VI-BAMD-CM

12 1-800-735-6200 VI-HAM Harmonic Attenuator Modules Features ■ Unity Power Factor ■ Safety Agency Approvals: UL, CSA, TÜV, BABT ■ Meets IEC 6100-3-2 for Line Current Harmonic Content ■ Reduces Peak and RMS Line Currents ■ Universal Input: 85-264Vac: 50/60 Hz ■ Up to 600W of Power ■ Power Density Up to100W/in3 ■ Adaptive Output Voltage Control ■ Short-Circuit Protection ■ Input Surge Current Limiting ■ Converter Enable ■ Power OK Output ■ Size: 4.6" x 2.4" x 0.5" (116,8mm x 61,0mm x 12,7mm) ■ Efficiency: 90-94% Typical ■ CE Marked Unity Power Factor Conventional capacitive-input front ends draw energy from the AC line in short bursts of current at the peaks of the line voltage waveform. These current bursts are characterized by high peak currents and high harmonic content. The effect of the distorted line current can be appreciated by measuring the rms line current drawn by a conventional front end: the product of the measured rms current and the rms line voltage — the "apparent power" being delivered by the line — will be significantly greater (typically 1.6X) than the DC power delivered by the front end. The "extra" rms current at the input is circulating harmonic currents which deliver no power to the load but which flow in the delivery system and contribute to losses. Only the fundamental component of the line current contributes to "real" power flow. Power factor — the ratio of "real" to "apparent" power — is a measure of the effectiveness with which an AC load can extract usable power from an AC source. The VI-HAM (see Fig. 2) consists of a full-wave rectifier, a proprietary high-frequency zerocurrent switching (ZCS) boost regulator (patents applied for), active inrush, short-circuit protection, control and housekeeping circuitry. The incoming AC line is rectified and fed to the ZCS boost converter. The control circuitry varies the operating frequency of the ZCS boost converter so as to simultaneously maintain the output voltage of the VI-HAM at a DC voltage value above the peak of the incoming line, while forcing the input current to the ZCS converter to follow the waveshape of the rectified line. By this means, the AC input current follows the AC voltage waveform and a power factor better than 0.99 is achieved. Operating efficiency of the ZCS boost converter is optimized at any incoming line voltage by a patented adaptive output voltage control scheme. The VI-HAM also includes active circuitry which controls inrush currents when power is applied and active short circuit protection circuitry — features not normally found in conventional power factor correctors. Housekeeping circuitry provides two signals of use to the system designer (see Fig. 2): Module Enable and Power OK. Referencing the timing diagram (see Fig. 3), the Module Enable signal, which is connected to the Gate In inputs of the Vicor DC-DC converters powered by the VI-HAM, will come high and enable the DC-DC converters when the VI-HAM output voltage exceeds 240Vdc. The DC-DC converter voltage outputs will be up approximately 10 ms after Module Enable goes high. Typically, 20 ms after Module Enable goes high the VI-HAM Power OK signal, which can be used by the system designer to enable circuitry powered by the DC-DC converter modules, goes low. On loss of power or brownout, the Power OK signal will go high when the VI-HAM DC output voltage drops below 230V, signaling an impending loss of input power to the converter modules. When the DC output dips below 195V, the Module Enable signal will toggle low, disabling the converter modules and unloading the VI-HAM. The VI-HAM will provide at least 16 ms of ride-through or holdup time, and at least 5 ms of AC fail warning time with a 1000 µF output capacitor. Figure 1a. AC Line Rectifier ZCS Boost Converter Current Sense Inrush & Short Circuit Protection + DC Out – Note: Non-Isolate Output Voltage Waveform High Frequency Control Output Voltage Control Module Enable & Housekeeping Power OK Circuitry Aux. Supply Figure 1b. Above: Oscilloscope photos showing input voltage and current without power factor correction (A) and with power factor correction as provided by the VI-HAM (B). Gate In Gate Out NOTE: No input to output isolation. Figure 2 • VI-HAM Block Diagram Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 HAM, Harmonic Attenuator Module Rev. 1.1 Page 1 of 6 Set your site on VICOR at www.vicorpower.com 12 1-800-735-6200 AC Mains 120V RMS 230 Vdc DC Output of HAM Boost Voltage 240 Vdc Rectified Line 195 Vdc Module Enable Off at 195 Vdc 25 ms Power OK Off at 230 Vdc Vicor varies the output voltage of the VI-HAM as a function of incoming AC line voltage (see Fig. 4, patent applied for). On a nominal 120Vac line the output voltage of the VI-HAM is 260Vdc — well within the input operating voltage range of standard Vicor converters. As input line increases, so does the VI-HAM output voltage; at 220Vac the delivered voltage