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VICOR VI-200 Series, Design Manual & Applications Manual

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VICOR VI-200 Series Design Manual & Applications Manual Download Page 33

Design Guide & Applications Manual

For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies 

VI-200 and VI-J00 Family Design Guide

Rev 3.4 

vicorpower.com

Page 32 of 97

Apps. Eng. 800 927.9474

800 735.6200

V

TRIM

I

TRIM

I

MON

+OUT

–OUT

To Front End:

AIM,

HAM,

IAM, or

Off-Line

Front End

+IN

–IN

GATE
IN

GATE
OUT

BatMod VI-2x1-CU-BM

Error

Amp

R5

10 k

Ω

REF

2.5 V

R

ITRIM

≈

 50 k

Ω

10 mA

R1

820 

Ω

D1

5.1 V

Zener

1 mA

R2

5 k

Ω

R3

115 k

Ω

12 V

Figure 11–3

— Basic charging circuit using a current source module (BatMod)

V

TRIM

I

TRIM

I

MON

Control Circuitry
• Voltage
• Battery Temp.
• Ambient Temp.
• Other

+OUT

–OUT

System

Status

Figure 11–4

— The BatMod in an advanced battery charging system

11. Battery Charger (BatMod)

Summary of Contents for VI-200 Series

Page 1: ...Design Guide Applications Manual For VI 200 and VI J00 Family DC DC Converters and Configurable Power Supplies Buy an Genuine Vi J01 CY from PowerStream ...

Page 2: ...11 30 32 Filter Front End Modules AC Input Module AIM MI AIM 12 33 36 Harmonic Attenuator Module HAM 13 37 42 Input Attenuator Module IAM MI IAM 14 43 46 Ripple Attenuator Module RAM MI RAM 15 47 Offline Front End 16 48 51 Configurable Products DC Input Power System ComPAC MI ComPAC Family 17 52 54 AC Input Power System FlatPAC Family 18 55 57 AC Input Power System PFC FlatPAC 19 58 59 General The...

Page 3: ...ction is needed between modules with all module s power inputs and outputs connected together no trimming adjustments or external components are required to achieve load sharing LOSSLESS ENERGY TRANSFER Referring to Figure and Table 1 1 below turn on of the MOSFET switch transfers a quantized energy packet from the input source to an LC tank circuit composed of inherent transformer leakage inducta...

Page 4: ... voltage dropout loss of regulation moves down Trimming Up Reverses the above effects S S SENSE SENSE Provides for locating the point of optimal voltage regulation external to the converter Output OVP in VI MI 200 will trip if remote sense compensates output voltage measured at output pins above 110 of nominal Discrete wire used for sense must be tightly twisted pair Do not exceed 0 25 V drop in n...

Page 5: ...s Input Source Impedance The converter should be connected to an input source that exhibits low AC impedance A small electrolytic capacitor should be mounted close to the module s input pins C3 Figure 3 1 This will restore low AC impedance while avoiding the potential resonance associated with high Q film capacitors The minimum value of the capacitor in microfarads should be C µF 400 Vin minimum E...

Page 6: ...B or by insertion into one of the recommended PCB socket solutions CAUTION Use of discrete wires soldered directly to the pins may cause intermittent or permanent damage to the module therefore it is not recommended as a reliable interconnection scheme for production as a final released product See Section 21 for packaging options designed for discrete wire connections BusMod MegaMod In addition m...

Page 7: ...ule input fusing The VI x7x VI x6x and VI x5x require the use of a Buss PC Tron fuse or other DC rated fuse See below for suggested fuse ratings The safety approvals section of the Vicor website should always be checked for the latest fusing and conditions of acceptability information for all DC DC converters including the MegaMod family Package Size Required Fuse Package Size Required Fuse VI 27x...

Page 8: ...a constant current load Some constant current loads have the ability to pull full current at near zero volts This may cause a latchup condition Also when performing a short circuit test it is recommended to use a mercury wetted relay to induce the output short as other methods may induce switch bounce that could potentially damage the converter STRAIGHT LINE CURRENT LIMITING The VI MI 200 modules ...

Page 9: ...of nominal of the VI MI 200 VI MI J00 ComPAC MI ComPAC FlatPAC and MegaMod MI MegaMod Families Modules with nominal 3 3 V outputs and above have the 2 5 V precision reference and 10 k internal resistor For trim resistor calculations on modules with 2 0 V outputs use 0 97 V in place of the 2 5 V reference and substitute 3 88 kΩ for the internal 10 kΩ resistor Resistors are 0 25 W When trimming down...

Page 10: ... or down with the addition of one external resistor either Ru for programming up or Rd for programming down Figure 5 4 Example 2 Fixed Trim Up 12 V to 12 6 V To determine Ru the following calculation must be made 2 5 V 5 2 625 V VR5 VTRIM Vref VR5 2 625 2 5 0 125 V Knowing this voltage the current through R5 can be found IR5 VR5 0 125 12 5 µA R5 10 kΩ VRu 12 6 V 2 625 V 9 975 V Ru 9 975 798 kΩ 12 ...

