NEPTUNE ConverterNEPTUNE Converter

John Michael MorookianJohn Michael Morookian

Vatche VorperianVatche Vorperian

Converter Packaging ConceptConverter Packaging Concept

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4

1.4x1.4 1.4x1.4

13” ID

Input connecting plane

Output connecting plane Power stage boards

Overall PCB Connection Overall PCB Connection Schematics Schematics

Inp

ut C

on

nectin

g P

lan

e(w

/ startu

p circu

it)

Ou

tpu

t Con

nectin

g P

lan

e(w

/ gate

driv

e co

ntro

l circuit)-10kV

sea 2-Stage PCB

6-Stage PCB

8-Stage PCB

8-Stage PCB

8-Stage PCB

8-Stage PCB

6-Stage PCB

2-Stage PCB

400V

400Vreturn

2-Stage Power Board Layout2-Stage Power Board Layout

C4A C5A

R2A R3A

C1AR1A

C4B C5B

R2B R3BC1B

R1B

L1AC2A

L2A

C3A

Q1A

Q2A

L1BC2B

L2B

TX2A

TX1A

Q3

A

Q4

AC

6AR

4A

Q1B

Q2B

TX2B

L3A

L3B

TX3A TX3B

TO

PB

OTTO

MIN

NER

Power Stage Schematic Power Stage Schematic

Power Stage w/Sense Schematic Power Stage w/Sense Schematic

2-Stage Power Board Root 2-Stage Power Board Root SchematicSchematic

6-Stage Power Board Root 6-Stage Power Board Root SchematicSchematic

8-Stage Power Board Root 8-Stage Power Board Root SchematicSchematic

8-Stage Power Board BOM8-Stage Power Board BOMBill Of Materials September 2,2003 18:41:02 Page1

Item Quantity Reference Part______________________________________________

1 8 C1h,C1g,C1f,C1e,C1d,C1c, 0.01uF RAD/.800X.325/LS.600/.034 P3476-NDC1b,C1a

2 8 C2h,C2g,C2f,C2e,C2d,C2c, 1uF AX/1.500X0.600/.050 VW2G105KC2b,C2a

3 8 C3h,C3g,C3f,C3e,C3d,C3c, 2uF AX/1.500X0.800/.050 VW2G205KC3b,C3a

4 16 C4h,C4g,C4f,C4e,C4d,C4c, 10uF AX/2.500X1.100/.050 VW2G106KC4b,C4a,C5h,C5g,C5f,C5e,C5d,C5c,C5b,C5a

5 8 C6h,C6g,C6f,C6e,C6d,C6c, 1nF AX/.675X.225/.034C6b,C6a

6 56 C7h,C7g,C7f,C7e,C7d,C7c, 1uF SM/C_1812 PCC2248CT-NDC7b,C7a,C8h,C8g,C8f,C8e,C8d,C8c,C8b,C8a,C9h,C9g,C9f,C9e,C9d,C9c,C9b,C9a,C10h,C10g,C10f,C10e,C10d,C10c,C10b,C10a,C11h,C11g,C11f,C11e,C11d,C11c,C11b,C11a,C12h,C12g,C12f,C12e,C12d,C12c,C12b,C12a,C13h,C13g,C13f,C13e,C13d,C13c,C13b,C13a

7 8 C14h,C14g,C14f,C14e,C14d, 0.1uF SM/C_1210 399-1268-1-NDC14c,C14b,C14a

8 1 C15a 6800pF SM/C_06039 32 D1h,D1g,D1f,D1e,D1d,D1c, 1N6621U SM/A_MELF

D1b,D1a,D2h,D2g,D2f,D2e,D2d,D2c,D2b,D2a,D3h,D3g,D3f,D3e,D3d,D3c,D3b,D3a,D4h,D4g,D4f,D4e,D4d,D4c,D4b,D4a

8-Stage Power Board BOM8-Stage Power Board BOMBill Of Materials September 2,2003 18:41:02 Page1

Item Quantity Reference Part______________________________________________

10 2 D6a,D5a 1N6328 SM/B_MELF11 2 D8a,D7a 1N5804 SM/A_MELF12 17 JP1Qh,JP1Qg,JP1Qf,JP1Qe, connector JUMPER100

JP1Qd,JP1Qc,JP1Qb,JP1Qa,JP2Qh,JP2Qg,JP2Qf,JP2Qe,JP2Qd,JP2Qc,JP2Qb,JP2Qa,JP5

13 9 JP1,JP2,J5,J6,J7,J8,J9, CON1 TPJ10,J11

14 40 J1h,J1g,J1f,J1e,J1d,J1c, JUMPER JUMPER100J1b,J1a,J2h,J2g,J2f,J2e,J2d,J2c,J2b,J2a,J3h,J3g,J3f,J3e,J3d,J3c,J3b,J3a,J4h,J4g,J4f,J4e,J4d,J4c,J4b,J4a,J5h,J5g,J5f,J5e,J5d,J5c,J5b,J5a

