DCM3623EA5N0480T00

USER GUIDE | UG:017 Analog Control DCM3623 and DCM4623 ChiP™ Evaluation Board Arthur Russell VI Chip® Applications Engineering October 2014 Contents Page Introduction Introduction 1 The Analog Control DCM3623 and DCM4623 ChiP evaluation boards described in this document are designed to be used with the DCM family of isolated, DC-DC converters. The DCM3623 board is used for the analog control, low input voltage DCM3623 ChiP products, while the DCM4623 board is used for the analog control, high input voltage (offline) DCM4623 ChiP products. Contents 3 Features 3 Board Description 4 General Components 4 Test Points Description 6 Schematic, Assembly Drawing and Bill of Materials 7 Recommended Test Equipment 14 Basic Connections 14 Board Operation Details 14 Trim Control 15 Fault Monitoring 15 Chassis Ground 16 Paralleling 16 The DCM evaluation board can be configured for various enabling and fault monitoring schemes, as well as to exercise various modes of trimming, depending on the application requirements. The evaluation board can be used to evaluate DCMs in either a stand-alone configuration, or as an array of modules. Enable options: 1. Onboard mechanical switch (default) 2. External control Trim options: 1. Fixed trim operation (default): the TR pin is permitted to float at initial start up. The DCM disables output trimming and the output trim is programmed to the nominal rated VOUT. 2. Variable trim operation, onboard variable resistor: The trim pin voltage is ratiometric, with a rheostat working against a pull-up resistor inside the DCM to VCC. 3. Variable trim operation, off-board control: The trim pin voltage is controlled via external programming control, which is referenced to the –IN of each specific DCM in the system. Fault monitor options: 1. Onboard LED: the FT pin drives a visible LED for visual feedback on fault status. 2. Onboard optocoupler: the FT pin drives an onboard optocoupler to bring fault status across the primary-secondary isolation boundary. UG:017 Page 1  IMPORTANT NOTICE: Hazardous voltages are present on the DCM Evaluation Board under power. PERSONAL CONTACT WITH LINE VOLTAGE MAY RESULT IN SEVERE INJURY, DISABILITY, OR DEATH. IMPROPER OR UNSAFE HANDLING OF THIS BOARD MAY RESULT IN SERIOUS INJURY OR DEATH. Read the precautions below entirely BEFORE using the DCM Evaluation Board. Do not operate the evaluation board unless you have the appropriate safety precautions in place on your bench to guarantee safety. The list below is not comprehensive and is not a substitute for common sense and good practice. n During operation, the power devices and surrounding structures can be operated safely at high temperatures. n Remove power and use caution when connecting and disconnecting test probes and interface lines to avoid inadvertent short circuits and contact with hot surfaces. n Never use a jumper in place of the fuse. n When testing electronic products always use approved safety glasses. Follow good laboratory practice and procedures. n Avoid creating ground loops when making measurements of the isolated input or output voltage. n Care should be taken to protect the user from accidental contact when under power. n Care should be taken to avoid reversing polarities if connecting to the opposite (solder) side of the board. n The product evaluation boards described in this document are designed for general laboratory evaluation, and are not suitable for installation in end user equipment. n Refer to the specific DCM module data sheet for electrical, thermal, and mechanical product details UG:017 Page 2 These boards provide a convenient way to evaluate/demonstrate the performance of Vicor DCM products. Kelvin connections are provided for accurate voltage measurements on power nodes. Sockets are provided to permit quick installation and changing of bulk filtering capacitors. The evaluation board also provides lugs for input/output connections, test points and sockets for easy connection to standard test-equipment, and a high performance air cooled heat sink assembly. Contents The evaluation board arrives with the following contents: n 1 x DCM evaluation