NBM6123E60E12A7T0R

USER GUIDE | UG:019 NBM6123 ChiP™ Analog Low-Voltage Non-Isolated Bus Converter Module Evaluation Board Contents Page Introduction 1 Contents 3 Features 3 Board Description General Components 3 3 Test Points Description 5 Bill of Materials 8 Recommended Test Equipment 9 Basic Connections 9 Board Operation Details 9 Thermal Considerations 10 Paralleling 10 Introduction The Converter housed in a Package (ChiP) Non-Isolated Bus Converter Module (NBM) evaluation board described in this document is designed to be used with the the through-hole NBM6123 ChiP family (PNs: NBM6123T46C15A6T0R, NBM6123T60E12A7T0R). The NBM evaluation board can be configured for various enabling and fault-monitoring schemes, as well as to exercise various loading conditions depending on the application requirements. The evaluation board can be used to evaluate NBMs in either a stand-alone configuration or as an array of modules. It is important to remember the fast response of NBMs can readily show the limitations of the source, load and associated wiring connected to the evaluation board. Care should be exercised to minimize the stray source and load impedance in order to fully exercise the NBM. The NBM non-isolated topology allows start up in forward and reverse directions and provides bidirectional protections. However, if powertrain is disabled by any protection, and VSEC is present, then voltage equal to VSEC minus two diode drops will appear on the primary side. UG:019 Page 1  IMPORTANT NOTICE: Read the precautions below entirely BEFORE using the NBM™ 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. nn During operation, the power devices and surrounding structures can be operated safely at high temperatures. nn Remove power and use caution when connecting and disconnecting test probes and interface lines to avoid inadvertent short circuits and contact with hot surfaces. nn Never use a jumper in place of the fuse. nn When testing electronic products always use approved safety glasses. Follow good laboratory practice and procedures. nn Avoid creating ground loops between the SGND and PGND pins when making measurements. nn Care should be taken to protect the user from accidental contact when under power. nn Care should be taken to avoid reversing polarities if connecting to the opposite (solder) side of the board. nn The product evaluation boards described in this document are designed for general laboratory evaluation and are not suitable for installation in end-user equipment. nn Refer to the specific NBM module data sheet for electrical, thermal and mechanical product details. This board provides a convenient way to evaluate or demonstrate the performance of Vicor NBM 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. Enable Options 1. Apply input voltage to the NBM primary or secondary pins greater than the undervoltage lockout. (Default) 2. On-board mechanical switch. 3. External control using available test point. Fault Monitor Options 1. On-board LED: the VAUX pin drives a visible LED for visual feedback on the NBM status such as enabled or fault condition. UG:019 Page 2 Contents The evaluation board ships with the following contents: nn 1 x NBM™ evaluation board nn 1 x Top heat sink pre-installed nn 1 x hardware kit: nn1 x through-hole aluminum electrolytic output capacitor (C121) nn3 x Connector Receptacle 8 position nn2 x Connector socket 2 position nn5 x size 10 screws, lugs and washers Features The NBM evaluation board has the following features: 1. Input and output lugs for source and load connections 2. Appropriately rated input fuse 3. Input aluminum electrolytic capacitor for additional source decoupling 4. Basic output filtering footprint, including sockets to add through-hole output aluminum electrolytic capacitors 5. Toggle switch for enabling and disabling the NBM via the enable (EN) pin 6. Oscilloscope probe jack for accurate, high frequency output voltage measurements 7. Connectors for NBM signal pins (TM, EN, and VAUX) and temperature monitor filtered signal 8. Kelvin voltage test points for all power pins Board Description The following section provides a detailed description of the evaluation board components, test points and sockets. General Components 1. (PS01): The NBM is inherently a reversible product. This means that a voltage source placed at the secondary will bias the powertrain and allow the units to power up. Note if the units is held in a disabled state using the EN pin any voltage applied to the secondary pins of NBM will appear on the primary pins minus two diode drops. Loading the primary in this state may permanently damage the unit since the load current path would be through the body diode of the primary stage FETs . See the NBM data sheet for additional insight. 