vicor technology and products - biakombiakom.com/vicor/seminar.pdf · every module should be...

Vicor Technology and products

CTRL

Vin

I1 I2

D1

D2CRES

LD

SW 1

+LOAD

DC-DC Converter Power Train

Simplified ZCS cell

Topology: ZCS Power Transfer

A ZCS quasi-resonant converter regulates the output voltage by varying its switching frequency.The LC resonant frequency is fixed so the “on” time of the switchis approximately 400 to 500ns.

t

t

t

t4t3t2t1OFF

ON

VCres

I

OFF

ONQ1

V/LD

I/Cres

D1t

IQ1

V

Zero Current Switching TopologyEnergy transfer differences

T1

T3 T3

T3T3

T2T2

T2

Load Step

T2

T1

T1

T1 I

I

PWM ZCST1 On time of the switching Variable FixedT2 Pulse repetition rate/operating frequency Fixed VariableT3 Rise and fall time of the current in the switching device Fixed Fixed

Zero Current Switching TopologyZCS vs. PWM: Differences

Quantized (fixed) energy transfer

Flatter efficiency curve

Lower harmonic noise

Variable energy transfer

Variable efficiency due to line and load

Higher harmonic noise

Zero current switching

Pulse width modulation

00.10.20.30.40.50.60.7

1st

6th 11th

16th

21th

26th

31s t

36th

41s t

46th

00.10.20.30.40.50.60.7

1st

6th 11th

16th

21s t

26th

31s t

36th

41s t

46th

Zero Current Switching TopologyHarmonic Comparison

ZCS

PWM

Zero Current Switching Topology Conducted Input Noise

Performance & Features VI-200 and VI-J00 VI-200/MI-200 maximum baseplate temperature 85°C and are

available with minimum temperatures down to -55°C and up to 200W output power

VI-J00/MI-J00 maximum baseplate temperature of 100°C and are available with minimum temperatures down to -55°C and up to 100W output power

Modules all have over current and short circuit protection. Straight line except for 5V or less MI-200 & VI-200

VI-200/MI-200 have output over voltage protection and over temperature protection

PARD always less than 3% (20MHz bandwidth) No load regulation.

VI-200 & VI-J00 Block Diagram

Parallel Arrays (VI-200) ‘Gate Out’ when connected to

‘Gate In’ synchronizes driver with boosters

Modules with identical power chain and common input voltage will share power

Boosters are only available in VI-200 package

Booster do not have control electronics

Sharing is dynamic and typically within 5%

Booster OVP set at 131% of nominal.

Maxi, Mini and Micro Series

Constructions of Maxi, Mini, Micro

Maxi, Mini, Micro block diagram

L1

C1

Q1

T2

D1

C3

L2

C4

T3

C2

Q2

+IN

PC

PR

-IN

+OUT+S

SC

-S-OUT

PrimaryController

SecondaryController

Q3

D2

T1

Common Drain FET

Transformer Coupling

Reverse Boost FET

L1

C1

Q1

T2

D1

C3

L2

C4

T3

C2

Q2

+IN

PC

PR

-IN

+OUT+S

SC

-S-OUT

PrimaryController

SecondaryController

Q3

D2

T1

Electrical PerformanceStandard features of Maxi, Mini, Micro

Over voltage protection Over current limiting (approximately straight line) No load to full load regulation Under voltage lockout Remote sensing (Maxi, Mini) Primary and secondary fault monitoring ability Over temperature limiting 10% to 110% trim range Scalability (paralleling).

Basic requirements

Basic requirements for DC-DC converters An input fuse (for fire

protection). An input capacitor (to

restore low source impedance).

Common-mode by-pass capacitors to improve EMI and transient immunity.

Sense connections must be made.

Baseplate earthed.

