Vicor VI-Brick-AC User Manual

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USER GUIDE | UG:111
VI Brick® AC Front End Evaluation Board
November 2012
Contents Page
Features 1
Introduction 1
Set Up 3
Bill of Materials 5
Recommended 6 Hardware
Thermals 6
Ordering Info 6
Features
n Simple to use
n Ring lug, screw terminal, and solder connection options
n Replaceable fuse (5 A, 216 Littelfuse recommended)
IMPORTANT NOTICE:
Please read this user guide before operating evaluation board.
Introduction
The VI Brick® AC Front End Evaluation Board oers a convenient means to evaluate the performance of Vicor’s VI Brick AC Front End module and has been optimized for user convenience. Refer to the table below for operating conditions and limits.
This product 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® AC Front End
Evaluation Board layout and
dimensional drawing,
component side.
Evaluation Board Basic Specifications and Operating Limits
Please use the following table for operating limits:
Table 1
Operating Limits
Description Specification Notes
Input Range 85 – 264 Vac Universal input Output voltage 48 Vdc Partially Regulated, SELV Output Power 330 W Over entire input range
Operating temperature -40 to 85°C and Z01
Output capacitance 6,000 to 12,000μF 63V rating
Note: VI Brick AC Front End Module operating temperature will depend on its Product Grade as specified in the datasheet.
Limited by hold-up capacitor
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.
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DANGER! HIGH VOLTAGE! DANGER! HOT SURFACE!
The VI Brick® AC Front End Evaluation Board contains exposed hazardous voltages. These voltages are within the area marked by the hashed line on the board.
The VI Brick AC Front End 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 sucient 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.
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.
Table 2
Output Connector Ratings
+OUT, –OUT
There are several connections available on the VI Brick AC Front End Evaluation Board. Table 1 lists the available connectors and their current rating. Do not exceed the rating of the connector or the module.
Connector
J02 10 A Hold-up capacitor
J03 boards
Ring Lugs 100 A General Purpose
Rating
12 A (3 A/contact)
Mating PRM and BCM eval
Recommended Connection
Output bulk (electrolytic) capacitance must be attached across the output of the VI Brick AC Front End Evaluation Board. It is recommended that the hold-up capacitor is to be applied between H12 and H10 or H14 and H10. RTV adhesive should be used if laying the capacitor on its side. Refer to table 1 from previous page for the appropriate range of output capacitance.
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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 sucient 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 module is intended. However the interconnect impedances between the evaluation board and the application can greatly aect the transient response. For applications where transient response is critical, the user should consider mounting the VI Brick® AC Front End module directly to the target application PCB. Test points TP12 (–OUT) and TP07 (+OUT) can be used to monitor the output and are located on the PCB adjacent to the output terminals of the AC Front End module.
Earth Connections
There are several earth connections available on the board. Earth must be connected via a low impedance connection in order for the internal line filter to function. These earth connections also provide a safety ground for the baseplate of the module.
Earth may optionally be connected to either of the VI Brick AC Front End outputs in order to provide a positive or negative voltage rail with respect to earth.
Output Voltage Measurement Jack (J12)
This connector is provided to make accurate measurements of the output ripple voltage of the VI Brick AC Front End. 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.
Figure 2
VI BRICK AC Front End
Output capacitor (C29) can be
added to reduce switching frequency
voltage ripple at the probe.
(Click on drawing to view larger.)
