Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converter and Accessory Modules
Table of Contents Maxi, Mini, Micro Family DC-DC Converters Section Pages High Density DC-DC Converter Technology 1 2–4 Control Pin Functions and Applications 2 5 – 11 Design Requirements 3 12 – 17 EMC Considerations 4 18 – 19 Current Sharing in Power Arrays 5 20 – 24 Thermal Performance Information 6 25 – 30 Autoranging Rectifier Module (ARM) 7 31 – 35 Filter / Autoranging Rectifier Module (FARM) 8 36 – 40 Modular AC Front-end System (ENMod) 9 41 – 47 High Boost HAM 10 48 –
1. High Density DC-DC Converter Technology Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The Maxi, Mini, Micro Family of DC-DC converters are an integral part of the company’s overall component power solution strategy, (Figure 1–1), which includes advanced factory and design automation.
1. High Density DC-DC Converter Technology Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Key to the design of Maxi, Mini, Micro converters is its high level of component-level integration. (Figure 1–2) With the aid of hybrid technology, the device packs all control functions and active circuitry into two (primary and secondary side) ICs occupying a total volume of less than 1/10 in3 (1,6 cm3) each.
1. High Density DC-DC Converter Technology Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The Maxi, Mini, Micro’s ZCS / ZVS power-processing architecture (Figure 1–3) enables efficient, low-noise, high-frequency operation. The main switch is common drain for improved thermal and noise management, the reset switch located within the primary control IC is common source for ease of control.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies PRIMARY CONTROL (PC PIN) Module Enable / Disable. The module can be disabled by pulling the PC below 2.3 V with respect to the –Input. This should be done with an open-collector transistor, relay, or optocoupler. Multiple converters may be disabled with a single transistor or relay via “ORing” diodes.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Fault PC +IN Optocoupler 40 μs typ. 5.7 V PC 4 kΩ PR SC 1.23 V 2–20 ms typ. –IN Figure 2–4 — PC / SC module alarm timing +OUT Figure 2–5 — Isolated on-state indicator Comparator +IN +S Comparator PC SC SC Alarm 1.00V –IN Figure 2–6a — Secondary side on-state (Maxi / Mini) Alarm PR –S –OUT +OUT –OUT 1.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies PARALLEL OPERATION CONSIDERATIONS Care must be taken to avoid introducing interfering signals (noise) onto the parallel bus that may prevent proper load sharing between modules, instability, or module failure. One possible source of interference is input ripple current conducted via the + and –Input power pins.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies CONTROL FUNCTIONS AND OUTPUT CONSIDERATIONS Parallel Operation (PR Pin). The PR pin supports paralleling for increased power with N+1or N+M redundancy. Modules of the same part number will current share if all PR pins are suitably interfaced.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies CONTROL FUNCTIONS, SECONDARY CONTROL (SC PIN) Output Voltage Programming. The output voltage of the converter can be adjusted or programmed via fixed resistors, potentiometers or DACs. Trim Down. The converter is not a constant power device; it has a constant current limit.
2. Control Pin Functions and Applications Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Error Amp +OUT +IN +S PC SC 1 kΩ 0.033 μF Load RD Trim Down –S PR +OUT RU Trim Up Error Amp SC 1 kΩ Load RD Trim Down 0.033 μF –OUT –IN –OUT 1.23 V 1.23 V RD (ohms) = RD (ohms) = 1,000 Vout Vnom – Vout 1,000 Vout Vnom – Vout RU (ohms) = 1,000 (Vout –1.23) Vnom – 1,000 1.
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3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies SAFETY CONSIDERATIONS Fusing. Safety agency conditions of acceptability require that the module positive (+) Input terminal be fused and the baseplate of the converter be connected to earth ground. The following table lists the acceptable fuse types and current rating for the Maxi, Mini, Micro Family of DC-DC converters.
3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Acceptable Fuse Types and Current Rating for the Maxi, Mini, Micro Family of Converters Package Size Input Voltage Output Voltage Output Power Maxi (A) Maxi (A) Maxi (A) 72 72 72 3.3 5, 8 12, 15, 24, 28, 36, 48 264 300 400 Bussmann ABC-12 Bussmann ABC-12 Bussmann ABC-12 Mini (B) Mini (B) Mini (B) 72 72 72 3.
