USER GUIDE | UG:016 For use with PCB part numbers: 39573 and 38693 VI Chip® Remote Sense PRM Evaluation Board Written by: Ankur Patel Applications Engineer June 2014 ContentsPage Introduction Introduction1 The Remote Sense PRM evaluation boards described in this document are designed to use with the PRM family of PRM regulators and demonstrate the benefits of the Factorized Power Architecture™. These evaluation boards are not designed for installation in end user equipment. The system demonstrates the use of a PRM (the pre-regulator module) and a VTM (the current multiplier or the voltage transformation module) for general laboratory evaluation only. Considerations for Remote Sense only PRM 3 Contents3 Features4 Board Description 5 General Components 6 Test Points 8 Sockets9 Schematic10 Assembly Drawings 12 Bill of Materials 14 VTM Evaluation Boards 17 Recommended Test Equipment 18 Board Operating Modes Common Features 19 20 Remote Sense Operating Mode: PRM 21 Remote Sense Operating Mode: PRM & VTM Trim and Soft Start Adjustment Current Limit Adjustment 22 Slave Operating Mode 24 IMPORTANT NOTICE: 23 Be sure to read this design guide manual thoroughly before using this product. Pay attention to all cautions and warnings. 24 This user guide is not comprehensive and is not substitute for common sense and good practice. For example: Paralleling25 Conclusion25 n When testing electronic product always use approved safety glasses. n Provide a strain relief for wires and place the system on the bench in such a way as to prevent accidental displacement from bench top. n Remove the power and use caution when connecting and disconnecting test probes and interface lines to avoid unintentional short circuits and contact with hot surfaces. n Never use a jumper in place of the fuse. Replace the fuse only with its equivalent type and rating. n Never attempt to disconnect the evaluation board from a VTM® evaluation board while power is applied. This system is not designed to demonstrate the hot plug capability. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 1 The Remoste Sense PRM evaluation board can be used to demonstrate a standalone buck-boost regulator or in conjunction with a VTM evaluation board to enable evaluation of a Factorized Power Architecture™ (FPA) system. There are many combinations possible using PRM and VTM evaluation boards, but the focus in this user guide is using one PRM evaluation board and one VTM evaluation board, with a brief overview of how to parallel boards. In Remote Sense Operation the internal regulation circuitry is disabled and an external control loop and current sensor maintain regulation. This affords flexibility in the design of both voltage and current compensation loops to optimize performance in the end application. The Remote Sense PRM module evaluation board can be used to configure the PRM in local sense mode or in non-isolated remote sense mode depending on the application. Table 1. Evaluation board numbers and their ratings Remote Sense PRM Part Number (PS10) Evaluation Board Number Description Input Voltage (V) Output Voltage (V) Output Power (W) 38 V to 55 V 5 V to 55 V 600 W 38 V to 55 V 5 V to 55 V 400 W 38 V to 55 V 5 V to 55 V 200 W Full-Chip Remote Sense PRM48BF480T600A00 PRD48BF480T600A00 PRM Evaluation Board Full-Chip Remote Sense PRM48BF480T400B00 PRD48BF480T400B00 PRM Evaluation Board Half-Chip Remote Sense PRM48BH480T200B00 PRD48BH480T200B00 PRM Evaluation Board Refer to the specific PRM data sheet for detail ratings of the device. It is important to remain within the device limits when testing. These boards make it convenient to evaluate the performance of Vicor’s PRM products. All evaluation boards include sockets to allow easy "plug and play" insertion and removal of through-hole components and wires while providing kelvin voltage measurements test points of all pins of the PRM. Evaluation boards are designed to simplify testing of the product by providing test points and sockets for easy connection to standard test-equipment, lugs for input/output connections, connectors to allow easy insertion and removal of the PRM evaluation board and VTM evaluation board. Please note that Not all evaluation board part numbers have been listed here. Full chip and half chip PRMs of different output power level may be using common full chip and half chip evaluation boards. Design specific components have been arranged in table 6 based on PRM output power level. It is recommended that the user should, first, find out which PRM part number is mounted on evaluation board. Second, please refer to appropriate data sheet for pin functions of PRM and modes of operation. Third, follow the appropriate section of the user guide to use the PRM evaluation board in specific modes of operation. