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UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 1 Introduction The Analog Control 3623 and 4623 ChiP DCM evaluation boards described in this document are designed to be used with the DCM family of isolated, DC-DC converters. The 3623 DCM board is used for the analog control, low input voltage 3623 ChiP products, while the 4623 DCM board is used for the analog control, high input voltage (offline) 4623 ChiP products. The DCM evaluation board can be configured for various enabling and fault monitoring schemes, as well as to exercise various modes of trimming, depending on the application requirements. The evaluation board can be used to evaluate DCMs in either a stand-alone configuration, or as an array of modules. Enable options: 1. On-board mechanical switch (default) 2. External control Trim options: 1. Fixed trim operation (default): the TR pin is permitted to float at initial startup. The DCM disables output trimming and the output trim is programmed to the nominal rated VOUT. 2. Variable trim operation, on-board variable resistor: The trim pin voltage is ratiometric, with a rheostat working against a pull-up resistor inside the DCM to VCC. 3. Variable trim operation, off-board control: The trim pin voltage is controlled via external programming control, which is referenced to the –IN of each specific DCM in the system. Fault monitor options: 1. On-board LED: the FT pin drives a visible LED for visual feedback on fault status. 2. On-board optocoupler: the FT pin drives an on-board optocoupler to bring fault status across the primary-secondary isolation boundary. Analog Control 3623 and 4623 ChiP DCMs Evaluation Board USER GUIDE | UG:017 Arthur Russell VI Chip® Applications Engineering October 2014 Contents Page Introduction 1 Contents 3 Features 3 Board Description 4 General Components 4 Test Points Description 6 Schematic, Assembly Drawing and Bill of Materials 7 Recommended Test Equipment 14 Basic Connections 14 Board Operation Details 14 Trim Control 15 Fault Monitoring 15 Chassis Ground 16 Paralleling 16
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 2 IMPORTANT NOTICE: Hazardous voltages are present on the DCM Evaluation Board under power. PERSONAL CONTACT WITH LINE VOLTAGE MAY RESULT IN SEVERE INJURY, DISABILITY, OR DEATH. IMPROPER OR UNSAFE HANDLING OF THIS BOARD MAY RESULT IN SERIOUS INJURY OR DEATH. Read the precautions below entirely BEFORE using the DCM Evaluation Board. Do not operate the evaluation board unless you have the appropriate safety precautions in place on your bench to guarantee safety. The list below is not comprehensive and is not a substitute for common sense and good practice. nn During operation, the power devices and surrounding structures can be operated safely at high temperatures. nn Remove power and use caution when connecting and disconnecting test probes and interface lines to avoid inadvertent short circuits and contact with hot surfaces. nn Never use a jumper in place of the fuse. nn When testing electronic products always use approved safety glasses. Follow good laboratory practice and procedures. nn Avoid creating ground loops when making measurements of the isolated input or output voltage. nn Care should be taken to protect the user from accidental contact when under power. nn Care should be taken to avoid reversing polarities if connecting to the opposite (solder) side of the board. nn The product evaluation boards described in this document are designed for general laboratory evaluation, and are not suitable for installation in end user equipment. nn Refer to the specific DCM module data sheet for electrical, thermal, and mechanical product details
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 3 These boards provide a convenient way to evaluate/demonstrate the performance of Vicor’s DCM products. Kelvin connections are provided for accurate voltage measurements on power nodes. Sockets are provided to permit quick installation and changing of bulk filtering capacitors. The evaluation board also provides lugs for input/output connections, test points and sockets for easy connection to standard test-equipment, and a high performance air cooled heatsink assembly.