will be about 350V. For any given input line voltage, the VI-HAM maintains enough headroom between the output voltage and peak input voltage to ensure high quality active power factor correction without unnecessarily sacrificing operating efficiency. VI-HAM Protection Features Overtemperature Shutdown The VI-HAM incorporates overtemperature shut-down, and is designed to shut down when the temperature of the baseplate exceeds 90–100°C. It is not safe to run the VI-HAM for extended periods above its maximum operating temperature of 85°C. Short Circuit Protection The VI-HAM contains a short circuit shutdown function. Operation of this function does not clear the input fuse and the output will resume normal operation after removal of the short. A small period of time may be required to allow for cooling of an internal PTC. Overcurrent protection is provided by the Vicor DC-DC converters. Output Overvoltage Protection The VI-HAM contains output overvoltage protection. In the event the output voltage exceeds approximately 420Vdc, the boost will decrease to maintain 420Vdc on the output. When the peak of the AC line exceeds 420V (approximately 293Vac) the boost will have been reduced to zero. Beyond this the protection circuit will be enabled and the output voltage will decrease. Outputs VI-200 DC-DC Converter(s) 10 ms 400Vdc 350Vdc 300Vdc 250Vdc 200Vdc 80Vac 260Vdc 152Vac 85Vac 250Vac 46V Boost Output Voltage as a Function of Input Voltage Figure 3 • Functional Timing Diagram Active power factor correctors incorporate a boost regulator which must operate over a range of incoming AC line voltages. Conventionally, the output voltage of the boost regulator is set to a value greater than the maximum anticipated peak value of the incoming AC line. 150Vdc 100Vdc 50Vdc Vin x 2 Operating Region 75 50 100 125 150 Vac 275 250 300 296 264Vac 25 175 200 225 Figure 4 • Input Voltage vs. Output Voltage Pin Function Description • L1 and L2/N (VI-HAM): These pins are to be connected to the AC mains output of a suitable EMI/RFI filter (Vicor P/N 07818 or equivalent). Do not connect an X capacitor across these pins as power factor correction will be slightly degraded. • +IN, –IN (VI-HAMD, VI-BAMD): These pins are connected to the output of the external bridge rectifier. • Gate Input (VI-HAM): This pin disables the boost converter only. Rectified line current may still be present on the output. This pin does not provide the same function as the gate input pin of VI-200/VI-J00 modules. The user should not make any connection to this pin. • Gate Input (VI-HAMD): This pin serves as a rectified AC following pin for power factor correction synchronization to line. This connection must be made through the synchronization diodes between the line filter and bridge rectifier (see Fig. 10). • Gate Input (VI-BAMD): The Gate Input pin is an interface pin to the Gate Out pin of a VI-HAM, VI-HAMD or VI-BAMD depending on configuration. The user should not make any other connection to this pin. • Gate Output: The Gate Output pin is an interface pin to BAMDs; the user should not make any other connection to this pin. • +Output and -Output and Holdup Capacitor: These outputs should be connected to the respective inputs of Vicor DC-DC converters. In addition, an external holdup capacitor of 1000 µF with a minimum voltage rating of 450Vdc, is required across the output for 16 ms ride through time at 600W (500 µF for 300W, etc). Do not exceed 3000 µF of total output capacitance. Lower values of capacitance may be used for reduced holdup requirements, but not less than 330 µF. Lower capacitance values may degrade power factor specifications. • Auxiliary Supply (A/S): The VI-HAM and VI-BAMD contain an internal low voltage output (A/S) that may be used to power primary side logic. This output is 19-23Vdc, referenced to -OUT, at 3 mA max. Do not overload or short this output as the VI-HAM will fail. A typical use for A/S is to power an optical coupler that isolates the Power OK signal. This provides sufficient time for the converters to turn on and their outputs to stabilize prior to P/OK being asserted. When the AC mains is removed and the output of the VI-HAM drops below 230V, P/OK goes to an open circuit state. When the output voltage drops below 195V the converters are disabled via Module Enable. P/OK will provide power fail warning at least 1 ms prior to converter shutdown. D LOGIC G S P/OK -OUT Figure 6 • Power OK (P/OK) + 19 - 23V – A/S ≤ 3mA -OUT "Power OK" Status Low = OK + OUT P/OK E/O A/S – OUT 18 kΩ, 1/4W Figure 5 • Auxiliary Supply (A/S) • Power OK (P/OK) P/OK is a monitor signal that indicates the status of the AC mains and the DC output voltage of the VI-HAM. P/OK, during normal operation, is an active low (see Fig. 6). In the event AC mains or DC output fails, this pin goes to an open circuit state. P/OK is asserted when the output bus voltage is within normal operating range and 