains
has exceeded 87 Vac. Once the HAM has started, it will
operate down to 85 Vac. The HAM contains 2.5 – 6 V
of input hysteresis, therefore if the AC line impedance is
high, i.e., when using a variable autotransformer, the
HAM may start, but the AC line may then fall enough
to drop below undervoltage lockout. When this
happens the AC line will go up, the HAM starts and the
cycle repeats. Therefore avoid soft AC lines at or near
low line.
Rev 3.5
Apps. Eng. 800 927.9474
vicorpower.com
800 735.6200