15
UG:306 Page 1 PI3740-00-EVAL1, -EVAL2 Cool-Power ® ZVS Switching Regulators Buck-Boost Evaluation Board User Guide Introduction The PI3740-00 evaluation board comes in two versions, EVAL1 and EVAL2. EVAL1 should be used to evaluate the PI3740 in constant-voltage or standard constant-current applications where V OUT is above 8V. EVAL2 is designed for specialized constant-current applications using high-side current sense where V OUT is below 8V. These boards have been designed to showcase various constant-voltage and constant-current applications and can be configured with a few selectable jumpers. This guide will walk the user through the various options. The PI3740-00-LGIZ is a high-efficiency, wide-input-range DC-DC ZVS Buck-Boost regulator with integrated controller, power switches and support components all within a high-density 0.4 x 0.55in System-in-Package (SiP). The evaluation board measures 2.5 x 2.25in and contains all the components necessary for a variety of applications. Not all components will be needed for all applications. Part Ordering Information The customer evaluation boards can be ordered following the link to Vicor Cool-Power ZVS Buck-Boost Switching Regulators. USER GUIDE | UG:306 Introduction 1 Part Ordering Information 1 Box Contents 2 Features 3 General Information 3 Power Up Procedure 3 Constant-Voltage Operation (EVAL1) 4 Constant-Current Operation (EVAL1, EVAL2) 4 Constant-Current Float Voltage Adjustment 4 Adjusting the Charging Current 5 Constant-Current Configuration #1: (PI3740-00-EVAL1 Board) 5 Constant-Current Configuration #2: (PI3740-00-EVAL1 Board) 6 Constant-Current Configuration #3: (PI3740-00-EVAL1 Board) 7 Constant-Current Configuration #4: (PI3740-00-EVAL2 Board) 8 Current-Sense Element in Each Board 8 Only One Current-Sense Element 8 Stability 8 Test Points 9 Schematics 10 Bill of Materials 12 Additional or Changed Components for PI3740-00-EVAL2 Board 14 Contents Page

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Page 1: ug PI3740 EvalBrd1 2 - Vicor Corporation · EVAL2 is designed for specialized constant-current applications using high-side current sense where V OUT is below 8V. These boards have

UG:306 Page 1

PI3740-00-EVAL1, -EVAL2Cool-Power® ZVS Switching RegulatorsBuck-Boost Evaluation Board User Guide

Introduction

The PI3740-00 evaluation board comes in two versions, EVAL1 and EVAL2. EVAL1 should be used to evaluate the PI3740 in constant-voltage or standard constant-current applications where VOUT is above 8V. EVAL2 is designed for specialized constant-current applications using high-side current sense where VOUT is below 8V. These boards have been designed to showcase various constant-voltage and constant-current applications and can be configured with a few selectable jumpers. This guide will walk the user through the various options.

The PI3740-00-LGIZ is a high-efficiency, wide-input-range DC-DC ZVS Buck-Boost regulator with integrated controller, power switches and support components all within a high-density 0.4 x 0.55in System-in-Package (SiP). The evaluation board measures 2.5 x 2.25in and contains all the components necessary for a variety of applications. Not all components will be needed for all applications.

Part Ordering Information

The customer evaluation boards can be ordered following the link to Vicor Cool-Power ZVS Buck-Boost Switching Regulators.

USER GUIDE | UG:306

Introduction 1

Part Ordering Information 1

Box Contents 2

Features 3

General Information 3

Power Up Procedure 3

Constant-Voltage Operation (EVAL1) 4

Constant-Current Operation (EVAL1, EVAL2) 4

Constant-Current Float Voltage Adjustment 4

Adjusting the Charging Current 5

Constant-Current Configuration #1: (PI3740-00-EVAL1 Board) 5

Constant-Current Configuration #2: (PI3740-00-EVAL1 Board) 6

Constant-Current Configuration #3: (PI3740-00-EVAL1 Board) 7

Constant-Current Configuration #4: (PI3740-00-EVAL2 Board) 8

Current-Sense Element in Each Board 8

Only One Current-Sense Element 8

Stability 8

Test Points 9

Schematics 10

Bill of Materials 12

Additional or Changed Components for PI3740-00-EVAL2 Board 14

Contents Page

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IMPORTANT NOTICE:

Be sure to read the precautions below entirely BEFORE using the evaluation board. Do not operate the evaluation board unless you have the appropriate safety precautions in place on your bench to ensure a successful experience.

