AC-DC Converter Evaluation Board User Guide

USER GUIDE | UG:100
PF175 AC-DC Converter Evaluation Board
with External Input Filter
January 2013
ContentsPage
Set Up
2
Recommended4
Hardware
Features
n Oscilloscope probe jack for output voltage and ripple measurements
n Simple to use
n Ring lug, screw terminal, and solder connection options
n Replaceable fuse (5A, 216 Littelfuse recommended)
Theory of Operation 5
Thermals
Ordering Information8
Bill of Materials 8 – 10
IMPORTANT NOTICE
Please read this document before setting up an evaluation board.
Introduction
This Evaluation Board offers a convenient means to evaluate the performance of Vicor’s
VI Brick® PFM Isolated AC-DC Converter modules with Power Factor Correction, and
has been optimized for user convenience. Refer to Table 1 for operating conditions
and limits.
This reference design contains an input line filter. It is important to remember the
response of the AC line filter is dependent upon the wiring connected to the evaluation
board. Care should be exercised to minimize stray source impedances in order to fully
exercise the features of the converter.
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vicorpower.com Applications Engineering: 800 927.9474
Page 1
Figure 1.
VI Brick PFM AC DC Converter
Evaluation Board layout
and dimensional drawing,
component side
Basic Specifications and Operating Limits
Please use the following table for operating limits:
Table 1.
Description
Specification
Notes
Input range
85 – 264 Vac
Universal input
Output voltage
48 Vdc
Regulated
Output power
330 W
Over entire input range
Operating temperature
-40 to 85°C
Limited by C37, T01-T03, U01, Z01-Z04
Output capacitance
6,000 to 12,000 μF
63 V rating, 20% tolerance
NOTE: Module operating temperature will depend on its Product Grade as specified in the data sheet.
Please refer to Figure 1 for locations of the input and output connections as viewed from
the component side. Wires may be soldered directly to the pads instead of ring lugs if
desired to minimize circuit impedances.
DANGER! HIGH VOLTAGE!
DANGER! HOT SURFACE!
The VI Brick® AC-DC Converter Evaluation Board contains exposed hazardous
voltages. These voltages are within the area marked by the letter H on the PCB.
The VI Brick DC-DC Converter Evaluation Board may be operated at surface
temperatures which may pose a thermal hazard to the operator. Because of the thermal
and voltage hazards, be careful not to touch any exposed surface unless the power
is disconnected and the evaluation board has been given sufficient time to cool. The
evaluation board is not intended for use in end item equipment.
Set Up
The Customer Evaluation Board should be set up as follows:
Note: Care should be taken to avoid reversing polarities if connecting to the opposite (solder) side of
the board.
AC Input Connections (J01)
DANGER! HIGH VOLTAGE!
J01, the screw terminal connector, is for connection of AC input to the AC-DC converter
evaluation board. The interconnect leads should be appropriate for the current and
voltage supplied to the board.
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For single phase power, connect LINE to the pin marked L, NEUTRAL to the pin marked
N and earth ground to the pin marked EARTH. Corresponding wires in an IEC cable are
brown, blue, and yellow with a green stripe.
The board can be used with three phase power. Connect LINE1 to L and LINE2 to N.
Earth ground should still be connected to the EARTH terminal of J1.
+OUT, –OUT
There are several connections available on the VI Brick AC-DC converter. Table 1 lists
the available connectors and their current rating. Do not exceed the rating of the
connector or the AC-DC converter.
Table 2.
Connector
Output Connector Ratings
Rating
Recommended Connection
J02
10 A
Hold-up capacitor
J03
12 A (3 A/contact)
Mating PRM and BCM eval boards
Ring lugs
100 A
EARTH, +OUT, -OUT
2 mm holes beside C37
12 A
Snap-in type capacitor 10 mm sp
Output bulk (electrolytic) capacitance must be attached across the output of the
VI Brick® AC-DC converter evaluation Board. Refer to the table above for the
appropriate range of output capacitance.
