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REV.: 0/2019 P-1

R-REF04-RIA12

Reference Design

Features

Reference

Design

• Evaluation platform for railway DC/DC converters up to 240W

with either high voltage (-1) or high current (-2) layouts

• Includes RIA12 surge stopper with reverse polarity protection

• On-board EN50121-3-2 EMC ﬁ lter layout

• Suitable for 2”x1”, quarter brick or half brick converters

• External hold-up capacitor

• Cage clamp terminals, isolated enable and fan connectors

Description

The R-REF04-RIA12-1 and R-REF04-RIA12-2 are complete reference designs for railway applications.

R-REF04-RIA12-1 is populated with components rated for higher DC input voltages up to 110VDC

nominal input; the R-REF04-RIA12-2 is populated with components rated for higher DC input currents

up to 10A. Both boards are input side fused and can be used with DC/DC converters with single output

currents up to 45A. The reference designs include a RIA12-conform surge stopper capable of blocking

surge voltages up to 385VDC.

The reference design has a universal pinout to accommodate DC/DC converters with 2”x1”,

Quarter Brick or Half Brick standard case dimensions (sold separately).

The following converters are suitable:

Caution:

ESD sensitive. Always follow ESD preventative procedures when

handling the product!

Selection Guide

Part Input Input Output

Number Voltage Range Current max. Current max.

[VDC] [A] [A]

R-REF04-RIA12-1 40 - 160 3.8 45

R-REF04-RIA12-2 12 - 75 10 45

Converter nom. Input Voltage Output Voltage Case Recommended

Series [VDC] [VDC] Dimension Reference Design

RP40-FR 24 3.3, 5, 12, 15, 24 2” x 1” R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RPA60-FW 24 5, 12, 15, 24 2” x 1” R-REF04-RIA-2

RP75H-RW 24 3.3, 5, 12, 15, 24 Half Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RP40Q-RUW 16 - 160 5, 12, 15, 24, 48 Quarter Brick R-REF04-RIA-1

RP60Q-RUW 16 - 160 5, 12, 15, 24, 48 Quarter Brick R-REF04-RIA-1

RP90Q-RW 24 5, 12, 15, 24, 48 Quarter Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RP100H-RW 24 5, 12, 15, 24, 48 Half Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RP120Q-RW 24 5, 12, 15, 24, 48 Quarter Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RP180H-RW 24 5, 12, 15, 24, 48 Half Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

RP240H-RW 24 5, 12, 15, 24, 48 Half Brick R-REF04-RIA-2

48, 110 R-REF04-RIA-1

Summary of content (12 pages)

PAGE 1
Features Reference Design • Evaluation platform for railway DC/DC converters up to 240W with either high voltage (-1) or high current (-2) layouts • Includes RIA12 surge stopper with reverse polarity protection • On-board EN50121-3-2 EMC filter layout • Suitable for 2”x1”, quarter brick or half brick converters • External hold-up capacitor • Cage clamp terminals, isolated enable and fan connectors Reference Design R-REF04-RIA12 Selection Guide Part Number Input Voltage Range [VDC] 40 - 160 12 - 75 R-R
PAGE 2
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Quick Start Guide 1. Fit the appropriate DC/DC converter (mounting holes are provided for fixing screws) on to the board. Carefully solder the pins, checking that the solder connections are clean and there are no dry joints 2. If required, mount a suitable cooling fan (supply voltage = DC/DC output voltage) and connect to the fan supply connector, CON6 3.
PAGE 3
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Schematic CON7 FB7 GND 3 C4 2 C11 CASE FB11 C14 2 3 C15 1 GATE OUT 8 7 FB 6 BASE 5 V SS 4 TIMER V DD +VIN +VOUT 9 2 CTRL +SENSE 8 TRIM 7 3 CASE -SENSE 6 4 -VIN C7 -VOUT C10 5 +VOU T 9 Gate In +SENSE 8 T RIM 7 Gate Out -SENSE 6 -VOUT 5 -VIN R3 U1 SD 1 FB4 D2 R7 CTRL 1 -IN GND R5 4 L4 3 C MC1 4 L5 3 2 1 CMC3 2 1 IN -IN V IN 1 C
PAGE 4
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Background to RIA12 Requirements The R-REF04-RIA12 reference designs include a RIA12-conform surge stopper circuit. RIA12 is a legacy railway standard that precedes the current EN50155 standard, but is still relevant for older rail installations. The maximum surge voltage according to RIA12 is 3.5x the nominal input voltage, much higher than the EN50155 limit of 1.
PAGE 5
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Surge Stopper Function CON7 CON4 The converters are protected from high surge voltages with a clamp circuit based on LTC4366 surge stopper IC.
PAGE 6
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Component Placement 185mm L4 FH1 Bridge Surge Stopper CON7 L1 C2 L2 C3 C4 C8 C1 FB7 D2 D3 C14 R12 FB1 C11 C9 + Hold-up - HTSK1 CON4 D1 +Vin Q1 R3 FB11 FB10 FB4 M3 M4 M2 M1 R7 R9 P1 R6 R10 120mm FB2 FB3 C15 U1 R8 -Vin FB8 C16 R5 R4 CON1 CON5 GND L5 EN CON3 FB5 L3 U2 -Vout FB6 R14 FB9 C7 C5 R2 R1 C10 CON6 C6 +Vout Connector Description
PAGE 7
1 CO OLINGFA N CON6 1 2 Reference Design P1 R-REF04-RIA12 +VOUT R10 R1 2 -VOUT Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) GND GND Enable Schematic ENABLE FB5 CON5 2 1 M1 R13 R14 L3 1 U2 4 1 2 3 2 4 CTRL 3 -VIN M M M M FB6 Description CON5 is used to enable or disable the device. Which control logic is used, depends on converter chosen: Positive logic: Converter is preset to be enabled (ON). A voltage on CON5 disables the converter.
PAGE 8
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) BOM: R-REF04-RIA12-1 Comp.
PAGE 9
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Comp. Description Manufacturer Manufacturer Part Number Remarks U2 OPTO_VOS617A-3X001T VISHAY VOS617A-3X001T C1 CAEMR-68U400V-16x26.5 NICHICON UCY2G680MHD9TN C2 CAEMR-150U200V-16x26.5 NICHICON UCS2D151MHD C3 CAEMR-150U200V-16x26.5 NICHICON UCS2D151MHD C4 CAEMR-150U200V-16x26.
PAGE 10
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Comp.
PAGE 11
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Comp.
PAGE 12
R-REF04-RIA12 Reference Design Specifications (measured @ Ta= 25°C, full load after warm up unless otherwise stated) Contents • R-REF04-RIA12 Reference Design • Terms and Conditions The product information and specifications may be subject to changes even without prior written notice.The product has been designed for various applications; its suitability lies in the responsibility of each customer.