Auxiliary Component Requirements

Inputs to baseplate 4n7F or two 4n7F in parallel Outputs to baseplate normally 10nF Fuses see safety certification:

http://www.vicr.com/library/technical_documentation/quality_and_certification/safety_approvals/

Input capacitance function is to restore negative impedance. The source impedance should be a tenth of the negative impedance of the module of the modules control loop gain bandwidth product.

Recommended minimum C3

For VI-200s & VI-J00s & MI range C3 (µF) = 400 ÷Vin(min)

For V375 & V300 min 2µF For V48 min 15µF For V24 min 47µF Unless there are other conflict design constraint use

at least five time the above as a rule of thumb..

+IN

-IN

PC

PR

+OUT

-OUT

+S

-S

SC Load

Electrical Performance

Remote sense with reverse sense and open sense protection

Primary control pin (PC)–Module enable/disable–On-state indicator

Secondary control pin (SC)–Output voltage adjust–Module status

Parallel pin (PR)

Control Functions

Control Functions Primary Control

DC Only Primary side module disable 5.7V / 1.5mA primary referenced bias supply Module status

PC Pin

Control Functions Module enable/disable

+ In

PC

PR

- In

Disable

Disable = PC <2.3V

Control Functions Secondary control

SC Pin

Output voltage programming Module status Converts driver to booster

Control Functions Parallel (PR)

PR Pin

Input Side Connection For Parallel Operation Bi-directional transceiver bus DC or AC coupled Supports fault tolerant configurations

Unique Paralleling Methods

Eliminates serial connections Single wire or fault tolerant architecture AC or DC connection Instantaneous current sharing.

Unique Paralleling MethodsSingle wire DC architecture

Simple

Not fault tolerant

Unique Paralleling MethodsSingle wire AC architecture

Simple

Fault tolerant

Unique Paralleling MethodsPR bus isolation transformer

Developed for isolation of PR Bus signal when used with 2nd Generation parallel configurations

Unique Paralleling MethodsAC coupled single-wire interface

Unique Paralleling MethodsTransformer coupled interface

Module Dos and Don’tsConnection technique

Module Dos and Don’tsModule array output connections

Large power bus to minimize and balance parasitic impedance from each module output to the load

Sense pins should be tied to the same point on the respective power bus

To minimize interconnections, modules may be configured as slaves by shorting SC to -S

Or'ing diodes, in series with each +Out pin, provide module output fault tolerance.

Module Dos and Don’tsFault tolerant

Or'ingdiode

+ Out

+ S

SC

- Out

- S

+Sense fromother modules

in the array

Module Dos and Don’tsClosing the Loop

Maxi and Mini DC-DC converters require proper termination of their sense pins in order to prevent an open loop condition.

Module Dos and Don’tsHigh power arrays

Every module should be fused Every module should be by-passed using Y-type capacitors

between each input lead and the baseplate and a capacitor across the input leads of the modules for lower input source impedance

Up to 12 modules can be directly connected in parallel using the PR pin

-In bus should have common low impedance as the PR pin is referenced to –In.

Thermal and mechanical considerations

Electrical PerformanceThermal Considerations

Power Input = Power Dissipated as Heat + Power Output

Power Dissipated = (1 x Power Output

Power Input x Efficiency = Power Output

Heat is removed through the flat metal baseplate on top of the module

The baseplate is thermally coupled to, but electrically isolated from heat generating components

Methods of cooling:1. Conduction2. Convection3. Radiation

Efficiency Performance of a Typical V48C12C150B

36 40 45 49 53 58 62 66 71 75

1.25

2.5

3.75

5

6.25

7.5

8.75

10

11.25

12.5

52

57

62

67

72

77

82

87

92

Effi

cien

cy (%

)

Input Volta ge (V)

Output Curre nt (A)

Efficiency vs. Input Voltage and Output Current

87-9282-8777-8272-7767-7262-6757-6252-57

Ambient BaseplateTemp

Electrical PerformanceThermal considerations

Longitudinal fins

Transverse fins

Heat sinks

Cooling and Heatsinks Do not operate the module outside its specified baseplate

temperature range. However, the module can be fully loaded within that temperature range