The load should be connected to +OUT and –OUT terminals of the evaluation board
with short leads of suitable gauge to carry the output current and minimize losses. A
sufficient number of terminal connections should be used to ensure that no terminal
sees more than its maximum rated current. The evaluation board can be connected
directly to the application for which the AC-DC converter is intended. However the
interconnect impedances between the evaluation board and the application can greatly
affect the transient response. For applications where transient response is critical, the
user should consider mounting the VI Brick AC-DC converter directly to the target
application PCB.
Earth Connections
There is one EARTH connection available on the board, in the lower left hand corner,
P01 in the schematic diagram. The EARTH connection used for local return for the EMI
filter is the same as safety ground.
EARTH may optionally be connected to either of the AC-DC converter outputs in order
to provide a positive or negative voltage rail with respect to earth.
The default configuration of the evaluation board is to have the EARTH terminal
connected to –OUT through jumper JP02, while JP03 is unpopulated. To leave the
outputs floating, remove JP03 so that both JP02 and JP03 are unpopulated. To connect
EARTH to +OUT, remove JP02 and populate JP03.
The insulation of the AC/DC converter modules supported by this evaluation board
has not been designed to exceed SELV voltages, and should not exceed +/-60Vdc from
EARTH potential by stacking.
Input Current Measurement
A current probe can be passed around either input lead connected to the VI Brick
evaluation board. This can be used to measure DC currents and AC currents in front of
the EMI filter and transient suppression circuits.
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Output Voltage Measurement Jack (J12)
This connector is provided to make accurate measurements of the output ripple
voltage of the VI Brick® AC-DC converter. Many types of scope probes may be directly
connected to this point if the probe is equipped with a removable plastic sheath. To
avoid creating ground loops when making measurements of the output or input
voltage, these measurements should be made separately. Clamp on ferrite chokes, such
as Digikey PN 240-2132-ND placed over the leads of passive oscilloscope probes also
help to reduce common mode high frequency switching noise pickup. A capacitor can
be added at C29 to reduce high frequency noise at the probe if necessary.
Enable (EN)
DANGER! HIGH VOLTAGE!
The EN pin can be used to disable the VI Brick AC-DC converter. Connecting EN to
the –IN-PFM pin will disable the AC-DC converter. This will also clear any latching
output OVP fault if one has occurred. Note that the EN pin is referenced to the primary
(hazardous voltage) side of the converter. The EN pin can be accessed from J04, for
which a mating connector can be used. The mating connector is Molex P/N 43645-0500
with Molex 43030 series pins.
An optocoupler has been provided to allow connection to output referenced equipment.
The input to the optocoupler is connected to –OUT by default. Jumper JP04 can be
removed, allowing the customer to provide their own reference for the enable input.
This input can be floated up to +/-1000V from EARTH.
Efficiency Measurement
As the VI Brick AC-DC Converter can deliver and consume large currents, the effect of
the PCB must be considered when making an efficiency measurement. When testing
your design based on this reference design, be sure to probe different points in the input
filter and rectifier section to verify that voltage drops are not excessive in your layout.
If efficiency tests are to be automated, then Kelvin type connections are recommended
to reduce common current errors during voltage measurements.
Recommended Hardware
The hardware kit provided with the evaluation board includes the following:
n 6 #10 lock washers
n 3 #10-32 screws
n 3 #10-32 hex nuts
Ring lugs are also recommended for making output connections.
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Theory of Operation
The schematic diagram is presented in functional blocks with text descriptions.
Component values are given in Bill of Materials, layout in PCB Layout (Figure 7).
Soft copies are available with download.
Input, Rectifier, and Filter Section
Input power is connected to screw terminal block J01. A 5 A fuse in F01 protects against
overcurrent. 330 W at 93% efficiency draws 355W. At 85 V input, 4.17A is drawn. Z01 is a 20 mm disk MOV that can withstand higher surges than Z02-Z04. R11 and R12
discharge the input capacitors when the line cord is pulled. Capacitors C15, C17-C20,
C24, and C25 return high frequency differential current before it exits the line cord. D01 through D04 form the input bridge rectifier. T01 is a high frequency common mode
inductor chosen for its high impedance up to 5 MHz. C01 and C03 are Y caps that return
common mode high frequency currents to GND (EARTH) rather than through LINE or NEUTRAL.
