® PI2003-EVAL1 Cool-ORing ™ Series PI2003-EVAL1 Active ORing Evaluation Board User Guide Cool-ORing™ Series Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 PI2003 Product Description . . . . . . . . . . . . . . . . . . Page 2 Evaluation Board Terminal Description . . . . . . . . Page 2 Evaluation Board Schematic . . . . . . . . . . . . . . . . . Page 3 Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3 Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 4 PCB Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 7 Evaluation Board Mechanical Drawing . . . . . . . . Page 7 PI2003-EVAL1 Evaluation Board featuring the Cool-ORing PI2003 Active ORing controller. The PI2003-EVAL1 Evaluation Board is intended to acquaint the user with the benefits and features of the Cool-ORingTM PI2003 full function Active ORing solution. It is not designed to be installed in end-use equipment. Please read this document before setting up the PI2003-EVAL1 Evaluation Board and refer to the PI2003 product data sheet 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 PI2003-EVAL1 allows the user to test the basic principle and operational characteristics of a low side Active ORing function in a redundant power architecture, while also experiencing the benefits and value of the PI2003 solution versus conventional Active ORing solutions. The PI2003-EVAL1 evaluation board is configured to receive two independent power source inputs, per a typical redundant power architecture, through two Active ORing channels that are combined to form a redundant power output. Each channel contains a PI2003 controller and an N-channel power MOSFET. The MOSFET foot print can take an SO-8 or Power SO-8 MOSFET package. Each channel is capable of up to 6 A. simple way to test the electrical and thermal performance of the PI2003 Active ORing controller. Both dynamic and steady state testing of the PI2003 can be completed on the PI2003-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 start-up and configuration of the evaluation board. Further information on the functionality of the PI2003 can be found in the PI2003 product data sheet. The PI2003-EVAL1 evaluation board is designed with optimized PCB layout and component placement to represent a realistic high density final design for an embedded low side Active ORing solution for -48 Vbus applications requiring up to 6 A. This evaluation board is intended as an easy and Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 1 of 8 Cool-ORingTM PI2003 Product Description The Cool-ORing PI2003 with an external industry standard 100V N-channel MOSFET provides a complete Active ORing solution designed for use in -48 Vbus redundant power system architectures. The PI2003 controller with an N-channel MOSFET enables extremely low power loss with fast dynamic response to fault conditions, critical for high availability systems. The PI2003 controller with a low Rds(on) N-channel MOSFET provides very high efficiency and low power loss during steady state operation. The PI2003 controller provides an active low fault flag output to the system during excessive forward current, light load, or reverse current. Figure 1 shows a photo of the PI2003-EVAL1 evaluation board, with two PI2003 controllers and two N-channel MOSFET used to form the two Active ORing channels. The board is built with two identical Active ORing circuits with options and features that enable the user to fully explore the capabilities of the PI2003 universal Active ORing controller. Terminals Rating Vin1+ to Vin1-, 60 V / 8 A Vin2+ to Vin2- 60 V / 8 A VC1, VC2 -0.3 V to 17.3 V / 40 mA FT1, FT2 -0.3 V to 17.3 V / 10 mA Figure 1 – PI2003 -EVAL1 Evaluation Board (1.8" x 1.8") Terminal Description Vin1+ and Vin1- Power Source Input #1: or bus input designed to accommodate up to 60 V and 6 A continuous current. Vin1+ and Vin1- Power Source Input #2: or bus input designed to accommodate up to 60 V and 6 A continuous current. VC1 Optional Auxiliary Input Voltage #1: to supply PI2003 VC power. VC1 should be 10 V or higher to fully enhance the MOSFET. VC2 Optional Auxiliary Input Voltage #1: to supply PI2003 VC