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 2 Considerations for Remote Sense only PRM This board is designed to accomodate different types of PRMs. Therefore, certain circuitry on the board is not populated and there are additional considerations for using Remote Sense only PRMs. The Remote Sense PRM Evaluation Board does not operate in default switch S10 setting which has all switches in the OFF position. Switch at position 1 must remain in the OFF position. Putting switch at position 1 in the ON position could short the TM pin which would cause damage. Switch at position 6 must remain in the OFF position as well. Please see appropriate section for switch setting and mode of operation. The silkscreen may not match the pin names for Remote Sense PRM. Following table maps pin names of the Remote Sense PRM to silkscreen and standard PRM. Remote Sense PRM PRM Silkscreen on the Board PR SHARE/CONTROL NODE SH/CN Table 2. PC ENABLE EN TM TRIM TRIM NC NC TP20 NC NC TP19 NC AL AL VC VC VC RE REF/REF_EN RE SG SGND SG IF IFB IFB VS VAUX VAUX NC VT VT Contents All Remote Sense PRM evaluation boards arrive with the following contents. (The user guide can be downloaded from the www.vicorpower.com) 1 x Remote Sense PRM evaluation board 1 x VI Chip push pin heat sink 2 x VI Chip push pins for heat sink installation 2 x VI Chip push pin heat sink grounding clips 1 x hardware kit 1 x through-hole aluminum-electrolytic input capacitor (CIN) 1 x through hole resistor for default compensation (R28) 1 x through hole capacitor for default compensation (C20) 2 x jumpers n n n n n n n n n UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 3 Features 1. Input and output lugs for source and load connections. 2. Input fuse (appropriately rated). 3. Input filtering and sockets to place through-hole input aluminum-electrolytic capacitor for source decoupling. 4. Output filtering and sockets to place through-hole output aluminum-electrolytic capacitor. 5. Switch for enabling and disabling the PRM through the ENABLE pin. 6. Open drain MOSFET for enabling and disabling the PRM using external source. 7. Mode selection switch for Remote Sense PRM configurations. 8. Trim control selection. (Not applied) 9. Adaptive Loop control selection. (Not applied) 10. Output current sensing for output current measurement and current feedback in Remote Sense Operation. 11. Sockets and circuits to optimize the external control circuits in Remote Sense Operation. 12. Voltage reference to trim pot for adjusting output voltage set point in Remote Sense Operation. 13. Dual output connectors for transferring the power and signal connections to downstream VTM® evaluation board. 14. Oscilloscope probe jack for making accurate output voltage measurements. 15. Dual paralleling connectors for PC, PR and SG signal connections to other PRM evaluation board. 16. Kelvin voltage test points and sockets for all pins of PRM. 17. Test points for current sensing and AC signal injection (RS mode). 18. Provision for installing the heat sink. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 4 Board Description The following section provides a detailed description of the evaluation board components, test points and sockets. Figure 1. Board description Figure 2. Power/signal connectors pinout, front view -OUT 10 VC 8 -OUT +OUT +OUT 6 4 2 -S 10 9 -OUT 7 VC 5 3 1 -OUT +OUT +OUT 9 +S J13 Power/signal connector UG:016 vicorpower.com V T M_-IN 4 2 8 6 7 5 3 1 V _T M V _PC V _IM J10 Signal connector Applications Engineering: 800 927.9474 Page 5 General Components 1. Remote Sense PRM (PS10) 2. Input lugs: Sized for #10 hardware. Use these for making connection to the input source. This board does not contain reverse polarity protection. Check for proper polarity before applying the power. 3. Input fuse (F10): Appropriately rated. 4. Input filtering: Input capacitor (CIN) and filtering (inductor and ceramic capacitors) allows for stable operation with most input sources. Sockets can be used for easy installation of aluminum-electrolytic input capacitor. It is recommended to place the 22 uF, 100 V input electrolytic capacitor in the sockets at the input of the PRM®. 5. Enable/Disable switch (S11) and FET switch: When actuator is in top position towards “ON” text on the board, the ENABLE pin will be open and PRM device will be enabled. When actuator is in bottom position towards “OFF” text on the board, the ENABLE pin will be connected to SGND and PRM device will be disabled. When switch S11 is ON, open drain FET can be selected to control the ENABLE pin using external source. 6. Header-jumper for Adaptive Loop control (P10): Provides the option to select and enable Adaptive Loop control. Note: Not Populated for Remote Sense PRM Evaluation Boards. 7. Header-jumper for trim control (P11): Provides the option to select and enable the trim control. Note: Not Populated for Remote Sense PRM Evaluation Boards. 8. Operating Mode selection switch (S10): For selecting one of the following operating modes: a. Slave Operation (used in PRM paralleling) b. Remote Sense: Local sensing (single ended) c. Remote Sense: Non-isolated remote sensing (differential) 9. Output lugs: Sized for #10 hardware. Use these lugs to connect the output directly to the load. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 6 General Components (Cont.) 10. Signal connector (J10): Used to transfer VTM® PC, IM, TM, -IN and Output Sense signals between the PRM and VTM boards. TM pin of VTM provides feedback to VT pin of PRM to enable temperature compensation in Adaptive Loop Operation of PRM® and VTM. 11. Power/Signal connector (J13): Used to transfer power (+OUT/-OUT) and VC to downstream VTM board when used. 12. Output oscilloscope probe Jack (J14): Used for making the accurate scope measurements of the output voltage (i.e. ripple). Remove scope grounding lead and insert probe directly into jack ensuring a good connection between the jack and the probe ground barrel. Do not attempt to install while power is applied. May not be compatible with all scope probes. 