Figure 2.
Input, rectifier, and filter
section schematic
Active Transient Suppression Section
Input power enters from the filter at left. C24 and C01 are repeated in the schematic
snippet. Q01 through Q03 transistors turn off during a transient event, and can block up
to 200 V each. R04/R05 through to C22 form the control mechanism for the transistors.
T02 works with the capacitors inside the VI Brick® PFM® module as part of the
conducted emissions filter.
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Figure 3.
Active transient suppression
section schematic
Output Enable Control
The EN pin is pulled low to disable the AC-DC converter. If pulled high to 3.3 V or
left floating, the VI Brick® PFM® will operate. A 1x5 0.100” spaced socket allows easy
connection to automated test equipment. This part of the circuit is referenced to
primary ground.
Users can connect their own secondary referenced control circuit by connecting
through the optocoupler U01, and connecting to TP12 and TP11 as needed. JP04 can be
removed to allow a floating reference for the enable input. On this TP12 input, a high
signal will result in shutdown of the AC-DC converter.
Figure 4.
Output enable control
schematic
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Output Filter Section
A common mode inductor should be used at the output to isolate switching noise from
this converter so it does not cause beat frequencies with downstream converters. The
one used in this reference design is the same used at the input so that a single part
number can be stocked. If space is at a premium, a smaller common mode inductor can
be substituted. Peak impedance should be between 500 kHz and 5 MHz.
C37 is the bulk capacitor default on this board. Hold time will be increased roughly 50%
and power factor increased roughly 0.5% if a 10,000 uF capacitor is substituted. This
default capacitor is a 25 mm x 45 mm capacitor that is laid on its side. There are also two
2 mm holes, 10 mm spacing, which can be used for snap in type electrolytic capacitors.
Diameters up to 35 mm will clear other components on the PCB. This capacitor filters
the rectified line ripple, which is twice the input frequency. RMS ripple current rating
should be 80% of output current or higher for longer lifetime. Ripple current ratings
vary as a function of ambient temperature.
C30 through C34 are output ceramic filter capacitors. There are used to reduce the
switching ripple on the 48 V bus near 1 MHz. Screw terminal J02 or 0.100” spaced J03
can be used to connect output wires to the load or connect an external capacitor.
J12 is a probe socket with a local capacitor to reduce switching noise. R09 and R10 are
used to connect either the positive or negative output terminal to GND (EARTH). Only
one should be connected at a time. Both can be removed for a floating output.
Figure 5.
Output filter section schematic
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vicorpower.com Applications Engineering: 800 927.9474
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Thermals
For most lab environments a fan blowing across the evaluation board is recommended
See VI Brick® Thermal Management Application Note at:
www.vicorpower.com/documents/application_notes/AN200_VIBrickTherm.pdf
or contact Vicor Applications Engineering for assistance (800) 927-9474.
Ordering Information
Two models of the evaluation board are available:
Order Number
Power Module On PCB
AC-DC Format
PFM-DISCRETE-FILTR
PS01 PFM175D480C330A00
VI Chip
PFB-DISCRETE-FILTR
PS02 PF175B480C033FP-00
VI Brick
Bill of Materials
Ref. Des.
