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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.
EMI SourcesSwitchmode power supply
The MOSFET and the diodes are coupled through parasitic capacitance.
EMI SourcesSwitchmode power supply
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.
EMI SourcesSwitchmode power supply
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
EMI ComplianceDifferential-mode capacitor
50% FL 100% FL
EMI ComplianceDifferential-mode capacitor
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
EMI ComplianceCommon mode filter
50% FL 100% FL
V48C48C150AL
EMI ComplianceCommon mode filter
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.
Measuring Output RippleThe importance of good technique
A metal shield laid on the module‘s belly could be enough to avoid most of the common mode coupling...
Measuring Output RippleThe importance of good technique
... however, the best results are obtained by using proper coax connector with low inductance.
Measuring Output RippleThe importance of good technique
- =
The common mode component can also be eliminated from the measurement by using a differential technique
Measuring Output RippleThe importance of good technique
The right measuring method is essential to appreciate very low level differential mode ripple components.
Measuring Output RippleThe importance of good technique
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 RippleCapacitive filter
8 A 40 A 80 A
Improving Output RippleCapacitive filter
8 A 40 A 80 A
Improving Output RippleLC 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 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.
Improving Output RippleThe Q-PAC concept
8 A 40 A 80 A
Improving Output RippleThe Q-PAC concept
8 A 40 A 80 ADespite an improper measurement set up, the common mode component has a minimal effect on the overall output ripple