3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The fuse must be in series with the positive (+) Input lead. Fusing the negative (–) Input lead does not provide adequate protection since the PR and PC terminals of the converter are referenced to the –Input. If a fuse located in the –Input lead were to open, the PR and PC terminals could rise to the potential of the +Input.
3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies To calculate the required source impedance, use the following formula: Z = 0.1(VLL)2 / Pin where: Z is required input impedance VLL is the low line input voltage Pin is the input power of the module Filters, which precede the module, should be well damped to prevent ringing when the input voltage is applied or the load on the output of the module is abruptly changed.
3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies ABSOLUTE MAXIMUM RATINGS IMAX Vout Please consult the latest module data sheets available on the Vicor website for maximum ratings concerning pin-topin voltages, isolation, temperature, and mechanical ratings.
3. Design Requirements Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies C1a Standoffs also provide necessary mechanical support in order to prevent mechanical stresses from damaging the module during shock / vibration. C2a +IN +OUT Maxi, Mini, Micro DC-DC Converter CIN –IN –OUT C1b C2b Standoff sitting on pad / plated through-hole that is connected to the chassis ground plane within the PCB.
4. EMC Considerations Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies FILTERING AND TRANSIENT PROTECTION All switching power supplies generate potentially interfering signals as a result of high-frequency, high-power switching. The Vicor power converter topology, to a large extent, addresses the problem at the source by the use of a quasi-resonant, zero-current switching (ZCS) and zerovoltage switching (ZVS) topology.
4. EMC Considerations Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies C2* 4.7nF C4* 4.7nF +IN F1* C1* 0.2µF +OUT +S PC SC PR –S –IN –OUT C3* 4.7nF C5* 4.7nF For C1 – C5, keep leads and connections short. Figure 4–1 — Recommended bypassing capacitors must be in close proximity, i.e., have short lead length to be effective.
5. Current Sharing In Power Arrays Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Whenever power supplies or converters are operated in a parallel configuration — whether for higher output power, fault tolerance, or both — current sharing is an important consideration.
5. Current Sharing In Power Arrays Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies In general, it is not recommended to mix and match converters, especially those with incompatible current-sharing schemes. The droop-share method, however, is more forgiving in this regard than with any of the other methods.
5. Current Sharing In Power Arrays Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies CURRENT SHARING IN FAULT TOLERANT ARRAYS Current sharing is an essential element in fault-tolerant arrays, and regardless of the approach, there is an inherent additional cost incurred by the addition of at least one redundant converter or supply.
5. Current Sharing In Power Arrays Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The synchronous current-sharing method applies to quasi-resonant, frequency-modulated converters with the necessary intelligence, such as the Vicor Maxi, Mini, Micro Family of high-density DC-DC converters, where the energy per pulse is fixed.
5. Current Sharing In Power Arrays Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies +VIN +OUT +IN +S PC DC-DC Converter T1 SC +VOUT PR –S –IN –OUT +IN +OUT -VIN +VIN +S PC DC-DC Converter SC Return PR T2 –S –IN –OUT -VIN Parallel Bus Figure 5–3 — Transformer-coupled interface provides load sharing and SELV isolation from the primary source. Maxi, Mini, Micro Design Guide Page 24 of 88 Rev 4.9 Apps. Eng. 800 927.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Simplified thermal management is one of the benefits of using Vicor converters. High operating efficiency minimizes heat loss, and the low-profile package features an easily accessible, electrically isolated thermal interface surface. Consideration should be given to the module baseplate temperature during operation.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THERMAL PERFORMANCE CURVES (Maxi) Table Usage: The forced convection thermal impedance data shown in the tables on the next three pages assumes airflow through the heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Maxi data sheets. Use as a design guide only.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THERMAL PERFORMANCE CURVES (Mini) Table Usage: The forced convection thermal impedance data shown in the tables on the next three pages assumes airflow through the heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Mini data sheets. Use as a design guide only.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THERMAL PERFORMANCE CURVES (Micro) Table Usage: The forced convection thermal impedance data shown in the tables on the next three pages assumes airflow through the heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Micro data sheets. Use as a design guide only.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Typical Examples — Thermal Equations (Maxi, Mini, Micro) EXAMPLE 1 Determine the maximum output power for a Maxi module without a heat sink delivering 5 V in 400 LFM airflow at a maximum ambient temperature of 40ºC. Maximum output power = (Tbmax – Tamax) / [θba • (1/η – 1)] Tbmax = 100ºC Tamax = 40ºC For Maxi module without a heat sink @ 400 LFM, θba = 2.
