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NEPTUNE Converter

NEPTUNE Converter. John Michael Morookian Vatche Vorperian. Converter Packaging Concept. 13” ID. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4. 1.4x1.4.

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NEPTUNE Converter

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  1. NEPTUNE Converter John Michael Morookian Vatche Vorperian

  2. Converter Packaging Concept 13” ID 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 1.4x1.4 Input connecting plane Power stage boards Output connecting plane

  3. Overall PCB Connection Schematics Input Connecting Plane (w/ startup circuit) 2-Stage PCB Output Connecting Plane (w/ gate drive control circuit) sea 400V 6-Stage PCB 8-Stage PCB 8-Stage PCB 8-Stage PCB 8-Stage PCB 6-Stage PCB 400V return -10kV 2-Stage PCB

  4. 2-Stage Power Board Layout C1A R1A C3A C2A C4A C5A L1A L2A Q1A R2A R3A Q2A R3B R2B C1B L1B L2B R1B C2B C4B C5B R4A TX1A TX3A TX3B L3A Q3A Q4A C6A TX2A TX2B L3B Q1B Q2B TOP INNER BOTTOM

  5. Power Stage Schematic

  6. Power Stage w/Sense Schematic

  7. 2-Stage Power Board Root Schematic

  8. 6-Stage Power Board Root Schematic

  9. 8-Stage Power Board Root Schematic

  10. 8-Stage Power Board BOM Bill Of Materials September 2,2003 18:41:02 Page1 Item Quantity Reference Part ______________________________________________ 1 8 C1h,C1g,C1f,C1e,C1d,C1c, 0.01uF RAD/.800X.325/LS.600/.034 P3476-ND C1b,C1a 2 8 C2h,C2g,C2f,C2e,C2d,C2c, 1uF AX/1.500X0.600/.050 VW2G105K C2b,C2a 3 8 C3h,C3g,C3f,C3e,C3d,C3c, 2uF AX/1.500X0.800/.050 VW2G205K C3b,C3a 4 16 C4h,C4g,C4f,C4e,C4d,C4c, 10uF AX/2.500X1.100/.050 VW2G106K C4b,C4a,C5h,C5g,C5f,C5e, C5d,C5c,C5b,C5a 5 8 C6h,C6g,C6f,C6e,C6d,C6c, 1nF AX/.675X.225/.034 C6b,C6a 6 56 C7h,C7g,C7f,C7e,C7d,C7c, 1uF SM/C_1812 PCC2248CT-ND C7b,C7a,C8h,C8g,C8f,C8e, C8d,C8c,C8b,C8a,C9h,C9g, C9f,C9e,C9d,C9c,C9b,C9a, C10h,C10g,C10f,C10e,C10d, C10c,C10b,C10a,C11h,C11g, C11f,C11e,C11d,C11c,C11b, C11a,C12h,C12g,C12f,C12e, C12d,C12c,C12b,C12a,C13h, C13g,C13f,C13e,C13d,C13c, C13b,C13a 7 8 C14h,C14g,C14f,C14e,C14d, 0.1uF SM/C_1210 399-1268-1-ND C14c,C14b,C14a 8 1 C15a 6800pF SM/C_0603 9 32 D1h,D1g,D1f,D1e,D1d,D1c, 1N6621U SM/A_MELF D1b,D1a,D2h,D2g,D2f,D2e, D2d,D2c,D2b,D2a,D3h,D3g, D3f,D3e,D3d,D3c,D3b,D3a, D4h,D4g,D4f,D4e,D4d,D4c, D4b,D4a

  11. 8-Stage Power Board BOM Bill Of Materials September 2,2003 18:41:02 Page1 Item Quantity Reference Part ______________________________________________ 10 2 D6a,D5a 1N6328 SM/B_MELF 11 2 D8a,D7a 1N5804 SM/A_MELF 12 17 JP1Qh,JP1Qg,JP1Qf,JP1Qe, connector JUMPER100 JP1Qd,JP1Qc,JP1Qb,JP1Qa, JP2Qh,JP2Qg,JP2Qf,JP2Qe, JP2Qd,JP2Qc,JP2Qb,JP2Qa, JP5 13 9 JP1,JP2,J5,J6,J7,J8,J9, CON1 TP J10,J11 14 40 J1h,J1g,J1f,J1e,J1d,J1c, JUMPER JUMPER100 J1b,J1a,J2h,J2g,J2f,J2e, J2d,J2c,J2b,J2a,J3h,J3g, J3f,J3e,J3d,J3c,J3b,J3a, J4h,J4g,J4f,J4e,J4d,J4c, J4b,J4a,J5h,J5g,J5f,J5e, J5d,J5c,J5b,J5a 15 16 L1h,L1g,L1f,L1e,L1d,L1c, 622uH CYL/D1.700/LS1.350/.040/2P L1b,L1a,L2h,L2g,L2f,L2e, L2d,L2c,L2b,L2a 16 16 TX2h,TX2g,TX2f,TX2e,TX2d, XFRM_LINEAR CYL/D1.700/LS1.350/.040 TX2c,TX2b,TX2a,L3h,L3g, L3f,L3e,L3d,L3c,L3b,L3a 17 32 Q1h,Q1g,Q1f,Q1e,Q1d,Q1c, IRFPS43N50K TO247AC Q1b,Q1a,Q2h,Q2g,Q2f,Q2e, Q2d,Q2c,Q2b,Q2a,Q3h,Q3g, Q3f,Q3e,Q3d,Q3c,Q3b,Q3a, Q4h,Q4g,Q4f,Q4e,Q4d,Q4c, Q4b,Q4a