Page 11: ...l voltage range is further restricted by the allowable trim range of the converter Voltages in excess of 2 75 V 10 over nominal may cause overvoltage protection to be activated For applications where the module will be programmed on a continuous basis the slew rate should be limited to 30 Hz sinusoidal TRIMMING ON THE WEB VICORPOWER COM Trim values are calculated automatically Design Calculators a...

Page 12: ... to disable both Driver modules C3 is used to minimize the effects of switch bounce associated with mechanical devices NOTE GATE IN voltage needs to be 0 65 V referenced to IN to ensure modules are disabled IN IN GATE OUT GATE IN IN IN GATE OUT GATE IN Vicor DC DC Converter F1 C1 Z1 C3 SW1 F2 DISABLE D2 Z2 C2 D1 Vicor DC DC Converter 6 Multiple GATE IN Connections C1 C2 C3 1 µF Z1 Z2 15 V 1N5245B ...

Page 13: ...s and outputs making negative input configurations easy Fusing should always be placed in the positive lead Remote Sensing Figure 7 4 Output voltage between OUT and OUT must be maintained below 110 of nominal Do not exceed 0 25 V drop in negative return as the current limit setpoint is moved out proportionately The sense should be closed at the module if remote sensing is not desired Applies to VI...

Page 14: ...ds to the maximum trim up voltage This circuit or functional equivalent must be used when charging batteries Do not exceed the nominal current ratings of the converter Example Pout Vnominal Dual Output Voltages Figure 7 7 Vicor modules have isolated outputs so they can easily be referenced to a common node creating positive and or negative rails 7 Application Circuits Converter Array Design Consid...

Page 15: ...t current sharing schemes employed with power converters involve analog approaches One analog method artificially increases the output impedance of the converter modules while another actually senses the output current of each module and forces all of the currents to be equal by feedback control Synchronous current sharing offers an alternative to analog techniques In a synchronous scheme there is...

Page 16: ...eling converters for power expansion are Driver Booster arrays and analog current sharing control They appear to be similar but the implementation of each is quite different Driver Booster arrays usually contain one intelligent module or Driver and one or more power train only modules or Boosters Analog current sharing control involves paralleling two or more identical modules each containing inte...

Page 17: ...single intelligent module in the array determines the transient response which does not change as modules are added Slaved modules require only one connection between units when their outputs are connected No trimming adjustments or external components are required to achieve load sharing The load sharing is dynamic and usually guaranteed within 5 It s important to remember that when using Booster...

Page 18: ...module for 2 1 redundancy a total of 600 W in a volume of about 16 5 in3 Alternatively four 100 W half size modules might be used with a fifth 100 W module to provide 4 1 redundancy a total of 500 W and 14 in3 Although the second solution uses less space it increases the accumulated failure rate because it employs more converters more ORing diodes more monitoring circuitry and more assembly ORing ...

Page 19: ...ilter the following will provide valuable information relative to the attainment of system conducted noise objectives System requirements such as Tempest military or UL544 EN60601 medical require a somewhat different approach Medical requirements vary as a function of the application and country please contact Vicor Applications Engineering for additional details Common Mode Noise with No Addition...

Page 20: ... noise The plots in Figure 9 2 are representative of fixed frequency converters with input filtering NOTE In most cases a fixed frequency converter generates more input conducted noise with a filter than Vicor s zero current switching converter without a filter Also note that fixed frequency converters using a construction technique involving control circuitry on the same metal plate as power proc...

Page 21: ...3a L1 CM 3 Amp Load 15 Amp Load 30 Amp Load Conducted Noise vs Load Figure 9 3 Conducted input noise with common mode choke Typical Vicor Module VI 230 CV 48 V Input 5 V Output Three common mode chokes are offered as standard accessories NOTE Common mode filters may be common to one or more modules but only one should be used with modules interconnected via GATE IN s or GATE OUT to GATE IN As an e...

Page 22: ... 700 pF Vicor Part 01000 C3a C3d 0 01 µF Vicor Part 04872 C4 2 2 µF L1 3 000 µH Vicor Part 31742 L2 20 µH Conditions Light Load 3 A Nominal Load 15 A Full Load 30 A CM Figure 9 4 Conducted noise multiple zero current switching converters 3 Amp 3 Amp Load 3 Amp 6 Amp Load 15 Amp 15 Amp Load 3 Amp 30 Amp Load 15 Amp 30 Amp Load 30 Amp 30 Amp Load Differential and Common Mode Filter with More than On...

Page 23: ...uld be placed close to the module to reduce loop cross sectional area Care should be taken to reduce the loop cross sectional area of differential mode current flowing between the source and C1 Since differential mode input current is by definition opposite in phase twisting the input leads causes noise cancellation PCB power planes can reduce radiated noise if the traces are on opposite sides of ...