board n 1 x top and belly heat sink assembly (pre-installed) n 1 x hardware kit Features The DCM evaluation board has the following features: 1. Input and output lugs for source and load connections 2. Input fuse (appropriately rated) 3. Basic input filtering, including sockets to add through-hole input aluminum-electrolytic capacitors for additional source decoupling Note: The filtering used in the eval board is for demonstration purposes only and might not be the optimal solution for all applications. For optimal filter design for parallel array application, consult the data sheet of the DCM in use and the online filter design tool at: https://app2.vicorpower.com/filterDesign/intiFilter.do 4. Basic output filtering, including sockets to add through-hole output aluminum-electrolytic capacitors 5. Toggle switch for enabling and disabling the DCM via the ENABLE pin 6. Trim control selection a. Using potentiometer b. Using external voltage source c. Open, to disable trimming and latch the model nominal trim condition 7. Provisions to replace input and output differential mode inductors with wire loops, for oscilloscope/shunt based current measurements 8. Oscilloscope probe jack for accurate, high frequency output voltage measurements 9. Dual paralleling connectors for ENABLE, TRIM, FAULT and SGND signal connections, for daisy chaining control to other DCM evaluation boards in an array 10. Kelvin voltage test points for all power pins 11. Top and bottom heat sink assembly for the DCM UG:017 Page 3 Board Description The following section provides a detailed description of the evaluation board components, test points and sockets. General Components 1. DCM (PS01) 2. Input lugs: Sized for #10 hardware. Use these for making connection to the input source. This board does not contain reverse polarity protection. Check for proper polarity before applying the power. 3. Input fuse (F01 and F02): Appropriately rated for the DCM model on the board. 4. Input filter: Ceramic input capacitors (C15-C22), filtering inductor (L01) and damping resistor (R08) provide input filtering. Sockets (H01-H02, H03-H04) can be used for easy installation of aluminum‑electrolytic input capacitors. The DCM3623 board also adds H09-H10 for additional input bypassing. 5. Enable / Disable switch (SW01): When actuator is in top position towards “ON” text on the board, the ENABLE pin will be open and the DCM will be enabled. When actuator is in bottom position towards “OFF” text on the board, the ENABLE pin will be connected to SGND and the DCM will be disabled. When switch SW01 is ON, an external voltage source can control the ENABLE state. 6. Header-jumper for trim control (J09): Provides the option to enable the trim function to set the DCM programmed trim value via either the onboard trim rheostat or an external voltage source: a. Using potentiometer (R26) b. Using external voltage source. 7. Output lugs: Sized for #10 hardware. Use these lugs to connect the output directly to the load. 8. Output oscilloscope probe Jack (J01): Used for making accurate scope measurements of the output voltage (e.g., ripple). The jack is directly compatible with many common passive voltage probes models. Remove the grounding lead and insulating barrel of the probe and insert the probe tip and barrel directly into the jack, ensuring that the probe tip seats in the center socket of the jack. To avoid the risk of an inadvertent short circuit, do not attempt to install while power is applied. 9. Output filter: Output capacitor (C201), filtering inductor (L02) and damping resistors (R16-R17), and ceramic output capacitors (C02-C05) provide output filtering. Sockets H05-H06, and H03-H04 can be used for easy installation of aluminum-electrolytic output capacitors. 10. High-side current-sense wire loops: By depopulating the associated inductor and damping resistors, all input or output currents can be passed through a wire loop or use with an oscilloscope current probe. The wire loop is installed at the large pair of plated through-holes near the applicable inductor location. 