6. Thermal Performance Information Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THERMAL MANAGEMENT ACCESSORIES (All parts are RoHS compliant unless otherwise noted) Transverse Fins Longitudinal Fins Maxi Heat Sinks Mini Heat Sinks Micro Heat Sinks Threaded Through Hole Threaded Through Hole Threaded Through Hole 0.4" (10,1 mm) Fin P/N 30482 0.4" (10,1 mm) Fin P/N 30718 0.4" (10,1 mm) Fin P/N 32188 0.
7. Autoranging Rectifier Module (ARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The Autoranging Rectifier Module (ARM) provides an effective solution for the AC front end of a power supply designed with Vicor DC-DC converters. This high-performance power system building block satisfies a broad spectrum of requirements and agency standards.
7. Autoranging Rectifier Module (ARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies OFF-LINE POWER SUPPLY CONFIGURATION capacitors were being charged through an un-bypassed thermistor, preventing the bus voltage from reaching the thermistor bypass threshold, thus disabling the power supply. The Enable output (the drain of a N channel MOSFET) is internally pulled up to 15 V through a 150 kΩ resistor.
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7. Autoranging Rectifier Module (ARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Rearranging equation 2 to solve for the required capacitance: C = 2P∆t / (V12–V22) The approximate operating ripple current (rms) is given by: Irms = 2P / Vac (3) (6) where: P = operating power level The power fail warning time (∆t) is defined as the interval between (BOK) and converter shutdown (EN) as illustrated in Figure 7–7.
8. Filter / Autoranging Rectifier Module (FARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The Filter / Autoranging Rectifier Module (FARM) provides an effective solution for the AC front end of a power supply built with Vicor DC-DC converters. This highperformance power-system building block satisfies a broad spectrum of requirements and agency standards.
8. Filter / Autoranging Rectifier Module (FARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies OFF-LINE POWER SUPPLY CONFIGURATION The FARM maintains the DC output bus voltage between 250 and 370 Vdc over the entire input-voltage range, which is compatible with the Maxi, Mini, Micro 300 V input converters as well as VI-260 family and VI-J60 family DC-DC converters.
8. Filter / Autoranging Rectifier Module (FARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Bus OK (BOK) Pin. (Figure 8–5) The Bus OK pin is intended to provide early-warning power-fail information and is also referenced to the negative output pin. CAUTION: There is no input-to-output isolation in the FARM. It is necessary to monitor Bus OK via an optoisolator if it is to be used on the secondary (output) side of the converters.
8. Filter / Autoranging Rectifier Module (FARM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies EXAMPLE In this example, the output required from the DC-DC converter at the point of load is 12 Vdc at 320 W. Therefore, the output power from the FARM would be 375 W (assuming a converter efficiency of 85%). The desired hold-up time is 9 ms over an input range of 90 to 264 Vac. Determining Required Capacitance for Power Fail Warning.
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9. Modular AC Front-end System (ENMod) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The ENMod component power front-end system for EN compliance provides an effective solution for an AC front end of a power supply enabled with Vicor DC-DC converters. The ENMod system’s basic building blocks are the MiniHAM passive harmonic attenuation module, the FARM3 autoranging AC-DC front-end module (Figure 9–3) and a discrete EMI filter.
9. Modular AC Front-end System (ENMod) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Harmonic Current 10.00 Current (A) 1.00 Odd Harmonic Limits * Even Harmonic Limits Measured Values 0.10 0.01 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Harmonic Number Figure 9–2 — Measured harmonic current at 230 Vac, 575 W vs.
9. Modular AC Front-end System (ENMod) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies POWER-UP SEQUENCE (Figure 9–4) 1.1 Upon application of input power, the hold-up capacitors begin to charge. The thermistor limits the charge current, and the exponential time constant is determined by the hold-up capacitor value and the thermistor cold resistance.
9. Modular AC Front-end System (ENMod) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies FILTERING AND TRANSIENT PROTECTION The ENMod system maintains the DC output bus voltage between 250 and 370 Vdc over the entire input-voltage range, which is compatible with all Vicor 300 V input converters.