Lower temperature operation results in longer MTBFs Thermal interface must be used between module and

heatsink/cold plate Thermal calculators are available on our website.http://www.vicr.com/support/technical/calculators/calc_thermal.htmhttp://www.vicr.com/support/technical/apps-info/xls/calc_t~1.xlscalc_t~1.xls

Thermal Interface Options

ThermMate (see opposite). Maxi, Mini and Micro size thermal pads utilizing phase change interface material

ThermScreen. Pre-applied phase change to baseplate of module phase change compound

Thermal grease.

Mounting Methods Module fixed to the PCB by stand-

off. Available for standard VI-200 & VI-J00 modules, plus a large range for Maxi, Mini, Micro depending on baseplate options etc.

Module either soldered or socketed into PCB

Sockets available for VI-J00 & VI-200

SurfMate and InMates sockets available for Maxi, Mini, Micro.

Accessory ModulesAccessory Modules

IAM (Input Attenuator Modules)

Five ‘VI’ input range and one ‘MI’ range The IAM provides EMI filtering plus active transient filtering IAM are only compatible with the appropriate VI or MI range

module IAM feature over-current protection Inrush current limiting Reverse polarity protection.

Block Diagram of an IAM

Typical connection diagram of IAM

Filter Input Attenuator Modules for Maxi, Mini, Micro Series

One telecom input and two military input ranges EMI filtering Active surge and transient protection Inrush current limiting Reverse polarity protection.

Typical Connections

A Discrete Transient and Surge Protection Circuit

Active EMI Filters from Picor Very small size, extremely high

power density A range of 24Vdc and 48Vdc input

parts SMD and RoHS compatible low

profile LGA Typical efficiency greater than 99%

at full load Hot swap versions available Greater than 70dB differential and

40dB common mode noise attenuation at 250KHz.

QPI 12A Filter 1.0 x 1.0 x 0.2"

Recommended Schematic and Layout

Not required for Vicor converters

Output Ripple Attenuation with the RAM 10A and 20A versions available in 4

grades Less than 10mV ripple with

VI-J00 family Less than 3mV ripple with

VI-200 family Half size brick RoHS available (VE-RAM) 5-50Vdc input operation Compatible with VI-200 and VI-J00 Military version available for MI-200

and MI-J00 Active and passive noise attenuation.

Output Ripple Attenuation with the µRAM 20A and 30A versions available in 4

grades Over 40dB of noise attenuation from

100Hz-1MHz Improves transient performance of

any Vicor DC-DC converter and may be used with some competitor products

Quarter brick package 3-30Vdc input operation Integral ‘Oring’ diode RoHS available (‘F’ and ‘G’ pin styles) Active and passive noise attenuation.

Output Ripple Attenuation from PicorQPO

Greater than 30dB of PARD attenuation from 1KHz – 500KHz

Can trade off dissipation against noise attenuation

Improves the transient performance of the PSU

Designed to be used with a variety of DC-DC converters and PSU

QPO-1L 3 – 30Vdc input 10A rated QPO-2L 0.3 – 5.5Vdc input 20A rated

Typical Schematics

AC-DC System ModulesVx-AIM

Alternating input module Universal AC input 85-264 Vac Output power 250W (to converters) Compatible with Vx-27x/Vx-J7x for full range Compatible with Vx-25x/Vx-J5x for 110V only Compatible with Vx-26x/Vx-J6x for 220V only EN61000-4-5 level 3 EN55022 class A EMI RoHS versions available (order VE-AIM).

Variable output voltage vs input Universal ac input 85-264 Vac Output power 600-675W (to converters) at 110 TO 264 Vac Output power derated below 110 TO 85 Vac Must use 30205 EMI filter or like design HAMD –BAMD for expanded power Compatible with Vx-26x, Vx-J6x or Maxi, Mini, Micro V375

series modules Meets EN61000-3-2 for harmonic currents EN61000-4-5 level 3 (with 30205) EN55022 class A EMI (with 30205) RoHS compliant versions available (order VE-HAM).