Page 24: ...pulse is fixed and is ultimately the energy stored in this capacitor 1 2 CV2 Since the energy in every pulse is fixed the repetition rate of the pulse train is varied as a function of load to regulate the output voltage Maximum repetition rate occurs at minimum line full load and is approximately twice the LC time period or 1 µs If the load drops by 50 then the repetition rate is approximately one...

Page 25: ...oise observed at the same test point NOTE The output return must be at the same relative potential as the earth ground of the oscilloscope or damaging current may flow through the oscilloscope ground lead Capacitors are required from the IN to the baseplate thereby shunting common mode current thus reducing noise current on the input power lines The capacitor must have very short leads since the f...

Page 26: ...e additional output filtering See additional output filter choices in Table 9 1 Line Related Output Noise Line related output noise can be determined from the converter specification Input Ripple Rejection As an example a VI 260 CV 300 Vin to 5 Vout has a rejection specification at 120 Hz of 30 20 Log Vin Vout Vin 300 and Vout 5 hence its rejection is 30 35 56 65 56 dB which provides an attenuatio...

Page 27: ...acitor should be used on the output preferably tantalum 3 Amp Load 15 Amp Load 30 Amp Load IN IN OUT OUT C3a GATE IN GATE OUT S TRIM S C4 C2a C1 C2b C3b C1 100 µF C2a C2b 4 700 pF Vicor Part 01000 C3a C3b 0 01 µF Vicor Part 04872 C4 270 µF Tant Conditions Light Load 3 A Nominal Load 15 A Full Load 30 A Figure 9 11 Output noise additional output capacitance Output Ripple vs Load Addition of Output ...

Page 28: ...1 100 µF C2a C2b 4 700 pF Vicor Part 01000 C3a C3b 0 01 µF Vicor Part 04872 C4 270 µF Tant L1 200 nH Vicor Part 30268 Conditions Light Load 3 A Nominal Load 15 A Full Load 30 A IN IN OUT OUT C3a GATE IN GATE OUT S TRIM S C2a C1 C2b C3b C4 L1 Figure 9 12 Output noise additional output inductor and capacitor L C Filter Output Ripple vs Load LC Output Filter Typical Vicor Module VI 230 CV 48 V Input ...

Page 29: ...e of the RAM MI RAM is very straightforward but a couple of precautions should be noted The LC filter is in the positive output lead so if that lead is shorted then the high frequency attenuation is compromised The active circuit is in the negative output lead so if that lead is shorted the low frequency attenuation is compromised The RAM must be used with a common mode choke at the input of the c...

Page 30: ...uts will function with either remote sense or local sense with the recommended capacitance Lower ESR is achieved with capacitors in parallel Ripple data measured at 20 MHz bandwidth limit Adding excessive amounts of external filtering may compromise the stability of the converter and result in oscillation FILTER COMPONENTS FOR 5 V OUTPUT L1 Vicor P N 30268 or Micrometals T38 26 90 core with 2T 14 ...

Page 31: ...e Adjust VTRIM An input for controlling or setting the output setpoint this is similar to the trim function on the VI 200 Section 5 A maximum voltage can be set by a fixed resistor or adjusted with an external voltage source A source voltage referenced to OUT adjusted from 1 25 2 5 V will program a 50 100 of rated voltage setting It is important to note the nominal output voltage for each BatMod t...

Page 32: ...utput Current 4 10 A 1 3 76 V 14 5 A To set the input voltage at ITRIM to 3 76 V adjust the potentiometer R2 appropriately In Figure 11 3 the configuration will charge the battery at a maximum of 10 A with a 13 8 V float voltage Other charge rates and float voltages may be similarly calculated If a fixed charge current is desired the potentiometer can be replaced with two fixed resistors In applic...

Page 33: ... To Front End AIM HAM IAM or Off Line Front End IN IN GATE IN GATE OUT BatMod VI 2x1 CU BM Error Amp R5 10 kΩ REF 2 5 V RITRIM 50 kΩ 10 mA R1 820 Ω D1 5 1 V Zener 1 mA R2 5 kΩ R3 115 kΩ 12 V Figure 11 3 Basic charging circuit using a current source module BatMod VTRIM ITRIM IMON Control Circuitry Voltage Battery Temp Ambient Temp Other OUT OUT System Status Figure 11 4 The BatMod in an advanced ba...

Page 34: ...rigger A fully loaded AIM 200 W of module output power requires a minimum of 680 µF of capacitance hold up requirements can be met with this capacitor and maximum total capacitance should not exceed 1 200 µF refer to Selecting Capacitors for AIM Modules section that follows The voltage rating of this capacitor will be determined by the input operating voltage It is necessary to connect all Driver ...

Page 35: ... X T5 T3 1 2 2 solving for C1 C1 2 X PIM x T5 T3 2 Vp2 Vdo2 Where PIM is power delivered from the AIM PIM Module Output Power POM 3 Module Efficiency Eff 100 The energy Joules delivered from the AIM from the time power is lost T4 until loss of an output Figure 12 2 T5 Energy Joules PIM x T5 T4 Watt Seconds 4 where POM Output power from all the modules PIM Input power to the modules output power fr...