power. VC1 should be 10.V or higher to fully enhance the MOSFET. FT1 PI2003 (U1) Fault Pin: Monitors U1 fault conditions FT2 PI2003 (U2) Fault Pin: Monitors U2 fault conditions Vout + Output +: connected to input return Vout- Output -: connected to MOSFETs sources Table 1 – PI2003-EVAL1 Evaluation Board terminals description Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 2 of 8 Vin1+ Vin2+ BUS(+) A BUS(+) B R5 VC1 R2 24K Not Installed U1 8 SN VC 3 VC1 6 FT1 R1 11k D1 2 Vin1- BUS(- ) A 7 4 Q1 IRF7853 1 5 6 7 8 GATE PI2003 FT SP FC Vout+ C1 1uF 5 C3 2.2uF GND 1 2 3 C4 Not Installed C5 22uF FT1 Vout- R6 VC2 R4 24K Not Installed U2 8 SN VC 2 Vin2- BUS(- ) B 5 6 7 8 7 4 Q2 IRF7853 1 GATE PI2003 FT SP FC VC2 3 6 R3 11k FT2 D2 C2 1uF 5 GND 1 2 3 FT2 Figure 2 – PI2003-EVAL1 Evaluation Board schematic. Item 1 2 QTY 2 1 4 5 2 4 6 6 9 10 11 12 16 2 2 2 2 2 Reference Designator C1, C2 C3 C4 C5 D1, D2 FT1, FT2, VC1, VC2 Vin1+, Vin1-, Vin2+, Vin2-, Vout+, VoutQ1, Q2 R1, R3 R2, R4 R5, R6 U1, U2 Value 1 µF 2.2 uF Not installed 22 µF IRF7853 11 KΩ 24 KΩ Not Installed PI2003 Description Capacitor, MLCC X5R, 1 µF,16 V Capacitor, MLCC X7R, 2.2 uF, 100 V Footprint 0603 1812 1812 Manufacturer Capacitor, Electrolytic, 22 µF 100 V LED, Super Red Turret Test point THIN 0603 TURRET-1528 Lite-On, Inc., Keystone Electronics Turret Test point TURRET-1502 Keystone Electronics 100 V, 8.3 A, N-MOSFET Resistor, 11 KΩ,1/4 W, 5% Resistor, 24 KΩ,1/8 W, 5% SO-8 0805 0805 0805 3mmx3mm; 10-TDFN International Rectifier Picor Active ORing Controller PICOR Table 2 – PI2003-EVAL1 Evaluation Board bill of materials Reference Designator C1, C2 C3, C4, C5, D1, D2 Q1, Q2 R1, R3 R2, R4 R5, R6 U1, U2 Value 1 uF LED N-MOSFET 11 KΩ 24 KΩ Not Installed PI2003 Functional Description VC Bypass Capacitor Output (Load) Capacitor To indicate a fault exists when it is on ORing MOSFET VC Bias resistor LED current limit resistor Optional to connect VC to separate source Picor Active ORing Controller Table 3 – Component functional description Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 3 of 8 Initial Test Set Up Baseline Test Procedure (Refer to Figure 3) 1.0 Recommended Equipment 1.1 Two Isolated DC power supplies - 0 – 60 V; 10 A 1.1.1 If the DC power supply outputs are not isolated, two 10 A 100 V Schottky diodes are required, as shown in Figure 4. 1.2 DC electronic load - 10 A minimum. 1.3 Digital Multimeter 1.4 1.5 1.6 1.7 Oscilloscope. Appropriately sized interconnect cables. Safety glasses. PI2003 Product Data sheet. Figure 3 – Layout configuration for a typical redundant power application, using isolated power supplies. Figure 4 – Layout configuration for a typical redundant power application, using non-isolated power supplies. Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 4 of 8 2.2.3 Before initial power-up follow these steps to configure the evaluation board for specific end application requirements: 2.0 Controller Bias Voltage (VC): 2.1 The PI2003 Controller has a separate input (VC) that provides power to the control circuitry and the gate driver. An internal voltage regulator (VC) clamps the VC voltage to 11 V typically. PI2003 EVAL1 is configured to bias the controllers directly from the bus voltage (Vin1 and Vin2). Two bias resistors (R1 and R3: 11 kΩ, 1/4 W, 0805) are connected from the return input (Vin1+ and Vin2+) to each controller VC pin, see schematic in figure 2. The bias resistors are selected to support -48 V bus voltage (36 V to 60 V). 2.2 If the bus voltage (Vin1 and Vin2) range is different from 36 V to 60 V and higher than the Clamp voltage, 11 V typical, the Rbias value has to be changed using the following equations: 2.2.1 Rbias = Vbusmin – VCclampMAX ICMAX Rbias = 36 V – 12 V = 12 KΩ 2.0 mA Rbias maximum power dissipation is at maximum input voltage. PDRbias = (Vbusmax – VCclampMIN)2 Rbias = (60 V – 10 V)2 12 KΩ = 208 mW Select the value of Rbias using the following equations: Rbias = 2.2.2 For example, if the minimum V(bus) = 36 V and the maximum V(bus) = 60 V Vbusmin – VCclampMAX ICmax 2.3 The PI2003-EVAL1 is configured to allow the customer to use a direct bias voltage to the controller VC pin independent of the bus input. VC1 and VC2 terminals can be connected directly to the controller VC pins after removing R1 and R3 and populating R5 and R6. Calculate Rbias maximum power dissipation: PdRbias = (Vbusmax – VCclampMIN )2 Rbias 3.0 Hook Up of the Evaluation Board, refer to Figures 3 and 4. 