PFEVAL-1 Evaluation Board Kit Application Notes WARNING! HAZARDOUS VOLTAGES!

PFEVAL-1 Evaluation Board Kit Application Notes WARNING!  HAZARDOUS VOLTAGES!
PFEVAL-1 Evaluation Board Kit
Application Notes
PFEVAL-1 Evaluation Board Kit
WARNING! HAZARDOUS VOLTAGES!
In setting up a laboratory station for conducting electrical
tests of the PF600-1 using the PFEVAL-1 Evaluation Board,
operator safety must be the first and foremost consideration. Because the PFEVAL-1 Evaluation Board was designed to provide users with access to all input, output,
status, and control leads on the PF600-1, it was impractical to incorporate all conceivable safeguards to protect
the operator against potential shock hazards. For this
reason, only fully trained, qualified personnel should attempt to perform any qualification tests of the PF600-1
using the PFEVAL-1 Evaluation Board.
Qualified personnel must have the skills necessary to distinguish exposed live parts from other parts of the assembly, to recognizethe precautions for avoiding shock, and
to understand the consequential hazards of contact. Exposed live parts are those parts of the circuit which are
energized and which the operator may contact during testing. The operator should be trained in the proper techniques for use of tools and equipment used to perform
such testing, and in emergency procedures required to
release a victim from contact with exposed live parts or
circuits. The operator must be able to determine the degree and extent of the hazard and the personal protective
equipment and advance planning necessary to perform
the testing safely.
The test station cannot be considered safe without the
proper training of any individuals involved in or exposed
to the testing. In addition, the station needs to be configured to provide the operator with every possible protection against exposure to hazardous voltages.
For guidelines regarding the proper set up of an electrical
testing workstation, refer to the European Normative standard EN 50191 Erection and Operation of Electrical Test
Equipment.
INTRODUCTION
The PFEVAL-1 Evaluation Boardwasdesigned to facilitate
the testing and verification of functional performance
of the PF600-1 AC-DC converter at roomtemperature.
This evaluation board provides access to theinput, output,
control, and status leads on the PF600-1 forthe express
purpose of demonstrating the functionality ofthe
PF600-1 converter when connected to a specific application load and input source and to permit measurement
of various associated electrical parameters. The Kit includes:
• PFEVAL-1 Evaluation Board
• PF600-1 Product
• PF600T-1 Heatsink (Transverse)
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DESCRIPTION
With reference to the PWB Top Layer Silkscreen Component Layout in Figure 2 and the PFEVAL-1 Evaluation Board
Reference Schematic in Figure 3, the PFEVAL-1 Evaluation
Board includes the following circuit elements to simulate
the support circuits found in a typical application and to
accommodate connection:
• Three-position input terminal block, TB1. Terminals TB11, TB1-2, and TB1-3 provide accommodation for input
Line, Neutral, and Earth Ground connections, respectively. Table 1 below provides additional detail in tabular form.
Table 1: PFEVAL-1 Evaluation Board Input Terminal Block
Connections
Eval. Bd. TB
Designation
PF600-1 Pin
Reference
Pin
Name
Function
TB1-1
P1
LINE
AC Input Line
TB1-2
P2
NEU
AC Input Neutral
TB1-3
P3
GND
Input Earth Ground
• Input fusing is provided in both Line and Neutral feeds
by fuses F1 and F2, respectively. Additional information
on input fusing and inrush current limiting with the PF6001 can be found in Application Note ACAN-13.
• Surge immunity from line-to-neutral surges to EN610004 is provided by MOV RV1, while MOVs RV2 and RV3 in
conjunction with gas tube SG1, provide for immunity
from line-to-ground and neutral-to-ground surges. These
are intended to shunt high-energy transients imposed
on the input lines to ground to protect the module. The
high AC impedance of the EMI module will also provide
additional transient suppression. Additional information
on input transient suppression with the PF600-1 can be
found in Application Note ACAN-12.
Technical enquiries - email: [email protected], tel: +1 508 339 3000
ACAN-24
Application Notes
• Integrated input EMI filter U1 was selected based on
simplicity and is not optimum. Optimized discrete conducted EMI filter solutions are the subject of ACAN-14.