13. Output capacitor (COUT) and output filtering (inductor and ceramic capacitors): Helps to minimize the switching ripple of the output voltage. Sockets can be used for easy installation of aluminum-electrolytic output capacitor. 14. High-side current-sense resistor and current-sense IC (R25 and U10): Current- sense shunt monitors the output current and IC provides the feedback to the IFB pin for constant current limit protection in Remote Sense Operation. Gain is programed using resistor R26. Constant current limit is set at ~10% above the rated output current of the PRM on all boards. 15. Voltage sense and error amplifier: Dual op-amp provides the voltage sensing and error amplifier function. It can be configured for local voltage sensing at the PRM output or a differential amplifier to allow for non-isolated remote sensing at the VTM output or load in Remote Sense Operation. Sockets are provided for compensation components. 16. Voltage reference and output voltage trim pot (R44) for external voltage control loop: Remote Sense Operation trim pot adjusts the output voltage by increasing and decreasing the error amplifier reference voltage (VREF). Turn clockwise to increase the output voltage and counterclockwise to decrease the output voltage. Sockets can be used for easy installation of soft start ceramic capacitor. 17. Dual paralleling wire to board connectors (J17 and J18): Used for transferring signal pins (PC, PR and SG) in parallel operation from one board to other board. Provides simple strip and insert option. Accepts 18-24AWG solid wires. Spring loaded contact will grab solid wire with no need for soldering. Connection requires for parallel regulator operation are grouped together. 18. Push-pin heat sink and grounding clip mounting holes: Use these holes for installing the optional push pin heat sink and grounding clips included with the board. Use of the heat sink with fan is highly recommended for appropriate cooling of the PRM module. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 7 Test Points Description Each test point has a socket which accepts 0.015 – 0.025 inch diameter leads for easy installation of solid wires and through-hole components. All the test points are brought out to the edge of the board to allow for easy measurement and/or connection to the user’s external circuitry. All test points are labeled and routed to the edge of the board. Each test point is accompanied with an adjacent socket for adding a test lead or to facilitate wiring to external circuitry. Table 3. Test points description Note: for RS PRM, silkscreen may not match pin name. See section: Considerations for Remote Sense only PRM Reference Functional Functional Designator Name Description TP30,+IN, TP33-IN Input voltage test points provide kelvin connection to input pins of the PRM®. Use these test points for measuring the input voltage of the PRM to avoid error due to interconnect losses. TP31,+OUT, TP32-OUT Output voltage test points provide kelvin connection to output pins of the PRM. Use these test points for measuring the output voltage of the PRM to avoid error due to interconnect losses. TP34, Signal Ground (SG) test points are the ground reference for all control circuitry TP21, SG and signal pins of the PRM. TP22 TP28, CS+, Used to measure the output current of the PRM across shunt resistor R25. TP29 CS- TP35, IM, Used to measure the output of current sense IC with reference to SG. TP36 SG TP10PR Used to measure the PR signal of the PRM with reference to SG test point. TP11 NC No Connect. For internal use only. TP12 TM Used to measure the TM signal of the PRM with reference to SG test point. TP13 VS Used to measure the VS signal of the PRM with reference to SG test point. TP14 Used to measure the RE signal of the PRM with reference to SG. RE TP15 NC No Connect. For internal use only. TP16 PC Used to measure the PC signal with reference to SG. TP17 VC Used to measure the VC signal with reference to SG. TP18IF Used to measure the IF signal of the PRM with external constant current circuit with reference to SG in Remote Sense Operation. TP43, VREF TP44 Used to measure the voltage reference signal of the error amplifier with reference to SG in Remote Sense Operation. TP19, NC No connect. For internal use only. TP20 TP37, TP38 Can be used to inject the isolated signal of network analyzer for bode plot measurement to measure the stability in Remote Sense Operation. TP23, TP24 Can be used to connect function generator to control the open drain MOSFET in ENABLE control. TP39, TP41 Not Applied. TP40, TP42 Not Applied. VG, SG UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 8 Sockets Description Each socket accepts 0.015 – 0.025 inch diameter leads for easy installation of solid wires and through-hole components for use with external circuit and test equipment. Table 4. Sockets description Reference Functional Functional Designator Name Description Input H57, Sockets are used for easy installation of through-hole 100 V rated H58Capacitor aluminum-electrolytic capacitor. (CIN) H32, H33 Output Capacitor (COUT) Sockets are used for easy installation of through-hole 100 V rated aluminum-electrolytic capacitor. Ensure proper polarity with short leads while installing. H49, Not Applied. H53 H50, Not Applied. H54 H41, H43 Compensation Capacitor (C20) Used for easy installation of through-hole compensation capacitor C20 