11. Dual paralleling wire-to-board connectors (J02 and J03): Used for bussing control signals and their reference (ENABLE, SHARE, FAULT, and SGND) across board assemblies during parallel operation. The connector style provides simple “strip and insert” use with 18 – 24AWG solid wires. Once inserted, a spring-loaded barb retains each wire with no need for soldering. To release the wire, insert a thin-bladed tool (AVX 06-9276-7001-01-000 or similar) into the slot above each wire entry point. UG:017 Page 4 Figure 1 DCM3623 evaluation board photo, top side Figure 2 DCM4623 evaluation board photo, top side UG:017 Page 5 Test Points Description Test nodes are labeled and include a SMT test point for attaching miniature probes, clips or hooks. Table 1 Primary-referred test point descriptions Name +IN_FUSED, +IN_FILT, –IN +IN_DCM, –IN_DCM Table 2 Secondary-referred test point descriptions Provide measurement test points for the input voltage to the board in various locations, relative to the –IN board lug. +IN_FUSED is taken after input fusing, +IN_FILT is taken after the input filtering network. Provide Kelvin connection to input pins of the DCM. Use these test points for measuring the input voltage at the module, excluding errors due to finite connection resistance leading up to the module. PRI_SG Test point for Signal Ground on the primary/input side of the isolation boundary. This is the reference for all primary side control circuitry and all control pins of the DCM. EXT_EN Test point to drive the ENABLE signal (relative to PRI_SG) using an external source. PRI_EN Test point to measure the ENABLE signal (relative to PRI_SG). EXT_TR Test point to drive the TRIM signal (relative to PRI_SG) using an external source. PRI_TR Test point to measure the TRIM signal (relative to PRI_SG). PRI_FT Test point to measure the FAULT signal (relative to PRI_SG). Name Description +OUT_DCM, –OUT_DCM +OUT_DCM_SHNT, +OUT, –OUT Description Output voltage test points provide Kelvin connection to output pin group of the DCM. Use these test points for measuring the output voltage at the module, excluding voltage errors due to finite connection resistance and the module output current. Provides measurement test points for the output voltage in various locations, relative to the –OUT board lug. +OUT_DCM_SHNT is taken before the output filtering, and +OUT is taken at the +OUT board lug. SEC_SG Test points for the +5V bias supply return, and for measuring the FT_SEC fault monitor output. FT_SEC Test point to measure the FAULT signal relative to SEC_SG once it has passed through the opto-coupler, if used. Bias power must be supplied to +5V for voltage output to appear here. +5V Test point to provide a bias voltage (relative to secondary ground) for the fault opto-coupler, if used. UG:017 Page 6 UG:017 TP33 EXT_EN TP28 EXT_TRIM J105 J104 -IN +IN 1206 FB1 R27 0603 F01 TP27 -IN 1206 2 H02 J09 OFF ENABLE CONTROL PRI_SG R02 0603 ON/External_Ctrl 3SW01 2 1 3 1 PRI_SG 0603 0603 R05 2220 C19 +IN_FILT C01 RES TRIM POT 500K OHM 1/2W 10% TH R26 TRIM CONTROL PRI_SG R01 0603 2 C18 2220 External_Trim 4 Trim_Pot 2 2220 H10 C17 2220 C16 2220 C15 L01 R08 H01 H09 One plated through-hole on each side of L02 for optional current loop +IN_FUSED TP2 1 3 1 PRI_TR 2220 C20 C21 2220 PRI_EN +IN_FILT TP3 PRI_PWM PRI_FT H03 PRI_SG J10 TP34 TP32 TP31 R32 0603 4 2 29581 1612 S102 29581 1612 S101 0603 R119 0603 3 1 PRI_FT R22 0603 4 2 4 2 J02 J03 3 1 3 1 PARALLELING CONNECTORS PRI_TR PRI_EN PRI_FT PRI_SG 5 2 4 6 3 PS01 3623 SEC_SG R23 0603 FT_SEC TP29 -OUT +OUT SECONDARY ISOLATION BOUNDRY R24 0603 +5V PRIMARY PRI_SG -IN +IN FT EN TR M02 1 0603 R04 TP100 TP101 R21 0603 PRI_SG TP7 -IN_DCM -IN_DCM +IN_DCM C25 0402 R505 0402 TP102 TP103 TP104 PRI_SG C24 0402 R504 0402 +IN_DCM TP5 C23 0402 R503 0402 CL DA AD FAULT INDICATOR 0603 PRI_SER_OUT R118 R19 TP30 PRI_FT PRI_EN PRI_TR PRI_SG D01 LED-0805 R09 0603 H04 2220 C22 0603 R120 0603 R20 PRI_SER_IN PRI_EN R18 0603 TP9 -OUT_DCM TP107 S104 29581 1612 -OUT_DCM 29581 1612 S103 +OUT_DCM +OUT_DCM TP6 TP106 C201 L02 -IN_DCM +IN_DCM +OUT_DCM_SHNT 1210 C09 1210 C07 2512 R17 2512 R16 GND HS01 GND 1206 1206 HS02 C03 C05 1206 C04 One plated through-hole on each side of L02 for optional current loop +OUT_DCM_SHNT TP1 C02 1206 1210 C11 1210 C13 H08 TP8 -OUT J107 -OUT_DCM CHASSIS-GND CHASSIS_GND J108 Note: Scope Jack +OUT_DCM J01 H06 -OUT J106 +OUT TP4 +OUT H07 R25 2010 H05 Figure 3 DCM3623 evaluation board schematic 3 PRI_TR Schematic, Assembly Drawing and Bill of Materials Page 7 UG:017 TP33 EXT_EN TP28 EXT_TRIM J105 -IN J104 +IN -IN +IN 1206 FB1 R27 0603 F02 F01 TP27 -IN 2 ENABLE CONTROL PRI_SG R02 0603 OFF ON/External_Ctrl 3SW01 2 1 3 1 C19 PRI_SG 0603 R05 2220 0603 C01 RES TRIM POT 500K OHM 1/2W 10% TH TRIM CONTROL PRI_SG R01 0603 2 R26 J09 2220 C18 +IN_FILT External_Trim 4 Trim_Pot 2 C17 2220 1 C16 2220 C15 L01 1206 R08 One plated through-hole on each side of L02 for optional current loop 2220 H01 H02 +IN_FUSED TP2 1 3 1 PRI_TR 2220 C20 H04 2220 C21 H03 PRI_EN +IN_FILT TP3 PRI_PWM PRI_FT PRI_SG PRI_FT J10 TP34 TP32 TP31 R32 0603 4 2 29581 S102 29581 S101 0603 0603 R119 0603 3 1 PRI_FT R22 0603 4 2 4 2 J02 J03 3 1 3 1 PARALLELING CONNECTORS PRI_TR PRI_EN PRI_FT PRI_SG 4 5 2 PRI_SG 6 3 PS01 SEC_SG R23 0603 FT_SEC TP29 SECONDARY -OUT +OUT 4623 ISOLATION BOUNDRY R24 0603 +5V PRIMARY -IN +IN FT CL DA EN AD TR M02 1 0603 R04 TP100 TP101 R21 0603 PRI_SG TP7 -IN_DCM -IN_DCM +IN_DCM C25 0402 R505 0402 TP102 TP103 TP104 PRI_SG C24 0402 R504 0402 +IN_DCM TP5 C23 0402 R503 0402 CL DA AD FAULT INDICATOR 0603 0603 PRI_SER_OUT R118 R19 TP30 D01 PRI_EN PRI_TR PRI_SG R09 0603 2220 C22 0603 0603 R120 0603 R20 PRI_SER_IN PRI_EN R18 0603 -IN_DCM +IN_DCM TP9 -OUT_DCM TP107 S104 29581 -OUT_DCM 29581 S103 +OUT_DCM +OUT_DCM TP6 TP106 1210 C07 1210 C08 1210 C10 1210 C09 GND HS02 C201 +OUT_DCM_SHNT HS01 GND L02 2512 R17 2512 1210 C14 1210 C13 1210 C11 1210 C12 +OUT_DCM 1206 C05 -OUT_DCM CHASSIS-GND CHASSIS_GND J108 H05 H06 1206 1206 1206 C02 C04 C03 One plated through-hole on each side of L02 for optional current loop +OUT_DCM_SHNT TP1 R16 J01 TP8 -OUT -OUT -OUT J107 +OUT J106 +OUT TP4 +OUT note:ScopeJack H08 R25 2010 H07 Figure 4 DCM4623 evaluation board schematic 3 PRI_TR Schematic, Assembly Drawing and Bill of Materials (Cont.) Page 8 Schematic, Assembly Drawing and Bill of Materials (Cont.) Figure 5 DCM3623 evaluation board, assembly drawing, top side J108 TP4 J106 TP1 R504 R04 C501 TP20 C02 C03 R538 FB500 R543 R544 R546 R537 D500 U500 U01 SW13 TP8 TP03 TP25 TP26 TP23 TP21 TP08 U501 R530 R527 D202 R525 C504 TP16 TP15 TP09 TP17 TP18 C506 R551 C505 R532 R520 R531 D501 R529 TP22 TP14 R227 R223 SW04 R526 TP07 C206 R214 R124 TP05 C502 J107 J001 R548 R566 R547 R550 R549 R553 C503 R517 R555 R554 TP04 R510 C520 R565 R56 SW03 C500 U502 R524 TP06 TP24 J10 R11 TP01 J09 R23 TP29 J02 Q201 R229 R225 R224 R228 Q200 D01 J03 R14 R226 R230 TP10 R32 R09 R12 R521 R512 R522 TP12 R22 M02 R21 R24 R27 TP28 TP34 R01 TP31 TP32 TP30 R26 R207 L203 R205 R206 L204 R208 R243 L211 R242 R13 U201 TP11 FB1 R545 TP7 TP9 C11 TP27 H06 H08 TP33 C01 R02 R05 SW01 R204 L202 R202 R201 L201 R203 R241 L210 R240 C04 S104 HS02 HS01 J105 C05 R505 C07 H02 TP02 R120 H04 TP13 R119 S102 C201 R503 R25 J01 R17 TP19 R18 C23 R19 C24 R20 C25 R118 C22 C21 C20 C19 C18 C17 H05 H07 R16 S103 PS01 R502 FB501 S101 H01 H10 L02 H03 TP2 C16 C15 H09 C13 L01 C09 TP3 R08 TP6 TP5 F01 J104 J204 J504 TOP VIEW Figure 6 DCM4623 evaluation board assembly drawing, top side J108 F01 TP4 J106 R04 TP6 R520 R531 R551 C505 R532 U01 C02 C03 FB500 R543 TP20 R537 R538 R544 R546 R545 TP19 TP9 SW04 R526 U500 SW13 R527 TP03 TP25 TP26 TP23 TP21 TP08 D202 C206 R214 TP05 TP13 J504 TP04 R124 TP02 TP16 TP15 TP09 TP17 TP18 TP14 TP22 TP10 TP06 TP8 U501 R530 R525 C504 TP12 TP07 C503 R517 C502 D501 R227 R223 J107 J001 R548 R566 R547 R550 R549 R553 D500 R555 R554 C501 U502 R524 C506 R11 R565 R56 SW03 C500 R529 R24 Q201 R229 R225 R224 R228 TP11 J10 TP01 J09 TP29 J02 R14 R226 R230 R521 R512 R522 Q200 R23 D01 J03 R12 TP24 R32 R09 M02 R22 R21 R510 C520 U201 R27 TP28 TP34 R01 TP31 TP30 TP32 R26 R207 L203 R205 R206 L204 R208 R243 L211 R242 R13 R502 FB501 TP7 TP27 H06 H08 TP33 C01 R02 R05 SW01 R204 L202 R202 R201 L201 R203 R241 L210 R240 C04 S104 HS02 HS01 FB1 C05 C201 C08 C07 H04 R25 J01 R17 R18 C23 R503 R19 R119 R504 C24 R20 R120 C25 R505 C22 C21 C20 C19 C18 C17 C16 PS01 S102 H02 R16 R118 C12 C11 TP2 S103 S101 