Description
C01
CAPY X7R 4700pF 10% 250V 2220
C02
NOT APPLIED
C03
CAPY X7R 4700pF 10% 250V 2220
C04
NOT APPLIED
Digi-Key
Manufacturer
Digi-Key
Part Number
Future
Manufacturer
Future
Part Number
Murata
490-3482-2-ND
Murata
GA355DR7GF472KW01L
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
Murata
490-3482-2-ND
Murata
GA355DR7GF472KW01L
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
CAP X7R .1uF 10% 25V 0805
Kemet
399-1170-2-ND
AVX
08053C104KAT2A
C12
CAPY X7R 4700pF 10% 250V 2220
Murata
490-3482-2-ND
Murata
GA355DR7GF472KW01L
C13
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
C15
0.47uF/20/275VAC X2 CAP
Kemet
399-5429-ND
Wima
MKS4 0.47/630/10 PCM 27.5
CAP X7T 0.47uF 10% 630V 2220
TDK
445-8876-2-ND
TDK
C5750X7T2J474K
C21
CAP X7R .015uF 10% 630V 1206
TDK
445-4489-2-ND
TDK
C3216X7R2J153M
C22
CAP X7R 4.7uF 10% 25V 0805
TDK
445-5972-2-ND
TDK
CL21A475KAQNNNG
C23
CAP X7T 0.033uF 10% 630V 1206
.060MAXHT
TDK
445-7762-2-ND
Yageo
CC1206KKX7RZB333
CAP X7T 0.47uF 10% 630V 2220
TDK
445-8876-2-ND
TDK
C5750X7T2J474K
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
TDK
445-4467-2-ND
TDK
C3216X7R2A105K
C09
C10
C11
C17
C18
C19
C20
C24
C25
C29
NOT APPLIED
C30
C31
C32
CAP X7R 1.0uF 10% 100V 1206
C33
C34
C35
CAP ALUM 100UF 63V 20% RADIAL
Nichicon
UVY1J101MPD-ND
Nichicon
UVY1J101MPD
C37
CAP ALEL 6800uF 20% 63V 25X50
Kemet
493-1135-ND
Nichicon
UVZ1J682MRD
Diodes Inc
S8MCDITR-ND
Diodes Inc
S8MC-13
D01
D02
D03
D04
DPN 1000V 8A DO214AB
DPN 1000V 5A SMC
*Stocked by Arrow NAC, Manufacturer: Taiwan Semiconductor, Part#: HS5M R7
UG:100
vicorpower.com Applications Engineering: 800 927.9474
Page 8
Ref. Des.
Digi-Key
Manufacturer
Digi-Key
Part Number
Future
Manufacturer
Future
Part Number
DZEN 16V 2% 300mW SOD523
NXP
Semiconductor
BZX585-B16,115-ND
NXP
Semiconductor
BZX585-B16,115
DZEN 13V 2% 300mW SOD523
NXP
Semiconductor
BZX585-B13,135
NXP
Semiconductor
BZX585-B13,135
Diodes Inc
BAV19W-7-F
Description
D05
D06
D07
D08
D10
DPN 100V 200mA SOD-123
Diodes Inc
BAV19W-7-F
F01
FUSE HOLDER, SMD, 5x20
Wickmann
F4546-ND
Schurter
31.8225
FUSE
FUSE 5A 250V FAST 5X20 CARTRIDGE
Littelfuse
F2369-ND
Littelfuse
6005.HXP
FW
Generic
Generic
Generic
Generic
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
CON 3CKT TERM BLK SMD
No Stock
No Stock
Weco
140-A-126-SMD/03
J02
CON 2 CKT TERM BLK SMD
No Stock
No Stock
Weco
140-A-126-SMD/02
J03
CONN 10POS 90DEG THRUHOLE
FEMALE 0.1SPC
Sullins Electronics
S5519-ND
Sullins Electronics
PPTC052LJBN-RC
Molex
WM1893-ND
TE Connectivity
1445057-5
HS01
J01
OUTPUT WASHER, FLATPAC
NOT APPLIED
J04
CONN 5POS SINGLE ROW RIGHT
ANGLE
J12
JACK VERTICAL MECH THRU HOLE
JP02
RES 0 OHM 3/4W 5% 2010
JP03
NOT APPLIED
JP04
RES 0 OHM 3/4W 5% 2010
LARGE_PIN
*Stocked by Tektronix, Part#: 131-5031-00
Vishay Dale
541-0.0WTR-ND
Vishay Dale
CRCW20100000Z0EF
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
Vishay Dale
541-0.0WTR-ND
Vishay Dale
CRCW20100000Z0EF
PIN .081 DIA X .21LG VICBRICK
