Military 440V 3-Phase Non- Isolated PFC EVAL-KIT-1000040-01 SynQor has developed the...

Advancing thePower Curve®

www.synqor.com | QMS#065-0000067 | Rev. A | 03/17/20 | Advancing the Power Curve -

®

Military 440V 3-Phase Non-Isolated PFC EVAL-KIT-1000040-01Evaluation KIT for Non-Isolated 440V 3-Phase PFC Converters SummarySynQor has developed the EVAL-KIT-1000040-01, an evaluation kit to facilitate testing of our 440V 3-Phase Non-Isolated PFC converter and its associated 3-Phase AC line filter.

IntroductionThis application note is a guide to the features, schematic, component placement, and BOM for this evaluation kit. The applicable converter modules are the MACF-440-3PH-UNV-MP 3-Phase AC Line Filter and the MPFC-440-3PH-400-LE 3-Phase Non-Isolated PFC.

ContentsSection 1 – Converter Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Section 2 – Evaluation Board Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Section 3 – Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4Section 4 – Component Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5Section 5 - Input and Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Section 6 – Switches, Lights, LEDs and External Transient Protections . . . . . . .7Section 7 – Basic Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8Appendix A – Bill of Materials (BOM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

This evaluation board and schematic are intended for demonstration purposes only and no guarantees are made for standards compliance.

Application Note Military 440V 3-Phase Non-Isolated PFC EVAL-KIT



Section 1 – Converter DescriptionThe Military 3-Phase Non-Isolated PFC converter has two stages. The input stage has a nominal 3-Phase input of AC (254 Vrms L-N / 440 Vrms L-L) and shapes and balances the three AC input currents. Phase relation (A, B, C phases) are not connection specific. The PFC will work in any orientation. The output of the first stage is called +MIDBUS and it has an external capacitor on the evaluation board (see Capacitor Bank on the Evaluation Board section of the application note for more details). The +MIDBUS output voltage is around 400 Vdc, with a controlled output resistance to facilitate parallel operation. During line dropout events, the +MIDBUS voltage can droop as low as 215 Vdc. A second boost stage maintains 400 Vdc regulation of the main output during these brownout or dropout conditions. The 3-Phase Non-Isolated PFC will startup and operate under any valid load condition.

Thermal Considerations: When testing EMI filters and converters on an evaluation board, be sure to provide adequate cooling. Apply cooling air with a fan blowing across the EMI filter and the converter or across the heatsinks attached to the EMI filter and converter. Monitor the EMI filter and converter temperatures to ensure they don’t exceed the maximum rated temperatures shown in the module datasheets.

Shock Warning: There are areas of this evaluation board that have exposed access to hazardous voltage levels. The plastic covers are in place to reduce the chance of contact with high voltages. Do not remove the covers. Exercise caution to avoid contact with any high voltage areas. Also note that the evaluation board may temporarily retain high voltage after the input power has been removed. Exercise caution when handling all board components and connectors.

Isolation Warning: Circuitry on this evaluation board is non-isolated with respect to the AC line inputs. This requires great care in making connections and taking measurements. Be aware that the 400 Vdc output and 400 Vdc +MIDBUS are non-isolated with respect to input AC lines. As such, take great care before taking any measurement with equipment that may make a connection to ground. The return line for either DC voltage is NOT ground. Connecting a scope probe to any power DC voltage on this board may result in damage to the board and/or the scope or scope probe. Use isolated differential probes or clamp on style current probes to avoid these issues.

In most applications, the output of the 3-Phase Non-Isolated PFC is followed by an isolated DC-DC converter. The USB port, enable switch, and control signals are isolated from the AC line.




Section 2 – Evaluation Board Block Diagram

BoostConverter

SHIELD1

+VOUT1.5

1.5

1.5

µH

LEAVEFLOATING

+MIDBUSµH

µH

>150µF>450V rating

>15µF>450V rating

-VOUT

BASIC ISOLATION

CLOSE SWITCH TO ENABLE

A1ST

ART

SYN

C

A2CT

L RE

TURN

A3SE

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IN

A4SE

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OU

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3V A

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A10

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SynQor 3-Phase PFC Module

Baseplate

TVS A

LINE A

TVS B

LINE B

TVS C

LINE C

PFCRectifier

TVS2TVS1

GDT1

F1

PFC B

PFC C

PFC A

LINE B

LINE A

LINE C

PE GND

SynQor 3-PhaseAC Line Filter

BASIC ISOLATION

Figure 1. Typical connection diagram for the MPFC-440V-3PH-400-LE AC-DC converter.