Contents
The evaluation board arrives with the following contents: nn 1 x DCM evaluation board nn 1 x top and belly heatsink assembly (pre-installed) nn 1 x hardware kit
Features
The DCM evaluation board has the following features: 1. Input and output lugs for source and load connections 2. Input fuse (appropriately rated) 3. Basic input filtering, including sockets to add through-hole input aluminum-electrolytic capacitors for additional source decoupling Note: The filtering used in the eval board is for demonstration purposes only and might not be the optimal solution for all applications. For optimal filter design for parallel array application, consult the datasheet of the DCM in use and the online filter design tool at: http://app2.vicorpower.com/filterDesign/intiFilter.do 4. Basic output filtering, including sockets to add through-hole output aluminum-electrolytic capacitors 5. Toggle switch for enabling and disabling the DCM via the ENABLE pin 6. Trim control selection a. Using potentiometer b. Using external voltage source c. Open, to disable trimming and latch the model nominal trim condition 7. Provisions to replace input and output differential mode inductors with wire loops, for oscilloscope/shunt based current measurements 8. Oscilloscope probe jack for accurate, high frequency output voltage measurements 9. Dual paralleling connectors for ENABLE, TRIM, FAULT and SGND signal connections, for daisy chaining control to other DCM evaluation boards in an array 10. Kelvin voltage test points for all power pins 11. Top and bottom heatsink assembly for the DCM
UG:017 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. General Components 1. DCM (PS01) 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 (F01 & F02): Appropriately rated for the DCM model on the board. 4. Input filter: Ceramic input capacitors (C15-C22), filtering inductor (L01) and damping resistor (R08) provide input filtering. Sockets (H01-H02, H03-H04) can be used for easy installation of aluminum-electrolytic input capacitors. The 3623 board also adds H09-H10 for additional input bypassing. 5. Enable / Disable switch (SW01): When actuator is in top position towards “ON” text on the board, the ENABLE pin will be open and the DCM will be enabled. When actuator is in bottom position towards “OFF” text on the board, the ENABLE pin will be connected to SGND and the DCM will be disabled. When switch SW01 is ON, an external voltage source can control the ENABLE state. 6. Header-jumper for trim control (J09): Provides the option to enable the trim function to set the DCM programmed trim value via either the on board trim rheostat or an external voltage source: a. Using potentiometer (R26) b. Using external voltage source. 7. Output lugs: Sized for #10 hardware. Use these lugs to connect the output directly to the load. 8. Output oscilloscope probe Jack (J01): Used for making accurate scope measurements of the output voltage (e.g. ripple). The jack is directly compatible with many common passive voltage probes models. Remove the grounding lead and insulating barrel of the probe and insert the probe tip and barrel directly into the jack, ensuring that the probe tip seats in the center socket of the jack. To avoid the risk of an inadvertent short circuit, do not attempt to install while power is applied. 9. Output filter: Output capacitor (C201), filtering inductor (L02) and damping resistors (R16-R17), and ceramic output capacitors (C02-C05) provide output filtering. Sockets H05-H06, and H03-H04 can be used for easy installation of aluminum-electrolytic output capacitors. 10. High side current sense wire loops: By depopulating the associated inductor and damping resistors, all input or output currents can be passed through a wire loop or use with an oscilloscope current probe. The wire loop is installed at the large pair of plated through-holes near the applicable inductor location. 11. Dual paralleling wire-to-board connectors (J02 and J03): Used for bussing control signals and their reference (ENABLE, SHARE, FAULT, and SGND) across board assemblies during parallel operation. The connector style provides simple “strip and insert” use with 18 – 24 AWG solid wires. Once inserted, a spring loaded barb retains each wire with no need for soldering. To release the wire, insert a thin bladed tool (AVX 06-9276-7001-01-000 or similar) into the slot above each wire entry point.
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 5 Figure 1
3623 DCM evaluation
board photo, top side Figure 2
4623 DCM evaluation
board photo, top side
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 6 Test Points Description Test nodes are labeled and include a SMT test point for attaching miniature probes, clips or hooks. Table 1 Primary referred test point descriptions Table 2 Secondary referred test point descriptions Name Description +IN_FUSED, +IN_FILT, –IN Provide measurement testpoints for the input voltage to the board in various locations, rela- tive to the –IN board lug. +IN_FUSED is taken after input fusing, +IN_FILT is taken after the input filtering network. +IN_DCM, –IN_DCM Provide Kelvin connection to input pins of the DCM. Use these test points for measuring the input voltage at the module, excluding errors due to finite connection resistance leading up to the module. PRI_SG Testpoint for Signal Ground on the primary/input side of the isolation boundary. This is the reference for all primary side control circuitry and all control pins of the DCM. EXT_EN Testpoint to drive the ENABLE signal (relative to PRI_SG) using an external source. PRI_EN Testpoint to measure the ENABLE signal (relative to PRI_SG). EXT_TR Testpoint to drive the TRIM signal (relative to PRI_SG) using an external source. PRI_TR Testpoint to measure the TRIM signal (relative to PRI_SG). PRI_FT Testpoint to measure the FAULT signal (relative to PRI_SG). Name Description +OUT_DCM, –OUT_DCM Output voltage test points provide Kelvin connection to output pin group of the DCM. Use these test points for measuring the output voltage at the module, excluding voltage errors due to finite connection resistance and the module output current. +OUT_DCM_SHNT, +OUT, –OUT Provides measurement testpoints for the output voltage in various locations, relative to the –OUT board lug. +OUT_DCM_SHNT is taken before the output filtering, and +OUT is taken at the +OUT board lug. SEC_SG Testpoints for the +5V bias supply return, and for measuring the FT_SEC fault monitor out- put. FT_SEC Testpoint to measure the FAULT signal relative to SEC_SG once it has passed through the opto-coupler, if used. Bias power must be supplied to +5V for voltage output to appear here. +5 V Testpoint to provide a bias voltage (relative to secondary ground) for the fault opto-coupler, if used.
