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. 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. vicorpower.com Applications Engineering: 800 927.9474 Page 2 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. 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. Output Connector Ratings Connector 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. vicorpower.com Applications Engineering: 800 927.9474 Page 3 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. 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. vicorpower.com Applications Engineering: 800 927.9474 Page 4 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 5A fuse in F01 protects against overcurrent. 330W at 93% efficiency draws 355W. At 85V input, 4.17A is drawn. Z01 is a 20mm 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 5MHz. 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 200V 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. vicorpower.com Applications Engineering: 800 927.9474 Page 5 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 3.3V 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 vicorpower.com Applications Engineering: 800 927.9474 Page 6 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 500kHz and 5MHz. 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 10,000uF capacitor is substituted. This default capacitor is a 25mm x 45mm capacitor that is laid on its side. There are also two 2mm holes, 10mm spacing, which can be used for snap in type electrolytic capacitors. Diameters up to 35mm 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 48V bus near 1MHz. 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 vicorpower.com Applications Engineering: 800 927.9474 Page 7 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/AN_Vibrick%20%20 thermManage.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 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 C01 CAPY X7R 4700pF 10% 250V 2220 C02 NOT APPLIED C03 CAPY X7R 4700pF 10% 250V 2220 C04 NOT APPLIED 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 vicorpower.com Applications Engineering: 800 927.9474 Page 8 D05 D06 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 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 OUTPUT WASHER, FLATPAC Generic Generic Generic Generic NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED No Stock No Stock Weco 140-A-126-SMD/03 FW HS01 J01 NOT APPLIED CON 3CKT TERM BLK SMD 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 J04 CONN 5POS SINGLE ROW RIGHT ANGLE Molex WM1893-ND TE Connectivity 1445057-5 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 FOOT, FLIP FIXTURE Generic Generic Generic Generic PAD1 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 R09 RES 2.2 OHM 1/4W 1% 1206 Vishay Dale 541-2.20FFTR-ND Vishay Dale CRCW12062R20FKEA R10 NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED Vishay Dale 541-42.2KFTR-ND Vishay Dale CRCW120642K2FKEA R04 R05 R11 R12 RES 42.2K OHM 1/4W 1% 1206 vicorpower.com Applications Engineering: 800 927.9474 Page 9 R13 R14 SCREW SMALL_PIN STNDFF_ LGFF T01 T02 T03 RES 100 OHM 1/8W 1% 0805 Vishay Dale 541-100CTR-ND Vishay Dale CRCW0805100RFKEA 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 vicorpower.com Applications Engineering: 800 927.9474 Page 10 Figure 6. Schematic diagram vicorpower.com Applications Engineering: 800 927.9474 Page 11 Figure 7. PCB Layout Left, top layer, right, bottom layer. The Power Behind Performance Rev 1.0 02/13 vicorpower.com Applications Engineering: 800 927.9474 Page 12