AC-DC System ModulesVx- HAM

Autoranging module Input 90 – 132 Vac and 180 – 264 Vac Output power 500W and 750W at 90 – 132 Vac Output power 1,000W and 1,500W AT 180 – 264 Vac Compatible with all 300V input Vicor dc-dc converters Standard quarter brick package Inrush current limit 30A EN61000-4-5 Level 3 (with recommended filter) RoHS-compliant versions available (order VE-ARM).

AC-DC System ModulesVx- ARM

Filter autoranging module Input 90 – 132 Vac and 180 – 264 Vac Output power 500W and 750W at 90 – 132 Vac Output power 750W and 1,000W at 180 – 264 Vac Compatible with all 300V input Vicor dc-dc converters Inrush current limit 30A EN61000-4-5 level 3 EN55022 class A EMI (preliminary) RoHS-compliant versions available (‘F’ & ‘G’ pin styles).

AC-DC System ModulesFARM

AC-DC System ModulesEnMods

Two modules (FARM3 & Mini HAM) EN61000-3-2 compliant Input 90 – 132 Vac and 180 – 264 Vac Output power 500W and 750W at 90 – 132 Vac Output power 750W and 1,000W at 180 – 264 Vac Compatible with all 300V input Vicor dc-dc converters Inrush current limit 30A (EN61000-3-3) EN61000-4-5 level 3 EN61000-4-11 EN55022 class A EMI (preliminary) RoHS compliant versions available

(‘F’ & ‘G’ pin styles)

Applications Notes and Online Tools

Vicor Applications Manual for VI-200 & VI-J00 module There also is a comprehensive listing of Applications Notes for

all products, covering issues from soldering to battery charging Module Design Guides are available for Maxi, Mini, & Micro

products Online to help you calculate correct component values.

http://www.vicr.com

Configurable Product FamiliesConfigurable Product Families

ComPAC ComPAC 11--3 independent outputs3 independent outputs5050--600 600 WWattsatts24, 48 and 300 V24, 48 and 300 Vdcdc inputsinputsBellcore and BT compliantBellcore and BT compliant

FlatPACFlatPAC 11--3 independent outputs3 independent outputs5050--600 600 WWatts at 115/230VACatts at 115/230VACAutorangingAutoranging

MegaPACMegaPAC 5 user5 user--configurable versionsconfigurable versionsUp to 20 regulated outputsUp to 20 regulated outputsAC and DC inputs availableAC and DC inputs availableUp to 2000 Up to 2000 WWattsatts

Complete power solutionsComplete power solutions

Configurable Product FamiliesConfigurable Product Families

VIVIPACPAC 1,2 or 3 1,2 or 3 ooutputsutputsUUp to 900 p to 900 WWatts atts AC or 48Vdc AC or 48Vdc iinputnput7 package configurations7 package configurations5 heatsink options5 heatsink optionsConfigure on lineConfigure on line

LoPACLoPAC 3 factory3 factory--configurable versionsconfigurable versions11--6 outputs, up to 1500 Watts6 outputs, up to 1500 WattsPower factor correctedPower factor correctedPower density of up to 11W/inPower density of up to 11W/in33

UltraUltra--low profile low profile

Complete power solutionsComplete power solutions

Questions??

Electromagnetic InterferenceElectromagnetic InterferenceHow to get the lowest noise

EMI SourcesSwitchmode power supply

For thermal reasons the power semi-conductors are mounted onto a metal surface. An insulating layer (Kapton or ceramic tab) guarantees galvanic insulation.


The MOSFET and the diodes are coupled through parasitic capacitance.