in feedback path of error amplifier. Default through-hole 4700 pf capacitor is added in the box. Used only with Remote Sense Operation. H42, H44 Compensation Resistor (R28) Used for easy installation of the through-hole compensation resistor R28 in feedback path of the error amplifier. Default through-hole 20 K resistor is added in the box. Used only with Remote Sense Operation. Integrator H39, Capacitor Used for easy installation of through-hole compensation capacitor C19. H40 (C19) Differential H47, Input Used for easy installation of through-hole resistor R33 for non-isolated H48 Resistor differential sensing in Remote Sense Operation. (R33) Differential H51, Input Used for easy installation of through-hole resistor R41 for non-isolated H52 Resistor differential sensing in Remote Sense Operation. (R41) H55, H56 Soft-start Used for easy installation of the through-hole capacitor on top of default 0.1uF Capacitor to soft-start the PRM output voltage in Remote Sense Operation. (C24) H46, H45 Used to insert wires to hook up the network analyzer measuring probes to measure stability in Remote Sense Operation. H30, CS+ Used to insert test leads to measure the voltage across R25. H31 CS- UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 9 UG:016 vicorpower.com J15 J11 H26 TP24 TP23 H23 TP62 TP61 G SG Q10 SOT23_3 F10 C16 2220 C15 2220 PIN i ON/OFF CONTROL R21 0603 PIN i TP66 TP65 D S 2220 C17 L10 1206 R24 1 S11 2 3 H58 H57 TP58 Cin TP55 TP53 TP51 TP49 2220 H35 TP33 H22 TP47 C25 TP30 H28 NC2 NC1 PR NC3 TM PC H15 TP13 TP21 R12 0603 TM H16 TP14 SG R13 0603 VS H17 TP15 R14 0603 RE H10 TP16 R15 0603 NC4 H18 H34 PRM2_HALF_JLEAD -IN +IN NC2 NC1 PR GND TP34 SG SG TP60 HS10 -OUT +OUT VC NC4 IF NC3 VS PS10 TP22 RE SG TP17 R16 0603 PC H11 TM PC PRM SIGNAL PIN TEST POINTS AND FIXED RESISTORS TP12 R11 0603 NC3 TP45 TP11 R10 0603 PR PIN TP56 i TP10 H14 TP18 H36 H29 TP36 TP35 H37 -OUT H38 IMON TP59 TP32 2220 C26 1206 R22 SG V OUT V- +IN V+ RG -IN TSOT23_6 U10 2512 6 5 4 TP68 H31 TP29 0603 VCC C18 SG R26 1206 L11 1206 R23 VS 1210 C11 C13 TP26 C14 TP27 TP25 2 9 -OUT -OUT 10 3 7 VC 5 +SENSE 4 2 4 6 8 10 2 4 6 8 10 7 VC_OUT 1 3 5 7 9 J13 1 3 5 7 9 J10 6 Applications Engineering: 800 927.9474 9 9 +S -S 10 -SENSE 8 7 8 TP64 J16 J12 VTM_-IN 4 2 J14 5 3 1 V_TM V_PC V_IM 6 -OUT TP63 VTM_-IN 10 SLAVE REMOTE SENSE (Differential) LOCAL SENSE (Single Ended) CONNECTOR FRONT VIEW 5 3 1 -OUT +OUT +OUT -OUT +OUT +OUT 6 4 2 H33 VC 8 H32 VTM_TM VTM_PC VTM_IM H24 1 1210 1210 1210 Cout C12 POUT i H27 NC4 IF H25 PRM_+OUT PR i +S i -S S10 SW_21910MST RE MODE SELECT VCC i POUT LOCAL SENSE_+ i POUT +SENSE_B -SENSE_B VTM_TM -SENSE +SENSE POUT i ON 20 19 18 17 16 15 14 13 12 11 TM SG EAO IMON REF_EN_B CURRENT SENSE AMPLIFIER 1 2 3 TP67 R25 TP28 VC_OUT R20 0603 NC2 POUT H30 i R19 0603 TP20 NC1 H20 TP57 PRM_+OUT VC NC4 IF RE VS TP31 TP54 TP52 TP50 TP48 TP19 H19 R18 0603 IF H21 TP46 R17 0603 VC H12 Remoste Sense PRM evaluation board schematic 1 2 3 4 5 6 7 8 9 10 H13 Schematic Schematic for half-chip and full-chip Remote Sense PRM evaluation board is same. Figure 3a. Page 10 SG SGND TRIM POT EXT TRIM R46 0603 PR PC SG P11 2 4 6 T P72 CN 6_DIGIKEY_95278 1 3 5 CO NN3PIN J17 CONN3PIN J18 TRIM/TM CONTROL SELECT R3 5 0603 R4 0 SIGNALS FOR PARALLELING H54 R3 8 1206 T P70 T P42 T P40 T P71 3 2 1 H50 3 2 1 T P69 TM EXT AL SGND AL POT H53 R3 7 1206 T P74 T P41 T P39 H49 T P73 SG T P75 P10 2 4 6 NC3 T P76 CN6_DIGIK EY_95278 1 3 5 AL/NC CONTROL SELECT R3 4 0603 R3 9 Note: Components for TRIM and AL controls are not applied. REF_ EN_ B EAO 0603 C23 H43 1 IN U12 SG R4 5 1206 R4 4 1 1206 C19 R4 3 1206 SG 3 2 U11A SO8 R28 1206 H42 H40 H56 1206 C24 H55 1206 C22 H44 VREF T P43 T P44 R36 1206 1206 R3 2 SG VOLTAGE SENSE AND ERROR AMPLIFIER 7 6 5 U11B R42 1206 R31 1206 REMOTE SENSE CONTROL CIRCUITRY VOLTAGE REFERENCE SG SOT 23_3 C21 0603 VCC C20 1206 H41 H39 2 OUT vicorpower.com G ND UG:016 3 8 H51 R41 1206 R3 3 1206 R2 9 H47 1206 R2 7 1206 T P37 H52 H48 H46 T P38 -SENSE_B +SENSE_ B R3 0 1206 IMON LOCA L SENSE_+ H45 Remoste Sense PRM evaluation board schematic 4 ADAPTIVE LOOP CONTROL CIRCUITRY Schematic (Cont.) Figure 3b. Applications Engineering: 800 927.9474 Page 11 Assembly Drawings H57 C17 L10 PS10 PF43 PF44 H56 PF46 R23 J13 H32 J14 C14 C13 C11 C12 PF19 H35 PF49 H33 H36 H27 H25 H24 H11 H17 H34 H12 H16 H18 H13 H21 H10 H22 H15 H19 H14 PF16 J16 PF17 TP26 TP25 PF15 TP27 PF14 TP17 PF13 PF12 TP14 PF11 TP34 PF10 TP18 PF09 TP13 PF08 TP15 PF07 TP21 TP16 PF06 TP10 PF05 TP12 PF04 TP22 PF03 TP11 TP19 PF02 PF01 TP20 J17 J18 R46 H20 TP33 FID01 TP31 H44 H43 C20 R28 H42 J10 L11 PF18 J15 PF41 PF38 H41 C19 H29 R26 PF45 R25 PF20 TP44 TP43 H55 H40 U11 R32 U10 C18 PF39 PF40 FID02 PF37 PF48 H58 C16 R29 PF36 PF35 C21 R36 J12 PF42 H26 R24 C15 R27 R15 R13 R18 R14 R17 R22 HS10 PF32 TP37 PF47 TP32 Q10 PF22 R10 R16 R12 R19 R20 R11 R30 TP38 S11 R21 PF23 TP24 F10 TP23 H23 H45 PF33 H39 P11 PF31 P10 H28 R33 PF30 H48 PF50 H51 R41 PF29 TP29 H31 H52 TP30 R31 C22 R42 C24 PF28 TP36 H38 R35 S10 PF27 PF34 TP39 R34 TP41 PF26 R43 H46 H47 PF24 R45 R44 TP28 H30 R38 PF25 U12 C23 TP35 H37 R37 H53 R40 TP40 H50 J11 H49 R39 TP42 Top view: Half-chip evaluation board assembly drawing H54 Figure 4a. C17 H57 H31 H30 TP44 H56 J13 L11 H32 UG:016 vicorpower.com PF16 H27 PF17 J16 TP27 H25 H24 PF15 TP26 PF14 TP25 H11 H17 PF13 TP17 PF12 TP14 H34 H12 PF11 TP34 PF10 TP18 H16 H18 PF09 TP13 H21 PF08 TP15 PF07 TP21 H13 H10 PF06 TP10 PF05 TP16 H15 H22 