PI2161-EVAL1 Series PI2161-EVAL1 60V/12A High Side High Voltage Load Disconnect Switch Evaluation Board User Guide Series Content Page Introduction ........................................................... 1 Product Description ................................................ 2 Schematic. .............................................................. 2 Bill of Materials ...................................................... 3 Test Procedure: ...................................................... 4 Recommended Material ......................................... 4 PCB layout .............................................................. 7 Mechanical drawing. .............................................. 7 PI2161-EVAL1 Evaluation Board featuring the Cool-Switch PI2161 Full-Function Load Disconnect Switch. The PI2161-EVAL1 Evaluation Board is intended to acquaint the user with the benefits and features of the PI2161 full function Load Disconnect Switch solution. It is not designed to be installed in enduse equipment. Please read this document before setting up the PI2161-EVAL1 Evaluation Board and refer to the PI2161 product datasheet for device specifications, functional description and characteristics. During operation, the power devices and surrounding structures can be operated safely at high temperatures. Remove power and use caution when connecting and disconnecting test probes and interface lines to avoid inadvertent short circuits and contact with hot surfaces. When testing electronic products always use approved safety glasses. Follow good laboratory practice and procedures. Introduction The PI2161-EVAL1 allows the user to test the basic principles and operational characteristics of a Load Switch function, while also experiencing the benefits and value of the PI2161 solution. The PI2161-EVAL1 evaluation board is configured to be installed between the input power source and the load. PI2161 is capable of up to 12A, and is suitable for a bus voltage up to 48V. The PI2161-EVAL1 evaluation board is designed with an optimized PCB layout and component placement to represent a realistic high density final design for an embedded Load Switch solution for 48V BUS applications requiring up to 12A. This evaluation board is intended as an easy and simple way to test the electrical and thermal performance of the PI2161 Full-Function Load Switch solution. Both dynamic and steady state testing of the PI2161 can be completed on the PI2161-EVAL1 evaluation board, in addition to using the key features of the product. Dynamic testing can be completed under a variety of system level fault conditions to check for response time to faults. This document provides basic instructions for initial startup and configuration of the evaluation board. Further information on the functionality of the PI2161 can be found in the PI2161 product datasheet. Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 1 of 8 PI2161 Product Description The Cool-Switch® PI2161 is a complete full-function Load Disconnect Switch solution for medium voltage applications with a high-speed electronic circuit breaker and a very low on-state resistance MOSFET. It is designed to protect an input power bus from output load fault conditions. The PI2161 Cool-Switch solution is offered in an extremely small, thermally enhanced 7mm x 8mm LGA package. The PI2161 enables an extremely low power loss solution with fast dynamic response to an over current fault or high conditions. The PI2161 senses a small portion of the total MOSFET current and has a low voltage threshold allowing the use of low power sense resistors. Figure 1, shows a photo of the PI2161-EVAL1 evaluation board with one load disconnect switch PI2161 SiP. The board is built with options and features that enable the user to fully explore the capabilities of the PI2161 Load Disconnect Switch. Figure 1: PI2161-EVAL1 Evaluation Board (1.8” x 1.8”) Terminals Absolute Maximum Rating Vin+ 60V/12Adc Vout+ 60V/12Adc EN, VO Terminal Description Vin+ Power source Input: or bus input designed to accommodate up to 12A continuous current. Vin- Input Ground: Connect to the power source low side. EN Enable input: Inverse of Vout+ Output: Connect to the load high side. VO PI2161 Load Status pin: When the internal MOSFET gate is enabled Vout- Output Ground: Connect to the load low side. -0.3V to 17.3V / 10mA , set SW1 to Off position when EN input is used Table 1: PI2161-EVAL1 Evaluation Board Terminals Description Sc Figure 2: PI2161-EVAL1 Evaluation Board schematic. Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 2 of 8 Ref. Designator Value/Part NO. Description 1 C1 0.1μF MLCC Capacitor, X7R, 0.1μF,50V 0805 2 2 C2, C3 1μF MLCC Capacitor, X7R, 1μF,50V 1206 3 1 C4 22μF ELEC Capacitor, 22μF,100V 4 2 EN, VO 1528 Turret Test point TURRET - 1528 Keystone Electronics 5 4 Vin+, Vin-, Vout+, Vout- 1502 Turret Test point TURRET - 1502 Keystone Electronics 6 1 Q1 DTC114EUAT106 Transistor, Digital NPN,50V SOT-323 Rohm Semiconductor 7 1 R1 120mΩ Resistor, 0.12Ω,1%,0.25W 0805 R2 Not installed Resistor 0805 Item QTY 1 8 Footprint 9 1 R3 6.04kΩ Resistor,6.04K,1%,0.25W 1206 10 1 R4 16.9kΩ Resistor,16.9K,1%,0.1W 0603 11 1 R5 150kΩ Resistor,150K,1%,0.1W 0603 12 1 SW1 Switch 13 1 U1 PI2161-01-LGIZ Manufacturer CAS-120 SW SPDT SM Picor Cool-Switch Controller IC 7mmx8mm 17-pin PICOR LGA SiP Table 2: PI2161-EVAL1 Evaluation Board Bill of Materials