VICOR VI-200 Series Guide

Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Conv rt rs
and Configurabl Pow r Suppli s
Buy an Genuine Vi-J01-CY from PowerStream

Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
VI-200 and VI-J00 Family Design Guide Rev 3.4 vicorpower.com
Page 1 of 97 Apps. Eng. 800 927.9474 800 735.6200
VI-/MI-200 and VI-/MI-J00 DC-DC Converters Section Page(s)
Zero-Current-Switching 12
DC-DC Converter Pinouts 23
Module Do’s and Don’ts 3 4 – 6
Overcurrent Protection 47
Output Voltage Trimming 5 8 – 10
Multiple GATE IN Connections 6 11
Application Circuits / Converter Array Design Considerations 7 12 – 13
Using Boosters and Parallel Arrays 8 14 – 17
EMC Considerations 9 18 – 28
Optional Output Filters 10 29
Battery Charger (BatMod) 11 30 – 32
Filter & Front-End Modules
AC Input Module (AIM / MI-AIM) 12 33 – 36
Harmonic Attenuator Module (HAM) 13 37 – 42
Input Attenuator Module (IAM / MI-IAM) 14 43 – 46
Ripple Attenuator Module (RAM / MI-RAM) 15 47
Offline Front End 16 48 – 51
Configurable Products
DC Input Power System (ComPAC / MI-ComPAC Family) 17 52 – 54
AC Input Power System (FlatPAC Family) 18 55 – 57
AC Input Power System (PFC FlatPAC) 19 58 – 59
General
Thermal and Module Mounting Considerations 20 60 – 67
Thermal Curves 21 68 – 77
Lead Free Pins (RoHS) 22 78 – 82
Tin Lead Pins 23 83 – 87
Module Packaging Options (SlimMod, FinMod, BusMod and MegaMod Families) 24 88
Product Weights 25 89
Glossary of Technical Terms 26 90 – 97
NOTE This Design Guide and Applications Manual does NOT address Vicor’s Maxi, Mini and Micro DC-DC
converters. For more information on these products go to vicorpower.com .
Table of Contents

Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
VI-200 and VI-J00 Family Design Guide Rev 3.4 vicorpower.com
Page 2 of 97 Apps. Eng. 800 927.9474 800 735.6200
OVERVIEW
Vicor offers RoHS compliant modules. These modules have
a “VE” prefix. The information presented herein applies to
both versions, and “VI” will be the default designation.
The heart of Vicor’s VI-/MI-200 and VI-/MI-J00 module
technology, zero-current-switching, allows Vicor
converters to operate at frequencies in excess of 1 MHz,
with high efficiency and power density. Depending on
input voltage and load, the converters operate at
frequencies ranging from the low hundreds of kilohertz
(light load, high line) to approximately one megahertz (full
load, low line). Another aspect of the Vicor topology is
that two or more power trains driven at the same
frequency will inherently load-share if their outputs are
tied together. Load sharing is dynamic and is within 5%.
The VI-200 and MI-200 product line offer both Driver and
Booster modules:
• Drivers and Boosters must have identical power trains.
• Drivers close the voltage loop internally, Boosters do not.
• Boosters may be slaved to a Driver, allowing
configurations of multi-kilowatt arrays, which
exhibit dynamic current sharing between modules.
• Only a single control connection is needed between
modules with all module’s power inputs and outputs,
connected together — no trimming, adjustments, or
external components are required to achieve load sharing.
LOSSLESS ENERGY TRANSFER
Referring to Figure and Table 1–1 below, turn-on of the
MOSFET switch transfers a quantized energy packet from
the input source to an LC “tank” circuit, composed of
inherent transformer leakage inductance of T1 and a
capacitive element, C, in the secondary. Simultaneously,
an approximately half-sinusoidal current flows through the
switch, resulting in switch turn-on at zero current and
turn-off when current returns to zero. Resonance, or
bidirectional energy flow, cannot occur because D1 will
only permit unidirectional energy transfer. A low-pass filter
(Lo, Co) following the capacitor produces a low ripple DC
output. The result is a virtually lossless energy transfer
from input to output with greatly reduced levels of
conducted and radiated noise.
Ip: Primary current
Vp: Primary voltage
Vs: Secondary voltage
OVP: Overvoltage protection (output)
OTS: Over temperature shutdown
OC1, OC2: Opto-coupler
E/A: Error amplifier
REF: Bandgap reference
C/L: Current limit amplifier
Referenced
to –Vin
[a] Not in VI-J00 Series
Gate
Out
Vs
Vout
Vin
Ip
Vp
2.5 V
REF.
Output Filter
Integrator
Vs
Ip
Vp
MOSFET
Input
Filter
OC2
OC1[a]
–S
TRIM
+S
E/A
+
+–
+Vout
–Vout
Co
Lo
CD2
D1
Reset
Control
GATE
IN
-Vin
+Vin
Logic
Control
Load
C/L
OTS[a]
OVP[a]
GATE
OUT
–
T1
1. Zero-Current-Switching
Figure 1–1 — VI-/MI-200 and VI-/MI-J00 series zero-current-switching block diagram
Table 1–1

Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
VI-200 and VI-J00 Family Design Guide Rev 3.4 vicorpower.com
Page 3 of 97 Apps. Eng. 800 927.9474 800 735.6200
–IN, +IN. DC voltage inputs. See Tables 2–1 and 2–2 for
nominal input voltages and ranges for the VI-/MI-200 and
VI-/MI-J00 Family converter modules (data sheets contain
Low Line, 75% Max. Power and Transient ratings).
GATE OUT. The pulsed signal at the GATE OUT pin of a
regulating Driver module is used to synchronously drive
the GATE IN pin of a companion Booster module to effect
power sharing between the Driver and the Booster. Daisy-
chaining additional Boosters (connecting GATE OUT of
one unit to GATE IN of a succeeding unit) leads to a
virtually unlimited power expansion capability.
GATE IN. The GATE IN pin on a Driver module may be
used as a logic Enable / Disable input. When GATE IN is
pulled low (<0.65 V 6 mA, referenced to –Vin), the
module is turned off; when GATE IN is floating (open
collector), the module is turned on. The open circuit
voltage of the GATE IN pin is less than 10 V.
–OUT, +OUT. DC output pins. See the Table 2–3 and 2–4
below for output voltages and power levels of VI-/MI-200
and VI-/MI-J00 Family converter modules.
Special output voltages from 1 – 95 V; consult factory.
T (TRIM). Provides fixed or variable adjustment of the
module output.
Trimming Down. Allows output voltage of the module to
be trimmed down, with a decrease in efficiency. Ripple as
a percent of output voltage goes up and input range
widens since input voltage dropout (loss of regulation)
moves down.
Trimming Up. Reverses the above effects.
–S, +S (–SENSE, +SENSE). Provides for locating the point
of optimal voltage regulation external to the converter.
Output OVP in VI-/MI-200 will trip if remote sense
compensates output voltage measured at output pins
above 110% of nominal. Discrete wire used for sense
must be tightly twisted pair. Do not exceed 0.25 V drop in
negative return; if the voltage drop exceeds 0.25 V in the
negative return path, the current limit setpoint will increase.
Connect +SENSE to +OUT and –SENSE to –OUT at the
module if remote sensing is not desired. (Figure 7–4)
Figure 2–1 — VI-/MI-200, VI-/ MI-J00
GATE
IN
GAT E
OUT
+IN
–OUT
–S
T
+S
+OUT
GATE
IN
GATE
OUT
+IN
–OUT
–S
T
+S
–IN –IN
+OUT
Designator Low Nominal High
0 10 V 12 V 20 V
V 10 V12/24 V 36 V
1 21 V 24 V 32 V
W 18 V 24 V 36 V
2 21 V 36 V 56 V
3 42 V 48 V 60 V
N 36 V 48 V 76 V
4 55 V 72 V 100 V
T 66 V 110 V 160 V
5 100 V 150 V 200 V
6 200 V 300 V 400 V
7 100 V 150/300 V 375 V
Designator Low Nominal High
2 18 V 28 V 50 V
5 100 V 155 V 210 V
6 125 V 270 V 400 V
7 100 V 165 V 310 V
2. DC-DC Converter Pinouts
VI-200, VI-J00 Input Voltage Ranges
Table 2–1 — VI-200, VI-J00 input voltage ranges
MI-200, MI-J00 Input Voltage Ranges
Table 2–2 — MI-200, MI-J00 input voltage ranges
Designator Output Designator Output
Z2V 215 V
Y 3.3 VN18.5 V
05V 324 V
X 5.2 VL28 V
W 5.5 VJ36 V
V 5.8 VK40 V
T 6.5 V448 V
R 7.5 VH52 V
M 10 VF72 V
1 12 VD85 V
P 13.8 VB95 V
VI-200, VI-J00 Standard Output Voltages
Table 2–3 — VI-200, VI-J00 output voltage designators
Output Power Level Power Level
Voltage VI-200 VI-J00 MI-200 MI-J00
<5 Vdc 10 – 40 A 5 – 20 A 10 – 30 A 5 – 10 A
5 Vdc 50 – 200 W 25 – 100 W 50 – 100 W 10 – 50 W
Table 2–4 — Output voltage vs. power level