PF04 TP12 PF03 TP22 H14 H19 PF02 TP11 TP20 PF01 TP19 H20 J18 R46 J17 PF42 H36 TP33 J14 TP32 PF49 H33 C14 C13 C12 C11 PF19 H35 FID01 PF41 FID02 R28 C20 R23 PF18 J15 TP31 H44 H43 H40 C19 H42 J10 PF46 R25 PF20 PF38 R26 PF45 TP29 R22 PS10 PF44 U10 H29 PF48 H58 C16 C15 C18 PF39 PF40 R36 R32 R29 PF43 R24 L10 R27 TP28 PF22 F10 TP24 H26 R15 R13 R18 R14 R17 H37 R10 R16 R12 R19 R20 R11 PF37 C21 TP37 TP35 Q10 PF23 S11 R21 TP23 H23 R30 TP38 HS10 J12 H41 H45 PF32 P11 PF31 PF36 PF35 H39 PF30 R33 PF33 PF50 P10 C24 H55 H51 R41 PF29 U11 H52 R31 C22 R42 H48 H28 PF47 PF28 H38 S10 TP30 TP43 R43 TP36 R35 PF27 H46 H47 TP41 TP39 R34 PF26 PF34 R38 PF24 PF25 R45 R44 U12 H50 R37 H53 C23 R40 TP40 J11 H49 R39 TP42 Top view: Full-chip evaluation board assembly drawing H54 Figure 4b. Applications Engineering: 800 927.9474 Page 12 Assembly Drawings (Cont.) Figure 4c. Bottom view: Half-chip/Full-chip evaluation board assembly drawing TP73 TP69 TP70 TP74 TP61 TP63 TP72 TP76 TP71 TP75 TP65 TP68 TP67 TP57 C25 C26 TP66 TP59 TP56 TP58 TP64 TP62 TP46 TP48 TP54 UG:016 TP50 vicorpower.com TP60 TP52 TP49 TP45 TP51 TP47 TP55 TP53 Applications Engineering: 800 927.9474 Page 13 Bill of Materials Following table describes the most common components of full chip and half chip Remote Sense PRM evaluation boards. Table 5. Common components Reference Manufacturer Description Manufacturer Part Number Designator C11, C12, C13, C14 CAP X7R 2.2uF 10% TDK CORP OF AMERICA C3225X7R2A225KT5LOU 100V 1210 .102 MAX HT C15, C16, C17 CAP X7R 4.7uF 20% 100V 2220 TDKC5750X7R2A475M C18, C21, C23 CAP X7R .01uF 10% 100V 0603 MURATAGRM188R72A103KA01J C20* not applied– use sockets CAP X7R 4700pF 10% 50V RADIAL AVX CORP SR155C472KAR CAP X7R .10uF 10% AVX CORP 12061C104KATMA C24 100V 1206 CIN CAP ALEL 22uF 20% 100V RADIAL 8 X 11.5 PANASONICEEU-FC2A220 F10 Design Specific – see Table 5 H10 to H58 PIN RECPT .015/.025 DIA 0667 SER TH MILL-MAX MFG CORP J10, J13 CONN 10 PINS 2.54MM PITCH DUAL ROW SM HO GCTBG225-10-A-N-A J14 JACK VERTICAL MECH THRU HOLE TEKTRONIX131-5031-00 J17, J18 CONN 3 POS WIRE TO BOARD SMD AVX CORP 478-6170-2-ND JUMPER_HEADER JUMPER SOCKET XJ8A OMRON ELECTRONICS XJ8A-0211 L10, L11 IND 0.1uH 20% 32.5A 2525 VISHAY/DALEIHLP2525CZERR10M01 0667-0-57-15-30-27-10-0 P10, P11 Not Applied PCB Design Specific – see Table 5 PS10 Design Specific – see Table 5 Q10 FET 2N7002 SOT-23 ON SEMICONDUCTOR 2N7002LT1G R21 RES 10K OHM 1/10W 1% 0603 KOA SPEER RK73H1J1002FTD R22 RES ZERO OHM JUMPER 2A 1206 KOA SPEER RK73Z2BTTD R23, R24 RES 1 OHM 1/4W 5% 1206 KOA SPEER RK73B2BTTE1R0J R25 UG:016 Design Specific – see Table 5 vicorpower.com Applications Engineering: 800 927.9474 Page 14 Bill of Materials (Cont.) Following table describes the most common components of all four versions of PRM® evaluation boards. Table 5 (Cont.). Common components Reference Manufacturer Manufacturer Description Designator Part Number R26 Design Specific – see Table 5 – Remote Sense Operation – set the constant current limit R28* – not applied – use sockets RES 20K OHM 1/4W 1% AXIAL KOA SPEER MF1/4DCT52R2002F R29 RES 54.9K OHM 1/4W 1% SMD 1206 KOA SPEER RK73H2BTTE5492F R30 RES 20 OHM 1/4W 1% 1206 KOA SPEER RK73H2BTTD20R0F R31, R42 RES 1.27K OHM 1/4W 1 % SMD 1206 KOA SPEER RK73H2BTTE1271F R34 Not Applied R35 Not Applied R36 KOA SPEER RES 1K OHM 1/4W 1% 1206 RK73H2BTTE1001F R39, R40 Not Applied R43 RES 10K OHM 1/4W 1% 1206 KOA SPEER RK73H2BTTE1002F R44 RES TRIM POT 10K OHM 1/2W 10% TH COPAL ELECTRONIC CT94EY103 R45 RES 1K OHM 1/4W 1% KOA SPEER RK73H2BTTE1001F SMD 1206 R46 RES 1 OHM 1/10W 1% 0603 PANASONIC ERJ-3RQF1R0V S10 MECH SMD 10-POS DIP SWITCH CTS ELECTROCOMPONENTS 219-10MSTRF S11 SW TOGGLE SPDT C & K COMPONENTS GT11MSCBE 1 POS SMD TP10 to TP44 TEST POINT, SURFACE MOUNT KEYSTONE U10 IC HV I SENSE LMP8645HV TSOT-6 NATIONAL SEMICONDUCTOR LMP8645HVMKE/NOPB U11 IC DUAL OPAMP LM6142AIM 8PIN SO NATIONAL SEMICONDUCTOR LM6142AIMNOPB U12 IC VREF 1.25V REF3312 SOT23 3 TI 5017 REF3312AIDBZT Please note that R28 and C20 are through-hole default compensation components required for Remote Sense operation. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 15 Bill of Materials (Cont.) Following table describes the design specific components of all four versions of PRM® evaluation boards. Table 6. Design specific components Reference Manufacturer Description Manufacturer Designator Part Number Evaluation board number: PRD48BF480T400B00 PS10 REMOTE SENSE PRM FULL VICORPRM48BF480T400B00 CHIP 400W R26 RES 215K OHM 1/4W 1% 1206 KOA SPEER R25 RES I SENSE 5m OHM 1W 1% 2512 VISHAYWSL25125L000FEA F10 FUSE 20A 125VAC FAST 10.1X3.1 SMD LITTELFUSE0456020.ER PCB SNGLTD PCB FULL PRM CONFIG CB VICOR39573 Evaluation board number: PRD48BH480T200B00 PS10 REMOTE SENSE PRM HALF VICORPRM48BH480T200B00 CHIP 200W R26 RES 215K OHM 1/4W 1% 1206 KOA SPEER R25 RES I SENSE 10m OHM 3W 1% 2512 BOURNSCRA2512-FZ-R010ELF F10 LITTLE FUSE 10 AMP R451010.MRL LITTELFUSE0451010.MRL PCB SNGLTD PCB HALF PRM CONFIG CB VICOR38693 RK73H2BTTE2153F RK73H2BTTE2153F Evaluation board number: PRD48BF480T600A00 PS10 REMOTE SENSE PRM FULL CHIP 600W VICOR R26 RES 178K OHM 1/4W 1% 1206 KOA SPEER RES I SENSE 4m OHM 1W 1% 2512 PANASONIC ERJM1WSF4M0U F10 FUSE 25A 125VAC FAST 10.1X3.1 SMD LITTELFUSE 0456025.ER PCB SNGLTD PCB FULL PRM CONFIG CB VICOR 39573 R25 UG:016 vicorpower.com PRM48BF480T600A00 RK73H2BTTE1783F Applications Engineering: 800 927.9474 Page 16 VTM® Evaluation Boards The Remote Sense