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 7 Schematic, Assembly Drawing and Bill of Materials J104 J105 +OUT_DCM_SHNT TP1 TP106 TP107 J106 J107 -OUT TP8 +OUT -OUT 1206 C05 L01+IN 1206 C04 1206 C03 1206 C02 L02 +OUT TP4 2512 R17 2512 R16 CHASSIS-GND -IN_DCM +IN_DCM +OUT_DCM 1210 C07 2220 C15 1206 R08 J03 PRI_EN PRI_FT PRI_TR TRIM CONTROL 0603 R09 LED-0805 D01 PRI_SG ENABLE CONTROL 0603 R04 PRI_SG TP104 TP103 TP102 0603 C01 PRI_SGPRI_SG EXT_EN TP33 1210 C09 1210 C11 1210 C13 2220 C16 2220 C17 2220 C18 2220 C19 2220 C20 2220 C21 2220 C22 0603 R19 0603 R20 0603 R18 0402 R504 0402C24 0402 R505 0402C25 PRI_SG 29581 1612 S101 H03 TP101 29581 1612 S102 29581 1612 S103 29581 1612 S104 +OUT_DCM -OUT_DCM J02 2 5 M02 0603 R21 PRI_SG 0603 R22 0603 R23 SEC_SG FT_SEC TP29 1206 FB1 0603 R02 0603 R05 CHASSIS_GND J108 0603 R32 +IN_DCM TP5 -IN_DCM TP7 +OUT_DCM TP6 -OUT_DCM TP9 PRI_SG 0603 R01 EXT_TRIM TP28 PARALLELING CONNECTORS +IN_FUSED TP2 -IN TP27 -IN +IN_FILT TP100 +IN_DCM -IN_DCM +IN_FILT TP3 AD DA CL PRI_EN PRI_FT PRI_TR 0402C23 0402 R503 0603 R118PRI_SER_OUT 0603 R119 0603 R120 PRI_SER_IN PRI_PWM PRI_FT TP32 PRI_TR TP30 PRI_EN TP31 -OUT_DCM +OUT_DCM_SHNT PRI_TR PRI_EN PRI_FT PRI_SG PRI_SG TP34 0603 R24 +5V FAULT INDICATOR 0603 R27 H04 H05 H06 H09 H10 Trim_Pot External_Trim ON/External_Ctrl OFF J09 J10 H08 H07 +OUT -IN +IN -OUT FT EN TR PRIMARY SECONDARY ISOLATION BOUNDRY 3623 PS01 GND HS02 GND HS01 F01 Note: Scope Jack H01 H02 C201 11 3 3 2 2 RES TRIM POT 500K OHM 1/2W 10% TH R26 2010 R25 J01 SW01 One plated through-hole on each side of L02 for optional current loop One plated through-hole on each side of L02 for optional current loop Figure 3
3623 DCM evaluation board
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 8 Schematic, Assembly Drawing and Bill of Materials (Cont.) J104 +IN J105 -IN +OUT_DCM_SHNT TP1 TP106 TP107 J106 +OUT J107 -OUT -OUT TP8 J01 note:ScopeJack One plated through-hole on each side of L02 for optional current loop +OUT -OUT L01 +IN 1206 C02 L02 +OUT TP4 2512 R17 2512 R16 DA CL +IN -IN +OUT -OUT AD PRIMARY SECONDARY ISOLATION BOUNDRY 4623 PS01 CHASSIS-GND -IN_DCM +IN_DCM +OUT_DCM GND HS01 1210 C07 2220 C15 1206 R08 J03 PRI_EN PRI_FT PRI_TR TRIM CONTROL 0603 R09 D01 PRI_SG ENABLE CONTROL 0603 R04 PRI_SG TP104 TP103 TP102 0603 C01 PRI_SGPRI_SG EXT_EN TP33 1210 C08 1210 C09 1210 C10 1210 C11 1210 C12 1210 C13 1210 C14 2220 C16 2220 C17 2220 C18 2220 C19 