AC VP

CFETCRectifier

Primary Secondary

ICM

VP

ICM

Base plate

On each switching cycle of the MOSFET an impulsive current (the common mode current) flows through the parasitic capacitors.

This current flows on the protective earth connection and disturbs other systems on the same AC net.


External decoupling capacitors and common mode chokes reduce the effects of the common mode current.

AC VP

CFET CRectifier

Primary SecondaryBase plate

CexternalY caps

Cexternal

IDM

+INPR

PC-IN

+Out

-Out

Sc+S

-S

C1Input 2nd Gen

GND

Load

EMI ComplianceDifferential-mode capacitor

C1: 120µF 100V Electrolytic Capacitor Ensures low input impedance Creates stability and good transient response Should be as close as possible to the module input

50% FL 100% FL

V48C3V3C75AL


50% FL 100% FL


V48C48C150AL

EMI ComplianceBypass capacitors: common-mode attenuation

C1: 120µF 100V Electrolytic CapacitorC2, C3: 4.7nF ‘Y’ Capacitors C2, C3, C4, C5 should be as close as possible to module input The baseplate GND connection should be available next to the input

and output pins

EMI ComplianceBypass capacitors: common mode attenuation

50% FL 100% FL

V48C3V3C75AL

50% FL 100% FL

V48C48C150AL

EMI ComplianceBypass capacitors: common mode attenuation

EMI ComplianceDifferential mode inductor

C1: 120µF 100V electrolytic capacitorC2, C3: 4.7nF ‘ Y ’ capacitorsL1: 27µH P/N 14563 differential mode inductor

50% FL 100% FL

V48C3V3C75AL

EMI ComplianceEMI ComplianceDifferentialDifferential mode mode iinductornductor

EMI ComplianceDifferential mode inductor

50% FL 100% FL

V48C48C150AL

EMI ComplianceCommon mode filter

C1: 120µF 100V electrolytic capacitor

C2, C3: 4.7nF ‘Y’ capacitors

C4: 2.2µF polyester capacitor

L: 2x 0.42mH Vicor P/N 36-00037 common mode inductor

50% FL 100% FL

V48C3V3C75AL


50% FL 100% FL

V48C48C150AL


Bypass capacitorsnext to the module

V48C48C150AL

100% FL

EMI ComplianceImplementation effect of bypass capacitors

Bypass capacitorsfar from the module

V48C3V3C75AL

EMI ComplianceImplementation effect of bypass capacitors

100% FLBypass capacitorsnext to the module

Bypass capacitorsfar from the module

Output Filtering

Any asymmetry in the measuring system will convert a common modecomponent to a differential mode component, and this will be indicatedas superimposed to the real differential mode ripple

Measuring Output RippleThe importance of good technique

The high frequency components of the common mode noise can be radiated and coupled to the oscilloscope grounding clip.


A metal shield laid on the module‘s belly could be enough to avoid most of the common mode coupling...


... however, the best results are obtained by using proper coax connector with low inductance.


- =

The common mode component can also be eliminated from the measurement by using a differential technique


The right measuring method is essential to appreciate very low level differential mode ripple components.


Improving Output Ripple Using additional components

The output ripple can be reduced by using someadditional components such as: Extra capacitors LC groups More complex filter, including common mode

chokes.

Improving Output RippleCapacitive filter

8 A 40 A 80 A

Improving Output RippleLC filter

8 A 40 A 80 A

Improving Output RippleLC filter (balanced)

8 A 40 A 80 A

Improving Output RippleThe Q-PAC concept

8 A 40 A 80 A

A common mode choke on the output side, together with the ´Y´ de-coupling capacitors, will attenuate the common mode noise component at the source.

The parasitic inductance of the common mode choke builds an LC filter for the differential ripple.


8 A 40 A 80 A


8 A 40 A 80 ADespite an improper measurement set up, the common mode component has a minimal effect on the overall output ripple

vicor technology and products - biakombiakom.com/vicor/seminar.pdf · every module should be...

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