  12. 8-Stage Power Board BOM Bill Of Materials September 2,2003 18:41:02 Page1 Item Quantity Reference Part ______________________________________________ 18 32 Q5h,Q5g,Q5f,Q5e,Q5d,Q5c, PMBT2222A SM/SOT23_BEC Q5b,Q5a,Q7h,Q7g,Q7f,Q7e, Q7d,Q7c,Q7b,Q7a,Q9h,Q9g, Q9f,Q9e,Q9d,Q9c,Q9b,Q9a, Q11h,Q11g,Q11f,Q11e,Q11d, Q11c,Q11b,Q11a 19 32 Q6h,Q6g,Q6f,Q6e,Q6d,Q6c, PMBT2907A SM/SOT23_BEC Q6b,Q6a,Q8h,Q8g,Q8f,Q8e, Q8d,Q8c,Q8b,Q8a,Q10h, Q10g,Q10f,Q10e,Q10d,Q10c, Q10b,Q10a,Q12h,Q12g,Q12f, Q12e,Q12d,Q12c,Q12b,Q12a 20 8 R1h,R1g,R1f,R1e,R1d,R1c, 2Meg AX/.450X.100/.031 R1b,R1a 21 16 R2h,R2g,R2f,R2e,R2d,R2c, 24 AX/1.000X.225/.034 R2b,R2a,R3h,R3g,R3f,R3e, R3d,R3c,R3b,R3a 22 8 R4h,R4g,R4f,R4e,R4d,R4c, 75 AX/.300X1.000/.028 TA310PA75R0J R4b,R4a 23 9 R5h,R5g,R5f,R5e,R5d,R5c, 10 SM/C_1210 P10.0AACT-ND R5b,R5a,R14a

  13. 8-Stage Power Board BOM Bill Of Materials September 2,2003 18:41:02 Page1 Item Quantity Reference Part ______________________________________________ 24 64 R6h,R6g,R6f,R6e,R6d,R6c, 1k SM/C_1210 P1.00KAACT-ND R6b,R6a,R7h,R7g,R7f,R7e, R7d,R7c,R7b,R7a,R8h,R8g, R8f,R8e,R8d,R8c,R8b,R8a, R9h,R9g,R9f,R9e,R9d,R9c, R9b,R9a,R10h,R10g,R10f, R10e,R10d,R10c,R10b,R10a, R11h,R11g,R11f,R11e,R11d, R11c,R11b,R11a,R12h,R12g, R12f,R12e,R12d,R12c,R12b, R12a,R13h,R13g,R13f,R13e, R13d,R13c,R13b,R13a 25 1 TX1a XFRM_LINEAR TRANS\CURRENT\1300\200 26 8 TX3h,TX3g,TX3f,TX3e,TX3d, TX_GATE_TRIGGER TRANS\140\700\10P TX3c,TX3b,TX3a 27 8 U1h,U1g,U1f,U1e,U1d,U1c, TC4420 SOG.050/8/WG.275/L.250 U1b,U1a

  14. 8-Stage Power Board Parts List

  15. Input Inductor design Pin diameter 59 mils MAX NOTE: Pins 3 & 4 are not electrically Connected, but are for mechanical Stability. 1 2 TOP VIEW On dia. 1.35” 1 2 Pin diameter 25 mils MAX 4 3 30 deg (4) PLS TOP 1.70 MAX 1.2 MAX INPUT INDUCTOR BOTTOM

  16. Output Inductor design Pin diameter 59 mils MAX 1 2 TOP VIEW 2 1 On dia. 1.35” 3 4 Pin diameter 25 mils MAX 4 3 30 deg (4) PLS TOP 1.70 MAX 1.2 MAX OUTPUT INDUCTOR BOTTOM

  17. Power Transformer design Pins 3 & 4 (front) Dummy Pin diameter 59 mils MAX TOP VIEW 2 1 On dia. 1.35” 3 4 Dummy Pin diameter 25 mils MAX 30 deg (4) PLS Pins 1 & 2 (rear) TOP 1.70 MAX 3 (front) 1 (rear) 1.2 MAX 4 (front) 2 (rear) POWER TRANSFORMER BOTTOM

  18. Input Inductor design TOP Pin diameter 35 mils MAX TOP VIEW 5 1 5 1 DUMMY PINS 6 2 7 .700 .850 8 3 9 4 10 6 2 0.075 .700 7 3 0.075 .850 8 4 9 10 PULSE TRANSFORMER

  19. Status • Converter Power Stage Boards • Schematics Nearly Complete for 2,6,8 Stage Boards • 2-Stage Power Board PCB Layout 90% complete • Parts List with Price/Delivery 70% complete • Preliminary Magnetics Mechanical Drawings Generated, RFQ sent to Coast Magnetics • Input connecting plane • Start-Up Circuit • Schematics need some modification • Not Yet Built • Not Needed for 16-Stage Converter Testing • Output connecting plane • Control Circuit Schematics Ready for Inclusion

  20. Remaining design issues • Method of interconnecting the inputs of the 48 power stages on the input connecting board. • Defining the connector to the –10kV input line. • Method of changing over to the back up converter. • Defining the output connector to the output bus. • Modify the start-up circuit to operate from –10kV. • Limit input inrush current when the relay is closed. • Define which side of the 400V output will be referenced to sea ground potential (Case). (Most likely the negative side.) Define this connector. • Define internal –10kV harness to the back up converter.

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