9. Modular AC Front-end System (ENMod) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Bus OK (BOK) Pin. (Figure 9–12) The Bus OK pin is intended to provide early-warning power fail information and is also referenced to the SR pin. Energy is given up by the capacitors as they are discharged by the converters. The energy expended (the power-time product) is: CAUTION: There is no input-to-output isolation in the ENMods.
9. Modular AC Front-end System (ENMod)s Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The approximate conduction angle is given by: θ = cos-1(V2 / V1) (5) Another consideration in hold-up capacitor selection is their ripple current rating. The capacitors’ rating must be higher than the maximum operating ripple current.
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10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies THE HIGH-BOOST HARMONIC ATTENUATOR MODULE COMPATIBLE WITH V375, VI-26x AND VI-J6x FAMILIES The HAMD version does not contain an internal bridge rectifier and is intended for configuring higher power arrays with Booster versions, referred to as the VI-BAMD (Figure 10–5).
10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies GATE IN (BAMD) Pin. The Gate In pin is an interface pin to the Gate Out pin of a HAMD or BAMD depending on configuration. The user should not make any other connection to this pin. GATE OUT Pin. The Gate Out pin is a synchronization pin for HAMD/BAMD arrays; the user should not make any other connection to this pin. +OUT and -OUT Pin.
10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies F3 C5 V1 F1 L1 L1 GND GATE IN R1 R2 R3* D1 D2, D3 D4, D5 V1 C5–C8 F1, F2 F3 L2/N +IN P/OK E/O A/S VI-HAM-xL GATE OUT L2/N D2 R2 R1 C1 PR C2 D1 Description V375 DC-DC Converters PC D4 -IN – OUT C6 LOAD LINE Component Designation C1 C2, C3 C4 L1 Vicor Line Filter P/N 30205 6.3 A L2/N + OUT Y-Capacitor Vicor Part Number 0.1 µF ceramic, 50 V 0.
10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies +OUT P/OK E/O + A/S – –OUT DO NOT OVERLOAD or directly connect a capacitor to the A/S terminal.
10. High Boost HAM Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies RATED CURRENT VS AMBIENT TEMPERATURE 90 4.60 ±0.02 2.50 ø0.080 PIN 6 PLACES LINE LOAD 1.200 2.40±0.02 2.00 0.100 OPERATING TEMP (DEG C) 4-40 INSERT 0.25 DP 4 PL 0.060 FACE MAY BE BOWED 0.04 MAX 1.800 0.900 0.30 ±0.02 0.13 ±0.02 0.500 1.45 ±0.02 1.00 MAX 0.500 2.800 80 70 60 50 40 1.0 INSERTION LOSS (db) .060 SEE NOTE 1 2.260 2.000 2 PL 1.
11. Filter Input Attenuator Module (FIAM) Family Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Description: The FIAM family of front-end modules (Figure 11–1) provides EMI filtering, transient protection, and inrush current limiting in DC-DC applications.
11. Filter Input Attenuator Module (FIAM) Family Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies FIAM1 FIAM2 M-FIAM3 Notes Input voltage 36 – 76 Vdc 36 – 76 Vdc 180 – 375 Vdc Continuous Recommended fusing (F1): Bussman ABC–10 Bussman ABC-20 Bussman ABC-3 Output current: 10 A 20 A 3A External capacitance (C1) 10 µF min – 150 µF max 100 µF min – 330 µF max 10 µF min – 22 µF max Inrush limiting 0.014 A/µF 0.014 A/µF 0.
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12. Output Ripple Attenuator Module (MicroRAM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies RSENSE 5.
12. Output Ripple Attenuator Module (MicroRAM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies The SC or trim-up function can be used when remote sensing is not available on the source converter or is not desirable. It is specifically designed for converters with a 1.23 V reference and a 1 kΩ input impedance like Vicor Maxi, Mini, Micro converters.
12. Output Ripple Attenuator Module (MicroRAM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies -0 Rhr = 28 k (Vheadroom = 90 mV) 27 k (100 mV) 26 k (110 mV) 25 k (122 mV) 24 k (135 mV) 23 k (150 mV) 22 k (160 mV) Vout = 3 V load = 20 A 100 degrees baseplate temperature -25 -50 17 k (260 mV) 18 k (240 mV) 19 k (217 mV) 20 k (197 mV) 21 k (180 mV) -75 10 Hz 100 Hz 1.0 KHz ... DB(V(VOUT)) 10 KHz 100 KHz 1.