Design Guide & Applications Manual
For VI-200 and VI-J00 Family DC-DC Converters and Configurable Power Supplies
VI-200 and VI-J00 Family Design Guide Rev 3.4 vicorpower.com
Page 4 of 97 Apps. Eng. 800 927.9474 800 735.6200
ELECTRICAL CONSIDERATIONS
GATE IN AND GATE OUT PINS
Logic Disabl . When power is applied to the input pins,
the GATE IN pin of a Driver can be pulled low with respect
to the –IN thus turning off the output while power is still
applied to the input. (Figure 7–1)
CAUTION With offline applications –IN is not
earth ground.
In Logic Disable mode, the GATE IN pin should be driven
from either an “open collector” or electromechanical
switch that can sink 6 mA when on (GATE IN voltage less
than 0.65 V). If driven from an electromechanical switch
or relay, a 1 µF capacitor should be connected from GATE IN
to –IN to eliminate the effects of switch “bounce”. The 1 µF
capacitor may be required in all applications to provide a
“soft start” if the unit is disabled and enabled quickly. Do
not exceed a repetitive on / off rate of 1 Hz to the GATE
IN or input voltage pins.
High Pow r Arrays. The pulsed signal at the GATE OUT
pin of a regulating Driver module is used to synchronously
drive the GATE IN pin of a companion Booster module to
effect power sharing between the Driver and the Booster.
(Figure 7–5) Daisy-chaining additional Boosters (i.e.,
connecting GATE OUT to GATE IN of a succeeding unit)
leads to a virtually unlimited power expansion capability.
VI-/MI-200 series modules of the same family and power
level can be paralleled (i.e., Driver, VI-260-CU with
Booster, VI-B60-CU).
In general:
• Don’t drive the GATE IN pin from an “analog”
voltage source.
• Don’t leave GATE IN pins of Booster modules
unterminated.
• Don’t overload GATE OUT; limit load to a single Vicor
module GATE IN connection, or 1 kΩ, minimum, in
parallel with 100 pF, maximum.
• Don’t skimp on traces that interconnect module –IN
pins in high power arrays. GATE IN and GATE OUT
are referenced to –IN; heavy, properly laid out traces will
minimize parasitic impedances that could interfere with
proper operation.
• Do use a decoupling capacitor across each module’s
input (see Input Source Impedance that follows).
• Do use an EMI suppression capacitor from +/– input and
output pins to the baseplate.
• Do use a fuse on each module’s + input to prevent fire
in the event of module failure. See safety agency
conditions of acceptability for the latest information on
fusing. Please see the Vicor website
for Safety Approvals.
Input Sourc Imp danc . The converter should be
connected to an input source that exhibits low AC
impedance. A small electrolytic capacitor should be
mounted close to the module’s input pins. (C3, Figure 3–1)
This will restore low AC impedance, while avoiding the
potential resonance associated with “high-Q” film
capacitors. The minimum value of the capacitor, in
microfarads, should be C (µF) = 400 ÷ Vin minimum.
Example: Vin, minimum, for a VI-260-CV is 200 V. The
minimum capacitance would be 400 ÷ 200 = 2 µF. For
applications involving long input lines or high inductance,
additional capacitance will be required.
The impedance of the source feeding the input of the
module directly affects both the stability and transient
response of the module. In general, the source impedance
should be lower than the input impedance of the module
by a factor of ten, from DC to 50 kHz.
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.
Input Transi nts. Don’t exceed the transient input
voltage rating of the converter. Input Attenuator Modules
or surge suppressors in combination with appropriate
filtering, should be used in offline applications or in
applications where source transients may be induced by
load changes, blown fuses, etc. For applications where the
input voltage may go below low line it is recommended
that an undervoltage lockout circuit be used to pull GATE
IN low to disable the converter module. The undervoltage
lockout circuit should induce a delay of at least one
second before restarting the converter module. Longer
delays will be required if external capacitance is added at
the output to insure the internal soft-start is re-initialized.
NOTE Do not allow the rate of change of the input
voltage to exceed 10 V/µs for any input voltage deviation.
The level of transient suppression required will depend on
the severity of the transients. A Zener diode, TRANSZORB™
or MOV will provide suppression of transients under 100 µs
and act as a voltage clipper for DC input transients. It may
be necessary to incorporate an LC filter for larger energy
transients. This LC filter will integrate the transient energy
while the Zener clips the peak voltages. The Q of this filter
should be kept low to avoid potential resonance problems.
See Section 14, Input Attenuator Module (IAM/ MI-IAM)
for additional information on transient suppression.
3. Module Do’s and Dont’s