3.1 3.1.1. Connect the positive terminal of PS1 power supply to Vin1+. Connect the negative terminal of PS1 Vin1-. Set the power supply to 48 V. Keep PS1 output disabled (OFF). Where: Vbusmin : V(bus) minimum voltage Vbusmax : V(bus) maximum voltage 3.1.2. Connect the positive terminal of PS2 power supply to Vin2+. Connect the negative terminal of PS2 Vin2-. Set the power supply to 48 V. Keep PS2 output disabled (OFF). VCclampMAX : Maximum controller clamp voltage, 12 V VCclampMIN : Minimum controller clamp voltage, 10 V ICMAX : Controller maximum bias current, use 2.0 mA If isolated power supplies are used, Figure 3. 3.2 If non-isolated power supplies are used, Figure 4. 3.2.1. Connect the positive terminal of PS1 power supply to Vin1+ through a Schottky diode. Connect the negative terminal of PS1 Vin1-. Set the power supply to 48 V. Keep PS1 output disabled (OFF). 3.2.2. Connect the positive terminal of PS2 power supply to Vin2+ through a Schottky diode. Connect the negative terminal of PS2 Vin2-. Set the power supply to 48 V. Keep PS2 output disabled (OFF). Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 5 of 8 3.3 Connect the electronic load to the output between Vout and Gnd. Set the load current to 1 A. 3.4 Enable (turn ON) PS1 power supply output. 3.5 Turn on the electronic load. 3.6 Measure the voltage across Q1, connect a voltmeter between Vout- and Vin1-, the voltmeter should read less than 30 mV to assure that the MOSFET is fully enhanced. 3.7 LED D1 should be off indicating that controller U1 has no fault. LED D2 should be on indicating that U2 is in a fault mode and the controller Gate pin output is low. 3.8 Disable (turn OFF) PS1 power supply output. 3.9 Enable (turn ON) PS2 power supply output. 3.11 LED D2 should be off indicating that controller U2 has no fault. LED D1 should be on indicating that U1 is in a fault mode and the controller Gate pin output is low. 3.12 Enable (turn ON) PS1 and PS2. 3.13 Increase output load to 5 A. The power source, PS1 and PS2, should share the load current equally if there output voltages are equal. Both LEDs, D1 and D2, should be off indicating that both controllers Gate pin output is high. 4.0 Input short circuit test 3.10 Measure the voltage across Q2, connect a voltmeter between Vout- and Vin2-, the voltmeter should read less than 30mV to assure that the MOSFET is fully enhanced. 4.1 Apply a short at one of the inputs (Vin1 or Vin2). The short can be applied electronically using a MOSFET connected between low side off the source (Vin1- or Vin2-) and the return (Vin1+ or Vin2+) or simply by connecting Vin- to the return. Measure the response time between when the short is applied and the MOSFET Gate turns off. An example for PI2003 response time to an input short circuit is shown in Figure 5. Figure 5 – Plot of PI2003 response time to reverse current detection Picor Corporation • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 6 of 8 Figure 6a – PI2003-EVAL1 layout top layer. Scale 2.0:1 Figure 6b – PI2003-EVAL1 layout Bottom layer. Scale 2.0:1 Mechancial Drawing 1.800 1.800 Vin1+ 1.600 Cool-ORing Vin2+ 1.300 R1 1.100 FT1 C1 1.450 R2 R5 VC1 Vout+ D1 C5 C3 1.145 C4 Vin1- 0.895 Q1 R3 R4 R6 VC2 0.500 C2 Vout- 0.650 0.535 FT2 D2 Vin2- 0.295 Q2 PI2003-EVAL1 rA 6/2008 Picor Corporation • www.picorpower.com 1.800 1.650 0.830 0.150 0.000 0.000 0.000 PI2003-EVAL1 User Guide Rev 1.0 Page 7 of 8 Vicor’s comprehensive line of power solutions includes high-density AC-DC & DC-DC modules and accessory components, fully configurable AC-DC & 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. No license is granted by implication or otherwise under any patent or patent rights of Vicor. 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 • www.picorpower.com PI2003-EVAL1 User Guide Rev 1.0 Page 8 of 8