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Vicor Test Board

HARDWARE DOCUMENTATION
BEINDER, AUSTIN J

Intended for Rev 1 TBD Austin Beinder

P15
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Revision History
Rev # Description Hardware Manager Approved By
Need 2/3 for approval:
eteam director or
assistant director,
eteam manager, or
alumni
Rev 1 Initial Release Austin Beinder N/A
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Contents
Theory of Operation..................................................................................................................................3
Description.............................................................................................................................................3
Board Placement....................................................................................................................................3
Purpose...................................................................................................................................................3
Application.................................................................................................................................................4
System Level..........................................................................................................................................4
Block Diagram...................................................................................................................................4
Pin Diagram.......................................................................................................................................4
Board Level............................................................................................................................................5
Schematic...........................................................................................................................................5
PCB Picture........................................................................................................................................5
Proof of Operation.....................................................................................................................................6
Test Procedure.......................................................................................................................................6
Test Results............................................................................................................................................6
Troubleshooting.....................................................................................................................................6
Appendix....................................................................................................................................................7
Reference................................................................................................................................................7
BOM List..............................................................................................................................................10
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Theory of Operation
Description
The Vicor test board is available as a testing device for the logical operation of both types of
Vicors present on p15 Powerboard. Either Vicor can be plugged into the board and a switch can
be triggered. The board will signal if the Vicor is operating correctly by allowing an LED to light
up when the switch is triggered one way and turning it off when the switch is triggered the other
way. This LED will flash on and off is a fault is detected in the Vicor.

Board Placement
This board will not be a permanent fixture of the car. When in use however it will be plugged
into a 150V terminal that would normally plug into Powerboard within the battery box.

Purpose
The Vicor test board has one purpose. To determine if the Vicors that we place onto the
Powerboard are logically intact before we place them on Powerboard. It does this by testing one
Vicor at a time. DO NOT PLUG TWO VICORS IN AT A TIME.
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Application
System Level
Block Diagram

Figure 1: System-Level Block Diagram

Pin Diagram
The Vicor test bench has one connector that is a 2 pin right angle connector.

Table 1: Pin diagram

Connector Connector Type Signal Pin # Description of
Designator Name Signal
J1 2-Pin “Micro-Fit Jr.” Main Pack Pin 1: Main Pack Positive The input from the
Right Angle In Pin 2: Main Pack Negative main battery pack.
(PGND)
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Board Level
Signal Descriptions
The following input and output signals exist on Powerboard:

Main Pack In
The “Main Pack In” signal is a 150V power signal which comes from the main battery
pack. The line enters the board through J3. The “Main Pack In” signal is expected to be
able to handle up to 1A.

Output Load
The “Output Load” signal is a 12V power signal which comes from the Vicor. The line
handles 3A and up to 3.5A.

LED Out
The “LED Out” signal powers the LED from the 5.75V at the PC terminal of the Vicor at
about 42 mA or less.
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Schematic
The Vicor Test Bench has only one schematic that goes through the entire operation of
the board.

A discussion of the schematic follows.

Figure 2: Vicor Test Bench.SchDoc

Vicor Test Bench.schdoc has one input port (J1) from the main battery pack and the only outputs
are the LED on the board as well as the 3.9 Ohm Power Resistor carrying a 3A load. Along the board
there is a filter circuit both before and after the Vicors. There exists both a diode and capacitor in this
filter to both stabilize voltage and prevent over-voltage.
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PCB Picture

Figure 3: Vicor_Test_Bench.PCBDOC

Though the LED is on the right side of the schematic, it is on the left side of the board.

Proof of Operation
Test Procedure
To begin, ensure that the Vicors are disconnected from the board. The following procedures will
test that the switching regulator (U4) and the switching logic are working correctly without a
load.
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1. Provide 150 V to the J1 connector and press the switch. Only one Vicor should be connected
at a time. Follow instructions on the board saying “If the Vicor is logically intact the light
should be on when the switch is triggered. It should be off if triggered the other way. If
there is a fault in the Vicor it will flash”.
2. Measure the voltage across the R1 resistor to ensure it is the voltage that the Vicor is rated
for.
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Appendix
Reference
150 V Vicor

http://cdn.vicorpower.com/documents/datasheets/ds_150vin-mini-family.pdf

110 V Vicor

http://cdn.vicorpower.com/documents/datasheets/ds_110vin-micro-family.pdf
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BOM List