Page 36: ...e rectified AC line the point of lowest energy in C1 the point at which if the AC line fails hold up time is shortest i e worst case T5 The time at which the converter s drop out of regulation T5 T4 Minimum hold up time Actual hold up time may vary up to a maximum of T5 T3 T3 T1 X 2 One line cycle The following values are calculated in a similar manner C1 values as a function of line voltage frequ...

Page 37: ...ter with AIM Figure 12 5 for recommended external components D3 D3 D3 Y capacitors not shown for clarity Universal AC In AIM GATE OUT PAR GATE IN OUT OUT L2 N NC NC L1 0 47 µF OUT S TRIM S OUT IN GATE IN GATE OUT IN VI 200 J00 Driver Load F2 0 01 µF Two 4 700 pF Y Rated Capacitors 0 01 µF Two 4 700 pF Y Rated Capacitors 0 01 µF Ceramic 0 01 µF Ceramic C1 a F1 a Consult factory or refer to Selectin...

Page 38: ...g efficiency The HAMD version does not contain an internal bridge rectifier and is intended for configuring higher power arrays with Booster versions referred to as the VI BAMD Figure 13 5 L1 and L2 N HAM Pin An appropriate line filter is required to limit conducted emissions and ensure reliable operation of the HAM see page 40 Connect single phase AC mains to the input of the line filter via a 10...

Page 39: ...E O pin ancillary circuitry illustrated in Figures 13 4 and 13 5 provides transient immunity The illustrated circuitry is the minimum required see Figures 13 4 and 13 5 Power OK P OK Pin Power OK is a monitor signal that indicates the status of the AC mains and the DC output voltage of the HAM P OK is asserted active low when the output bus voltage is within normal operating range 20 25 ms after D...

Page 40: ...2 D4 C2 C4 C5 C6 C7 C8 JMK Filter P N 1319 13 12 6 A IN GATE IN GATE OUT IN OUT OUT P OK E O A S VI HAMD xM GATE IN GATE OUT IN IN OUT OUT VI BAMD xM Input Bridge Rectifier Vicor P N 30660 L1 GND L2 N L1 L2 N 1N4006 1N4006 F3 R4 C1 V1 C9 C10 Consult Vicor s Applications Engineering for specific HAMD BAMD filtering information A 100 KΩ 2 W resistor is used for every 1 000 µF of hold up capacitance ...

Page 41: ... line filter is required to provide attenuation of conducted emissions generated by the HAM module and to protect it from line transients It also presents a well defined high frequency AC line impedance to the input of the HAM To meet the listed specifications Vicor s P N 30205 line filter transient suppressor or equivalent must be used Figure 13 10 The addition of a MOV external to this filter is...

Page 42: ...7 2 7 20 70 FREQUENCY MEGAHERTZ INSERTION LOSS db Figure 13 13 HAM filter insertion loss vs frequency 0 FACE MAY BE BOWED 0 04 MAX N 4 40 INSERT 0 25 DP 4 PL ø0 080 PIN 6 PLACES LOAD LINE M 0 900 0 100 1 200 0 500 0 500 4 60 0 02 0 060 1 00 MAX 0 13 0 02 1 45 0 02 2 800 2 50 2 00 0 30 0 02 1 800 PL PL PL 2 40 0 02 Figure 13 11 HAM filter mechanical diagram Table 13 2 HAM filter part 30205 specific...

Page 43: ...igh it still dissipates significantly more power than a VI 26x DC DC converter Care should be taken to cool it Do not rely on the internal overtemperature shut down to take the place of adequate planning relative to the cooling of the HAM Thermal compound should be used between the heat sink and baseplate of the HAM HAMD and BAMD Power factor is 0 997 at 120 Vac and 0 995 at 240 Vac Harmonic conte...

Page 44: ...fication self healing properties and safety agency approvals INPUT REVERSE POLARITY PROTECTION A Zener diode in the EMC filter provides reverse polarity protection when used with a properly rated fuse external to the IAM The characteristics of the recommended input line fuses permit normal full load operation with protection in the event of a reverse polarity by clearing of the fuse Table 4 3 INPU...

Page 45: ...00V Normal Operating Area I S W Full Load 100V Standard Wide Range 24 V Inputs 0 1 1 10ms 100 1000 800V Normal Operating Area I S W Full Load 300 V Input S D 160V 0 1 1 10ms 100 1000 Normal Operating Area I S W Full Load 48 V Input R E 276V Normal Operating Area I S W Full Load 0 1 1 10ms 100 1000 48 V Wide Range Input R E S D R E R E 32V 21V 36V 18V S D 76V 125V 60V 100V 42V 500V 400V 200V 36V S ...

Page 46: ...ssary to include a 100 Ω 1 4 W resistor between the negative outputs of the Input Attenuator Modules to ensure equal potential at these points when paralleling Input Attenuator Modules so as not to impact the effectiveness of the internal common mode choke Driver Booster C1 IN IN GATE OUT GATE IN Connection to module baseplate or ground plane connected to baseplate 4 700 pF 4 700 pF OUT OUT S S TR...