C15 H05 H07 H03 H01 J105 L02 TP1 TP3 R08 L01 C13 C14 C09 C10 TP5 F02 J104 J204 TOP VIEW UG:017 Page 9 Schematic, Assembly Drawing and Bill of Materials (Cont.) Table 3 DCM evaluation board BOM, components common to all boards Reference Designator Description Manufacturer Manufacturer Part Number Common Components C01 CAP X7R 0.10µF 10% 16V 0603 AVX 0603YC104KAT2A C02 – C05 CAP X7S 4.7µF 10% 100V 1206 AVX 12061Z475KAT2A C07 – C14 Board specific - See table 4 BOMs C15 – C22 Board specific - See table 4 BOMs C201 Design specific - See table 5 BOMs D01 LED RED 0805 ROHM SML-211UTT86 FB1 FERRITE BEAD 33Ω 6A 1206 MURATA BLM31PG330SN1L CONN 4 POS WIRE TO BOARD AVX 009276004021106 TESTPATH 131-5031-00 F01, F02 Design specific - See table 5 BOMs HS01 – HS02 Board specific - See table 4 BOMs J02 – J03 J01 PCB TP ADAPTER, 3.5mm PROBE L01 Board specific - See table 4 BOMs L02 IND 0.33µH 20% 50A WURTH 744309033 M02 IC 6 PIN OPTO VISHAY CNY17-3X017T RES 0 OHM JUMPER 0603 KOA RK73Z1JTTD PS01 Design specific - See table 5 BOMs VICOR R08 RES 1Ω ¼W 5% 1206 KOA RK73B2BTTE1R0J R16 RES 250mΩ 1W 2512 VISHAY WSL2512R2500FEA R09, R21 RES 1kΩ 1/10W 5% 0603 KOA RK73B1JTTD102J R22, R32 RES 49.9kΩ 1/10W 1% 0603 KOA RK73H1JTTD4992F R23 R02, R04, R05, R18, R19, R20 RES 4.99kΩ 1/1W 0.1% 0603 THIN FILM TECH CR0603E4991B-T5 R24, R01 RES 0Ω JUMPER 0603 KOA RK73Z1JTTD R25 RES 0Ω JUMPER 2010 VISHAY CRCW20100000Z0EF R26 RES TRIM POT 500kΩ 1/2W 10% COPAL CT-94EW504 S102 – S104 SW01 JMPSOK for J09 – J10 EXCELTOOL and RES 0Ω JUMPER 1612 COPPER DIE CandK COMPO- SW TOGGLE SPDT 1 POS NENTS JUMPER SOCKET XJ8A OMRON UG:017 29581 GT11MSABE XJ8A-0211 Page 10 Schematic, Assembly Drawing and Bill of Materials: (Cont.) Table 4a BOM additions, components common to low-voltage DCM3623 evaluation boards Reference Designator C11, C13 C08, C10, C12, C14 C15 – C22 L01 HS01 - HS02 Part Number CAP X7R 4700pF 10% 2kV 1210 KEMET C1210C472KGRAC7800 N/A (not present in design) N/A N/A CAP X7R 4.7µF 20% 100V 2220 TDK C5750X7R2A475M230KA IND 0.33µH 20% 50A WURTH 744309033 DCM3623 DUAL HTSNK VICOR 40526 EXCELTOOL S101 RES 0Ω JUMPER 1612 COPPER CIN at CAP ALEL 680µF 20% 63V RADIAL UNITED 18 X 20 CHEMI CON H01 - H02 Reference Designator and DIE Description 29581 ELXZ630ELL681MM20S Manufacturer Manufacturer Part Number 100V (nominal input voltage) DCM3623 board components C07, C09, C11, C13 C08, C10, C12, C14 C15 – C22 L01 HS01 - HS02 S101 CIN at H01 - H02 Table 4c BOM additions, components common to all DCM4623 evaluation boards Manufacturer Manufacturer Low-Voltage DCM3623 board components C07, C09, Table 4b BOM additions, components for 100V DCM3623 evaluation boards Description Reference Designator CAP X7R 4700pF 10% 2kV 1210 KEMET C1210C472KGRAC7800 N/A (not present in design) N/A N/A CAP X7T 2.2µF 20% 250V 2220 TDK C5750XT2E225M250KAA IND 0.33µH 20% 50A WURTH 744309033 DCM3623 DUAL HTSNK VICOR 40526 EXCELTOOL and RES 0Ω JUMPER 1612 COPPER DIE CAP ALEL 180µF 20% 200V 12.5x40 Description NICHICON 29581 UCY2D181MHD Manufacturer Manufacturer Part Number DCM4623 board components C07 – C14 CAP X7R 4700pF 10% 2kV 1210 KEMET C1210C472KGRAC7800 C15 – C22 CAP X7T 0.47µF 10% 630V 2220 TDK C5750X7T2J474K250KC IND 1.0µH 20% 13A BOURNS SRP7030-1R0FM DCM4623 DUAL HTSNK VICOR 40519 BEAD 680Ω 4A 1812 TAIYO YUDEN FBMH4532HM681-T L01 HS01 - HS02 S101 CIN at H01 - H02 UNITED AP ALEL 10µ 20% 450V RAD CHEMI CON UG:017 EKXG451ELL100MK20S Page 11 Schematic, Assembly Drawing and Bill of Materials: (Cont.) Table 5 Example: BOM additions, components which are DCM model specific. Reference Designator Description Manufacturer Manufacturer Part Number Evaluation board number: DCM3623E50M06A8M00 PS01 DCM3623 VICOR DCM3623T50M06A8M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P NICHICON URS1A103MHD1TN C201 CAP ALEL 10000µF 20% 10V RADIAL 18 x 26.5 Evaluation board number: DCM3623E50M13C2M00 PS01 DCM3623 VICOR DCM3623T50M13C2M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P NICHICON UVY1E472MHD C201 CAP ALEL 4700µF 20% 25V RADIAL 16 x 25 Evaluation board number: DCM3623E50M17C2M00 PS01 DCM3623 VICOR DCM3623T50M17C2M00 F02 FUSE 30A 125V AXIAL LITTELFUSE 324 030P NICHICON