NEPTUNE Converter John Michael Morookian Vatche Vorperian

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

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

2-Stage Power Board Layout C4AC5A R2A R3A C1A R1A C4BC5B R2B R3B C1B R1B L1A C2A L2A C3A Q1A Q2A L1B C2B L2B TX2A TX1A Q3A Q4A C6A R4A Q1B Q2B TX2B L3A L3B TX3ATX3B TOP BOTTOM INNER

Power Stage Schematic

Power Stage w/Sense Schematic

2-Stage Power Board Root Schematic

6-Stage Power Board Root Schematic

8-Stage Power Board Root Schematic

8-Stage Power Board BOM Bill Of Materials September 2, :41:02Page1 ItemQuantityReferencePart ______________________________________________ 18C1h,C1g,C1f,C1e,C1d,C1c,0.01uFRAD/.800X.325/LS.600/.034P3476-ND C1b,C1a 28C2h,C2g,C2f,C2e,C2d,C2c,1uFAX/1.500X0.600/.050VW2G105K C2b,C2a 38C3h,C3g,C3f,C3e,C3d,C3c,2uFAX/1.500X0.800/.050VW2G205K C3b,C3a 416C4h,C4g,C4f,C4e,C4d,C4c,10uFAX/2.500X1.100/.050VW2G106K C4b,C4a,C5h,C5g,C5f,C5e, C5d,C5c,C5b,C5a 58C6h,C6g,C6f,C6e,C6d,C6c,1nFAX/.675X.225/.034 C6b,C6a 656C7h,C7g,C7f,C7e,C7d,C7c,1uFSM/C_1812PCC2248CT-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 78C14h,C14g,C14f,C14e,C14d,0.1uFSM/C_ ND C14c,C14b,C14a 81C15a6800pFSM/C_ D1h,D1g,D1f,D1e,D1d,D1c,1N6621USM/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

8-Stage Power Board BOM Bill Of Materials September 2, :41:02Page1 ItemQuantityReferencePart ______________________________________________ 102D6a,D5a1N6328SM/B_MELF 112D8a,D7a1N5804SM/A_MELF 1217JP1Qh,JP1Qg,JP1Qf,JP1Qe,connectorJUMPER100 JP1Qd,JP1Qc,JP1Qb,JP1Qa, JP2Qh,JP2Qg,JP2Qf,JP2Qe, JP2Qd,JP2Qc,JP2Qb,JP2Qa, JP5 139JP1,JP2,J5,J6,J7,J8,J9,CON1TP J10,J J1h,J1g,J1f,J1e,J1d,J1c,JUMPERJUMPER100 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 1516L1h,L1g,L1f,L1e,L1d,L1c,622uHCYL/D1.700/LS1.350/.040/2P L1b,L1a,L2h,L2g,L2f,L2e, L2d,L2c,L2b,L2a 1616TX2h,TX2g,TX2f,TX2e,TX2d,XFRM_LINEARCYL/D1.700/LS1.350/.040 TX2c,TX2b,TX2a,L3h,L3g, L3f,L3e,L3d,L3c,L3b,L3a 1732Q1h,Q1g,Q1f,Q1e,Q1d,Q1c,IRFPS43N50KTO247AC 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

8-Stage Power Board BOM Bill Of Materials September 2, :41:02Page1 ItemQuantityReferencePart ______________________________________________ 1832Q5h,Q5g,Q5f,Q5e,Q5d,Q5c,PMBT2222ASM/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 1932Q6h,Q6g,Q6f,Q6e,Q6d,Q6c,PMBT2907ASM/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 208R1h,R1g,R1f,R1e,R1d,R1c,2MegAX/.450X.100/.031 R1b,R1a 2116R2h,R2g,R2f,R2e,R2d,R2c,24AX/1.000X.225/.034 R2b,R2a,R3h,R3g,R3f,R3e, R3d,R3c,R3b,R3a 228R4h,R4g,R4f,R4e,R4d,R4c,75AX/.300X1.000/.028TA310PA75R0J R4b,R4a 239R5h,R5g,R5f,R5e,R5d,R5c,10SM/C_1210P10.0AACT-ND R5b,R5a,R14a

8-Stage Power Board BOM Bill Of Materials September 2, :41:02Page1 ItemQuantityReferencePart ______________________________________________ 2464R6h,R6g,R6f,R6e,R6d,R6c,1kSM/C_1210P1.00KAACT-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 251TX1aXFRM_LINEARTRANS\CURRENT\1300\ TX3h,TX3g,TX3f,TX3e,TX3d,TX_GATE_TRIGGERTRANS\140\700\10P TX3c,TX3b,TX3a 278U1h,U1g,U1f,U1e,U1d,U1c,TC4420SOG.050/8/WG.275/L.250 U1b,U1a

8-Stage Power Board Parts List

Input Inductor design INPUT INDUCTOR Pin diameter 59 mils MAX TOP VIEW 30 deg (4) PLS On dia. 1.35” Pin diameter 25 mils MAX 1.70 MAX 1.2 MAX BOTTOM TOP NOTE: Pins 3 & 4 are not electrically Connected, but are for mechanical Stability. 12

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

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

Input Inductor design PULSE TRANSFORMER DUMMY PINS TOP VIEW TOP Pin diameter 35 mils MAX

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

Remaining design issues Method of interconnecting the inputs of the 48 power stages on the input connecting board. Method of interconnecting the inputs of the 48 power stages on the input connecting board. Defining the connector to the –10kV input line. Defining the connector to the –10kV input line. Method of changing over to the back up converter. Method of changing over to the back up converter. Defining the output connector to the output bus. Defining the output connector to the output bus. Modify the start-up circuit to operate from –10kV. Modify the start-up circuit to operate from –10kV. Limit input inrush current when the relay is closed. 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 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. Define internal –10kV harness to the back up converter.