U1 provides conducted common-mode and differentialmode noise attenuation from 150kHz to 30MHz. As this
filter has a maximum input current rating of 6A, it is
important to ensure that this level is not exceeded. It is
therefore recommended that the input line voltage be
kept above 120VAC for characterizations at or near the
full output load rating of 600W. Additional information
on input EMI filtering with the PF600-1 can be found in
Application Note ACAN-14.
• While the integrated EMI filter incorporates two sets of
“Y” capacitors and three “X” capacitors, discrete, safety-
rated “X” capacitor C1 (1uF) and “Y” capacitors C2 & C3
(0.005uF) were added for visual reference in the event
that a discrete EMI filter is intended in the end
application.
• Bulk capacitor C4 provides the input holdup during momentary line sags and outages. Application Note ACAN10 provides additional details for calculating the value
of this capacitor for the desired holdup time. At 470uF,
a minimum holdup time of 16msec should be demonstrated at full output power.
• Output inhibit switch SW1 is a three-position switch with
the center position open. Switching to either of the
other two positions will short Pins 10 & 11 of the PF6001 to disable the main output. The Auxiliary output will
Figure 2: PFEVAL-1 Evaluation Board Layout
Figure 3: PFEVAL-1 Evaluation Board Reference Schematic
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Technical enquiries - email: [email protected], tel: +1 508 339 3000
ACAN-24
Application Notes
remain active when the main output is inhibited in this
manner.
• Thermal management on the PFEVAL-1 Evaluation Board
is accomplished with three fans which force air transversely across the PF600T-1 heatsink. For simplicity, the
three 12V fans are connected in series across the main
48V output of the PFEVAL-1 with a series-connected resistor to drop the excess voltage. Because the fans are
connected across the main output, some commutation
noise from the fans will be present. At least two different fans are presently being used for the PFEVAL-1 Evaluation Board, and the characteristic frequencies may be
different. Typically, this noise component falls within
the frequency range of 400-1000Hz. In the event that
the application load is sensitive to noise in this frequency
range, it is recommended that the fans be driven from
an isolated source or that additional filtering be added.
For additional information on thermal management with
the PF600-1, please refer to Application Note
ACAN-15.
• Output filter capacitors C5 & C6 provide output filtering
of the low frequency and high frequency components,
respectively, of the output ripple and noise (PARD). While
these capacitors will attenuate the commutation noise
of the fans, this filtering is not optimum at this frequency.
• Terminal blocks TB2 & TB3 accomdation provide for connection to various output, status, and control leads on
the PF600-1. Table 2 provides detail in tabular form.
With these accommodations and typical laboratory test
equipment, the PFEVAL-1 Evaluation Board can be used
to verify the following features and functions of the
PF600-1:
• Input voltage operating range
• Input power factor
• Inrush current
• Input current harmonics
• Efficiency
• Output voltage regulation
• Output holdup
• Output ripple and noise (PARD)
• Overload protection and recovery
• Start-up delay
• Auxiliary output
• Remote On/Off
• DC OK signal
• Conducted EMI
Caution should be exercised when using ground-referenced
test equipment, such as an oscilloscope, to the primaryside circuits of the PF600-1 on the PFEVAL-1 Evaluation
Board. Such connections cannot be made without isolation
of either the PFEVAL-1 Evaluation Board or the test equipment to preclude the flow of current from the AC source to
ground through the test equipment. Such exposure will
damage the test equipment. An input isolation transformer
of appropriate rating may be used for this purpose.
The PFEVAL-1 Evaluation Board Kit is neither intended nor
suitable for any use other than room-temperature evaluation of the PF600-1 features and functions.
Table 2: PFEVAL-1 Evaluation Board Terminal Block Connections
Eval. Bd. TB
Designation
PF600-1 Pin
Reference
Pin Name
F u n c ti o n
TB2-1
P10
INH+
Output Inhibit/Temperature Monitor
TB2-2
P11
INH-
Return for Output Inhibit/Temperature Monitor
TB2-3
P8
AUX+
Auxiliary output positive
TB2-4
P9
AUX-
Auxiliary output negative
TB3-1
P7
Vo-
48V Negative Output
TB3-2
P6
Vo+
48V Positive Output
TB3-3
P12
DC OK+
Output Good signal
TB3-4
P13
DC OK-
Return for Output Good signal
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Technical enquiries - email: [email protected], tel: +1 508 339 3000
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