Generic
Generic
Generic
Generic
LOCK_
WSHR
PLTD #10 INT TOOTH LW PHOS/BR
Generic
Generic
Generic
Generic
OUTPT_
NUT
OUTPUT NUT, FLATPAC
Generic
Generic
Generic
Generic
PAD1
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PAD2
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PAD3
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PAD4
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PAD5
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PAD6
FOOT, FLIP FIXTURE
Generic
Generic
Generic
Generic
PP1
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
PP2
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
PP3
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
PP4
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
PS01
Model Specific
Vicor
Model Specific
Vicor
Model Specific
Infineon
BSC320N20NS3 GTR-ND
No Stock
No Stock
Q01
Q02
QMOS N 200V 32mR 36A 5X6 MLP
Q03
R01
RES 12.4K OHM 1/8W 1% 0805
Vishay Dale
541-12.4KCTR-ND
Vishay Dale
CRCW080512K4FKEA
R02
RES 2.49K OHM 1/8W 1% 0805
Vishay Dale
541-2.49KCTR-ND
Vishay Dale
CRCW08052K49FKEA
R03
RES 499 OHM 1/8W 1% 0805
Vishay Dale
541-499CTR-ND
Vishay Dale
CRCW0805499RFKEA
RES 2K OHM 1/4W 1% 1206
Vishay Dale
541-2.00KFTR-ND
Vishay Dale
CRCW12062K00FKEA
R07
RES 2K OHM 1/8W 1% 0805
Vishay Dale
541-2.00KCTR-ND
Vishay Dale
CRCW08052K00FKEA
R08
RES 1K OHM 1/8W 1% 0805
Vishay Dale
541-1.00KCTR-ND
Rohm
MCR10EZPF1001
R04
R05
UG:100
vicorpower.com Applications Engineering: 800 927.9474
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Ref. Des.
Digi-Key
Manufacturer
Digi-Key
Part Number
Future
Manufacturer
Future
Part Number
Vishay Dale
541-2.20FFTR-ND
Vishay Dale
CRCW12062R20FKEA
NOT APPLIED
NOT APPLIED
NOT APPLIED
NOT APPLIED
RES 42.2K OHM 1/4W 1% 1206
Vishay Dale
541-42.2KFTR-ND
Vishay Dale
CRCW120642K2FKEA
RES 100 OHM 1/8W 1% 0805
Vishay Dale
541-100CTR-ND
Vishay Dale
CRCW0805100RFKEA
Description
R09
RES 2.2 OHM 1/4W 1% 1206
R10
NOT APPLIED
R11
R12
R13
R14
SCREW
SMALL_PIN
STNDFF_
LGFF
T01
T02
T03
SCREW, 10-32 X 3/8 PHIL PH
Generic
Generic
Generic
Generic
PIN .031 DIA X .21LG VICBRICK
Generic
Generic
Generic
Generic
STANDOFF,.287 LG FEMALE-FEMALE
Generic
Generic
Generic
Generic
IND COM MODE 013 mH -30%+30%
016A Ø1.6mm
*Stocked by VACUUMSCHMELZE Gmbh, part#: T60405-R6123-X616
TP01
TP02
TP03
TP04
TP05
TP06
TEST POINT, SURFACE MOUNT
Keystone
5017-ND
Keystone
5017
U01
IC OPTO 70V 100mA SOP 4L
No Stock
No Stock
Vishay
TCLT-1009
Z01
VAR MOV, 300V 10KA 20mm DIA
RADIAL
Littelfuse
TMOV20RP300EL2T7-ND
Littelfuse
TMOV20RP300E
VAR MOV 300V 11.5X8.3 SMD
Littelfuse
F3551TR-ND
Littelfuse
V300SM7
TP07
TP08
TP09
TP10
TP11
TP12
Z02
Z03
Z04
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Figure 6.
Schematic diagram
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Figure 7.
PCB Layout
Left, top layer,
right, bottom layer.
The Power Behind Performance
Rev 1.0
12/2013
vicorpower.com Applications Engineering: 800 927.9474
Page 12