The list below is not comprehensive and is not a substitute for common sense and good practice.

nn When testing electronic products always use approved safety glasses. Follow good laboratory practice and procedures.

nn During operation, insure the power devices and surrounding structures can be operated safely.

nn Care should be taken to protect the user from accidental contact when under power.

nn Provide a strain relief for wires and place the system on the bench in such a way as to prevent accidental displacement from bench top.

nn Review thermal consideration and guideline associated with operating the evaluation board. Most notably use a bench top fan and use rubber feet to elevate the PCB as they allow air flow to the bottom.

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 Verify power connections to avoid reversing applied voltage polarities.

nn Avoid creating ground loops between the SGND and PGND pins when making measurements.

nn The product evaluation board is designed for general laboratory evaluation. It is not recommended for installation in end user equipment.

nn Refer to the specific regulator module data sheet for electrical rating of the device, thermal and mechanical product details. It is important to remain within the device rated range when testing.

The evaluation board is designed for user convenience to evaluate the performance of Vicors mounted ZVS Buck-Boost product. Sockets are provided to permit quick probing. The evaluation board provides lugs and top layer banana jack footprint for input and output connections, signal connectors allowing wire, signal test points for easy connection to standard test equipment, and Kelvin Johnson-Jack for accurate voltage measurements of power nodes.

Box Contents

The evaluation board ships with the following contents:

nn 1 x PI3740-00-EVAL1 or PI3740-00-EVAL2 customer evaluation board

nn 8 x jumpers

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Features1. Input and output lugs for source and load connections.

2. Location to place through-hole input aluminum-electrolytic capacitor. (CIN3)

3. Input source filter (L1, L200, RIN)

4. Oscilloscope probe jack for accurate, high-frequency output (JVOUT) and input (JVIN) voltage measurements.

5. Signal pins test points and wire connectors.

6. Kelvin voltage test points and sockets for all pins of PI3740.

7. Jumper selectable High-Side / Low-Side current sensing

8. Jumper selectable float voltage.

General Informationnn VIN Range: 8 – 60VDC

nn VOUT Range: 10 – 50VDC (for constant-voltage operation)

nn Output Power: 50 – 140W [a]

[a] See PI3740-00 data sheet for maximum power rating at your particular input and output voltages.

Power Up Procedure1. Ensure the jumpers are installed as shown in the following pictures depending on which

configuration is chosen.

2. Connect the load as shown in the following pictures making sure of the polarity. (Positive to VOUT and negative to GND or BAT–)

3. Connect the input source making sure of the polarity. ( Positive to +VIN and negative to GND)

4. Turn on input source ensuring it is within the range indicated in the general information section.

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Constant-Voltage Operation (EVAL1)For constant-voltage operation install JLGH, JPG, JISP, JISN, JVSP, JVSN, JSHUNT, as shown in Figure 1. The regulated output voltage can be adjusted by changing REA1 per the following equation.

VFLOAT = (1.5887*REA1) + 1.7 where REA1 is in kΩ. With the present values, the output voltage is about 24V.

Constant-Current Operation (EVAL1, EVAL2)Constant-Current mode is required for battery and super capacitor charging applications. Both EVAL1 and EVAL2 can be configured for constant-current operation. EVAL1 should be the default board for all constant-current applications with the exception of high-side current sense applications where VOUT can drop below 8V. Both evaluation boards can be configured to operate in a typical CC/CV charging scheme where the regulator output starts out in CC mode and then transitions to CV mode as soon as the battery voltage reached a predetermined float voltage.

Constant-Current Float Voltage Adjustment

The float voltage or the voltage where the converter transitions to constant-voltage mode, can be adjusted by changing REA1 per the following equation.

VFLOAT = (1.5887*REA1) + 1.7 where REA1 is in kΩ. The board is shipped with REA1 = 14kΩ which sets the float voltage to 24V. The board is also shipped for easy configuration for VOUT values of 48V and 12V.

