EVAL-1000007 Evaluation Board for DualQor Converters Advancing the Power Curve Summary ® SynQor has developed EVAL-1000007, an evaluation board to facilitate testing of our DualQor DC-DC converters. Introduction This application note is a guide to the features, schematic, component placement, and BOM for this evaluation board. The applicable modules are the DualQor DQ series of DC-DC converters. For assistance with testing the performance of our DC-DC power converters, please refer to our application note “Guidelines for Testing SynQor DC-DC Converters”. Contents Section 1 – Input and Output Connections Section 2 – Switches, Trim Resistors, and BNC Connectors Section 3 – Schematic Section 4 – Component Placement Section 5 – Bill of Materials (BOM) Note: This evaluation board was designed for lower voltage converters. Do not apply more than 100 Vdc on the input. Shock Warning: There are areas of this evaluation board that have exposed access to high voltage. Exercise caution to avoid contact with those voltages. Also note that the evaluation board may retain high voltage temporarily after input power has been removed. Exercise caution when handling Application of Input Power: Never apply input power to a converter with a switch closure, such as a knife switch or circuit breaker. That type of action applies input voltage with an uncontrolled very high rate of rise (dV/dt) that could be damaging to the converter and to external components before the converter. Instead, apply input voltage with a controlled rate of rise. Also, ensure input voltage is off before inserting or removing a converter module from the evaluation board Thermal Considerations: When testing converters on an evaluation board, ensure adequate cooling. Apply cooling air with a fan blowing across the converter or across a heatsink attached to the converter. Monitor the converter temperature to ensure it doesn’t exceed the maximum rated per the datasheet specification Sockets: This evaluation board uses sockets to provide the option of testing multiple converters. These sockets are not rated for continuous high currents. Short-term testing is fine, but be aware of this limitation for longerterm testing. The spring fingers in the sockets will add resistance in the power path, which will cause voltage drops at higher currents that could contribute significant errors in regulation and efficiency measurements. These spring fingers also do not provide the thermal cooling path from the module pins to PCB routing that is enabled by soldered connections. This may contribute to higher converter temperatures and error when performing thermal evaluations. For longer-term testing, thermal testing, and permanent installations use soldered connections. Page 1 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 Section 1 – Input and Output Connections Input power is applied through connector JIN1 as Vin(+) and Vin(-). Output power is applied through connectors JO1 and JO2 as Vout_2+, Vout(-), and Vout_1+. See Table 1, 2, and 3 for connector signal descriptions. Table 1: Connector JIN1 Terminal # of Connector Signal Name 1 VIN(+) 2 VIN(+) 3 VIN(+) 4 VIN(-) 5 VIN(-) 6 VIN(-) Terminal # of Connector Signal Name 1 Vout_2+ 2 Vout_2+ 3 Vout_2+ 4 Vout_2+ 5 Vout(-) 6 Vout(-) Terminal # of Connector Signal Name 1 Vout(-) 2 Vout(-) 3 Vout_1+ 4 Vout_1+ 5 Vout_1+ 6 Vout_1+ Table 2: Connector JO1 Table 3: Connector JO2 Note: Please refer to the appropriate SynQor converter datasheet for descriptions of these features. Page 2 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 Section 2 – Switches, Trim Resistors, and BNC Connectors Description of Switches Enable On/Off Switch Toggling switch SONOFF1 ON/OFF to the side closest to the power converter module (up) enables the positive enable converters to turn on and disables negative logic converters. Toggling switch SONOFF1 ON/OFF to the side furthest from the power converter module (down) enables the negative enable converters to turn on and disables positive logic converters. Voltage Trim Switches OUTPUT1 TRIM DualQor converters with a part number for the standard “S” Optional Feature Set have one TRIM pin (converter module pin 6), which adjusts both outputs, Vout1 and Vout2, simultaneously. The evaluation board OUTPUT1 TRIM switch adjusts both output voltages simultaneously by the same amount in the same direction for these converters. To increase both output voltages toggle OUTPUT1 TRIM switch away