15 16 L1h,L1g,L1f,L1e,L1d,L1c, 622uH CYL/D1.700/LS1.350/.040/2PL1b,L1a,L2h,L2g,L2f,L2e,L2d,L2c,L2b,L2a

16 16 TX2h,TX2g,TX2f,TX2e,TX2d, XFRM_LINEAR CYL/D1.700/LS1.350/.040TX2c,TX2b,TX2a,L3h,L3g,L3f,L3e,L3d,L3c,L3b,L3a

17 32 Q1h,Q1g,Q1f,Q1e,Q1d,Q1c, IRFPS43N50K TO247ACQ1b,Q1a,Q2h,Q2g,Q2f,Q2e,Q2d,Q2c,Q2b,Q2a,Q3h,Q3g,Q3f,Q3e,Q3d,Q3c,Q3b,Q3a,Q4h,Q4g,Q4f,Q4e,Q4d,Q4c,Q4b,Q4a

8-Stage Power Board BOM8-Stage Power Board BOMBill Of Materials September 2,2003 18:41:02 Page1

Item Quantity Reference Part______________________________________________

18 32 Q5h,Q5g,Q5f,Q5e,Q5d,Q5c, PMBT2222A SM/SOT23_BECQ5b,Q5a,Q7h,Q7g,Q7f,Q7e,Q7d,Q7c,Q7b,Q7a,Q9h,Q9g,Q9f,Q9e,Q9d,Q9c,Q9b,Q9a,Q11h,Q11g,Q11f,Q11e,Q11d,Q11c,Q11b,Q11a

19 32 Q6h,Q6g,Q6f,Q6e,Q6d,Q6c, PMBT2907A SM/SOT23_BECQ6b,Q6a,Q8h,Q8g,Q8f,Q8e,Q8d,Q8c,Q8b,Q8a,Q10h,Q10g,Q10f,Q10e,Q10d,Q10c,Q10b,Q10a,Q12h,Q12g,Q12f,Q12e,Q12d,Q12c,Q12b,Q12a

20 8 R1h,R1g,R1f,R1e,R1d,R1c, 2Meg AX/.450X.100/.031R1b,R1a

21 16 R2h,R2g,R2f,R2e,R2d,R2c, 24 AX/1.000X.225/.034R2b,R2a,R3h,R3g,R3f,R3e,R3d,R3c,R3b,R3a

22 8 R4h,R4g,R4f,R4e,R4d,R4c, 75 AX/.300X1.000/.028 TA310PA75R0JR4b,R4a

23 9 R5h,R5g,R5f,R5e,R5d,R5c, 10 SM/C_1210 P10.0AACT-NDR5b,R5a,R14a

8-Stage Power Board BOM8-Stage Power Board BOMBill Of Materials September 2,2003 18:41:02 Page1

Item Quantity Reference Part______________________________________________

24 64 R6h,R6g,R6f,R6e,R6d,R6c, 1k SM/C_1210 P1.00KAACT-NDR6b,R6a,R7h,R7g,R7f,R7e,R7d,R7c,R7b,R7a,R8h,R8g,R8f,R8e,R8d,R8c,R8b,R8a,R9h,R9g,R9f,R9e,R9d,R9c,R9b,R9a,R10h,R10g,R10f,R10e,R10d,R10c,R10b,R10a,R11h,R11g,R11f,R11e,R11d,R11c,R11b,R11a,R12h,R12g,R12f,R12e,R12d,R12c,R12b,R12a,R13h,R13g,R13f,R13e,R13d,R13c,R13b,R13a

25 1 TX1a XFRM_LINEAR TRANS\CURRENT\1300\20026 8 TX3h,TX3g,TX3f,TX3e,TX3d, TX_GATE_TRIGGER TRANS\140\700\10P

TX3c,TX3b,TX3a27 8 U1h,U1g,U1f,U1e,U1d,U1c, TC4420 SOG.050/8/WG.275/L.250

U1b,U1a

8-Stage Power Board Parts List8-Stage Power Board Parts ListQty 10kV# Total Qty Description Vendor Part Cost/Item Total Cost

8 1 48 CAP 1.0UF 400V POLYPROPYLENE American Capacitor VW2G105K 8.91 427.68$ 16 1 96 CAP 10.0UF 400V POLYPROPYLENE American Capacitor VW2G106K 21.87 2,099.52$ 8 1 48 CAP 2.0UF 400V POLYPROPYLENE American Capacitor VW2G205K 9.36 449.28$

16 1 96 622uH Coast Magnetics -$ 16 1 96 XFRM_LINEAR Coast Magnetics -$ 1 1 6 XFRM_LINEAR Coast Magnetics -$ 8 1 48 TX_GATE_TRIGGER Coast Magnetics -$ 8 1 48 CAP .01UF 400V POLYPROPYLENE DigiKey P3476-ND 0.435 20.88$ 8 1 48 CAP .10UF 100V CERAMIC X7R 1210 DigiKey 399-1268-1-ND 0.407 19.54$