Page 47: ...atings IAM IAM C2 Diodes 1N4148 a C2 470 pf 500 V 100Ω C2 VI 200 Driver IN IN GATE OUT GATE IN VI 200 Booster IN IN GATE OUT GATE IN VI 200 Booster IN IN GATE OUT GATE IN VI 200 Driver IN IN GATE OUT GATE IN VI 200 Driver IN IN GATE OUT GATE IN OUT OUT S S TRIM OUT OUT S S TRIM OUT OUT S S TRIM OUT OUT S S TRIM OUT OUT S S TRIM IN IN OUT OUT GATE IN IN GATE OUT IN PAR a For bus voltages greater th...

Page 48: ...le component of the incoming DC voltage effectively cancelling it out The power supply s sense leads feed through the RAM for connection at the RAM output for local sense or at the load for remote sense converter compensation is 0 5 V maximum The attenuation and insertion loss are constant up to 10 A or 20 A depending on model In overload above 10 A or 20 A the voltage drop will increase as the cu...

Page 49: ... power the fuse may not blow and the unit will not turn on If wire distance from front end to modules is greater than 3 feet 0 91 m install a TRANSZORB Part 1 5KE400A across the input of each module If unit is strapped for 115 V operation and 230 V is applied the input fuse will clear Replace fuse strap correctly and reapply power To control EMC most effectively the return path to ground from eith...

Page 50: ...unt versions of the front ends will increase reliability if the following data is used as the nominal design criteria The sigmoid shape of the curves at low airflow is due to the chassis mount cover restricting the airflow to the inboard components When an airflow of approximately 200 LFM is achieved the velocity of air rushing over the cover causes air to be pulled in through the side perforation...

Page 51: ...IN IN VI x6x Module IN GATE IN IN VI x6x Module F2 F3 F4 Fn Vce sat 0 4 V 1 5 mA V 70 V EARTH GROUND IN GATE IN IN VI x6x Module IN GATE IN IN VI x6x Module V 70 V Vdc Vdc AC OK AC OK BUS OK BUS OK L3 L2 L1 N GND F2 F3 F4 Fn Vce sat 0 4V 1 5 mA V 70 V MOD ENBL AC MAINS EARTH GROUND IN GATE IN IN VI x6x Module IN GATE IN IN VI x6x Module IN GATE IN IN VI x6x Module IN GATE IN IN VI x6x Module CAUTI...

Page 52: ...k marked as such 3 phase wye distribution 5 wire 208 Vac nominal 20 10 Connect the three phases L1 L2 L3 N neutral and GND earth to the five terminal barrier block marked as such Line frequency 47 440 Hz DC OUTPUT CONNECTIONS AND MODULE ENABLE A three terminal barrier block labeled Vdc Vdc and MOD EN provides both the DC input enable and enable control line for Vicor converters Vdc Negative DC inp...

Page 53: ... Class A Military 28 V 270 V MIL STD 461C Conducted Emissions CE01 CE03 CE07 Conducted Susceptibility CS01 CS02 CS06 Radiated EMC The ComPAC will conform to the following radiated specifications Military Radiated Emissions RE02 Radiated Susceptibility MIL STD 461C RS02 RS03 Input Transient Protection The input transient protection will suppress short term transients appearing on the input line Ref...

Page 54: ... 12 V and 15 V outputs standard trim range 10 3 3 V output trim range 2 20 to 3 63 V REMOTE SENSING SENSE and SENSE must be connected locally or remotely OUTPUT TERMINAL CONNECTIONS A hardware kit with parts for output terminal connections is provided with each ComPAC unit The following drawing shows the assembly of those parts for the proper connection of metal power terminals Assembly for PCB po...

Page 55: ...cation NOTE To ensure proper heat transfer from the internal module s to the heat sink the mounting holes through the heat sink must be properly torqued at all times during operation If the unit is operated unmounted insert a 6 or metric M3 5 flathead screw through each hole from below and secure with a nut on top torqued to 6 lb in 0 83 N m Thermal Impedance Free Convection Thermal resistance bas...

Page 56: ...eration it will be necessary to recycle the AC power to allow operation at 115 V If the unit is operating in the 115 V mode and a long duration transient is applied to the FlatPAC 150 Vac for 50 ms the unit will autostrap for 230 V operation The control circuit maintains the converter GATE IN pins low the PTC shunt inactive and the AC OK and BUS OK outputs in FAIL status until the DC bus potential...

Page 57: ...lator per status signal The collector terminals AC OK and BUS OK of the optocouplers in a typical application can be connected via current limiting resistors to a source no greater than 70 Vdc These resistors should limit the maximum current to the optocoupler output transistors to 1 5 mA The emitter terminals AC OK and BUS OK are connected to the return of the external source The status OK condit...