2. Input lugs: Sized for #10 hardware. Use for making connection to the input source. This board does not contain reverse polarity protection. Check for proper polarity before applying the power. It is important to remember that noise from the source and voltage drops, will appear at the output of the bus converter multiplied by transformation ratio (K). The K factor is the ratio of the output voltage to the input voltage (VOUT / VIN). 3. Input fuse (F101 & F102): Appropriately rated for the NBM model installed on the board. The fuse is meant to protect against excessive damage in a short-circuit event. 4. Input filtering: aluminum electrolytic input capacitor (C101). 5. Enable / Disable switch (SW101): When actuator is towards “ON” text on the board, the (EN) pin will be open and the NBM will be enabled. When actuator is towards “OFF” text on the board, the (EN) pin will be connected to (SGND) pin and the NBM will be disabled. When switch (SW101) is “ON”, an external voltage source can control the EN pin state. UG:019 Page 3 6. Signal connector (J102): provides access to the bus converter signal pins (TM, EN and VAUX) as well as (TM_DC) externally filtered signal. All signal pins are reference to the primary non-isolated voltage return (SGND) pin. Figure 1 NBM™ signal connector (J102) 2 4 6 8 SGND SGND SGND SGND 1 3 5 7 TM_PWM TM_DC EN VAUX nnTemperature Monitor (TM): The NBM (TM) pin outputs a 250kHz PWM signal. A 1kΩ and a 10nF is the recommended low-pass filtering solution. (TM_PWM) and filtered (TM_DC) are both accessible on (J102) connector header. (TM_DC) measures 1.27V for a 27°C internal temperature corresponding to a (TM_PWM) duty cycle of 38.48% nnEnable Control (EN): Connecting the NBM (EN) pin to (SGND) will disable the module. (SW101) can be used to turn off the powertrain and disable the module. The (EN) pin is internally pulled up. During a fault condition, this signal and will remain high while input voltage is applied and greater than VµC_ACTIVE. This connector can be used to bus the (EN) pin in an array allowing array synchronous start up. nnAuxiliary Voltage Source (VAUX): The NBM (VAUX) can be used as a fault flag it is internally driven low during a fault condition. The (VAUX) pin can also be used as a ready to process full power flag. A 2ms delay from powertrain active is introduced on this pin signaling the end of soft start. During normal operation this pin can be used as an auxiliary supply up to 4mA max load. 7. Output lugs: Sized for #10 hardware. Use these lugs to connect the output directly to the load. 8. Output oscilloscope probe Jack (J101): 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, insuring that the probe tip sits 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. This Johnson Jack is Kelvin connected to the module output pins. The effect of the output capacitors will not be noticeable. 9. Output filter: 10x output ceramic capacitors 1206 footprint provision (C103, C104 and C113 – C120). In addition to socket (C121) that can be used for easy installation of an aluminum electrolytic output capacitor included with in hardware kit of the evaluation board. 