UPW1E222MHD C201 CAP ALEL 2200µF 20% 25V RADIAL 16 x 25 Evaluation board numbers: DCM3623E50M26C2M00, DCM3623E50M31C2M00 One of PS01 DCM3623 VICOR DCM3623T50M26C2M00 DCM3623T50M31C2M00 F01 C201 FUSE 30A 125V AXIAL LITTELFUSE CAP ALEL 1000µF 20% 50V RADIAL UNITED 18 x 20 CHEMICON 324 030P EKY-500ELL102MM20S Evaluation board number: DCM3623E50M53C2M00 PS01 DCM3623 VICOR DCM3623T50M53C2M00 F01 FUSE 30A 125V AXIAL LITTELFUSE 324 030P NICHICON UPJ1K221MHD6TN C201 CAP ALEL 220µF 20% 80V RADIAL 18 x 16.5 Evaluation board numbers: DCM4623EC8G16F0T00, DCM4623ED2J13D0X00, DCM4623ED2H26F0X00 One of DCM4623TC8G16F0T00 PS01 DCM4623 VICOR DCM4623TD2J13D0T00 DCM4623TD2J13D0M00 DCM4623TD2H26F0T00 DCM4623TD2H26F0M00 F01 C201 FUSE 5A 450V FAST 6.3 X 32 RADIAL COOPER BUSSMANN CAP ALEL 1000µF 20% 50V RADIAL UNITED 18 x 20 CHEMICON UG:017 BK/PCD-5-R EKY-500ELL102MM20S Page 12 Schematic, Assembly Drawing and Bill of Materials: (Cont.) Table 5 (Cont.) Example: BOM additions, components which are DCM model specific. Reference Designator Description Manufacturer Manufacturer Part Number Evaluation board numbers: DCM4623ED2H31E0X00, DCM4623ED2H53E0X00 One of DCM4623TD2H31E0T00 PS01 DCM4623 VICOR DCM4623TD2H31E0M00 DCM4623TD2H53E0T00 DCM4623T02H53E0M00 F01 C201 FUSE 5A 450V FAST 6.3 X 32 RADIAL CAP ALEL 220µF 20% 80V RADIAL 18 x 16.5 COOPER BUSSMANN NICHICON BK/PCD-5-R UPJ1K221MHD6TN General BOM rules for various DCM Evaluation Boards n PS01: This is the Vicor DCM, whose part number is coded in the evaluation board part number. For example, eval board DCM4623ED2K53E0M00 uses DCM4623TD2K53E0M00. n F01: This is the input fuse. See the data sheet for the specific DCM for appropriate fuse needed to meet listed safety agency approvals. n C201: This is the external output capacitor for the DCM. It is an Aluminum electrolytic with value that satisfies the DCM data sheet COUT-TRANS minimum. UG:017 Page 13 Recommended Test Equipment The following is a list of recommended test equipment. 1. Safety glasses 2. DC power supply: Refer to the specific DCM model data sheet to ensure the supply has sufficient power and current capability, especially at low line, to satisfy current inrush when the DCM is started 3. Electronic load: Refer to the specific DCM model data sheet to ensure the load has sufficient power handling and current capability for testing 4. Cooling fan 5. Digital multi-meters (DMMs) 6. Oscilloscope and probes 7. Function generator 8. Auxiliary bench voltage supply (optional, for bias of secondary side fault monitor opto-coupler) 9. Interconnect wires, cables and fastening hardware 10. Calibrated input and output shunts, appropriately rated 11. Thin bladed tool for extracting wires from paralleling connectors (AVX 06-9276-7001-01-000 or similar) Basic Connections n Confirm bench equipment is powered off. n Connect the input DC power supply positive lead to the +IN input lug of the evaluation board, connect the input power supply negative lead to the –IN input lug of the evaluation board. n Connect the CHASSIS_GROUND lug of the evaluation board to a safety “green wire” earth ground. n Connect the +OUT lug of the evaluation board to the electronic load positive input, connect the –OUT lug of the evaluation board to the electronic load negative input. n Direct airflow from the cooling fan through the DCM heat sink fins. n Have the latest DCM data sheet on hand for reference. Board Operation Details n SW01 provides control over enable. n In the “OFF” position, the switch will connect SG the EN net, which disables the DCM. n In the “ON” position, SG is disconnected from the EN net. n External connection to EN is permitted using the PRI_EN test point. SW01 should be set to “ON” to permit external control. n The J02 and J03 paralleling connectors can be used to connect EN nets across different boards. Note: to enable the DCMs in a parallel array, all boards need SW01 set to “ON” to avoid pulling the EN node low. UG:017 Page 14 Trim Control n Jumper block J09 configures trimming. n With no jumpers installed, neither the trim potentiometer nor the test point for external trim control is connected to the TR net. Note that the