12. Output Ripple Attenuator Module (MicroRAM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies 450 mV VOUT=3 V Vheadroom 400 mV Rhr=16k 300 mV 17k 18k 19k 20k 21k 200 mV 1A 2A 4A 6A 8A 10A 12A 14A 16A 18A 20A lload Figure 12–5 — Headroom vs.
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12. Output Ripple Attenuator Module (MicroRAM) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Figure 12–14 — V48C5C100B and µRAM; Input and output ripple @ 50% (10 A) load CH1 = Vi; CH2 = Vo; Vi – Vo = 327 mV; RHR = 31 k (Configured as in Figures 12–1a and 12–1b) Figure 12–15 — V48C5C100B and µRAM; Input and output dynamic response no added CTRAN; 23% of 20 A rating load step of 4.5 A (10 A – 14.
13. Recommended Soldering Methods, Lead Free Pins (RoHS) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies OVERVIEW The following chapters contain soldering information for the following Vicor product families; Maxi, Mini, Micro; VE-200, VE-J00; VI BRICK®, and similar package filters and front-ends.
Design Guide & Applications Manual 13. Recommended Soldering Methods, Lead Free Pins (RoHS) For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies respect to the PCB to ensure no movement during the soldering process. The standoffs can be used for this process.
13. Recommended Soldering Methods, Lead Free Pins (RoHS) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies 8. Be careful not to jar the module or PCB while the solder is cooling. This could result in a cold solder joint, a void in the barrel, or a cracked joint. 9. If it is necessary to re-solder a joint, remove all existing solder from the pad and pin before reapplying solder. 10.
13. Recommended Soldering Methods, Lead Free Pins (RoHS) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Index of Common Soldering defects. 1. Solder Bridge. A short circuit between two electrically inadvertently forming a “bridge” or connection between the two points. Recommended Solution. Use a smaller soldering tip, or hold the tip at a different angle when soldering, so as to contact only one pad at a time. 2. Cold Solder.
13. Recommended Soldering Methods, Lead Free Pins (RoHS) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies References Organizations www.ipc.org Commercial www.aimsolder.com www.alphametals.com www.kester.com www.multicore-association.org Maxi / Mini / Micro Standoff Kits for Solder Mounted Modules Board Thickness Mounting Options Slotted Baseplate Nom. (Min/Max) Mounting Style Pin Style 0.062" (0.055"/0.
14. Recommended Soldering Methods, Tin Lead Pins, and InMate Sockets Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies OVERVIEW The following chapters contain soldering information for the following Vicor product families; Maxi, Mini, Micro; VI-200, VI-J00; VI BRICK®, and similar package filters and front-ends.
14. Recommended Soldering Methods, Tin Lead Pins, and InMate Sockets Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies SOLDERING PROCEDURES Hand Soldering. Before soldering, make sure that the PCB is clean and free of debris, chemical residue, or liquid.
14. Recommended Soldering Methods, Tin Lead Pins, and InMate Sockets Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Since there are so many factors that influence soldering time, listing actual times is difficult. In general, it is recommended that the joint be examined post-process to ensure a quality soldering joint. If necessary, different parameters can then be varied in order to ensure a solid process.
14. Recommended Soldering Methods, Tin Lead Pins, and InMate Sockets The power module is often much more massive than other components mounted to the PCB. During wave solder preheating, the pins will dissipate much of their absorbed heat within the module. Adjustments to preheaters alone, therefore, will not improve module soldering significantly. A more effective way to improve the soldering of the module is to lower the conveyor speed and increase the dwell time in the molten wave.
14. Recommended Soldering Methods, Tin Lead Pins, and InMate Sockets Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies 5. Dry Joint. The solder has a dull gray appearance as opposed to a bright silver surface. The solder joint may have a mottled look as well, with jagged ridges. It is caused by the solder joint moving before completely cooled. 7. Pinholes.
15. Surface Mount Socketing System (SurfMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies SurfMate is a surface-mount connector system for use with pin-compatible Maxi, Mini, Micro Family converters and input / front-end modules. For the first time, circuitboard designers and assemblers have the ability to surface mount high-density DC-DC converters having current ratings up to 50 A.