2220 C20 2220 C21 2220 C22 C201 GND HS02 0603 R19 0603 R20 0603 R18 0402 R504 0402C24 0402 R505 0402C25 PRI_SG 29581 S101 TP101 29581 S102 29581 S103 29581 S104 +OUT_DCM -OUT_DCM F01 J02 2 5 M02 0603 R21 PRI_SG 0603 R22 0603 R23 SEC_SG FT_SEC TP29 1206 FB1 0603 R02 0603 R05 CHASSIS_GND J108 0603 R32 2010 R25 +IN_DCM TP5 -IN_DCM TP7 +OUT_DCM TP6 -OUT_DCM TP9 11 3 3 2 2 R26 RES TRIM POT 500K OHM 1/2W 10% TH PRI_SG 0603 R01 EXT_TRIM TP28 PARALLELING CONNECTORS +IN_FUSED TP2 -IN TP27 -IN +IN_FILT TP100 +IN_DCM -IN_DCM +IN_FILT TP3 AD DA CL PRI_EN PRI_FT PRI_TR 0402C23 0402 R503 0603 R118 0603 PRI_SER_OUT 0603 R119 0603 0603 R120 0603 PRI_SER_IN PRI_PWM PRI_FT TP32 PRI_TR TP30 PRI_EN TP31 -OUT_DCM +OUT_DCM_SHNT PRI_TR PRI_EN PRI_FT PRI_SG PRI_SG TP34 0603 R24 +5V FAULT INDICATOR 0603 R27 SW01 Trim_Pot External_Trim ON/External_Ctrl OFF J09 J10 F02 H05 H06 H03 1206 C03 1206 C04 1206 C05 H04 H07 H08 H01 H02 TR EN FT One plated through-hole on each side of L02 for optional current loop Figure 4
4623 DCM evaluation board
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 9 TOP VIEW U201 R204 R203 R202 R201 L202 L201 J204 D202 C201 J105 J106J104 J107 C206 L203 L204 R205 R206 R207 R208 R214 R223 R224 R225 R226 Q200 Q201 R227 R228 R229 R230 S101 S102 S103 S104 J504 TP1 SW13 R243 R242 R241 R240 R124 R26 R25 R12 R11 L211L210 TP29 TP32 TP31 TP8 TP28 TP26 TP4 H04 H02 H01 R14 R05 R02 R01 J001 U502 U501 U500 U01 TP24 TP23 TP22 TP21 TP20 TP19 TP18 TP17 TP16 TP15 TP14 TP13 TP12 TP11 TP10 TP09 TP08 TP07 TP06 TP05 TP04 TP03 TP02 TP01 SW03SW01 R566 R565 R555 R554 R553 R551 R550 R549 R548 R547 R546 R545 R544 R543 R538 R537 R532 R531 R530 R529 R527 R526 R525 R524 R522 R521 R520 R517 R512 R510 R505 R503 R502 R56 R24 R23 R22 R21 R20 R19 R18 R17 R16 R13 R09 R08 R04 M02 L01 J03J 02 H06 H05H03 FB501 FB500 FB1 TP30 D501 D500 D01 C520 C506 C505 C504 C503 C502 C501 C500 C25 C23 C22 C21 C20 C19 C18 C17 C16 C15 C14C13C12C 11 C10C09C08 C07 C05 C04 C03 C02 C01 TP25 J108 HS01 HS02 PS01 L02 SW04 R32 TP5TP7 TP6TP9 C24 H07 H08 J09J 10 R27 R118 R119 R120 R504 TP2 TP3TP27 TP33 TP34 F01F02 J01 Figure 6 assembly drawing, top side TOP VIEW U201 R204 R203 R202 R201 L202 L201 J204 D202 C201 J105 J106J104 J107 C206 L203 L204 R205 R206 R207 R208 R214 R223 R224 R225 R226 Q200 Q201 R227 R228 R229 R230 S101 S102 S103 S104 J504 TP1 SW13 R243 R242 R241 R240 R124 R26 R25 R12 R11 L211L210 TP29 TP32 TP31 TP8 TP28 TP26 TP4 H04H02 H01 R14 