paralleling connectors always connect to the TR net. n With a jumper loaded across J09.1 and J09.2, the trim potentiometer R26 is connected as a rheostat between the TR node and SG. n With a jumper loaded across J09.3 and J09.4, the external trim test point is connected to the TR node. n The DCM contains an internal pull-up resistor to VCC (3.3V nominal). When VIN is applied to the DCM it samples the TR node voltage. If it has pulled up to VCC, the DCM disables trimming as long as it has input power, and the programmed trim condition will be nominal rated VOUT of the DCM model. n If the TR node is not permitted to pull-up to VCC when VIN is applied, trimming is enabled for as long as the DCM has input power. n Note: Any load on the TR node may cause the DCM to select trim mode when VIN is applied, including: the external trim test point (if selected with the jumper block), the trim potentiometer (if selected with the jumper block), and other DCM evaluation boards attached to the paralleling connectors. n The trim potentiometer adds a variable resistance between the TR node and SG, from between 0Ω nominal, to the value of the potentiometer (500kΩ). This resistance range will generate TR pin voltages which cover the entire functional range of the TR pin. Care should be taken to ensure the programmed trim condition is within the rated trim range of the DCM in order for the DCM to meet specifications. n In a parallel set up using the J02 and J03 paralleling connectors, all boards besides the top one should have the trim jumper select block at J09 open. n In a parallel set up with multiple DCM evaluation boards, each DCM contributes another internal pull-up resistor to a 3.3V nominal rail. With any resistive based trimming of the TR node, the resultant trim condition will be modified by the number of DCMs which are attached and have VIN applied. Conversely with a voltage source applied to the TR node, adding additional DCMs to the system has minimal impact on the resultant trim condition. Fault Monitoring n Jumper block J10 configures how the FT node is monitored. n With no jumpers installed, neither the visible LED nor the opto-coupler is connected to the FT net. Note that the paralleling connectors always connect to the FT net. n With a jumper loaded across J10.3 and J10.4, the visible LED at D01 and its bias resistor network R09 and R32 are connected to the FT node. n With a jumper loaded across J10.1 and J10.2, the opto-coupler at M02 and its bias resistor network R21 and R22 is connected to the FT node. n The DCM FT output is intended to be directly paralleled with the FT output of other DCMs in an array. The FT node in an array forms a “wired-OR”, where any DCM can drive the FT node high. UG:017 Page 15 n Both the visible LED and the opco-coupler draw current from the FT node in a fault condition. The FT pin on the DCM has limited drive-high capabilities, and so care must be taken to avoid excess loading of the pin. To avoid overload, do not configure J10 to use both the LED and opto-coupler indicators simultaneously. When connecting external circuitry or test equipment to the FT test point, ensure that the maximum load on the FT node is within the DCM data sheet ratings. n In a parallel set up using the J02 and J03 paralleling connectors, all boards besides the top one should have the fault jumper select block at J10 open. n When using the opto-coupler, the status of the FT node can be easily transferred to the secondary side of the DCM(s) isolation boundary. To resolve the fault state on the secondary side, the collector side of the opto requires a bias voltage. A 5V bench supply should be connected between the “+5V” and “SEC_SG” test points. With no fault present, “FT_SEC” will be at 0V, and when a fault occurs and the opto-coupler is active, “FT_SEC” will pull up to 5V, relative to SEC_SG. Chassis Ground The heat sink assembly of the DCM is connected to the CHASSIS_GND node of the board, as well as the y-caps from each power connection of the DCM. A connection from the CHASSIS_GND lug to earth ground is required. Paralleling The paralleling and sharing performance of multiple DCMs can be