Page 58: ...ure proper heat transfer from the internal module s to the heat sink the mounting holes through the heat sink two three and four holes on 1 up 2 up and 3 up models respectively must contain torqued screws at all times during operation whether or not the unit is mounted If the unit is operated unmounted insert a 6 or M3 5 panhead screw through each hole from below and secure with a nut on top torqu...

Page 59: ...sfy IEC950 Class I grounding requirements connect a ground lead to the terminal marked GND Use 2 5 mm2 14 AWG wire Input Voltage Connections Connect the line voltage to L1 hot and L2N neutral Use 14AWG input wire Recommended connector screw torque is 5 to 7 in lbs 0 5 to 0 8 N m Recommended strip length is 8 mm Refer to Figure 19 2 Output Wire Gauge Use the output wire gauge that corresponds to th...

Page 60: ...hole from below and secure with a nut on top torqued to 6 in lbs 0 7 N m NOTE 2 All PFC FlatPAC models are available with a conduction cooled flat plate instead of the top heat sink Go to vicorpower com for outline drawings Refer to Figure 19 4 for additional deratings for the cc variants 19 AC Input Power System PFC FlatPAC 0 100 200 300 400 500 600 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambie...

Page 61: ... to but electrically isolated from all internal heat generating components The basic thermal design problem is to transfer heat from the baseplate into the surrounding environment as a means of maintaining baseplate temperature at or below rated maximum Heat energy is transferred from regions of high temperature to regions of low temperature via three basic mechanisms radiation conduction and conv...

Page 62: ...ture rise in the interface and the temperature of the member to which the baseplate is attached Temperature rise across a surface interface can be significant if not controlled The area of the interface should be as large as possible and the surface flatness of the attached member should be within 5 mils Thermal compound or a thermal pad should be used to fill surface irregularities Thermal resist...

Page 63: ...nd worst case converter power output using the formula given in the section on Module Efficiency and Dissipated Power Figures 20 1a and 20 1b Power Dissipated Power Output X 1 1 n 2 Estimate or experimentally determine the surface interface thermal resistance Use of thermal compound or a thermal pad is recommended to minimize this resistance An estimate of 0 2 C Watt should provide an adequate saf...

Page 64: ...sure to mount the converters first mechanically then solder the units in place A fixture should be used to maintain alignment if soldering must be performed before attachment When mounting heat sinks to Vicor modules use 6 or M3 5 screws torqued uniformly through the mounting slots provided The following tightening sequence should be used Lightly finger tighten all screws Torque screws to 6 in lbs...

Page 65: ...M and CFM is dependent on the cross sectional area through which air is flowing CFM LFM X Area The cross sectional area between the fins is the area through which the total airflow must pass Figure 20 8 Correct interpretation of heat sink data requires that only the airflow through this area be considered Simply pointing a fan at a heat sink will clearly not result in all of the flow going through...

Page 66: ...θsa θsa θsa Free Air 2 1 1 3 1 0 3 6 1 7 1 4 4 4 2 1 1 7 50 LFM 1 5 1 1 0 9 2 7 1 4 1 3 3 3 1 7 1 6 100 LFM 1 2 0 9 0 7 2 3 1 3 1 1 2 8 1 6 1 3 250 LFM 0 7 0 5 0 4 1 6 1 0 0 8 2 0 1 2 1 0 500 LFM 0 4 0 3 0 3 1 2 0 7 0 6 1 5 0 9 0 7 750 LFM 0 3 0 2 0 2 0 9 0 5 0 5 1 1 0 6 0 6 1 000 LFM 0 2 0 2 0 2 0 8 0 4 0 4 1 0 0 5 0 5 a Longitudinal fins b Transverse fins c Assumes uniform loading of two and thr...

Page 67: ... 1 η Airflow LFM CFM Area Maximum output power Tmax Ta θsa 1 1 η Maximum thermal impedance Tmax Ta Pout 1 1 η Maximum ambient temperature Tmax θsa x Pout 1 1 η Temperature rise θsa x Pout 1 1 η Thermal drop θbm x Pout 1 1 η TYPICAL EXAMPLES Example 1 Determine the maximum output power for a 100 W VI 200 converter no heat sink delivering 5 V in 400 LFM at a maximum ambient temperature of 45 C Maxim...

Page 68: ...x 85 C θsa 0 3 C W Pout 600 W η 85 0 85 Maximum ambient temp 85 0 3 x 600 1 1 0 85 53 C Example 4 Determine the temperature rise of a 150 W VI 200 converter delivering 5 V at 132 W with a Part 30090 heat sink in 200 LFM Temperature rise θsa x Pout 1 1 η θsa 1 1 C W Pout 132 W η 81 0 81 Temperature rise 1 1 x 132 1 1 0 81 34 C Over ambient temperature Example 5 Determine the baseplate to coldplate ...

Page 69: ... 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 21 Thermal Curves Figure 21 1 VI 200 Family baseplate to air no heat sink 5 V output Figure 21 2 VI 200 Family baseplate to air no heat sink 12 48 V output Figure 21 3 VI 200 Family Part 30089 heat sin...

