VI-A66-CQ

VI-200 / VI-J00 Family Design Guide & Applications Manual DC-DC Converters and Configurable Power Supplies Design Guide & Applications Manual VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies Table of Contents VI-/MI-200 and VI-/MI-J00 DC-DC Converters 1. Zero-Current Switching 2 2. DC-DC Converter Pinouts 3 3. Module Dos and Don’ts 4 4. Overcurrent Protection 7 5. Output Voltage Trimming 8 6. Multiple GATE IN Connections 11 7. Application Circuits / Converter Array Design Considerations 12 8. Using Boosters and Parallel Arrays 14 9. EMC Considerations 18 10. Optional Output Filters 29 Filter & Front-End Modules 11. Battery Charger (BatMod™) 30 12. AC Input Module (AIM™ / MI-AIM™) 33 13. Harmonic Attenuator Module (HAM™) 37 14. Input Attenuator Module (IAM™ / MI-IAM™) 43 15. Ripple Attenuator Module (RAM™ / MI-RAM™) 47 16. Offline Front End 48 17. DC Input Power System (ComPAC™ / MI-ComPAC™ Family) 52 18. AC Input Power System (FlatPAC™ Family) 55 19. AC Input Power System (PFC FlatPAC™) 58 General 20. Thermal and Module Mounting Considerations 60 21. Thermal Curves 68 22. Lead-Free Pins (RoHS) 78 23. Tin-Lead Pins 83 24. Module Packaging Options (SlimMod™, FinMod™, BusMod and MegaMod™ Families) 88 25. Product Weights 89 26. Glossary of Technical Terms 90 NOTE: This Design Guide and Applications Manual does not address Vicor Maxi, Mini and Micro DC-DC converters. For more information on these products go to vicorpower.com. VI-200 and VI-J00 Family Design Guide Page 1 of 96 Rev 4.0 08/2021 1. Zero-Current Switching Design Guide & Applications Manual VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies Overview Lossless Energy Transfer Vicor offers RoHS compliant modules. These modules have a “VE” prefix. The information presented herein applies to both versions, and “VI” will be the default designation. 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 inductance of T1 and a capacitive element, C, in the secondary. Simultaneously, an approximately half-sinusoidal current flows through the switch, resulting in switch turn-on at zero current and turn-off when current returns to zero. Resonance, or bidirectional energy flow, cannot occur because D1 will only permit unidirectional energy transfer. A low-pass filter (Lo, Co) following the capacitor produces a low ripple DC output. The result is a virtually lossless energy transfer from input to output with greatly reduced levels of conducted and radiated noise. The heart of the Vicor VI-/MI-200 and VI-/MI-J00 module technology, zero-current-switching, allows Vicor converters to operate at frequencies in excess of 1MHz, with high efficiency and power density. Depending on input voltage and load, the converters operate at frequencies ranging from the low hundreds of kilohertz (light load, high line) to approximately one megahertz (full load, low line). Another aspect of the Vicor topology is that two or more power trains driven at the same frequency will inherently load-share if their outputs are tied together. Load sharing is dynamic and is within 5%. The VI-200 and MI-200 product line offer both Driver and Booster modules: n Drivers and Boosters must have identical power trains. n Drivers close the voltage loop internally, Boosters do not. n Boosters may be childed to a Driver, allowing configurations of multi-kilowatt arrays, which exhibit dynamic current sharing between modules. n Only a single control connection 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. T1 D1 Reset Control MOSFET -VIN Logic Control GATE OUT Primary voltage V S: Secondary voltage OVP: Overvoltage protection (output) OTS: Overtemperature shutdown OC1, OC2: Opto-coupler E/A: Error amplifie REF: Bandgap reference C/L: Current limit amplifier IP VP Vin +VOUT D2 Co Load –VOUT IP VP OC2 + OVP[a] OTS[a] – C/L + VOUT 2.5V REF. TRIM –S in VI-J00 Series Figure 1.1 — VI-/MI-200 and VI-/MI-J00 series zero-current-switching block diagram VI-200 and VI-J00 Family Design Guide Page 2 of 96 Vs +S – E/A [a] Not V P: Table 1.1 Lo VS C OC1[a] GATE IN Primary current Output Filter Integrator Input Filter +VIN IP: Rev 4.0 08/2021 Gate Out Referenced to –VIN 2. DC-DC Converter Pinouts Design Guide & Applications Manual VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies GATE IN: The GATE IN pin on a Driver module may be used as a logic Enable / Disable input. When GATE IN is pulled low (