15. Surface Mount Socketing System (SurfMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies module removal, Vicor highly recommends the use of our Module Exchange Tool in order to ensure that the sockets are not damaged during the module removal process. Removing the module at an angle should be avoided as this can damage the sockets.
15. Surface Mount Socketing System (SurfMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Materials Ratings Headers Material: Vectra E150i LCP Flammability Thermal stability (short term) Thermal stability (long term) Solder Cap Material Liquid Crystal Polymer UL94 V-0/5VA 500°F (260°C) 392°F (200°C) 260 cartridge brass (70 Cu, 30 Zn) 100 µ in. min. Cu, followed by 50 to 100 µ in. min.
15. Surface Mount Socketing System (SurfMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Module Exchange Tool Used in facilitating the proper extraction of modules from InMate or SurfMate sockets. Removal without using the Exchange Tool may cause damage to the sockets.
16. Through-hole Socket Mount System (InMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies InMates are an innovative solution for through-hole socket requirements. Consisting of individual plastic carriers for the input and the output, each contains an array of sockets for either a full, half or quarter-brick sized module.
16. Through-hole Socket Mount System (InMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies InMate: Through-hole Sockets 1. 2. 3. Board Thickness Full Brick (Maxi) 4. Half Brick (Mini) 5. Quarter Brick (Micro) Norm. (Min. / Max.) Mounting Style Input Output 5 Sets Input Output 5 Sets Input Output 5 Sets Pin Style 0.
16. Through-hole Socket Mount System (InMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Parameter Specification Value Reference F = short Au plated S = short Au plated Short RoHS pins Short ModuMate pins G = long Au plated N = long Au plated Long RoHS pins Long ModuMate pins Compatibility Module pin styles Mechanical Contact normal force 100 grams EOL min.
16. Through-hole Socket Mount System (InMate) Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Standoff Kits for InMate Mounted Modules* Board Thickness Slotted Baseplate Nom. (Min. / Max.) Mounting Style 0.062" (0.055"/ 0.071") 1,5 mm (1,4 mm /1,8 mm) Inboard 0.093" (0.084"/ 0.104") 2,4 mm (2,1 mm /2,6 mm) 0.125" (0.113"/ 0.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies A AC-OK Signal. The signal used to indicate the loss of AC input voltage from the 115 / 230 V line. Bridge Rectifier. A full wave rectifier circuit employing four rectifiers in a bridge configuration. Altitude Testing. Generally performed to determine the proper functionality of equipment in airplanes and other flying objects. MIL-STD-810.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Converter. An electrical circuit that accepts a DC input and generates a DC output of a different voltage usually achieved by high frequency switching action employing inductive and capacitive filter elements. Crest Factor. In an AC circuit, the mathematical ratio of the peak to rms values of a waveform.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies F Factorized Power Architecture (FPA). A power distribution architecture that is inherently more granular and leverages an allocation of the DC-DC converter functions consistent with efficient power distribution principles. An optimal power distribution architecture should efficiently support demanding low voltage, high current loads.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Impedance. The ratio of voltage to current at a specified frequency. Line Voltage (Mains). The sine wave voltage provided to the power supply, usually expressed in volts rms. Induced Noise. Noise generated in a circuit by varying a magnetic field produced by another circuit. Load Regulation. The change in output voltage when the load on the output is changed.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies N Nominal Input. The center value for the input voltage range. Nominal Value. A usual, average, normal, or expected operating condition. This stated value will probably not be equal to the value actually measured. O Offline.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Product Grade. The environmental and acceptance tests performed on Vicor products. Pulse Width Modulation (PWM). A switching power conversion technique where the on-time (or width) of a duty cycle is modulated to control power transfer for regulating power supply outputs. Push-Pull Converter.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Soft Line. A condition where there is substantial impedance present in the AC mains feeding input power to a power supply. The input voltage to the power supply drops significantly with increasing load. Split Bobbin Winding. A transformer winding technique where the primary and secondary are wound side-by-side on a bobbin with an insulation barrier between them.
17. Glossary of Technical Terms Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Y Y-Capacitor. Power conversion modules generally require bypass capacitors from line to chassis (earth ground) to shunt common-mode noise currents and keep them local to the converter.
Design Guide & Applications Manual For Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use.