Page 70: ...ure C Output Power Watts FREE AIR 200 LFM 400 LFM 600 LFM 800 LFM 1000 LFM Figure 21 7 VI 200 Family Part 30090 heat sink 5 V output Figure 21 8 VI 200 Family Part 30090 heat sink 12 48 V output 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 8...

Page 71: ...0 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts FREE AIR H FREE AIR V 200 LFM 400 LFM 600 LFM 800 LFM 1000 L...

Page 72: ... LFM 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts Figure 21 17 VI J00 Family Part 30140 heat sink 5 V output Figure 21 18 VI 200 Family Part 30140 heat sink 12 48 V output V...

Page 73: ...mbient Temperature C Output Power Watts 21 Thermal Curves Figure 21 19 FinMod VI 200 Family F1 F3 configuration 5 V output Figure 21 20 FinMod VI 200 Family F1 F3 configuration 12 48 V output 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 A...

Page 74: ...5 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts Figure 21 23 FinMod VI J00 Family F1 F3 configuration 5 V output Figure 21 24 FinMod VI J00 Family F1 F3 configuration 12 48 V output 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 Ambient Temperature C Output Power Watts 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 5...

Page 75: ...5 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 21 Thermal Curves FREE AIR 200 LFM 400 LFM 600 LFM 800 LFM 1000 LFM Figure 21 27 SlimMod VI 200 Family 5 V output Figure 21 28 SlimMod VI 200 Family 12 48 ...

Page 76: ...FM 400 LFM 600 LFM 800 LFM 1000 LFM 0 50 100 150 200 250 300 350 400 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 50 100 150 200 250 300 350 400 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts Figure 21 33 2 Up ComPAC 5 V output Figure 21 34 2 Up ComPAC 12 48 V output 0 75 150 225 300 375 450 525 600 0 5...

Page 77: ...Watts 0 50 100 150 200 250 300 350 400 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 0 25 50 75 100 125 150 175 200 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Ambient Temperature C Output Power Watts 21 Thermal Curves Fi...

Page 78: ... 225 275 325 375 425 475 525 575 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Output Power Watts Ambient Temperature C 0 Output Power Watts Ambient Temperature C 0 50 100 150 200 250 300 350 400 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Figure 21 43 Output power derating vs temperature Vout 12 V Figure 21 44 Output power derating vs temperature Vout 5 V Figure 21 45 Output power d...

Page 79: ...le of a good solder joint with a power module Notice that the solder forms a concave meniscus between pin and barrel This is an example of a properly formed fillet and is evidence of good wetting during the soldering process The joint between solder and pin as well as solder and pad should always exhibit a feathered edge In Figure 22 1 it can also be seen that the solder covers a good deal of the ...

Page 80: ... 491 F 215 225 C Pb free soldering requires a tip temperature of about 800 F A higher tip temperature will bring the barrel and pin above the melting point of solder faster However a higher tip temperature may cause damage to the pad printed circuit board or module pin 6 Type of Lead free Solder The actual melting point of the solder varies depending on the type of solder used and affects the nece...

Page 81: ...eters are consistent with generally accepted requirements for circuit card assembly The power module is often much more massive than other components mounted to the PCB During wave solder preheating the pins will dissipate much of their absorbed heat within the module therefore adjustments to preheaters alone will not improve module soldering significantly A more effective way to improve the solde...

Page 82: ...utput wattage if hand soldering If wave soldering lower conveyor speed or increase preheat temperature 3 PC Board Damage An intermittent or poor connection caused by damage to a trace pad or barrel A damaged pad is best identified by a burn mark on the PCB or a trace pad that moves when prodded with a mechanical object Recommended Solution Lower the soldering iron temperature or the soldering time...

Page 83: ...1 Kit 18146 Kit 18147 Kit 18146 0 055 0 071 Bag 19126 Bag 19127 Bag 19122 Bag 19123 Bag 19122 1 5 mm On Board G Kit 18156 Kit 18157 Kit 18150 Kit 18152 Kit 18150 1 4 mm 1 8 mm Bag 19132 Bag 19133 Bag 19126 Bag 19128 Bag 19126 0 093 0 084 0 104 In Board G Kit 18150 Kit 18151 Kit 18146 Kit 18147 Kit 18146 2 4 mm Bag 19126 Bag 19127 Bag 19122 Bag 19123 Bag 19122 2 1 mm 2 6 mm Table 22 2 Standoff Kits...

Page 84: ... cohesion and adhesion During the soldering process wetting can be identified by an even coating of solder on the barrel and pin In addition to coating the surface of barrel and pin the solder will gather at the intersection of the two and produce a trailing fillet along each surface Once wetting has occurred then upon solidification it will bond appropriately to both components producing a qualit...

Page 85: ...f a uniform size across a given product family The larger the pin the more soldering time required to form an adequate connection In addition to the sizing of the pin the time required to create a robust connection will vary depending on several parameters 1 PCB Thickness The thicker the printed circuit board is the more heat it is able to dissipate and thus it will require more soldering time 2 C...