To configure for one of these preset values simply remove REA1 and place a jumper on J302 for 48VOUT or J303 for 12VOUT.

Figure 1 Jumper Placement for

Constant‑Voltage Operation (EVAL1)

Figure 2 Jumper Locations for Preset

J302 48VOUT (shown) or J303 12VOUT

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Constant-Current Configuration #1: (PI3740-00-EVAL1 Board)

Low-Side Current Sense Using PI3740 Internal Amplifier

This configuration senses the current through R106 and uses the internal general purpose amplifier of the PI3740 to regulate the current. The jumpers need to be installed as shown. This configuration can be used for super-cap charging as well as battery charging. The benefit of this configuration is that you can use a standard value current sense resistor and adjust the current by changing a single 0603 resistor. It does require 6 resistors and a reference to implement the circuit. These components are contained within the evaluation board.

Install: JSHUNT, JVSN, JVSP, JLGH, JGP. Also install JISP & JISN between the 2 pins closest to JGP. This will short IS+ and IS– to ground.

Adjusting the Charging Current

The charging current can be adjusted by changing R104 per the following equation.

ICHARGE = (0.62 – (62µA*R104))/R106. In this example it would be: (0.62 – (62µA*5.11k)/0.1 or 3.03A.

Note: In configuration #1 for constant-current operation, RDIFF1 should be removed. RDIFF1 is used in configurations where LGH is used to provide soft start.

LOAD

VIN

Figure 3 Jumper Placement for

Constant‑Current Operation Configuration #1 (EVAL1)

Figure 4 RDIFF1 Location

RDIFF1

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UG:306 Page 6

Constant-Current Configuration #2: (PI3740-00-EVAL1 Board)

High-Side Current Sense Using RSENSE

For customers who prefer high-side current sense, this configuration senses the current through RSENSE and uses the internal Imon amplifier and the LGH pin of the PI3740. The LGH pin is the inverting input to an amplifier which has a 0.1V reference. Including RSENSE, only 4 components are required for the current control loop. VOUT minimum is 8V due to the common mode range of the IMON amplifier. This configuration cannot be used for super cap charging.

Install jumpers as shown.

Install: JISP, JISN connecting RSENSE to IS+ and IS–, J200 connecting IMON to LGH, JTRK.

Charging Current: The LGH amplifier has a reference of 100mv nominally. The Imon amplifier has a gain of 20. So the voltage across RSENSE will be 5mv when the circuit is active. Therefore, the current will be approximately 5mv/RSENSE.

Figure 5 Jumper Placement for

Constant‑Current Operation Configuration #2 (EVAL1)

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UG:306 Page 7

Constant-Current Configuration #3: (PI3740-00-EVAL1 Board)

Low-Side Current Sense and LGH

Current is sensed through R106 and, through a compensation network, fed into the LGH pin. This is a low-side current sense configuration which requires only 4 components including the current sense resistor.

Install jumpers as shown.

Install: J200 connecting R106 to R205/R206, JTRK, JISP and JISN shorting IS+ and IS– to ground.

Charging Current: The charging current will be approximately 100mv/R106. If a standard resistor value cannot be found that gives you the required current, use configuration #1.

Figure 6 Jumper Placement for

Constant‑Current Operation Configuration #3 (EVAL1)

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UG:306 Page 8

Constant-Current Configuration #4: (PI3740-00-EVAL2 Board)

High-Side Current Sense Using INA193 and LGH

For applications where VOUT is below 8V and high-side current sense is preferred, this configuration must be used. This configuration senses current through RSENSE and the output of the INA193 is fed into the LGH pin through a compensation network. The minimum recommended RSENSE is 20mΩ. The maximum output voltage in this configuration remains 50VDC.

Install jumpers as shown.

Install: J301, JTRK, JISP and JISN to connect IS+ and IS– to ground.

Charging Current: The INA193 has a gain of 20. The output of the INA193 is divided down by R301 and R302. The LGH voltage is 100mv. Therefore the charge current is approximately (100mv*8/20)/RSENSE, or 40mv/RSENSE.