Suggested Parts:TVS1: 430 Vrms, 10 kA; Littelfuse AK10-430 or Bourns PTVS10-430C-TH

TVS2: 430 Vrms, 3kA; Littelfuse AK3-430 or Bourns PTVS3-430C-TH

GDT1: 1.5kV, 3kA; Littelfuse GTCA28-152M-R03

F1: 500VAC, 30kA; Littelfuse 0505020.MXEP .

MPFC-440V-3PH-400-LE

MACF-440-3PH-UNV-MP

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Section 5 - Input and Output Connections Input power is applied through connector J16, see Table 1. The mating connector for J16 is DF22-5P-7.92DS(05) from Hirose Electric Company in Japan and is provided.

Output power is delivered through connectors J10 and J11 or J6 and J7. See Table 2. The mating connectors are provided.

+MIDBUS is connected to J6, see Table 2.

Table 1: Input Power Connector J16Connector Terminal # Signal Name Part Number

J16-1 AC Line A Input Hirose Electric Company, DF22-5P-7.92DS(05) J16-2 AC Line B Input Hirose Electric Company, DF22-5P-7.92DS(05) J16-3 AC Line C Input Hirose Electric Company, DF22-5P-7.92DS(05) J16-4 Not Used Hirose Electric Company, DF22-5P-7.92DS(05)J16-5 PE Ground Hirose Electric Company, DF22-5P-7.92DS(05)

Table 2: Output Power ConnectorConnector Terminal # Signal Name Part Number

J10 +VOUT Anderson, 1336G1J6 +MIDBUS Anderson, 1336G1

J7/J11 -VOUT Anderson, 1336G1

Table 3: Metering Power Connectors J8/J9Connector Terminal # Signal Name Part Number

J8/J9-1 AC Line A Input Molex, 172042-0301J8/J9-2 AC Line B Input Molex, 172042-0301J8/J9-3 AC Line C Input Molex, 172042-0301

Table 4: Output Power Connectors J3

Connector Terminal # Signal Name Part NumberJ3-1 +VOUT Molex, 172042-0301J3-2 +MIDBUS Molex, 172042-0301J3-3 -VOUT Molex, 172042-0301

Metering connectors have been included in the Eval to facilitate connection to some of the high voltage lines in the board. Use high voltage differential probes to measure these line voltages. This prevents a connection between the scope ground and -VOUT/+VOUT/+MIDBUS/LINE_X which are all at AC line potential. The metering J3, J8 and J9 connectors are 3 position Molex Super Sabre 7.5m connectors.

The boards have a set of isolated test points (black) which are referenced to CTL_RETURN and are safe to use a standard scope probe. Table 5 references each signal to the appropriate test point.




Table 5 . Eval board high voltage test points

Black Test Points Signal Names Test Point ColorTH14 CTL RETURN RedTH15 SERIAL IN RedTH16 SERIAL OUT RedTH17 AC GOOD RedTH18 DC GOOD RedTH19 PFC ENABLE RedTH20 BATTLE SHORT RedTH21 3.3V AUX RedTH22 SYNC OUT Red

Note: Test points are red in figure 3 but black on physical unit.

Section 6 – Switches, Lights, LEDs and External Transient Protections

Description of Switches

Enable On/Off Switch Toggling S1 switch to the ON position enables the 3-Phase Non-Isolated PFC converter. Toggling S1 switch to the OFF position disables the 3-Phase Non-Isolated PFC converter.

Description of Lights

Neon Lamp Indicator LI1: Blinking neon light warns that input power is present.