Page 86: ...while the solder is cooling This could result in a cold solder joint a void in the barrel or a cracked joint 9 If it is necessary to re solder a joint remove all existing solder from the pad and pin prior to reapplying solder 10 Use of a soldering gun is not recommended for soldering Vicor modules 11 It is not recommended that Maxi Mini Micro module pins be trimmed under any circumstances 12 The c...

Page 87: ...of de soldering a Vicor module from a printed circuit board without causing damage have not been qualified for use with Vicor modules For applications that require removal of a module with the intent of reuse use Vicor socketing systems Index of Common Soldering defects 1 Solder Bridge A short circuit between two electrically unconnected points caused by a piece of solder inadvertently forming a b...

Page 88: ...y occurring in wave solder systems Recommended Solution Increase preheat or topside heater temperature but not outside the recommended limits Organizations www ipc org Commercial www aimsolder com www alphametals com www kester com www multicore association org References Maxi Mini Micro Standoff Kits for Solder Mounted Modules Board Mounting Slotted Through Hole Threaded Thickness Options Basepla...

Page 89: ...r a For transverse fins add the suffix F3 0 25 6 35 mm or F4 0 5 12 7 mm to the standard part number BusMod The BusMod is a rugged module housing assembly that combines convenient chassis mounting with a screw lug wiring interface for all electrical connections To order the BusMod option add B1 to the standard part number NOTE The BusMod may be used with any of Vicor s VI MI 200 VI MI J00 IAM or V...

Page 90: ...bs 1 27 kg 2 8 lbs 1 23 kg 2 7 lbs NC Family 3 up 1 633 kg 3 6 lbs 1 91 kg 4 2 lbs 1 82 kg 4 0 lbs AC DC AC Input Module AIM MI AIM 85 g 3 0 oz Harmonic Attenuator Module HAM 170 g 6 0 oz FlatPAC CC LU Family 1 up 652 g 1 4 lbs 817 g 1 8 lbs PU MU Family 2 up 1 248 kg 2 75 lbs 1 59 kg 3 5 lbs NU QU RU Family 3 up 1 843 kg 4 0 lbs 2 32 kg 5 1 lbs Offline Front Ends Includes Industrial Grade VI FPE6...

Page 91: ...e configuration across a power transformer Bridge Rectifier A full wave rectifier circuit employing four rectifiers in a bridge configuration British Telecom Standards A telecommunications industry standard developed by the British PTT authorities Brownout A reduction of the AC mains distribution voltage usually caused deliberately by the utility company to reduce power consumption when demand exc...

Page 92: ...will operate to its published specifications Differential Mode Noise Noise that is measured between two lines with respect to a common reference point excluding common mode noise The resultant measurement is the difference of the noise components of the two lines The noise between the DC output and DC return is usually measured in power supplies Distributed Power Architecture DPA A power distribut...

Page 93: ... or off When GATE IN is pulled low the module is turned off When GATE IN is floating open collector the module is turned on The open circuit voltage of the GATE IN pin is less than 10 V referenced to Vin A GATE OUT GATE IN connection is necessary to run Driver Booster configurations GATE OUT The GATE OUT pin is the clock pulse of the converter It is used to synchronize Booster modules to a Driver ...

Page 94: ... caps Linear Regulator A regulating technique where a dissipative active device such as a transistor is placed in series with a power supply output to regulate the output voltage Line Regulation The change in output voltage when the AC input voltage is changed from minimum to maximum specified Line Voltage Mains The sine wave voltage provided to the power supply usually expressed in volts rms Load...

Page 95: ... See Setpoint Accuracy Overload Protection A power supply protection circuit that limits the output current under overload conditions Overshoot A transient output voltage change exceeding the high limit of the voltage accuracy specification caused by turning the power supply on or off or abruptly changing line or load conditions Overtemp Warning A TTL compatible signal that indicates an overtemper...

Page 96: ... power supply to be remotely turned on or off Turn on is typically performed by open circuit or TTL logic 1 and turn off by switch closure or TTL logic 0 Remote Sense Wires connected in parallel with power supply output cables such that the power supply can sense the actual voltage at the load to compensate for voltage drops in the output cables and or isolation devices Return The designation of t...

Page 97: ...f Bridge Full Bridge Resonant and Zero Current Switching Tracking A characteristic in a multiple output power supply where any changes in the output voltage of one output caused by line load and or temperature are proportional to similar changes in accompanying outputs Transient Recovery Time The time required for an output voltage to be within specified accuracy limits after a step change in line...

Page 98: ...mmended These capacitors contain a dielectric with unique self healing properties to help prevent against excessive leakage To meet general EMC requirements Section 9 Vicor recommends the use of Y capacitors with all power conversion modules Y capacitors meet IEC384 14 EN132400 and UL1283 standards Z Zero Current Switching The turn on and turn off of a switching device at zero current resulting in...

Page 99: ...pplies and complete custom power systems 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 ava...

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