R05 R02 R01 J001 U502 U501 U500 U01 TP24 TP23 TP22 TP21 TP20 TP19 TP18 TP17 TP16 TP15 TP14 TP13 TP12 TP11 TP10 TP09 TP08 TP07 TP06 TP05 TP04 TP03 TP02 TP01 SW03SW01 R566 R565 R555 R554 R553 R551 R550 R549 R548 R547 R546 R545 R544 R543 R538 R537 R532 R531 R530 R529 R527 R526 R525 R524 R522 R521 R520 R517 R512 R510 R505 R503 R502 R56 R24 R23 R22 R21 R20 R19 R18 R17 R16 R13 R09 R08 R04 M02 L01 J03J 02 H06 H05H03 FB501 FB500 FB1 TP30 D501 D500 D01 C520 C506 C505 C504 C503 C502 C501 C500 C25 C23 C22 C21 C20 C19 C18 C17 C16 C15 C13C11 C09C07 C05 C04 C03 C02 C01 TP25 J108 HS01 HS02 PS01 L02 SW04 R32 TP5TP7 TP6TP9 C24 H07 H08 J09J 10 R27 R118 R119 R120 R504 TP2 TP3TP27 TP33 TP34 F01 J01 H09 H10 Schematic, Assembly Drawing and Bill of Materials (Cont.) Figure 5
3623 DCM evaluation board,
assembly drawing, top side
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 10 Table 3 DCM evaluation board BOM, components common to all boards Reference Designator Description Manufacturer Manufacturer Part Number Common Components C01 CAP X7R 0.10µF 10% 16V 0603 AVX 0603YC104KAT2A C02 – C05 CAP X7S 4.7µF 10% 100V 1206 AVX 12061Z475KAT2A C07 – C14 Board specific - See table 4 BOMs C15 – C22 Board specific - See table 4 BOMs C201 Design specific - See table 5 BOMs D01 LED RED 0805 ROHM SML-211UTT86 FB1 FERRITE BEAD 33 OHM 6A 1206 MURATA BLM31PG330SN1L F01, F02 Design specific - See table 5 BOMs HS01 – HS02 Board specific - See table 4 BOMs J02 – J03 CONN 4 POS WIRE TO BOARD AVX 009276004021106 J01 PCB TP ADAPTER, 3.5mm PROBE TESTPATH 131-5031-00 L01 Board specific - See table 4 BOMs L02 IND 0.33µH 20% 50A WURTH 744309033 M02 IC 6 PIN OPTO VISHAY CNY17-3X017T R02, R04, R05, R18, R19, R20 RES 0 OHM JUMPER 0603 KOA RK73Z1JTTD PS01 Design specific - See table 5 BOMs VICOR R08 RES 1 OHM ¼ W 5% 1206 KOA RK73B2BTTE1R0J R16 RES 250 mOHM 1W 2512 VISHAY WSL2512R2500FEA R09, R21 RES 1 KOHM 1/10W 5% 0603 KOA RK73B1JTTD102J R22, R32 RES 49.9 KOHM 1/10W 1% 0603 KOA RK73H1JTTD4992F R23 RES 4.99 KOHM 1/1W 0.1% 0603 THIN FILM TECH CR0603E4991B-T5 R24, R01 RES 0 OHM JUMPER 0603 KOA RK73Z1JTTD R25 RES 0 OHM JUMPER 2010 VISHAY CRCW20100000Z0EF R26 RES TRIM POT 500 kOHM 1/2W 10% COPAL CT-94EW504 S102 - S104 RES 0 OHM JUMPER 1612 COPPER EXCELTOOL & DIE 29581 SW01 SW TOGGLE SPDT 1 POS C&K COMPO- NENTS GT11MSABE JMPSOK for J09 – J10 JUMPER SOCKET XJ8A OMRON XJ8A-0211 Schematic, Assembly Drawing and Bill of Materials (Cont.)