LED Indicators LED1: AC GOOD LED2: DC GOOD LED3: Bias On

Description of Transient Protection DevicesThe evaluation board includes protective Transient Voltage Suppressors (TVS) devices on all three input lines. The three TVS are connected to PE ground through an additional TVS in series with a gas discharge tube (GDT). These protections are in place to absorb energy from potential transients that may be present on the AC line.

An additional set of Transient voltage suppressors (TVS) are included after the filter to clamp the peak line-line voltage seen by the PFC rectifier switches behind the line input inductors, when stimulated by an input transient

TVS1-4 DevicesLine A to TVS4: TVS1 Line B to TVS4: TVS2Line C to TVS4: TVS3TVS1-3 to GND: TVS4

TVS5-7 DevicesPFC Line C Virtual Neutral: TVS5PFC Line A Virtual Neutral: TVS6PFC Line B Virtual Neutral: TVS7




Section 7 – Basic Operation InstructionsApply the 3-Phase input, 440 Vrms (L-L) at J16 in middle left, using the provided cable assembly. Earth ground, and Phases A, B, and C are labeled. There is no neutral connection, and phase rotation (A, B, C) does not matter to the device. Lamp LI1 indicates the presence of hazardous voltages at the input.

Connect the loads at:MIDBUS for loosely regulated 400 V and/or++VOUT for regulated 400 V

Use Switch S1 in top right for enable / disable control.

Be aware that the 400 Vdc output and 400 Vdc +MIDBUS are non-isolated with respect to input AC lines. As such, take great care before taking any measurement with equipment that may make a connection to ground. The return line for either DC voltage is NOT ground. Connecting a scope probe to any power DC voltage on this board may result in damage to the board and/or the scope or scope probe. Use isolated high voltage differential probes or clamp on style current probes to avoid these issues. This prevents a connection between the scope ground and -VOUT/+VOUT/+MIDBUS/LINE X which are all at AC line potential. Use the metering connectors to access the line input voltages, the +MIDBUS voltage or the output voltage in the board. Do not attempt to probe any of these voltages directly on the board. DC output Measurements may be taken at the MIDBUS and OUTPUT connectors or a converter can be added to test the PFC.

All test points referenced to the isolated CTL RETURN are colored black, indicating it is safe to use a standard scope probe.

Capacitor Bank on the Evaluation BoardThe test board includes a small amount of output capacitance on the MAIN OUTPUT (47µF, 450 Vdc). Although no large bulk hold-up capacitance is required for operation, the device will require a nominal amount of capacitance at the +MIDBUS node for normal operation. The board includes four 47µF capacitors across the MIDBUS and VOUT- terminals. The capacitors selected are rated from -55 °C to 125 °C, and arranged in groups in series due to their voltage rating. A single larger value electrolytic capacitor would also be acceptable. Capacitors on the output nodes serve to stabilize the input system both for this converter and downstream power converters.

On-Board Capacitance:188 µF @ +MIDBUS (four capacitors in parallel)47 µF @ +VOUT (one capacitor)

Please refer to the applications section of the datasheet for more detailed information on additional capacitance.

http://www.synqor.com/Datasheets/MPFC-440-3P-400-LE_Datasheet.pdf




Additional InformationTwo LEDs next to USB port indicate the status of the AC GOOD and DC GOOD signals.

Serial Communications InterfaceThe evaluation kit is equipped with a USB serial interface. In order to communicate to the MPFC, the serial terminal emulator interface has to be configured to: 9600 baud, 8 data bits, no parity, and one stop bit. Set the terminal emulator to send both a line-feed and carriage return. The MPFC does not echo any characters sent to the unit. In order to see the characters being sent to the module in your terminal emulator window, enable the echo feature on your terminal emulator. The USB port in the Evaluation board is a USB 2.0 Micro B female port. To communicate with the adaptor board via USB interface, a USB 2.0 Micro B male cable is needed (Table 7).

Table 6 . Suggested USB interface cableManufacturer Part Number Description

Qualtek 3021079-06 USB 2.0 A male to Micro B

Please refer to application note SynQor MPFC-440-3PH-400-LE PFC Terminal Commands for information regarding the communications standards and parameters available for monitoring.