PRM evaluation board is designed to work with all types of VTM® evaluation boards to facilitate testing of virtually any PRM®/VTM combination. The VTM evaluation board contains dual connectors designed to mate with J10 and J13 on PRM evaluation board. The additional signal connector is used to transfer VTM signal pins, as well as S+ and S- signals between boards. The S+ and S- signals are tied to the VTM output using local sense resistors and can be used for implementing non-isolated remote sense as described in a later section. Board also provides the ability to inject an AC signal for measuring the loop response and break the isolation for non-isolated remote sense using PRM and VTM. Figure 5. VTM evaluation board Figure 6. VTM evaluation board connector pin out (front view) VTM -IN NC VS- +IN +IN -IN VC -IN IM-VTM TM-VTM NC PC-VTM VS+ +IN +IN -IN VC -IN VTM evaluation board signal connector UG:016 vicorpower.com VTM evaluation board power/signal connector Applications Engineering: 800 927.9474 Page 17 Figure 7. Remote Sense PRM evaluation board connection to VTM evaluation board Recommended Test Equipment The following is a list of recommended test equipment. 1. DC power supply: 0 - 80 V, 600 W minimum 2. Load: Rated appropriately based on output voltage, current and power requirements. 3. Digital multi-meters (DMMs) 4. Oscilloscope + probes 5. Function generator (for external enable/disable) 6. Auxiliary bench voltage supply 7. Network analyzer 8. Interconnect wires, cables and fastening hardware. 9. Calibrated input and output shunts, appropriately rated (for efficiency measurements) 10. Trim pot screwdriver 11.Fan 12. Datasheets of requisite PRM® and VTM® device used. 13. Safety glasses 14. Thin bladed tool for wire extraction from paralleling connectors (AVX part number: 06-9276-7001-01-000) Push Pin Heat Sink Installation Each PRM and VTM evaluation board comes with its own heat sink and push pins for installation. Before testing, it is highly recommended that heat sinks be installed in the appropriate location for each board. When installing the push pin heat sink, use caution not to exceed the maximum compressive on the device listed in the data sheet. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 18 Line and Load Connections n Make sure that input power supply is OFF. n Connect the input power supply positive lead to the +IN input lug of the evaluation board. n Connect the input power supply return lead to the –IN input lug of the evaluation board. n Connect the output lug +OUT to the positive terminal of the electronic load. n Connect the output lug –OUT to the return terminal of the electronic load. n Verify proper polarity of the connections. n Place the input capacitance 22 uF, 100 V. n Turn the FAN ON. n Have the latest version of the datasheet. Board Operating Modes Remote Sense PRM evaluation board supports different Remote Sense configurations. Therefore, operating mode selection switch S10 is provided on the board for selection of the following operating modes: n Remote Sense: local sensing (single ended) n Remote Sense: non-isolated remote sense (differential) n Slave (for array operation) Figure 8. Mode select switch VCC REF_ EN_ B V T M_T M i POU T LOCA L SENSE_ + i POU T +SENSE_B -SENSE_B IMON SG S10 SW_ 21910MST 1 2 3 4 5 6 7 8 9 10 ON 20 19 18 17 16 15 14 13 12 11 EAO i -S TM -SENSE +SENSE PR PRM_ +OUT IF NC4 RE VS UG:016 vicorpower.com i +S Applications Engineering: 800 927.9474 Page 19 Figure 9. Switch configuration ON OFF LOCAL SENSE (Single Ended) using PRM ON OFF REMOTE SENSE (Differential) using PRM and VTM ON OFF SLAVE using PRM Postion number 1 2 3 4 5 6 7 8 9 10 Figure 9 provides the illustration for how to configure the switch for each operating mode. Common Features in all Modes of Operations n On / off control to enable and disable the PRM® in the presence of input power. n Using switch S11 or n Open drain MOSFET using external circuitry or function generator n Input filtering (inductor and ceramic capacitors) n Output filtering (inductor and ceramic capacitors) n Sockets for easy installation of input and output electrolytic capacitor n Test points for current sensing n Kelvin test points for measurement of input voltage, output voltage and all signal pins of the PRM. n Sockets for each test point for easy installation of through-hole components and solid wires to facilitate the wiring to external circuitry and test equipment. Figure 10. H23 1 S11 2 3 T P65 PC D ON / OFF control G Q10 SOT 23_3 R2 1 0603 S T P23 T P24 T P66 SG H26 ON / OFF CONTROL UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 20 Remote Sense Operating Mode using PRM®: Local Sensing (Single Ended) Mode select switch S10 setting: keep the switch S10 setting at all positions as shown in following illustration. Figure 11. ON OFF Local Sensing (single ended) Postion number LOCAL SENSE (Single Ended) 1 2 3 4 5 6 7 8 9 10 The following table describes the switch configuration. Table 7. Switch configuration in local sensing Switch Position Number ON or OFF Connection 1OFF TM pin must be left open. This switch position cannot be put in the ON position. PR pin is connected to output of external error amplifier. 2 ON 3ON IF pin is connected to output of external current sense amplifier to set constant current limit. 4ON RE pin is connected to input of the external voltage reference circuit to generate voltage reference for external error amplifier. 