Ref. Designator C1 C2, C3 Value/Part NO. 0.1μF Not installed C4 22μF Q1 DTC114EUAT106 Functional Description VC Bypass Capacitor Snubber to reduce high voltage noise after disconnect due to high current short. Recommended value 1μF. Output Electrolytic Capacitor PI2161 enable inverting polarity R1 120mΩ R2 Not installed R3 6.04kΩ Low side bias resistor (RPG) R4 16.9kΩ VO voltage divider. When the internal MOSFET gate is enabled R5 150kΩ SW1 Switch U1 PI2161-01-LGIZ Current sense resistor Optional high side bias resistor. pin pull-up resistor. Output Enable/Disable switch Full-Function Load Disconnect Switch Solution. Table 3: Component functional description Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 3 of 8 Test Procedure: Initial Test Set Up PI2161-EVAL1 is configured for 48V ±10% input bus. The current limit is set by the sense resistor R1. The sense resistor is selected (120mΩ) for minimum worst case trip current of 11.5A at 125°C. Baseline Test Procedure – PI2161 (Refer to Figure 4) 1. Recommended Material 1.1. Material Needed-Picor supplied 1.1.1. PI2161-EVAL1 1.1.2. PI2161 Product Datasheet 1.2. Recommended Users Supplied Equipment 1.2.1. One DC power supply: 0-60V; 15A. 1.2.2. One low power logic voltage power supply 1.2.3. Load: electronic Load, Power resistors or actual load. 1.2.4. Multimeter. 1.2.5. Oscilloscope. 1.2.6. Appropriately sized interconnect cables. 1.2.7. Safety glasses. Before initial power-up follow these steps to configure the evaluation board for specific end application requirement: 2. Sense resistor (Rs) selection 2.1. In a typical load switch application the sense resistor (Rs), R1 in the PI2161-EVAL1, is selected based on a minimum trip current to allow maximum normal load current without interruption. The sense resistor value can be determined from Overcurrent trip vs. sense resistor chart in Figure 3: Please refer to PI2161 Datasheet for more details on how to calculate the sense resistor value verses trip current. Note: Make sure that output capacitor inrush current is less than two times the minimum set trip current. Output capacitor inrush current is function of the output capacitor value and output voltage rise time. 32 30 Forward Overcurrent Trip [A] 28 26 24 22 Maximum Current trip [VOC-THL= 77mV; θJ-A= 25°C] 20 Typical Current trip [VOC-THL= 70mV; θJ-A= 25°C] 18 16 14 12 10 8 40 [VOC-THL= 63mV; θJ-A= 25°C] Minimum Current trip [VOC-THL= 63mV; θJ-A= 125°C] 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Sense Resistor [mΩ] Figure 3: PI2161 Overcurrent trip vs. sense resistor chart Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 4 of 8 Figure 4: Layout configuration for a typical Load Disconnect Switch application test using PI2161. 3. Control Circuitry Bias: As described in the Functional Description section in PI2161 datasheet; in a floating application it is required to place low side bias resistor RPG (R3) between the PG pin and system ground. RPG creates an offset voltage at the PG pin to regulate VC with respect to PG when the MOSFET is enabled. 5.2. Connect the electronic load to the output between Vout+ and Vout-. Set the load current to 5A The RPG resistor can be calculated using the following expression: 5.6. Verify that the load voltage (Vout) is few millivolts below 48V. This verifies that the PI2161 MOSFET is in conduction mode. 5.3. Position SW1 knob to On 5.4. Enable (turn on) PS1 power supply output. 5.5. Turn on the electronic load 5.7. Measure VO with respect to Vin-, it should be 10% of Vout, 4.5V. Please refer to application section in the PI2161 datasheet for more details. 4. 5. Enabling PI2161: PI2161-EVAL1 is set with two enabling options. 4.1. Mechanical switch (SW1) option. Moving SW1 knob to On position to enable (turn on MOSFET if conditions are met) PI2161, or moving SW1 knob to Off position to disable (turn off MOSFET) PI2161. 4.2. Logic input terminal (EN) option: to use this option slide WS1 knob to Off position. Apply logic high voltage (>2V) to enable PI2161 and logic low (<1V) to disable PI2161. Hook Up of the Evaluation Board 5.1. Connect the positive terminal of PS1 power supply to Vin+. Connect the ground terminal of PS1 to Vin-. Set the power supply to 48V. Keep PS1 output disabled, off. Picor Corporation • picorpower.com 5.8. Slide SW1 to Off position to disable the output. 5.9. Verify that the load voltage (Vout) is off, about 0V. This verifies that the M1 MOSFET is turned off. VO voltage should be at 0V. 6. Over current trip point: PI2161 has a very fast response (120ns) to over current fault condition. Measuring a fast disconnect after high current buildup requires attention to the test set-up. Before proceeding, consider the following: 6.1. To emulate a real application, the BUS supply for this test should have a solid output source such as a DC-DC converter that supply’s high current and can be connected very close to the evaluation board. This will reduce stray parasitic inductance. Or use the prospective supply sources of the end application where the PI2161 will be used. Typical bench power supplies have slow response to output load change. In this test when the output load is shorted, a high pulse of PI2161-EVAL1 User Guide Rev. 1.0 Page 5 of 8 current is sourced from the power supply and its output voltage will drop, but when the MOSFET disconnects the load (shorted) from the source, the bench power supply may produce high output voltage with high current capability that may damage the device under test. actual trip current is the current right before the PI2161 turns the output off, VO output will go to 0V to indicate that the output is disconnect from the source. After PI2161 turns the output off by pulling the MOSFET gate low, it will hold the MOSFET in an off condition until it is reset. If a bench power supply has to be used, or there is some wiring inter connection between PI2161EVAL1 input (Vin+ and Vin-) and the power source, add a large electrolytic capacitor between Vin+ and Vin- terminals to reduce power source high voltage transient after load disconnect. 