Host computer USB Serial Communications Interface SetupTo communicate with the evaluation board kit, the appropriate USB driver must be installed. The FT230XS driver can be found at FTDI chip web site1.

“Once the USB drivers are properly installed, a new serial port object should become available for application use. Under Windows, the serial port should become visible from the Windows Device Manager, in the “Ports (COM & LPT)” category, and should be assigned a new COMx name (where x is a number, ex: “COM2”). The exact COMx number assigned to the hardware will depend in part on how many COMx based hardware devices have previously been connected to the machine, as each new hardware instance must be assigned a new and unique number to avoid potential conflicts.

If a machine currently has more than one COMx based hardware device attached to the machine, multiple COMx entries (but different numbers, e.g., COM1 and COM2) may exist in the Windows Device Manager “Ports (COM & LPT)” category, and it may not be clear which COMx port number is specifically associated with the FT230X device. If this occurs, the COMx number can be manually identified by temporarily detaching the USB connection to the FT230X while watching the Windows Device Manager to identify which device entry disappears (and subsequently re-appears in the list upon re-attaching the FT230X).

Once the COMx port number assigned to the FT230X is known, any conventional serial port terminal program can be used to open/close/read/write to the COMx port. To communicate with the adaptor board kit, a USB Micro-B Male cable can be used for a direct connection to the USB port.”

1 Please refer to the FTDI website: https://www.ftdichip.com

http://www.synqor.com/MPFC-440-3PH-400-LE_Serial_Interface




Appendix A – Bill of Materials (BOM)

Table 7: Evaluation board bill of materials .Ref Des Value Package Description

C163 0.10uF 0402 X7R 16VC166 C37 10nF 0603 X7R 50VC38C39C40 C23 10nF 0603 X7R 50VC15 100nF 0603 X7R 25VC16 C17 C4 C165 0.022uF 0603 X7R 50VC7 0.22uF 0603 X7R 25VC164 1.0uF 0603 X7R 16VC3 4.7uF 0805 X7R 16VC10 10uF 1206 X7R 16VC11 C8 C9 C18 22nF 1210 X7R 1kVC19C20C21C22C23C14 0.47uF 1812 Capacitor, ceramic, 0.47uF, 450V, 10%, X7T, 1812C24 D1 800V SOD-323 High Voltage Signal Diode, 800V, SOD-323D10D11D12D2D3D4D5D6D7D8D9D20 5V SOT-23 TVS Double BIDI ESD Protection Diodes, 5V, SOT-23F4 250mA 2410 FuseF5 F6F7F8F9 FB1 120nH 0805 120nH, 25%, 0805 Ferrite BeadFB2




Ref Des Value Package Description

J1 Miniature SMT Coax ConnectorJ2J4 J5 J12 USB MICRO B USB Micro-B Female SMT ReceptacleJA OPEN JB LED1 LTST-C195 BI-COLOR GREEN/YELLOW LEDLED2 LED4 LED5LED6 LED3 1206 Orange LED Top-ViewLED7 Q1 20V SC-70-6 Dual 20V Low Threshold N-FetQ2 R190 49.9 0603 ResistorR191 R11 499 402 ResistorR12 R14 R16R23 R24 R25 698 402 ResistorR29R13 10.0K 0402 ResistorR15 R10 1.0uH 0402 Chip InductorR8 R6 20 0603 ResistorR9R53 49.9 0603 ResistorR55 R192 100 0603 ResistorR7 499 0805 ResistorR2 2.2 1206 ResistorR22 R1 1.0M 1206 Resistor, High VoltageR17 R18 R19 R20 R21 R3 R4 R5 2.2 1206 ResistorU1 SSOP-16 USB-UART Bridge by FTDIU10 SO-8 Dual-Channel Digital Isolator, SO-8, Bi-Directional, 150Mbps, Safety RatedU23 SO-8 Voltage Regulator, Charge pumpU46 SO-8 12-Bit DACU47 2.048V SOT-23-5 V-ReferenceU48 QSOP-16 Low Power, 5-Fwd-Channel Digital Isolator, 150 Mbps

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