5 ON VS pin is connected to power VCC of the op-amp and current sense IC. 6 OFF NC pin must be left open. This switch position cannot be put in the ON position. 7ON PRM +OUT pin is connected to local sense (single ended) of the remote sense control circuitry. 8 Don’t care 9 OFF See next Remote Sense Operation 10 OFF See next Remote Sense Operation Figure 12. Remote Sense: local sensing (single ended) control circuitry BLUE highlight = Pre-installed component GREEN highlight = user installed component H 39 Preinstalled component and connections H 43 H 41 H 40 1206 C19 H 42 OPEN 1206 C22 VCC SG OPEN 1206 R32 1 4 3 5 7 2 VREF U11A SO8 SG R36 1206 1K R29 H 47 1206 54.9K R31 1206 1.27K SG C21 0603 8 To PR through S10 TP38 H 45 H 46 R28 1206 20K C20 1206 4.7nF 6 H 51 AC signal injection IMON OPEN TP37 User installed component EAO R27 1206 H 44 H 48 R33 OPEN 1206 H 52 U11B R41 OPEN 1206 R30 1206 20Ω To PRM +OUT through S10 LOCAL SENSE_+ +SENSE_B -SENSE_B R42 1206 1.27K In this configuration, PRM operates in Remote Sense. PRM module output voltage is sensed through divider formed by R29 and R31. U11B is configured as buffer as shown in Figure 11 and provides the sense voltage to error amplifier U11A. R33, R41 and R27 are left open, reserved for differential sensing and current sensing. R29 is set to limit the upper trim range based on a maximum reference voltage of 1.25 V. Note that by default compensation components are not installed and required for operation. Default compensation components are provided with the board as described in a later section. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 21 Remote Sense operating mode using PRM® and VTM®: Non-Isolated Remote Sensing (Differential Sensing) Mode select switch S10 setting: keep the switch S10 setting at all positions as shown in the following illustration. Figure 13. ON OFF Remote Sense (differential) Postion number REMOTE SENSE (Differential) 1 2 3 4 5 6 7 8 9 10 Note: To use this configuration, the VTM isolation must be broken by tying VTM -IN and VTM -OUT together. The following table describes the switch configuration. Table 8. Switch configuration in differential sensing Switch Position Number ON or OFF Connection 1 OFF TM pin must be left open. This switch position cannot be put in the ON position. 2 ON PR pin is connected to output of external error amplifier. 3ON IF pin is connected to output of external current sense amplifier to set the constant current limit. 4ON RE pin is connected to input of the external voltage reference circuit to generate voltage reference for external error amplifier. 5 ON VS pin is connected to power VCC of the op-amp and current sense IC. 6 OFF NC pin must be left open. This switch position cannot be put in the ON position. 7OFF PRM +OUT pin is NOT connected to local sense (single ended) of the remote sense control circuitry. 8 Don’t care 9ON VTM +OUT (+SENSE) pin is connected to positive input (+SENSE_B) of the differential buffer of remote sense control circuitry. 10ON VTM –OUT (-SENSE) pin is connected to negative input (-SENSE_B) of the differential buffer of remote sense control circuitry. Figure 14. Remote Sense: non-isolated remote sensing (differential) control circuitry BLUE highlight = Pre-installed component GREEN highlight = user installed component H 39 Preinstalled component and connections H 43 H 41 H 40 1206 C19 H 42 OPEN TP37 User installed component OPEN 1206 C22 VCC SG 1 4 3 VREF SG UG:016 vicorpower.com R36 1206 1K R29 H 47 1206 R31 1206 1.27K 5 7 2 U11A SO8 OPEN 1206 R32 SG C21 0603 8 To PR through S10 IMON TP38 H 45 H 46 R28 1206 20K C20 1206 4.7nF EAO R27 1206 H 44 6 H 51 R33 1206 U11B R41 1206 H 48 R30 1206 LOCAL SENSE_+ +SENSE_B To VTM ouput (+S/–S) through S10 and J10 H 52 -SENSE_B R42 1206 1.27K Applications Engineering: 800 927.9474 Page 22 In this configuration, the PRM® and VTM® evaluation boards are connected together to form a PRM / VTM pair and regulation is performed at the VTM module output. The +SENSE and -SENSE connections are made at the VTM output through connector J10. This is a non-isolated configuration and therefore the VTM isolation must be broken by tying the VTM -OUT and VTM -IN pins together. The VTM evaluation board has provisions for easily breaking the isolation. U11B is configured as a differential amplifier with gain set for appropriate output voltage. R33 and R41 set the gain. POT R44 can be used to set the required voltage at the VTM output. Maximum output voltage can be set for maximum 1.25 V reference voltage. R33 and R41 is calculated using following equation. R33 = R41 = VOUT_SET (MAX) • 1.27kΩ 1.25 V Equation 1 Where: VOUT_SET (MAX) is the maximum VTM output trim voltage Please note that R33 and R41 are not populated by default. Sockets can be used to populate through-hole resistors R33 and R41. In order to configure the evaluation boards for non-isolated remote sense the following steps must be taken: Connect the PRM and VTM evaluation boards together 1. 