Vicor PF175-AC-DC User Manual
USER GUIDE | UG:100
PF175 AC-DC Converter Evaluation Board
with External Input Filter
January 2013
Contents Page
Set Up 2
Recommended 4
Hardware
Theory of Operation 5
Thermals
Ordering Information 8
Bill of Materials 8 – 10
Features
n Oscilloscope probe jack for output voltage and ripple measurements
n Simple to use
n Ring lug, screw terminal, and solder connection options
n Replaceable fuse (5A, 216 Littelfuse recommended)
IMPORTANT NOTICE
Please read this document before setting up an evaluation board.
Introduction
This Evaluation Board oers a convenient means to evaluate the performance of Vicor’s
VI Brick® PFM Isolated AC-DC Converter modules with Power Factor Correction, and
has been optimized for user convenience. Refer to Table 1 for operating conditions
and limits.
This reference design contains an input line filter. It is important to remember the
response of the AC line filter is dependent upon the wiring connected to the evaluation
board. Care should be exercised to minimize stray source impedances in order to fully
exercise the features of the converter.
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Figure 1.
VI Brick PFM AC DC Converter
Evaluation Board layout
and dimensional drawing,
component side
Basic Specifications and Operating Limits
Please use the following table for operating limits:
Table 1.
Description Specification Notes
Input range 85 – 264 Vac Universal input
Output voltage 48 Vdc Regulated
Output power 330 W Over entire input range
Operating temperature -40 to 85°C Limited by C37, T01-T03, U01, Z01-Z04
Output capacitance 6,000 to 12,000 μF 63 V rating, 20% tolerance
NOTE: Module operating temperature will depend on its Product Grade as specified in the data sheet.
Please refer to Figure 1 for locations of the input and output connections as viewed from
the component side. Wires may be soldered directly to the pads instead of ring lugs if
desired to minimize circuit impedances.
DANGER! HIGH VOLTAGE! DANGER! HOT SURFACE!
The VI Brick® AC-DC Converter Evaluation Board contains exposed hazardous
voltages. These voltages are within the area marked by the letter H on the PCB.
The VI Brick DC-DC Converter Evaluation Board may be operated at surface
temperatures which may pose a thermal hazard to the operator. Because of the thermal
and voltage hazards, be careful not to touch any exposed surface unless the power
is disconnected and the evaluation board has been given sucient time to cool. The
evaluation board is not intended for use in end item equipment.
Set Up
The Customer Evaluation Board should be set up as follows:
Note: Care should be taken to avoid reversing polarities if connecting to the opposite (solder) side of
the board.
AC Input Connections (J01) DANGER! HIGH VOLTAGE!
J01, the screw terminal connector, is for connection of AC input to the AC-DC converter
evaluation board. The interconnect leads should be appropriate for the current and
voltage supplied to the board.
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For single phase power, connect LINE to the pin marked L, NEUTRAL to the pin marked
N and earth ground to the pin marked EARTH. Corresponding wires in an IEC cable are
brown, blue, and yellow with a green stripe.
The board can be used with three phase power. Connect LINE1 to L and LINE2 to N.
Earth ground should still be connected to the EARTH terminal of J1.
+OUT, –OUT
There are several connections available on the VI Brick AC-DC converter. Table 1 lists
the available connectors and their current rating. Do not exceed the rating of the
connector or the AC-DC converter.
Table 2.
Output Connector Ratings
Connector Rating Recommended Connection
J02 10 A Hold-up capacitor
J03 12 A (3 A/contact) Mating PRM and BCM eval boards
Ring lugs 100 A EARTH, +OUT, -OUT
2 mm holes beside C37 12 A Snap-in type capacitor 10 mm sp
Output bulk (electrolytic) capacitance must be attached across the output of the
VI Brick® AC-DC converter evaluation Board. Refer to the table above for the
appropriate range of output capacitance.
The load should be connected to +OUT and –OUT terminals of the evaluation board
with short leads of suitable gauge to carry the output current and minimize losses. A
sucient number of terminal connections should be used to ensure that no terminal
sees more than its maximum rated current. The evaluation board can be connected
directly to the application for which the AC-DC converter is intended. However the
interconnect impedances between the evaluation board and the application can greatly
aect the transient response. For applications where transient response is critical, the
user should consider mounting the VI Brick AC-DC converter directly to the target
application PCB.
Earth Connections
There is one EARTH connection available on the board, in the lower le hand corner,
P01 in the schematic diagram. The EARTH connection used for local return for the EMI
filter is the same as safety ground.
EARTH may optionally be connected to either of the AC-DC converter outputs in order
to provide a positive or negative voltage rail with respect to earth.
The default configuration of the evaluation board is to have the EARTH terminal
connected to –OUT through jumper JP02, while JP03 is unpopulated. To leave the
outputs floating, remove JP03 so that both JP02 and JP03 are unpopulated. To connect
EARTH to +OUT, remove JP02 and populate JP03.
The insulation of the AC/DC converter modules supported by this evaluation board
has not been designed to exceed SELV voltages, and should not exceed +/-60Vdc from
EARTH potential by stacking.
Input Current Measurement
A current probe can be passed around either input lead connected to the VI Brick
evaluation board. This can be used to measure DC currents and AC currents in front of
the EMI filter and transient suppression circuits.
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Output Voltage Measurement Jack (J12)
This connector is provided to make accurate measurements of the output ripple
voltage of the VI Brick® AC-DC converter. Many types of scope probes may be directly
connected to this point if the probe is equipped with a removable plastic sheath. To
avoid creating ground loops when making measurements of the output or input
voltage, these measurements should be made separately. Clamp on ferrite chokes, such
as Digikey PN 240-2132-ND placed over the leads of passive oscilloscope probes also
help to reduce common mode high frequency switching noise pickup. A capacitor can
be added at C29 to reduce high frequency noise at the probe if necessary.
Enable (EN) DANGER! HIGH VOLTAGE!
The EN pin can be used to disable the VI Brick AC-DC converter. Connecting EN to
the –IN-PFM pin will disable the AC-DC converter. This will also clear any latching
output OVP fault if one has occurred. Note that the EN pin is referenced to the primary
(hazardous voltage) side of the converter. The EN pin can be accessed from J04, for
which a mating connector can be used. The mating connector is Molex P/N 43645-0500
with Molex 43030 series pins.
An optocoupler has been provided to allow connection to output referenced equipment.
The input to the optocoupler is connected to –OUT by default. Jumper JP04 can be
removed, allowing the customer to provide their own reference for the enable input.
This input can be floated up to +/-1000V from EARTH.
Efficiency Measurement
As the VI Brick AC-DC Converter can deliver and consume large currents, the eect of
the PCB must be considered when making an eciency measurement. When testing
your design based on this reference design, be sure to probe dierent points in the input
filter and rectifier section to verify that voltage drops are not excessive in your layout.
If eciency tests are to be automated, then Kelvin type connections are recommended
to reduce common current errors during voltage measurements.
Recommended Hardware
The hardware kit provided with the evaluation board includes the following:
n 6 #10 lock washers
n 3 #10-32 screws
n 3 #10-32 hex nuts
Ring lugs are also recommended for making output connections.
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