Paralleling Boards

Current-Sense Element in Each Board

If more current is required than can be supplied by one board, two boards may be used in parallel. Jumper the following pins together between boards; SGND, TRK, EAO, EN. Use short, low impedance jumpers especially on the SGND and EAO pins.

Only One Current-Sense Element

If only one board has a current-sense resistor, the LGH pins must also be connected together. Also, the connection to IMON, on the board which does not have the current-sense resistor, must be opened. (Remove J200).

Stability

The both evaluation boards are designed to be stable in a wide variety of applications. If instability is seen in your application, contact Vicor application support for assistance.

Figure 7 Jumper Placement for

Constant‑Current Operation Configuration #4 (EVAL2)

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Table 1 Test Point Descriptions

Test Points

Reference Designator/Functional Name

Description

VIN_F Input voltage test point close to VIN of the PI3740.

+VOUT SENSE1–VOUT SENSE 1

Output voltage test points.

VDRA 5.1V auxiliary supply with max loading of 2mA. If used this pin must have a series resistance such as R103 = 1kΩ with a decoupling cap of 0.1µF such as C124.

PGDPower good indicator. During a regulator fault this pin is pulled internally to signal ground.

ENInput to the regulator. If left floating or driven high (VEN_MAX = 5.5V) regulator will be enabled.

SGND Internal logic ground.

TRKSoft-start and track input. An external capacitor may be connected between TRK pin and SGND to increase the rise time of the internal reference during soft start.

IMON Output of the internal current sense amplifier.

EAOError Amp output. External connection for additional compensation and current sharing.

EXT_REF Error Amp Inverting Input separated with REA3 = 10kΩ.

VSP Non-inverting input to an independent amplifier.

VSN Inverting input to an independent amplifier.

VDIFF Output of the internal independent amplifier.

LGH Input for constant-current amplifier.

SYNCO Synchronization Output.

SYNCI Synchronization Input.

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Figure 8 PI3740 Evaluation Board

Schematic Page 1

Schematics

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UG:306 Page 11

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Figure 9 PI3740 Evaluation Board

Schematic Page 2

Schematics (Cont.)