easily demonstrated by stacking multiple evaluation boards and interconnecting the inputs and outputs with standoffs to create a parallel array. The DCM uses a negative load-line to implement wireless droop-sharing in an array. Each DCM in an array operates in the same way as it does as a stand-alone unit. With equal trim conditions, the load is effectively shared across multiple DCMs. Mismatches in this case are modest, and are further canceled by an effective negative voltage vs. temperature coefficient. See the DCM data sheet for more detail on load line and tempco. DCMs in an array require no derating of maximum output power or current. DCMs in an array with mismatched trim conditions will not share the load equally at light- to moderate‑load conditions. As the load increases, one or more DCMs (starting with those with the highest programmed output trim voltage) will go into current limit and their contribution to the overall output current will plateau. For DCMs, current limit is not a fault condition, rather it is a valid constantcurrent mode of operation and a DCM in current limit will provide constant current to the load. As long as the load does not exceed the maximum load rating of the array of DCMs, the output voltage will continue to be regulated by any remaining DCMs still in constant voltage mode. Even with mismatched trim conditions, the array can be safely loaded up to the full rated array capacity. The following connections and settings should be used for an array of DCM evaluation boards: n All DCMs in a parallel array must be the same model. n The boards should be physically stacked using metal standoffs at the +IN and –IN lugs, the +OUT and –OUT lugs, and the CHASSIS_GND lug. This also connects these nodes electrically so that a single source, single load, and earth ground connection can be made to the system. n The +IN lugs are not required to be connected together for an array of DCMs. The wireless sharing does not require the same differential input voltage be present on all DCMs in the array. In some applications dissimilar input voltages may be needed, which is fully supported. UG:017 Page 16 n The –IN lugs must be connected together if the paralleling connector is used, or if the EN, TR, or FT pins are interconnected in any fashion. However if all control signals of all DCMs are fully isolated from one another, then both the +IN and –IN lugs can remain independent across the evaluation boards, and the DCMs can be operated with fully independent input supplies. n Standoffs must be sufficient in length to avoid contact between boards, and to permit airflow to all DCMs in the system. n If coordinated enable control, trimming or fault monitoring is desired, then the paralleling connectors J09 and J10 can be used to easily interconnect the PRI_FT, PRI_EN, PRI_TR_ and PRI_FT nodes across boards. The paralleling connectors at J02 and J03 can be used for coordinated enable and trim control and fault monitoring. The enable, trim and fault monitor features of the top most board should be used for convenience, while the remaining boards should have their jumper blocks depopulated and enable switches set to enable. The paralleling wire-to-board connectors (at J02 and J03) are provided to daisy chain control signals and PRI_SG, with a simple strip-and-insert option. They will accept 18 – 24AWG solid wires. Figure 7 DCM evaluation boards stacked to form a high power parallel array, using common -IN and the paralleling connectors. UG:017 Page 17 Limitation of Warranties Information in this document is believed to be accurate and reliable. HOWEVER, THIS INFORMATION IS PROVIDED “AS IS” AND WITHOUT ANY WARRANTIES, EXPRESSED OR IMPLIED, AS TO THE ACCURACY OR COMPLETENESS OF SUCH INFORMATION. VICOR SHALL HAVE NO LIABILITY FOR THE CONSEQUENCES OF USE OF SUCH INFORMATION. IN NO EVENT SHALL VICOR BE LIABLE FOR ANY INDIRECT, INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES (INCLUDING, WITHOUT LIMITATION, LOST PROFITS OR SAVINGS, BUSINESS INTERRUPTION, COSTS RELATED TO THE REMOVAL OR REPLACEMENT OF ANY PRODUCTS OR REWORK CHARGES). 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