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Table 3
Bill of Materials
Ref. Description Digi-Key Digi-Key Future Future
Desc. Manufacturer Part # Manufacturer Part #
CAP X7R 2200pF
C01 10% 250V 2220
CAPY X7R 4700pF
C12
10% 250V 2220 C13
C29 C30 C31 C32 C33 C34 C35
C36 C37 C38
C39
F01 SMD, 5x20
H03 & CAP ALEL 6800uF H07 20% 63V 25X50
J01 BLK SMD
J02 BLK SMD
CONN 10POS J03 90DEG THRUHOLE FEMALE 0.1SPC CONN 5POS J05 SINGLE ROW Molex WM1893-ND TE Connectivity 1445057-5 RIGHT ANGLE
JP02 5% 2010
JP03 NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED
L01 10% 5mA 0805 150K-ND
L05 600uH 30% 10A
PS01 Model Specific Vicor Model Specific Vicor Model Specific
R01 1/8W 1% 0805
R09 1/4W 1% 1206
R10 NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED VAR MOV, 300V Z01 10KA 20mm Littelfuse DIA RADIAL
NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED NOT APPLIED
CAP X7R .1uF 10% 25V 0805
CAP ALUM 100UF 63V 20% RADIAL
FUSE HOLDER,
CON 3CKT TERM
CON 2 CKT TERM
RES 0 OHM 3/4W
IND 15.0uH Bourns Inc. CV201210- No Stock No Stock
IND COM MODE
RES 6.81 OHM
RES 2.2 OHM
Murata 490-3480-2-ND Murata GA355QR7GF222KW01L
Murata 490-3482-2-ND Murata GA355DR7GF472KW01L
Murata 490-1673-2-ND Murata GRM21BR71E104KA01L
Nichicon UVY1J101MPD-ND Nichicon UVY1J101MPD
Wickmann F4546-ND Schurter 31.8225
Kemet 493-1135-ND Nichicon UVZ1J682MRD
No Stock No Stock Weco 140-A-126-SMD/03
No Stock No Stock Weco 140-A-126-SMD/02
Sullins Electronics
Vishay Dale 541-0.0WTR-ND Vishay Dale CRCW20100000Z0EF
Vishay Dale 541-6.81CCTRND Vishay Dale CRCW08056R81FKEA
Vishay Dale 541-2.20FFTRND Vishay Dale CRCW12062R20FKEA
S5519-ND
Stocked by Vicor, part#: 37052-601
TMOV20RP30 0EL2T7-ND
Sullins Electronics
Littelfuse TMOV20RP300E
PPTC052LJBN-RC
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Input Current Measurement
A current probe can be passed around either input lead connected to the VI Brick® AC Front End Evaluation Board. Note that an input capacitor on the evaluation board is downstream of this measurement point.
Enable (EN) DANGER! HIGH VOLTAGE!
The EN pin can be used to disable the VI Brick AC Front End module. Connecting EN to the IN-PFM pin will disable the module. 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. Warning: The EN Pin, or the –IN PFM Pin must not be connected to line or output of the VI Brick AC Front End.
Efficiency Measurement
As the VI Brick AC Front End module can deliver and consume large currents, the eect of the PCB must be considered when making an eciency measurement. Be certain to accurately measure the voltage using test points TP08 (LINE1) , TP14 (LINE2/NEUTRAL), TP18 (–OUT), and TP01 (+OUT). Using these test points will more closely represent the eciency of the VI Brick AC Front End module.
Hardware
The hardware kit provided with the evaluation board includes the following:
n (3) #10-32 screws n (6) #10-32 lock washer
(for +OUT, -OUT, and Earth terminals) (for +OUT, -OUT, and Earth terminals)
n (3) #10-32 hex nut n (1) 6800 uF hold-up capacitor
(for +OUT, -OUT, and Earth terminals) (can be applied between H03 and H07, H12 and H10, or H14 and H10)  Ring lugs are also recommended for making output connections.
Thermals
For most lab environments a fan blowing across the evaluation board is recommended. See VI Brick Thermal Management Application Note at:
www.vicorpower.com/documents/application_notes/AN200_VIBrickTherm.pdf
or contact Vicor Applications Engineering for assistance (800) 927-9474.
Ordering Information
The evaluation board is specified by replacing the “–00” sux with “–CB” on the VI Brick AC Front End model number.
The Power Behind Performance
Rev 1.4 12/2013 vicorpower.com Applications Engineering: 800 927.9474 Page 6
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