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UG:306 Page 12

Bill of Materials

Table 1 Bill of Materials

Populated Components

Reference

DesignatorDescription QTY Manufacturer

Manufacturer

Part Number

C1, C2, C3,

C4, C5, C7,

C8, C9, C10,

C11, C12, C13,

C14, C203,

C204, C205,

C206, CIN1,

CIN2, CIN4,

CIN5, CIN6,

CIN7, CIN8,

CIN9, CIN10,

CIN11, COUT1,

COUT2,

COUT3,

COUT4,

COUT5,

COUT6,

COUT7, COUT8

Capacitor, X5R, Ceramic, 4.7µF,

80V, 120635 MURATA GRM32ER71K475KE14L

CCOMP Capacitor, X7R, 4700pF, 50V, 0603 1 MURATA GRM188R71H472KA01D

C201 Capacitor, X7R, 1nF, 50V, 0603 1 MURATA GRM188R71H102KA01D

C202 Capacitor, X7R, 100pF, 50V, 0603 1 MURATA GRM188R71H101KA01D

D1 Diode, LED, Red/Green, 1mm x 1mm 1 ROHM SML-P24MUWT86

D501Diode, Schottky, 30V, 200ma,

BAT54XV2CT1 FAIRCHILD BAT54XV2

J5, J200, JISN,

JISPConnector Header 3 Position 0.1" Pitch 4 3M 961103-6404-AR

L200 Inductor, 65nH, 20A, FP0404 1 EATON FP0404R1-R065-R

L201 Inductor, 48µH, 3.4A 1 PANASONIC ETQP5M470YFK

L1 Inductor, 1µH, 11A, SRP7030-1R0M 1 BOURNS SRP7030-1R0M

R5, R105 Resistor, 1.00k,1%,0.1W, 0603 2 ROHM MCR03EZPFX1001

RSYNCI, RPGD,

REA3, R100,

R101, R103

Resistor, 10.0k, 1%, 0.1W, 0603 6 ROHM MCR03EZPFX1002

R205 Resistor, 100k, 1%, 0.1W, 0603 1 ROHM MCR03EZPFX1003

R305 Resistor, 29.4k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL2942R

R306 Resistor, 6.49k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL6491

REA1 Resistor, 14.0k, 1%, 0.1W, 0603 1 MCR03EZHFL1402

RSENSE Resistor, .0015, 1%, 1W 1 PANASONIC ERJ-M1WTJ1M5U

R106, R208 Resistor, 0.10, 1%, 2W 2 BOURNS CRM2512-FX-R100ELF

RSCL, RSDA, RZ1, R206

Resistor, 0Ω, 1%, 0.1W, 0603 4 ROHM MCR03EZPJ000

U1Dual Schmitt Trigger Inverter, NC7WZ14,SC70-6

1 FAIRCHILD NC7WZ14EP6X

U1901 Adjustable shunt regulator, 1.24V 1 TI LMV431ACM5

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UG:306 Page 13

Bill of Materials (Cont.)

Table 1 (Cont.) Bill of Materials

Populated Components

Reference

DesignatorDescription QTY Manufacturer

Manufacturer

Part Number

RIN Resistor, 0.15, 1%, 0.25W, 1206 1 ROHM MCR18EZHFLR150

H1 4 Position, I2C Header 1 MOLEX 22-23-2041

PI3740 Wide Input Range BB 10X14 SiP 1 VICOR PI3740-00

JGP, J6, J301, J302, J303, JTRK, JVSN,

JVSP, JSHUNT, JLGH

Connector Header 2 Position 0.1" Pitch 10 3M 961102-6404-AR

R204 Resistor, 47K, 5%, 0.1W, 0603 1 ROHM MCR03EZPFX4702

CVDRCapacitor, X7R Ceramic, 0.1µF, 50V, 0603

1 TDKCGA3E3X7S2A104K-080AB

LMAG Inductor, 0.42µH, 42A, HCV1206 1 EATON HCV1206-R42-R

RIMON, REA2, RZ2, R1, R2, R3, R4, C6, C100, C301, C302,

CEAIN1, CEAO, CIN3, CTRK,

EAO, ENABLE, EXT_VREF, JVIN, LGH,

PGD, IMON, R107, R301 R302,R303,

R304, SGND, TRK, U1800,

SYNCI, SYNCO, VDIFF, VDR,

VIN_F, VOUT, VSN, VSP,

+ VO SENSE 1, – VO SENSE 1

Do Not Populate 38

REA4 Resistor, 1.07k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL1071

RDIFF1 Resistor, 200k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL2003

RDIFF2 Resistor, 1 MEG, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL1004

RGP Resistor, 49.9, 1%, 0.1W, 0603 1 ROHM MCR03ERTF49R9

R102 Resistor, 4.02k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL4021

JVOUT, JVIN Connector, Johnson Jack 2 TEKTRONIX 131503100

R104 Resistor, 5.11k, 1%, 0.1W, 0603 1 ROHM MCR03EZHFL5113

RDAMP Resistor, 0.51, 1%, 0.25W, 1206 1 ROHM MCR18ZEHFLR510

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UG:306 Page 14

Bill of Materials (Cont.)

Additional or Changed Components for PI3740-00-EVAL2 Board

Reference

DesignatorDescription QTY Manufacturer

Manufacturer

Part Number

C301Capacitor, X7R Ceramic, 0.1µF, 50V, 0603

1 TDK CGA3E3X7S2A104K080AB

RSENSE (Value Changed)

Resistor, 0.020, 1%, 1W 1 PANASONIC ERJ-M1WSF20MU

R301 Resistor, 6.98k, 1%, 0.1W, 0603 1 ROHM MCR03EZPFX6981

R302 Resistor,1.00k,1%, 0.1W, 0603 1 ROHM MCR03EZPFX1001

R303,R304 Resistor, 0Ω, 1%, 0.1W, 0603 2 ROHM MCR03EZPJ000

U1800 Current Shunt Monitor, INA193A 1 TI INA193AIDBVR

Table 2 Bill of Materials

for Additional or Changed Components

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03/18

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