6.4. Device Reset: To reset PI2161 after a fault (high load current), recycle PI2161 by sliding SW1 knob to Off position and then slide the knob back to On position. 6.5. Output short test Enable PS1 and then apply a short at the load (Vout). The short can be applied electronically using the electronic load, a MOSFET connected between Vout+ and Vout- or simply by connecting Vout+ to Vout-. Then measure the response time between when the output current reached the set trip point and when PI2161 disconnect the load. An example for PI2161 response time to an output short circuit is shown in Figure 5. 6.2. Place the scope probes very close to PI2161 D pin and SH pin to measure Vout and Vin, and make sure that the scope ground leads are very short. 6.3. Current trip point: To find the exact current trip level, repeat steps 5.1 to 5.9 and then increment the load current slowly. The current can be monitored by a current probe placed at the unit input or by reading the current display at the power supply (PS1) or at the electronic load display. The Output Voltage [SH] (5V/div) Input Voltage [D] (5V/div) Turn off & latch PG pin (5V/div) Input Current (5A/div) Input Voltage [D] (5V/div) MOSFET Avalanche At 69V PG pin (5V/div) Output Voltage [SH] (5V/div) Set Trip Current at 10.5A (Rs=200mΩ) 94.4ns Input Current (5A/div) Start Turn off & latch 120.4ns Test Setup: DUT: PI2161-EVAL1 Vin = 45V Output Load = 1.5A Rs (R1) = 200mΩ First applied slow ramping load current and determined the trip current: 10.5A Test: Apply output short PI2161 was enabled and load current is at 1.5A, then shorted Vout+ to Vout- with a MOSFET. The current ramped at 230A/μs. PI2161 turned the output off at load current of 33A, by pulling the MOSFET gate low and latch it low. PI2161 internal MOSFET starts to turn off 94ns after the current reach the trip point (10.5A). And current reached 0A within 120ns. Figure 5: Plot of PI2161 response time to a forward over-current condition Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 6 of 8 Figure 6: PI2161-EVAL1 layout top layer. Scale 2.0:1 Figure 7: PI2161-EVAL1 layout bottom layer 2. Scale 2.0:1 Figure 8: PI2161-EVAL1 evaluation board mechanical drawing. Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 7 of 8 Warranty Vicor products are guaranteed for two years from date of shipment against defects in material or workmanship when in normal use and service. This warranty does not extend to products subjected to misuse, accident, or improper application or maintenance. Vicor shall not be liable for collateral or consequential damage. This warranty is extended to the original purchaser only. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY, VICOR MAKES NO WARRANTY, EXPRESS OR LIMITED, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Vicor will repair or replace defective products in accordance with its own best judgment. For service under this warranty, the buyer must contact Vicor to obtain a Return Material Authorization (RMA) number and shipping instructions. Products returned without prior authorization will be returned to the buyer. The buyer will pay all charges incurred in returning the product to the factory. Vicor will pay all reshipment charges if the product was defective within the terms of this warranty. Information published by Vicor has been carefully checked and is believed to be accurate; however, no responsibility is assumed for inaccuracies. Vicor reserves the right to make changes to any products without further notice to improve reliability, function, or design. Vicor does not assume any liability arising out of the application or use of any product or circuit; neither does it convey any license under its patent rights nor the rights of others. Vicor general policy does not recommend the use of its components in life support applications wherein a failure or malfunction may directly threaten life or injury. Per Vicor Terms and Conditions of Sale, the user of Vicor components in life support applications assumes all risks of such use and indemnifies Vicor against all damages. Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. Vicor components are not designed to be used in applications, such as life support systems, wherein a failure or malfunction could result in injury or death. All sales are subject to Vicor’s Terms and Conditions of Sale, which are available upon request. Specifications are subject to change without notice. Vicor Corporation 25 Frontage Road Andover, MA 01810 USA Picor Corporation 51 Industrial Drive North Smithfield, RI 02896 USA Customer Service: [email protected] Technical Support: [email protected] Tel: 800-735-6200 Fax: 978-475-6715 Picor Corporation • picorpower.com PI2161-EVAL1 User Guide Rev. 1.0 Page 8 of 8