56 1 336 CAP 1.0UF 100V CERAMIC X7R 1812 DigiKey PCC2248CT-ND 1.1638 391.04$ 1 1 6 CAP 6800PF 50V CERAMIC X7R 0603 DigiKey 399-1090-1-ND 0.429 2.57$

40 1 240 HEADER SOLDERTAIL SIP 64POS DigiKey 351-10-164-00-003000 0.149601 35.90$ 8 1 48 IC MOSFET DRIVER 6A HS 8SOIC DigiKey TC4420COA-ND 1.01 48.48$

32 1 192 MOSFET 500V 47A SUPER-247 DigiKey IRFPS43N50K-ND 9.227 1,771.58$ 64 1 384 RES 1.00K OHM 1/4W 1% 1210 SMD DigiKey P1.00KAACT-ND 0.2036 78.18$ 9 1 54 RES 10.0 OHM 1/4W 1% 1210 SMD DigiKey P10.0AACT-ND 0.378 20.41$ 8 1 48 RES 2.00M OHM MTL FILM .40W 1% T DigiKey BC2.00MXCT-ND 0.06188 2.97$

16 1 96 RES 24.3 OHM METAL FILM .40W 1% DigiKey BC24.3XCT-ND 0.39 37.44$ 32 1 192 TRANSISTOR GP NPN AMP SOT-23 DigiKey MMBT2222AFSCT-ND 0.1232 23.65$ 32 1 192 TRANSISTOR GP PNP AMP SOT-23 DigiKey MMBT2907AFSCT-ND 0.1296 24.88$ 32 1 192 1N6621U -$ 2 1 12 1N6328 -$ 2 1 12 1N5804 -$ 8 1 48 220pF -$ 8 1 54 75 -$

TOTAL 5,454.02$

Input Inductor design Input Inductor design

INPUT INDUCTOR

Pin diameter 59 mils MAX

1 2

3 4

TOP VIEW

30 deg(4) PLS

On dia. 1.35”

Pin diameter 25 mils MAX

1.70 MAX

1.2 MAX

BOTTOM

TOP

NOTE: Pins 3 & 4 are not electricallyConnected, but are for mechanical Stability.

1 2

Output Inductor design Output Inductor design

OUTPUT INDUCTOR

Pin diameter 59 mils MAX

1 2

3 4

TOP VIEW

30 deg(4) PLS

On dia. 1.35”

Pin diameter 25 mils MAX

1 2

3 4

1.70 MAX

1.2 MAX

BOTTOM

TOP

Power Transformer design Power Transformer design

POWER TRANSFORMER

Dummy Pin diameter 59 mils MAX

TOP VIEW

30 deg(4) PLS

On dia. 1.35”

Dummy Pin diameter 25 mils MAX

1 2

3 4

Pins 3 & 4 (front)

Pins 1 & 2 (rear)

1.70 MAX

3 (front)

4 (front)1.2 MAX

BOTTOM

TOP

1 (rear)

2 (rear)

Input Inductor design Input Inductor design

PULSE TRANSFORMER

1

2

3

4

.850 .700

.700

56789

10

0.075

0.075

.850

5

6

7

8

9

10

DU

MM

Y

PIN

S

TOP VIEW

TOP

Pin diameter 35 mils MAX

1

2

3

4

StatusStatus Converter Power Stage BoardsConverter Power Stage Boards

Schematics Nearly Complete for 2,6,8 Stage BoardsSchematics Nearly Complete for 2,6,8 Stage Boards 2-Stage Power Board PCB Layout 90% complete2-Stage Power Board PCB Layout 90% complete Parts List with Price/Delivery 70% completeParts List with Price/Delivery 70% complete Preliminary Magnetics Mechanical Drawings Preliminary Magnetics Mechanical Drawings

Generated, RFQ sent to Coast MagneticsGenerated, RFQ sent to Coast Magnetics Input connecting plane Input connecting plane

Start-Up CircuitStart-Up Circuit Schematics need some modificationSchematics need some modification Not Yet BuiltNot Yet Built Not Needed for 16-Stage Converter TestingNot Needed for 16-Stage Converter Testing

Output connecting planeOutput connecting plane Control Circuit Schematics Ready for InclusionControl Circuit Schematics Ready for Inclusion

Remaining design issuesRemaining design issues Method of interconnecting the inputs of the 48 Method of interconnecting the inputs of the 48

power stages on the input connecting board.power stages on the input connecting board. Defining the connector to the –10kV input line.Defining the connector to the –10kV input line. Method of changing over to the back up converter.Method of changing over to the back up converter. Defining the output connector to the output bus.Defining the output connector to the output bus. Modify the start-up circuit to operate from –10kV. Modify the start-up circuit to operate from –10kV. Limit input inrush current when the relay is closed.Limit input inrush current when the relay is closed. Define which side of the 400V output will be Define which side of the 400V output will be

referenced to sea ground potential (Case). (Most referenced to sea ground potential (Case). (Most likely the negative side.) Define this connector.likely the negative side.) Define this connector.

Define internal –10kV harness to the back up Define internal –10kV harness to the back up converter.converter.