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ug:301 vicorpower.com applications engineering: 800 927.9474 page 1 pi31xx-xx-eval1 cool-power ? zvs isolated dc-dc converter evaluation board chris swartz principal applications engineer may 2013 introduction the pi31xx-xx-eval1 evaluation board allows the user to test the basic operating principles of the pi31xx series of high density dc-dc power converters and experience the performance and value of this solution compared to alternate conventional solutions. each evaluation board is populated with the components that could be used in a fnal design. it is not designed or intended to be used in end product applications. please read this document prior to the connection of test equipment and refer to the product datasheet for device specifcations, descriptions and characteristics. remember to follow good lab safety practices and use safety glasses at all times. the pi31xx-xx-eval1 is confgured to support one single input and one single output. each board ofers pin strap options for trimming the output voltage up and down, turning the converter on and of and adding emi system y capacitors. additional parts are included to compensate for line impedance associated with long leads from the bench power supply to the converter. additional component footprints are made available to allow the user to test diferent design confgurations that may be required to meet their end needs. kelvin type test points are included to allow for easy and convenient connections of testing instruments for evaluation of efciency, line/load regulation and transient response. a low impedance oscilloscope connection using a johnson jack is included for ripple measurement and evaluation of the output voltage during transient events. each demo board is equipped with a heatsink to allow high power operation with a small amount of air fow and to allow operation of the board over various temperature extremes. contents page introduction 1 product description 2 board connections 2 thermal considerations 3 max i/o ratings 5 schematic boms 6 test setup 11 pcb artwork 12 mechanical outline 14 ordering information 14 user guide | ug:301 figure 1. pi31xx-xx-eval1 evaluation board
ug:301 vicorpower.com applications engineering: 800 927.9474 page 2 cool-power ? pi31xx series product description the pi31xx operates over a wide range input, delivering 50 w or 60 w output power depending on the individual model number. the pi31xx series is available in a space saving surface mountable 0.87 x 0.65 x 0.265 power Csystem Cin C a C package (psip), achieving ~50% space reduction versus alternative solutions. the switching frequency of 900khz allows for small input and output flter components which further reduces the total size and cost of the overall system solution. the output voltage is sensed and fed back to the internal controller using a proprietary isolated magnetic feedback scheme which allows for high bandwidth and good common mode noise immunity. the pi31xx series requires no external feedback compensation and ofers a total solution with a minimum number of external components. a rich feature set is ofered, including + 10%, -20% output voltage trim capability (depending on the model number), remote enable, over-voltage protection, adjustable sof-start, over-current protection with auto-restart to protect against both short circuit and overload and over and under input voltage lockout. a unique temperature monitor and protection circuit is included that provides an analog voltage proportional to the internal die temperature, as well as over temperature shutdown, restart and over temperature fault alarm signal. board connections 1. connect test equipment a. connect the input dc power supply to the target board as shown in figure 6. the negative terminal should be wired to Cin and the positive terminal should connect to the positive terminal of the dmm wired as a dc ammeter. be sure that the proper sized wires are used to allow minimum voltage drop for a maximum input current of up to 4 a. use ring lugs mated to the included fasteners on the evaluation board. if your input power supply has remote sense capability, it can be wired to the inn and inp test points if desired. connect the positive terminal of the dmm to the +in lug on the evaluation board. b. connect the primary side dmm (for measuring the input voltage) to inn and inp respectively. c. connect the oscilloscope as shown in figure 6 if you are planning to measure both primary and secondary signals at the same time. if you do not have an isolated diferential amplifer, it is important to note that simultaneous measurement of both primary and secondary referenced signals using an oscilloscope with a grounded chassis is not recommended, as it will short circuit the primary to secondary isolation barrier. floating the oscilloscope is also not recommended due to the large capacitance introduced by this long standing practice. the best practice is to use an isolated diferential amplifer or use an oscilloscope with isolated channels. that is, the input returns are isolated from each other and earth ground. d. connect the output dc dmm to the test points outn and outp. these test points are done in a kelvin type manner so that they have no high current fowing in them. e. connect the dc load to the output lugs out+ and out-. it is critical for this connection to be low inductance.