from converter. This will connect Trim to O/P_RTN (Vout_M) through RTR3 and RTR4. To decrease both output voltages toggle OUTPUT1 TRIM switch towards the converter. This will connect Trim to Vout2 (Vout_2+) through RTR1 and RTR2. Leave OUTPUT1 TRIM switch in the center position when not trimming these outputs. For DualQor converters with a part number for the 2nd TRIM “T” Optional Feature Set, the evaluation board OUTPUT1 TRIM switch will only control the trim of the lower voltage output, Vout2. As described above, to increase Vout2 output voltage toggle OUTPUT1 TRIM switch away from converter. To decrease Vout2 output voltage toggle OUTPUT1 TRIM switch towards the converter. Leave OUTPUT1 TRIM switch in the center position when not trimming this output. The evaluation board comes with zero Ohm resistors installed in positions RTR1 and RTR3. This will produce a trim up of 10 % and a trim down of 10 % when toggling this switch. Refer to the datasheet of the unit under test to determine the resistor values for the desired increase/decrease of the output voltages. OUTPUT2 TRIM DualQor converters with a part number for the 2nd TRIM “T” Optional Feature Set have two TRIM pins (converter module pin 6 and pin A). This allows independent adjustment of each output voltage. The OUTPUT1 TRIM switch adjusts the lower voltage output Vout2 (see section above) and the OUTPUT2 TRIM switch adjusts the higher voltage output Vout1. To increase the output voltage of the higher voltage output Vout1, toggle OUTPUT2 TRIM switch away from converter. This will connect Trim2 to Vout_M (output return) through RTR5 and RTR6. To decrease the output voltage of the higher voltage output Vout1, toggle OUTPUT2 TRIM switch towards the converter. This will connect Trim2 to Vout_1+ through RTR7 and RTR8. Leave OUTPUT2 TRIM switch in the center position when not trimming this output. The evaluation board comes with zero Ohm resistors installed in positions RTR5 and RTR7. This will produce a trim up of 10 % and a trim down of 10 % when toggling this switch. Refer to the datasheet of the unit under test to determine the resistor values for the desired increase/decrease of the output voltages. Page 3 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 BNC Monitoring Point Descriptions JIN2 Converter input voltage +Vin JOUT3 Converter Vout_1 Kelvin sense JOUT4 Converter Iout_2 output current as measured across shunt ROUT1 JOUT6 Converter Iout_1 output current as measured across shunt ROUT2 JOUT9 Converter Vout_2 Kelvin sense CAUTION: Do not connect an oscilloscope probe to JOUT4 or JOUT6. Doing so would connect the scope ground to VOUT_1 and/or VOUT_2 output. Only use isolated DMM’s on these BNC connectors. Page 4 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 Section 3 – Schematic Page 5 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 Section 4 – Component Placement Page 6 www.synqor.com | QMS#065-0000037 | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ® Application Note EVAL-1000007 Section 5 – Bill of Materials (BOM) Table 4: EVAL-1000007 Ref Des Value Tolerance CIN1 47 uF 10 % Package Description CIN2 0.82 uF 10 % 1812 Capacitor, ceramic CIN5 0.1 uF 10 % 1812 Capacitor, ceramic Aluminum Electrolytic CIN6 0.82 uF 10 % 1812 Capacitor, ceramic COUT1 1.5 uF 10 % 1812 Capacitor, ceramic COUT2 OPEN 1206 Capacitor COUT3 0.1 uF 10 % 0805 Capacitor, ceramic X7R 25 V COUT4 1.0 uF 10 % 0805 Capacitor, ceramic X7R 10 V COUT5 0.1 uF 10 % 0805 Capacitor, ceramic X7R 25 V COUT6 1.0 uF 10 % 0805 Capacitor, ceramic X7R 25 V COUT7 0.1 uF 10 % 0805 Capacitor, ceramic X7R 25 V COUT8 OPEN D CASE Capacitor COUT9 OPEN D CASE Capacitor COUT10 OPEN D CASE Capacitor COUT11 OPEN D CASE Capacitor COUT12 OPEN D CASE Capacitor COUT13 OPEN D CASE Capacitor COUT14 OPEN 1206 Capacitor COUT15 0.1 uF 10 % 0805 Capacitor, ceramic X7R 25 V COUT16 1.5 uF 10 % 1812 Capacitor COUT17 OPEN D CASE Capacitor D CASE Capacitor 1812 Capacitor SMB Diode AGC Fuse COUT18 OPEN CY1 3300 pF DIN1 OPEN 10 % F1 15 A LIN 10 uH 20 % ROUT1 0.01 1% Precision Low Ohm 4-Terminal Shunt Resistor ROUT2 0.01 1% Precision Low Ohm 4-Terminal Shunt Resistor RTR1 0 5% RTR2 OPEN RTR3 0 RTR4 OPEN RTR5 0 RTR6 OPEN RTR7 0 RTR8 OPEN Page 7 www.synqor.com 5% 5% 5% | QMS#065-0000037 SMT Power Inductor 0603 Resistor 0603 Resistor 0603 Resistor 0603 Resistor 0603 Resistor 0603 Resistor 0603 Resistor 0603 Resistor | Rev. A | 02/23/15 | Advancing the Power Curve Advancing the Power Curve ®