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 11 Table 4a BOM additions, components common to all 3623 DCM evaluation boards Table 4b BOM additions, components common to all 4623 DCM evaluation boards Reference Designator Description Manufacturer Manufacturer Part Number 3623 board components C07, C09, C11, C13 CAP X7R 4700pF 10% 2kV 1210 KEMET C1210C472KGRAC7800 C08, C10, C12, C14 N/A (not present in design) N/A N/A C15 – C22 CAP X7R 4.7µF 20% 100V 2220 TDK C5750X7R2A475M230KA L01 IND 0.33µH 20% 50A WURTH 744309033 HS01 - HS02 3623 DUAL HTSNK VICOR 40526 S101 RES 0 OHM JUMPER 1612 COPPER EXCELTOOL & DIE 29581 CIN @ H01 - H02 CAP ALEL 680µF 20% 63V RADIAL
18 X 20
CHEMI CON ELXZ630ELL681MM20S Reference Designator Description Manufacturer Manufacturer Part Number 4623 board components C07 – C14 CAP X7R 4700pF 10% 2kV 1210 KEMET C1210C472KGRAC7800 C15 – C22 CAP X7T 0.47µF 10% 630V 2220 TDK C5750X7T2J474K250KC L01 IND 1.0µH 20% 13A BOURNS SRP7030-1R0FM HS01 - HS02 4623 DUAL HTSNK VICOR 40519 S101 BEAD 680 OHM 4A 1812 TAIYO YUDEN FBMH4532HM681-T CIN @ H01 - H02 AP ALEL 10µ 20% 450V RAD UNITED CHEMI CON EKXG451ELL100MK20S Schematic, Assembly Drawing and Bill of Materials: (Cont.)
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 12 Schematic, Assembly Drawing and Bill of Materials: (Cont.) Table 5 Example: BOM additions, components which are DCM model specific. Reference Designator Description Manufacturer Manufacturer Part Number Evaluation board number: DCM3623E50M06A8M00 PS01 DCM - 3623 VICOR DCM3623T50M06A8M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P C201 CAP ALEL 10000µF 20% 10V RADIAL 18 x 26.5 NICHICON URS1A103MHD1TN Evaluation board number: DCM3623E50M13C2M00 PS01 DCM - 3623 VICOR DCM3623T50M13C2M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P C201 CAP ALEL 4700µF 20% 25V RADIAL 16 x 25 NICHICON UVY1E472MHD Evaluation board number: DCM3623E50M17C2M00 PS01 DCM - 3623 VICOR DCM3623T50M17C2M00 F02 FUSE 30A 125V AXIAL LITTELFUSE 324 030P C201 CAP ALEL 2200µF 20% 25V RADIAL 16 x 25 NICHICON UPW1E222MHD Evaluation board numbers: DCM3623E50M26C2M00, DCM3623E50M31C2M00 PS01 DCM - 3623 VICOR One of DCM3623T50M26C2M00 DCM3623T50M31C2M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P C201 CAP ALEL 1000µF 20% 50V RADIAL 18 x 20 UNITED CHEMICON EKY-500ELL102MM20S Evaluation board number: DCM3623E50M53C2M00 PS01 DCM - 3623 VICOR DCM3623T50M53C2M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P C201 CAP ALEL 220µF 20% 80V RADIAL 18 x 16.5 NICHICON UPJ1K221MHD6TN Evaluation board numbers: DCM4623EC8G16F0T00, DCM4623ED2J13D0X00, DCM4623ED2H26F0X00 PS01 DCM - 4623 VICOR One of DCM4623TC8G16F0T00 DCM4623TD2J13D0T00 DCM4623TD2J13D0M00 DCM4623TD2H26F0T00 DCM4623TD2H26F0M00 F01 FUSE 5A 450V FAST 6.3 X 32 RADIAL COOPER BUSSMANN BK/PCD-5-R C201 CAP ALEL 1000µF 20% 50V RADIAL 18 x 20 UNITED CHEMICON EKY-500ELL102MM20S
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 13 Table 5 (Cont.) Example: BOM additions, components which are DCM model specific. Reference Designator Description Manufacturer Manufacturer Part Number Evaluation board numbers: DCM4623ED2H31E0X00, DCM4623ED2H53E0X00 PS01 DCM - 4623 VICOR One of DCM4623TD2H31E0T00 DCM4623TD2H31E0M00 DCM4623TD2H53E0T00 DCM4623T02H53E0M00 F01 FUSE 5A 450V FAST 6.3 X 32 RADIAL COOPER BUSSMANN BK/PCD-5-R C201 CAP ALEL 220µF 20% 80V RADIAL 18 x 16.5 NICHICON UPJ1K221MHD6TN Schematic, Assembly Drawing and Bill of Materials: (Cont.) General BOM rules for various DCM Evaluation Boards nn PS01: This is the Vicor DCM, whose part number is coded in the evaluation board part number. For example, eval board DCM4623ED2K53E0M00 uses DCM4623TD2K53E0M00. nn F01: This is the input fuse. See the datas heet for the specific DCM for appropriate fuse needed to meet listed safety agency approvals. nn C201: This is the external output capacitor for the DCM. It is an Aluminum electrolytic with value that satisfies the DCM datasheet COUT-TRANS minimum.