ug:301 vicorpower.com applications engineering: 800 927.9474 page 3 2. default pin strap confguration a. ensure the pin straps are in the following default locations before proceeding: n enable = not used (enabled) n trim_up = not used n trim_dn = not used n opt1 = not used n opt2 = not used 3. pin strap functions a. enable C adding a strap on this pin will cause the converter to shut down. b. trim_up C adding a strap in this location will adjust the output voltage up by 10%. c. trim_dn C adding a strap in this location will adjust the output voltage down by 10%. only one strap can be connected at a time. if both trim straps are out, the output voltage should be set to the models nominal output. 4. trimming and soft start a. for those customers who wish to trim to another voltage by changing the preset trim resistors to another value, the trim equation shown in figure 2 can be used: r low = ( ?v ) ? r int ( ?v out nom ) + v desire d desire d r high = ( ?rss ) ? ( ?v out nom ) ? v ero + v ? v re f v re f [ ( ?v out nom ) + v ] desire d desire d where: r1 = rlow r3 = rhigh vero = 4.9 and vref can be found in the appropriate model datasheet. figure 3 shows an equation for sof start confguration where c7 = c ref c ref = t ssdesir ed ? 230 ? 10 ?6 23000 enable trim/ss sgnd rss rhigh rlow vero vr ef pi31xx 10k ? ? ? pi31xx trimming equivalent circuit figure 2. pi31xx trim equation figure 3. pi31xx soft start equation
ug:301 vicorpower.com applications engineering: 800 927.9474 page 4 thermal considerations the pi31xx-xx-eval1 is supplied with optional heat sinks. at present, picor ofers four diferent heat sink options to accommodate the customers space and cooling needs. heatsinks are available in two sizes, one with 6.3mm fns and the other with 11mm fns. each of those heatsinks can be ordered with a specifc air fow direction in mind, both cross fow and longitudinal are supported. please refer to the product website www.vicorpower.com for more information. pin type description name in+ input/lug primary side positive input voltage terminal. in- input/lug primary side negative input voltage terminal. out+ output/lug isolated secondary dc output voltage positive terminal. out- output/lug isolated secondary dc output voltage negative terminal. tm test/pin temperature measurement output pin with respect to sgnd. 3v=300k 10mv/k sgnd test/pin signal ground, primary side referenced. trim/ss test/pin monitor pin for the soft start voltage and trim voltage reference with respect to sgnd. enable test/pin allows for monitoring of the enable signal with respect to sgnd. inn test/pin kelvin sense connection for input supply (-) and input voltage measurement test point. inp test/pin kelvin sense connection for input supply (+) and input voltage measurement test point. yn output/pad optional test pad for connection of optional yn capacitor to external system ground. yp output/pad optional test pad for connection of optional yp capacitor to external system ground. outp test/pin kelvin sense connection for output voltage (+) and output voltage measurement test point. outn test/pin kelvin sense connection for output voltage (-) and output voltage measurement test point. out test/pin pcb test jack for low noise measurement of the output voltage. name description enable if strap is installed, unit is turned off. if strap is removed, unit will be enabled. trim_up if strap is installed, pi3105 trims output voltage up 10% trim_dn if strap is installed, pi3105 trims output voltage down 10% opt1 allows optional connection of heat sink assembly to secondary return (-in) opt2 allows optional connection of heat sink assembly to secondary return (-out) table 1. pi31xx-xx-eval1 input-output pin description table 2. pi31xx-xx-eval1 evaluation board pin strap and jumper description