10. Chassis ground (R106): is a 2010 package. The footprint can be used to provide a convenient means to short the chassis and heat sink common ground to the power-ground plane. Figure 2 PCB#42142 evaluation board photo, top side UG:019 Page 4 Test Points Description Test nodes are labeled and include an SMT test point for attaching miniature probes, clips or hooks. Table 1 Test point descriptions Name +VIN, PGND EN, SGND Description Provide measurement test points for the input voltage of the NBM™ module. Test points are Kelvin connected to the module input pins. Used to measure the NBM EN pin relative to SGND pin. TM_DC, SGND Used to measure the filtered NBM TM signal using a recommended low pass filter relative to SGND pin. TM_PWM, SGND Used to measure the NBM TM pin which is a pulse width modulated output signal relative to SGND pin. VAUX, SGND Used to measure the NBM VAUX pin output signal relative to SGND pin. +VOUT, PGND Provide measurement test points for the output voltage of the NBM module. Test points are Kelvin connected to the module output pins. UG:019 Page 5 UG:019 PGND +IN SGND PGND +IN C102 29400-103 0603 0.01uF TM_DC 37688 40A FUSE F102 42153 70A FUSE F101 SGND 1SW101 2 3 PGND HS01 GND LED 40058 0805 D101 1 3 5 7 2 4 6 8 DNP R106 2010 DNP DNP CHASSIS_GND C103 1uF 1206 25185-105 DNP DNP NBM +OUT C115 1uF 1206 25185-105 DNP TP107 CHASSIS_GND TP102 SGND SGND TP106 Kelvin PS01 PGND +VOUT SGND C104 1uF 1206 25185-105 DNP C113 1uF 1206 25185-105 C114 1uF 1206 25185-105 DNP C116 1uF 1206 25185-105 DNP TP108 Kelvin C117 1uF 1206 25185-105 DNP C118 1uF 1206 25185-105 DNP PGND TP104 Kelvin TP103 +IN CL VAUX DA EN AD TM +VOUT SER-IN EN SER-OUT 6123 LV Non-Isoloated BCM TP101 TP105 TP111 TP110 TP109 +VIN +VIN 0603 15462-0R00 0603 14695-00R0 R105 0603 15462-0R00 R104 R103 Kelvin VAUX TP115 TM_PWM SGND 0603 14695-7500 750 R102 J102 EN TP112 CONN HEADER R/A .100 8P OS A33079-ND / 5103166-2 41009 TM_PWM TM_DC EN VAUX SGND C101 30799 CAP ALEL 10uF 20% 450V RAD SW_GT11MSABE 40538 NBM ON/OFF CONTROL 0603 15462-1001 R101 1K TM_PWM TP114 EMI TM_DC TP113 PGND 1 C119 1uF 1206 25185-105 DNP J101 33292 C120 1uF 1206 25185-105 DNP H02 30799 C121 H01 DNP PGND +VOUT PGND +OUT Figure 3 PCB#42142 evaluation board schematic Page 6 Figure 4 PCB#42142 evaluation board, top side Figure 5 PCB#42142 evaluation board, bottom side UG:019 Page 7 Bill of Materials Following table describes the design specific components of the NBM™ evaluation boards. Table 2 NBM evaluation board components common to all boards Reference Designator Description C101 CAP ALEL 10µ 20% 450V RAD C102 CAP X7R 0.010µF 10% 50V 0603 D101 DLED RED 0805 ManuFacturer Part Number United Chemi-Con EKXG451ELL100MK20S Murata Manuafacturing GRM188R71H103KA01D Rohm F101 SML-211UTT86 Design specific – see Table 3 F102 Design specific – see Table 3 J101 JACK VERTICAL MECH THRU HOLE J102 CONN HEADER R/A 0.100 8 POS 30 AU Tektronix 131-5031-00 TE Connectivity Ltd 5-103166-2 HTSNK Design specific – see Table 3 PCB Part Number Design specific – see Table 3 R103 R104 R105 RES 0Ω JUMPER 1A 0603 KOA Speer Electronics R102 RES 750Ω 1/10W 5% 0603 KOA Speer Electronics RK73B1JTTD751J R101 RES 1kΩ 1/10W 1% 0603 KOA Speer Electronics RK73H1JTTD1001F C&K Components GT11MSABETR ManuFacturer ManuFacturer Part Number SW101 Table 3 BOM additions, components which are NBM model specific ManuFacturer SW Horizontal SPDT 1 POS SMD Reference Designator Description RK73Z1JTTD Evaluation board numbers: NBM6123E60E12A7T0R; NBM6123E46C15A6T0R PS01 PCB Part Number F101 HTSNK LV NBM Vicor Corporation NBM6123T60E12A7T0R; NBM6123T46C15A6T0R NBM evaluation board Vicor Corporation 42142 Littelfuse 0TLS060.TXLS Vicor Corporation 42676 FUSE 60A 170VDC THRU HOLE BOM HEAT SINK, TOP UG:019 Page 8 Recommended Test Equipment The following is a list of recommended test equipment. 1. Safety glasses. 2. DC power supply: Refer to the specific NBM™ model data sheet to ensure the supply has sufficient power and current capability. 3. Electronic load: Refer to the specific NBM 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. Interconnect wires, cables and fastening hardware. Basic Connections nn Confirm bench equipment is powered off. nn 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 PGND input lug of the evaluation board. nn Connect the CHASSIS_GND lug of the evaluation board to a safety “green wire” earth ground. nn Connect the +OUT lug of the evaluation board to the electronic load positive input, connect the PGND output lug of the evaluation board to the electronic load negative input. nn Verify proper polarity of the connections. nn Verify (SW101) desired actuator position nn Direct airflow from the cooling fan through the NBM heat sink fins. nn Have the latest NBM datasheet on hand for reference. Board Operation Details nn SW01 provides control over enable. nnIn