April 20, 2008
` Overview
◦ Power needs to manage the power supply
to the entire system, ensuring appropriate
i
inputt voltage
lt ranges and
d minimum
i i iinputt
loads are delivered from HASP’s power
bus In the process eliminating noise and
bus.
ensuring the safety of the power bus and
system
y is essential.
` Trade study of step-down converters
◦ Linear regulators
Create too much heat,, complicate
p g
thermal management
Inefficient power conversion
Obviously, cannot provide negative outputs necessary for PMT
◦ Buck-boost and Buck Converters
Allows for negative voltages to be supplied
Have necessary efficiencies
Create noise at switching
g frequencies
q and resonant frequencies
q
◦ Flyback converters
Allow for negative and positive voltages to be supplied
simultaneously, which is necessary for the PMT
Have necessary efficiencies
Galvanic Isolation provides current separation between power
bus and system, which provides some degree of safety.
Creates noise at switching
h frequencies
f and
d resonant frequencies
f
` Flyback Converter Trade-offs
Key considerations when picking a converter were thermal
characteristics, EMI characteristics, efficiency, and ripple noise
C&D Technologies’ WP06R series operated at the highest and
lowest temperatures,
temperatures demonstrating superior thermal
characteristics, which is important as thermal problems were
the hardest to manage
The WP06R series also delivered the best EMI characteristics,,
being packaged in a metal case that provided shielding
The WP06R series demonstrated average efficiency, but power
constraints were not severe, and efficiency was more of a
th
thermal l concern than
th a power budget
b d t concern
The WP06R exhibited average ripple voltages, but additional
filtering options makes this less of a priority
This series has the most options within the same physical
package
` General
◦ Diode protected interface with power bus
y
◦ DB9 interface with all other subsystems
◦ A polyfuse on the input from the power bus will serve as
redundant surge protection
` Payload
y
◦ PMTs
Input voltage range ±11.5V to ±15.5V
Maximum inputp current 40mA (p (per PMT))
Noise into this device should remain minimal
◦ Payload and House Keeping Electronics
Needs +5V input and ±15V
Voltage and current monitors and controls needed to shut off
equipment if too much power is drawn
` Mechanical
◦ Conform
C f to board
b d interface
f agreements
Board size: 5.312 x 3.898 inches
No thru-hole parts 0.250 inches from the long edges
Connectors
C on onlyl one off the
h shorter
h width
id h sides
id off the
h board
b d
70mil thru holes on board for EMI shield mounting
` C&DH
◦ +5V input required
◦ Current, voltage, and wattage?
` Thermal
◦ Patch heaters
Wattage drawn? Voltage
Environmental?
` CD&H & Thermal
◦ Operate
O between
b -40°C
0°C and
d 100°C
00°C
◦ Max current 1A, min current 100mA
` Payload
◦ PMT
±15V input, max current ± 200mA, min current ± 20mA
◦ Payload and House Keeping Electronics
For ±15V input, max current ± 200mA, min current ± 20mA
For +5V input, max current 1A, min current 100mA
` Mechanical
◦ 62 mill board thickness
◦ One board for each of the two converters
◦ Space for two DB9 connectors per board
◦ EMI shielding structure over both boards
Requirements set by factory specifications
` Efficiency
◦ 79-80%
` Unfiltered Ripple voltage
◦ 50mV max
yp
◦ 30mV typical
` Filtered Ripple voltage
` Filter
◦ SSPL has
h had
h d problems
bl in
i the
th pastt with
ith noise
i ini powers lines
li
generated at or above the switching frequency
A parallel damped filter will be cascaded three times, giving a
60dB roll-off
roll off per decade
` Filter
◦ The
h filter
fl needs
d to eliminated
l d the
h noise created
d by
b theh dumping
d off
charge at the switching frequency of the converter (200kHz) and
the resulting higher frequency resonance
◦ The filter was designed to achieve 3dB at 20kHz
20kHz, and thus filter
out 200kHz
` EMI shielding
◦ It is important to shield
h ld the
h converter andd filter
fl to protect the
h
design from EMI and shield other components from the board’s
EMI
This is achieved by making a top layer of copper surround the
components, and connecting it to the bottom plane and the
shielding box and designating this as one large ground net
Yellow is the
Top plane Red is the
Bottom plane
Shield mounts
In g
green holes
+5V Patch
Filter DC-DC Filter
Heaters
HASP
Power Bus C&DH
± 15V
Filter DC DC
DC-DC Filter PMT
` Thermal Analysis Procedure
◦ Temperature Range: -40 C to 40
40°C 40°CC
◦ Number of Cycles: 3
◦ Duration of Peak Temperatures: 30 minutes
◦ Voltage Supplied to PCBs: 5 volts
◦ Pump Down Pressure: 150 mTorr
◦ Thermistor Sampling Rate: 5 seconds
` Additional Information
◦ One board at a time will be tested.
◦ Thermistors will be mounted to the board to monitor temperature.
◦ An Agilent Data Acquisition Unit and a Matlab program will be
used to sample the resistance of the thermistors.