20-25 ms after DC-DC converters are enabled by the Module Enable output of the VI-HAM. • Module Enable (E/O) The Module Enable output is used to disable the DC-DC converters until there is sufficient energy in the holdup capacitor (240V) to support normal operation, while limiting inrush current. Module Enable must be connected to the Gate Input of all driver DC-DC converters. It is not necessary to connect this pin to boosters as they are controlled by their respective driver. If the AC mains fail, Module Enable goes low when the DC output of the VI-HAM drops below 195V. Failure to connect Module Enable may result in the output of the VI-HAM latching low during turn-on. E/O D LOGIC G S -OUT Figure 7 • Enable/Output (E/O) Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 HAM, Harmonic Attenuator Module Rev. 1.1 Page 2 of 6 Set your site on VICOR at www.vicorpower.com 12 1-800-735-6200 VI-HAM Protection Features (continued) Inrush Current Limit Filter Requirements for the VI-HAM The VI-HAM requires an external filter to meet international standards for conducted EMI/RFI emissions. P/N 07818 (for use up to 600W) incorporates transient protection for compliance with IEC 61000-4-5 Level 3 and meets conducted emissions standards EN55022 and FCC Part 15 Level A (minimum loading of 150W required). The VI-HAM contains inrush current protection in the form of a PTC and a shunt device. The same PTC is used for overcurrent protection on the output. Input Transient Overvoltage Surge Protection This function is included in all VI-HAM compatible filters. If any other filter is used this function must be provided externally, typically by a transient suppressor. • Safety Note • All VI-HAM configurations must be preceded by an appropriately rated fast-blow 3AG fuse ahead of the line filter. This fuse would be a 10A for a single VI-HAM connected to line. For fusing information on other VI-HAM configurations, please contact Vicor’s Application Engineering Department. VI-HAM Configurations VI-HAM-CM Driver HAM: Fully configured power factor correcting front end. VI-HAMD-CM Driver HAM: No internal bridge rectifier or synchronization diodes. VI-BAMD-CM Booster HAM: Companion module to VI-HAMD-CM used for additional output power. No internal bridge rectifier. Compatible Modules Over the full range of input voltages (85 to 264 Vac), the output varies from 260 to 415Vdc. Therefore the modules used with the VI-HAM are from the VI-260 and VI-J60 families. When ordering add the prefix VI- to the part number below; i.e., VI-260-CU. VI-200 Family 5V 12V 15V 24V 48V Output Use the VI-HAM-CM for applications requiring up to 600W from the front end. For applications in excess of 600W, it is not possible to simply parallel two driver VI-HAMs due to conflicting control loops. Gate Out to Gate In connections on respective driver/boosters are used to ensure that the power train of the VI-HAMs current-share. However, this does not ensure that the diodes in the lower half of the bridge rectifier will current-share. A solution for this situation is illustrated (see Fig. 8). VI-HAMD 260-CU 261-CU 262-CU 263-CU 264-CU 200W 260-CV 261-CV 262-CV 263-CV 264-CV 150W 260-CW 261-CW 262-CW 263-CW 264-CW 100W 260-CX 261-CX 262-CX 263-CX 264-CX 75W 260-CY 261-CY 262-CY 263-CY 264-CY 50W Framed area available as boosters. Change VI-2XX-XX to VI-BXX-XX. Vac Line Filter VI-BAMD VI-BAMD Figure 8 • VI-HAMD with Booster HAMs (BAMDs) — No Internal Bridge Rectifier 48V Output VI-J00 Family 5V 12V 15V 24V J60-CW J61-CW J62-CW J63-CW J64-CW 100W J60-CX J61-CX J62-CX J63-CX J64-CX 75W J60-CY J61-CY J62-CY J63-CY J64-CY 50W J60-CZ J61-CZ J62-CZ J63-CZ J64-CZ 25W A solution to bridge rectifier current sharing issues is to remove the bridge rectifier from each VI-HAM and use one diode bridge sized to handle the entire load. Approximately 25% of the heat is removed from the VI-HAM in this approach; use a VI-HAMD-CM with one or more VI-BAMD-CMs. Note: Synchronization diodes are required when using this approach (see Fig. 10). Prod. Grade E C I M Baseplate Temp. -10°C to +85°C -25°C to +85°C -40°C to +85°C -55°C to +85°C Storage Temp. -20°C to +100°C -40°C to +100°C -55°C to +100°C Model VI-HAM-EM VI-HAM-CM VI-HAM-IM -65°C to +100°C VI-HAM-MM Vicor Corp. Tel: 800-735-6200, 978-470-2900 Fax: 978-475-6715 HAM, Harmonic Attenuator Module Rev. 1.1 Page 3 of 6 Set your site on VICOR at www.vicorpower.com 12 1-800-735-6200 Specifications VI-HAM and VI-HAMD With External Bridge and Synchronization Diodes, 1000 µF Output Capacitor and Vicor Line Filter P/N 07818. VI-BAMD When Operated with VI-HAM and VI-HAMD, Respectively. (Unless otherwise indicated, specifications apply over operating input voltage and temperature range) Parameter Line Input 47–63 Hz Output Power VI-HAM 85V to 264V (Volts AC) Up to 600W VI-HAMD 85V to 264V (Rectified AC) Up to 600W 90-91% (With ext. rectifier loss) 93-94% (With ext. rectifier loss) 0.99