2. Configure the operating mode switch as described 3. Break the isolation by connecting VTM-IN and -OUT together 4. Calculate and install the appropropriate differential sense resistors (R33 and R41) 5. Install compensation components C20 and R28 Remote Sense Compensation Components By default, compensation components are not populated, and are required for operation. Please note that board comes with default through-hole compensation components C20 and R28 that can be used to get a baseline for Remote Sense operation. Sockets can be used for easy installation of C20 and R28. These components are not optimized and will have low bandwidth response. Transient response can be improved by adjusting the compensation components as outlined in the PRM datasheet. It is recommended to use a network analyzer to measure the closed loop frequency response when adjusting compensation. The PRM and VTM boards provide test points which can be used to inject the network analyzer AC signal and measure the closed loop response. For PRM Remote Sense mode (single ended local sense), test points TP37/TP38 and H46/ H45 are in series between the PRM +OUT and the voltage sense resistors and should be used. For PRM-VTM Remote Sense mode (differential sense) test points are provided on the VTM board in series with the +S connections (Labeled “AC Sig Inj +/-“) and should be used. Trim and Soft-start Adjustment in Remote Sense Operation Trim and soft start adjustment in Remote Sense Operation is set by the reference voltage network shown below. The PRM evaluation board is normally configured for a 20 V to 55 V trim range. Trim POT R44 is used to trim the output voltage in Remote Sense Operation. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 23 The slew rate of the output voltage during startup may be controlled by controlling the rate-of-rise of the voltage at VREF node. This can be achieved using soft-start capacitance C24. By default, C24 is populated with 0.1 uF ceramic capacitance. Sockets H55 and H56 can be used for installation of additional through-hole soft-start capacitance. It is not recommended to extend the soft start beyond 10msec. Figure 15. Voltage reference circuit H55 REF_EN_B OUT 2 1 IN C23 3 TP43 R44 C24 R45 1206 GND 0603 VREF R43 1206 U12 1206 SOT23_3 TP44 SGND H56 VOLTAGE REFERENCE Current Limit Adjustment in Remote Sense Operation In Remote Sense Operation, current feedback is provided externally. The current limit set point is a function of the current sense amplifier gain, the shunt resistor and the internal current limit threshold of PRM. Full chip PRM evaluation board has 5 mΩ current shunt whereas half chip PRM evaluation board has 10mΩ current shunt. The IFB current limit threshold is fixed at 2.0 V. The gain of the current sense amplifier can be changed per Equation 2 in order to adjust the current limit. Resistor R26 set the gain of the current sense amplifier. R25 is the current shunt. GCS = VIFB_IL Equation 2 ILIMIT (SET) • R25 By default, R26 is installed for the current limit approximately 10% above rated output current. The current limit setpoint can be changed by adjusting the value of R26 and appropriately setting the gain of the current sense IC. Slave Operating Mode (Arrays) Mode select switch S10 setting: keep the switch S10 setting at all positions as shown in the following illustration. Figure 16. ON OFF Slave Postion number SLAVE 1 2 3 4 5 6 7 8 9 10 Slave operation is required for constructing arrays of parallel devices as described in the next section. Switch all the positions to OFF, except position #3. Slave PRMs receive their control signal (PR) from an external remote sense circuit. Switch at position #3 is on to enable the constant output current limit. External Remote Sense circuit controls the array of voltage. UG:016 vicorpower.com Applications Engineering: 800 927.9474 Page 24 Paralleling The paralleling and current sharing capability of the devices can be demonstrated by stacking multiple evaluation board and interconnecting the inputs and outputs with standoffs of sufficient current rating to create a parallel array. See Figure 17 below. One board should be configured normally for Remote Sense operation and placed on top for easy access to control circuitry. The remaining PRMs should be configured as Slaves and placed underneath. When paralleling PRMs, the PC, PR and SG pins should be connected together. Dual paralleling wire to board connectors (J17 and J18) are used for transferring signal pins (PC, PR and SG) in parallel operation from board to board. These connectors provide simple strip and insert option and accept 18-24 AWG solid wires. PR and SG wires can be twisted to minimize noise pick-up. Note that when using J17 and J18, SG pins will be connected together through an on board 1 OHM series resistors to decouple signal grounds. VTM® boards can also be connected in parallel to create high power PRM-VTM arrays. VTM input and outputs need to be connected in parallel using same size standoffs. Each VTM requires a VC signal from a PRM® in order to start and it is recommended to connect one PRM VC to one VTM VC using the connector J13 when possible. If needed a single PRM VC can be used to drive up to two VTMs (will require additional off board connections). Figure 17. Paralleling of PRM evaluation board Top - Master Bottom - Slaves Interconnect signals Conclusion The PRM® evaluation board is a flexible tool which allows users to implement and perform basic testing on various configurations, including PRM-VTM® module combinations. This user guide covers some basic topics; however, it cannot describe every scenario. If additional information required, please contact Vicor Applications Engineering. The Power Behind Performance Rev 1.2 12/14 vicorpower.com Applications Engineering: 800 927.9474 Page 25