ug:301 vicorpower.com applications engineering: 800 927.9474 page 5 name max voltage max current in+ 100 v 20 a in- 100 v 20 a out+ 20 v 20 a out- 20 v 20 a trim_dn 10 v 100 ma opt1 10 v 100 ma opt2 10 v 100 ma out 10 v 100 ma inp 10 v 100 ma inn 10 v 100 ma enable 10 v 100 ma trim/ss 10 v 100 ma sgnd 10 v 100 ma tm 10 v 100 ma outp 20 v 100 ma outn 20 v 100 ma table 3. pi31xx-xx-eval1 evaluation board maximum i/o ratings
ug:301 vicorpower.com applications engineering: 800 927.9474 page 6 +in sgnd pi31xx enabl e ?in +out ?out in+ tm trim/ss in? f1 l1 c1 c2 c3 c4 c5 + c20c 21 trim_dn trim_up r1 r3 c6 c7 90.9 k 301 k 390 pf dnp ena r2 100 k r4 100 enable trim/ss inn tm inp sgnd yp yn outp outn c8 c9 c10 c1 1 c12 c13 c14 c15 c16 c17 c18 c19 out+ out? scope out opt1 opt2 cy1 cy3 cy4 cy2 4.7nf 4.7nf 4.7nf 4.7nf hs hs yn yp figure 5. schematic diagram
ug:301 vicorpower.com applications engineering: 800 927.9474 page 7 item qty ref design part # value u/m description 1. 1 u1 pi3101-00-hviz na ea picor pi3101-00 high density psip 2. 12 c8-c19 grm- 21br71a106ke5 10u f murata x7r ceramic capacitor 10 v or equiv. 3. 6 c1-c4, c20- c21 grm- 31cr72a105ke1 1u f murata x7r ceramic capacitor 100v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-4r7-r 4.7u h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc2a470 47u f panasonic electrolytic capacitor 100v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154003dr 3 a littlefuse fuseblock 3a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" item qty ref design part # value u/m description 1. 1 u1 pi3105-00-hviz na ea picor pi3105-00 high density psip 2. 6 c8-c19 grm- 21br71a475ke5 4.7u f murata x7r ceramic capacitor 16v or equiv. 3. 6 c1-c4, c20- c21 grm- 31cr72a105ke1 1u f murata x7r ceramic capacitor 100v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-r47-r 470n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc2a470 47u f panasonic electrolytic capacitor 100v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154003dr 3 a littlefuse fuseblock 3a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 4. pi3101-00-eval1 evaluation board bom table 5. pi3105-00-eval1 evaluation board bom
ug:301 vicorpower.com applications engineering: 800 927.9474 page 8 item qty ref design part # value u/m description 1. 1 u1 pi3106-00-hvmz na ea picor pi3106-00 high density psip 2. 6 c8-c19 grm21br71e- 225ka73l 2.2u f murata x7r ceramic capacitor 25v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-r47-r 470n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc1j101l 100u f panasonic electrolytic capacitor 63v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154008dr 8 a littlefuse fuseblock 8a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" item qty ref design part # value u/m description 1. 1 u1 pi3106-01-hviz na ea picor pi3106-01 high density psip 2. 6 c8-c19 grm21br71e- 225ka73l 2.2u f murata x7r ceramic capacitor 25v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-r47-r 470n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc1j101l 100u f panasonic electrolytic capacitor 63v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154008dr 8 a littlefuse fuseblock 8a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 6. pi3106-00-eval1 evaluation board bom table 7. pi3106-01-eval1 evaluation board bom
ug:301 vicorpower.com applications engineering: 800 927.9474 page 9 item qty ref design part # value u/m description 1. 1 u1 pi3109-01-hviz na ea picor pi3109-01 high density psip 2. 6 c8-c19 grm21br71a- 106ke5 2.2u f murata x7r ceramic capacitor 25v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-r47-r 470n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc1j101l 100u f panasonic electrolytic capacitor 63v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154008dr 8 a littlefuse fuseblock 8a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 8. pi3109-00-eval1 evaluation board bom item qty ref design part # value u/m description 1. 1 u1 pi3109-00-hvmz na ea picor pi3109-00 high density psip 2. 6 c8-c19 grm21br71a- 106ke5 10u f murata x7r ceramic capacitor 10v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-r47-r 470n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc1j101l 100u f panasonic electrolytic capacitor 63v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154008dr 8 a littlefuse fuseblock 8a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 9. pi3109-01-eval1 evaluation board bom