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 14 Recommended Test Equipment The following is a list of recommended test equipment. 1. Safety glasses 2. DC power supply: Refer to the specific DCM model datasheet to ensure the supply has sufficient power and current capability, especially at low line, to satisfy current inrush when the DCM is started 3. Electronic load: Refer to the specific DCM model datasheet to ensure the load has sufficient power handling and current capability for testing 4. Cooling fan 5. Digital multi-meters (DMMs) 6. Oscilloscope and probes 7. Function generator 8. Auxiliary bench voltage supply (optional, for bias of secondary side fault monitor opto-coupler) 9. Interconnect wires, cables and fastening hardware 10. Calibrated input and output shunts, appropriately rated 11. Thin bladed tool for extracting wires from paralleling connectors (AVX 06-9276-7001-01-000 or similar) Basic Connections nn Confirm bench equipment is powered off. nn Connect the input DC power supply positive lead to the +IN input lug of the evaluation board, connect the input power supply negative lead to the –IN input lug of the evaluation board. nn Connect the CHASSIS_GROUND lug of the evaluation board to a safety “green wire” earth ground. nn Connect the +OUT lug of the evaluation board to the electronic load positive input, connect the –OUT lug of the evaluation board to the electronic load negative input. nn Direct airflow from the cooling fan through the DCM heatsink fins. nn Have the latest DCM datasheet on hand for reference. Board Operation Details nn SW01 provides control over enable. nn In the “OFF” position, the switch will connect SG the EN net, which disables the DCM. nn In the “ON” position, SG is disconnected from the EN net. nn External connection to EN is permitted using the PRI_EN testpoint. SW01 should be set to “ON” to permit external control. nn The J02 & J03 paralleling connectors can be used to connect EN nets across different boards. Note: to enable the DCMs in a parallel array, all boards need SW01 set to “ON” to avoid pulling the EN node low.
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 15 Trim Control nn Jumper block J09 configures trimming. nn With no jumpers installed, neither the trim potentiometer nor the test point for external trim con- trol is connected to the TR net. Note that the paralleling connectors always connect to the TR net. nn With a jumper loaded across J09.1 and J09.2, the trim potentiometer R26 is connected as a rheostat between the TR node and SG. nn With a jumper loaded across J09.3 and J09.4, the external trim test point is connected to the TR node. nn The DCM contains an internal pull-up resistor to VCC (3.3V nominal). When VIN is applied to the DCM it samples the TR node voltage. If it has pulled up to VCC, the DCM disables trimming as long as it has input power, and the programmed trim condition will be nominal rated VOUT of the DCM model. nn If the TR node is not permitted to pull-up to VCC when VIN is applied, trimming is enabled for as long as the DCM has input power. nn Note: Any load on the TR node may cause the DCM to select trim mode when VIN is applied, including: the external trim testpoint (if selected with the jumper block), the trim potentiometer (if selected with the jumper block), and other DCM evaluation boards attached to the paralleling connectors. nn The trim potentiometer adds a variable resistance between the TR node and SG, from between 0Ω nominal, to the value of the potentiometer (500kΩ). This resistance range will generate TR pin voltages which cover the entire functional range of the TR pin. Care should be taken to ensure the programmed trim condition is within the rated trim range of the DCM in order for the DCM to meet specifications. nn In a parallel setup using the J02 & J03 paralleling connectors, all boards besides the top one should have the trim jumper select block at J09 open. nn In a parallel setup with multiple DCM evaluation boards, each DCM contributes another internal pull-up resistor to a 3.3V nominal rail. With any resistive based trimming of the TR node, the resultant trim condition will be modified by the number of DCMs which are attached and have VIN applied. Conversely with a voltage source applied to the TR node, adding additional DCMs to the system has minimal impact on the resultant trim condition. Fault Monitoring nn Jumper block J10 configures how the FT node is monitored. nn With no jumpers installed, neither the visible LED nor the opto-coupler is connected to the FT net. Note that the paralleling connectors always connect to the FT net. nn With a jumper loaded across J10.3 and J10.4, the visible LED at D01 and its bias resistor network R09 & R32 are connected to the FT node. nn With a jumper loaded across J10.1 and J10.2, the opto-coupler at M02 and its bias resistor net- work R21 & R22 is connected to the FT node. nn The DCM FT output is intended to be directly paralleled with the FT output of other DCMs in an array. The FT node in an array forms a “wired-OR”, where any DCM can drive the FT node high.