the “OFF” position, the switch will connect SGND pin to the EN net, which disables the NBM. nnIn the “ON” position, the EN net is allowed to float. nn External connection to EN is permitted using the EN test point. (SW01) should be set to “ON” to allow external control. nn The (J102) paralleling connectors can be used to connect EN nets across different boards. Note: to enable the NBMs in a parallel array, all boards need (SW01) set to “ON” to avoid pulling the EN node low. nn The heat sink assembly of the NBM is connected to the CHASSIS_GND lug. A connection from the CHASSIS_GND lug to earth ground is required for safety as the heat sink will be floating otherwise. nn The visible LED at D101 and its bias resistor network (R102 & R105) are connected to the VAUX pin. LED turns “ON” when VAUX is high signaling that the NBM is ready to process full power. UG:019 Page 9 Thermal Considerations The evaluation board is supplied with a pre-installed 27mm top only for PCB#42142. A fan blowing across the evaluation board and heat sink assembly is required during operation at load. The fan should be placed about 4 inches away from the evaluation board facing the output voltage side. A typical bench-top fan is recommended providing about 1000LFM. Using the supplied rubber feet is also required in order to elevate the board about 0.4 inches off a flat surface and enable air flow underneath the PCB. The PCB top layer used of the PCB#42142 is required to be of the same potential of the heat sink; this is to allow heat transfer from the bottom of the ChiP™ and leads to the heat sink. Chromerics GEL-8010 is used on both top and bottom surface of the ChiP. (Between the ChiP top and heat sink as well as the ChiP bottom and the PCB). It is also required to apply to the heat sink extended surface resting on the PCB. Paralleling The paralleling and sharing performance of multiple NBMs can be easily demonstrated by stacking multiple evaluation boards and interconnecting the inputs and outputs with standoffs to create a parallel array. Each NBM in an array operates in the same way as it does as a stand-alone unit. With equal impedance, the load is effectively shared across multiple NBMs. Mismatches in this case are modest, and are further canceled by an effective negative voltage vs. temperature coefficient. The following connections and settings should be used for an array of NBM evaluation boards: nn All NBMs in a parallel array must be the same model. nn The boards should be physically stacked using metal standoffs at the +IN & PGND input lugs, the +OUT & PGND 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. nn The NBM is a three-terminal device; it is required to connect all PGND lugs to the same potential. nn Standoffs must be sufficient in length to avoid contact between boards and to permit airflow to all NBMs in the system. nn If coordinated enable control then the paralleling connectors (J102) can be used to easily interconnect the EN pin across boards. nn The paralleling connector receptacle (J102) is provided to daisy chain EN signal and SGND. The receptacle will accept a wire size range 26 – 22AWG, 0.12 – 0.3mm2 wires. The paralleling and current sharing capability of the devices can be demonstrated by stacking multiple evaluation board and interconnecting the inputs, outputs and power grounds with standoffs of sufficient current rating to create a parallel array. If synchronous start up is desired, connect EN pin 5 and SGND pin 6 in (J102) using a twisted pair to all respective pins in different paralleled units. Figure 6 NBM evaluation boards stacked to form a high‑power parallel array, using common PGND and both input and output power terminals UG:019 Page 10 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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Contact Us: http://www.vicorpower.com/contact-us Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 www.vicorpower.com email Customer Service: custserv@vicorpower.com Technical Support: apps@vicorpower.com ©2018 – 2019 Vicor Corporation. All rights reserved. The Vicor name is a registered trademark of Vicor Corporation. All other trademarks, product names, logos and brands are property of their respective owners. 02/19 Rev 1.2 Page 11