ug:301 vicorpower.com applications engineering: 800 927.9474 page 10 item qty ref design part # value u/m description 1. 1 u1 pi3110-01-hviz na ea picor pi3110-01 high density psip 2. 6 c8-c19 grm21br71e- 225ka73l 2.2u f murata x7r ceramic capacitor 25v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv.. 5. 1 l1 fp3-4r7-r 4.7n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc2a470 47u f panasonic electrolytic capacitor 100v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154003dr 3 a littlefuse fuseblock 3a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 10. pi3110-01-eval1 evaluation board bom item qty ref design part # value u/m description 1. 1 u1 pi3111-00-hvmz na ea picor pi3111-00 high density psip 2. 6 c8-c19 grm21br71e- 225ka73l 2.2u f murata x7r ceramic capacitor 25v or equiv. 3. 6 c1-c4, c20- c21 grm31cr71h- 475ka12k 4.7u f murata x7r ceramic capacitor 50v or equiv. 4. 4 cy1-cy4 grm- 31br73a472k 4700p f murata x7r ceramic capacitor 1kv or equiv. 5. 1 l1 fp3-4r7-r 4.7n h coilcraft inductor 6. 1 c6 08055c391k- at2a 390p f kemet x7r ceramic capacitor 50v 0805 7. 1 c5 eeu-fc1j101l 100u f panasonic electrolytic capacitor 63v 8. 1 r1 mcr10ezpf9092 90.9k ohm rohm resistor 0805 1% or equiv 9. 1 r3 mcr10ezpf3013 301k ohm rohm resistor 0805 1% or equiv 10. 1 r2 MCR10EZPF1003 100k ohm rohm resistor 0805 1% or equiv 11. 1 r4 mcr10ezpf1000 100 ohm rohm resistor 0805 1% or equiv 12. 1 f1 0154003dr 3 a littlefuse fuseblock 3a smt 13. 8 5015kct-nd n/a n/a digi-key smt pc test point 14. 1 out 131503100 n/a n/a tektronix test jack assembly 15. 6 enable, trim up, trim_dn tsw-148-07-f-s n/a n/a j,header 0.1" table 11. pi3111-00-eval1 evaluation board bom
ug:301 vicorpower.com applications engineering: 800 927.9474 page 11 + dc ammeter 0-5a ps1 0-100v dc 5a + - + - dmm dc elect. load 0-30 a min + - dmm oscilloscope dc-20mhz bw + in - in ch1 ch2 - isolated diff. amplifier + - figure 6. pi31xx-xx-eval1 test setup item qty part # u/m description 1. 1 pi31xx-xx-eval1 ea evaluation pcb assembly 2. 1 32786 ea 6.3mm heatsink assembly 3. 1 32784 ea 11mm heatsink assembly 4. 1 33855 ea heatsink grounding clip 5. 4 32434 ea heatsink pushpins 6. 4 n/a ea screw, 6-32 7. 4 n/a ea nut, 6-32 table 12. pi31xx-xx-eval1 packing list
ug:301 vicorpower.com applications engineering: 800 927.9474 page 12 t op layer midlayer 1 midlayer 2 figure 7. top layer artwork 3 oz copper figure 8. midlayer 1 artwork 2 oz copper figure 9. midlayer 2 artwork 2 oz. copper
ug:301 vicorpower.com applications engineering: 800 927.9474 page 13 midlayer 3 figure 10. midlayer 3 artwork 2 oz. copper midlayer 4 figure 11. midlayer 4 artwork 2 oz. copper bottom layer figure 12. bottom layer artwork 3 oz. copper
rev 1.0 6/13 vicorpower.com applications engineering: 800 927.9474 page 14 cool-power ? series evaluation board high density isolated dc-dc converter out+ out out? in? in+ enable trim_dn trim_up f1 l1 c21 c5 c1 c2 c3 c4 c22 c16 c17 c18 c19 c12 c13 c14 c15 c8 c9 c10 c1 1 enable trim/ss sgnd tm inp cy1 cy2 outp yp inn cy3 cy4 outn yn opt1 opt2 c7 r1 r4 r3 r2 c6 pi31 - ev al1 0.250? 0.150? 1.55? 0.750? 0.150? 0.335? 0.335? 3.100? 2.430? 0.250? 3.100? 2.600? 0.750? figure 13. mechanical drawing ordering information the pi31xx customer evaluation boards are specifed by adding the sufx -eval1 to the base pi31xx-xx model number. go to http://www.vicorpower.com/cms/home/company/contact-us for ordering information.

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