UG:017 vicorpower.com Applications Engineering: 800 927.9474 Page 16 nn Both the visible LED and the opco-coupler draw current from the FT node in a fault condition. The FT pin on the DCM has limited drive-high capabilities, and so care must be taken to avoid excess loading of the pin. To avoid overload, do not configure J10 to use both the LED and opto-coupler indicators simultaneously. When connecting external circuitry or test equipment to the FT test point, ensure that the maximum load on the FT node is within the DCM datasheet ratings. nn In a parallel setup using the J02 & J03 paralleling connectors, all boards besides the top one should have the fault jumper select block at J10 open. nn When using the opto-coupler, the status of the FT node can be easily transferred to the secondary side of the DCM(s) isolation boundary. To resolve the fault state on the secondary side, the collector side of the opto requires a bias voltage. A 5V bench supply should be connected between the “+5V” and “SEC_SG” testpoints. With no fault present, “FT_SEC” will be at 0V, and when a fault occurs and the opto-coupler is active, “FT_SEC” will pull up to 5V, relative to SEC_SG. Chassis Ground The heatsink assembly of the DCM is connected to the CHASSIS_GND node of the board, as well as the y-caps from each power connection of the DCM. A connection from the CHASSIS_GND lug to earth ground is required. Paralleling The paralleling and sharing performance of multiple DCMs can be easily demonstrated by stacking multiple evaluation boards and interconnecting the inputs and outputs with standoffs to create a parallel array. The DCM uses a negative load-line to implement wireless droop-sharing in an array. Each DCM in an array operates in the same way as it does as a stand-alone unit. With equal trim conditions, the load is effectively shared across multiple DCMs. Mismatches in this case are modest, and are further canceled by an effective negative voltage vs. temperature coefficient. See the DCM datasheet for more detail on load line and tempco. DCMs in an array require no derating of maximum output power or current. DCMs in an array with mismatched trim conditions will not share the load equally at light- to moderate-load conditions. As the load increases, one or more DCMs (starting with those with the highest programmed output trim voltage) will go into current limit and their contribution to the overall output current will plateau. For DCMs, current limit is not a fault condition, rather it is a valid constant- current mode of operation and a DCM in current limit will provide constant current to the load. As long as the load does not exceed the maximum load rating of the array of DCMs, the output voltage will continue to be regulated by any remaining DCMs still in constant voltage mode. Even with mismatched trim conditions, the array can be safely loaded up to the full rated array capacity. The following connections and settings should be used for an array of DCM evaluation boards: nn All DCMs in a parallel array must be the same model. nn The boards should be physically stacked using metal standoffs at the +IN & –IN lugs, the +OUT & –OUT lugs, and the CHASSIS_GND lug. This also connects these nodes electrically so that a single source, single load, and earth ground connection can be made to the system. nn The +IN lugs are not required to be connected together for an array of DCMs. The wireless sharing does not require the same differential input voltage be present on all DCMs in the array. In some applications dissimilar input voltages may be needed, which is fully supported.
Rev 1.6 04/17 vicorpower.com Applications Engineering: 800 927.9474 Page 17 nn The –IN lugs must be connected together if the paralleling connector is used, or if the EN, TR, or FT pins are interconnected in any fashion. However if all control signals of all DCMs are fully isolated from one another, then both the +IN and –IN lugs can remain independent across the evaluation boards, and the DCMs can be operated with fully independent input supplies. nn Standoffs must be sufficient in length to avoid contact between boards, and to permit airflow to all DCMs in the system. nn If coordinated enable control, trimming or fault monitoring is desired, then the paralleling connectors J09 & J10 can be used to easily interconnect the PRI_FT, PRI_EN, PRI_TR_ and PRI_FT nodes across boards. The paralleling connectors at J02 & J03 can be used for coordinated enable and trim control and fault monitoring. The enable, trim and fault monitor features of the top most board should be used for convenience, while the remaining boards should have their jumper blocks depopulated and enable switches set to enable. The paralleling wire-to-board connectors (at J02 and J03) are provided to daisy chain control signals and PRI_SG, with a simple strip and insert option. They will accept 18 – 24 AWG solid wires. Figure 7 DCM evaluation boards stacked to form a high power parallel array, using common -IN and the paralleling connectors. 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.