TRACO DCDC Converter Startup Tests ------------------------------------ Initial Rev. 1-May-2025 Current Rev. 5-May-2025 There are at least 2 aspects of the operation of the TRACO 96 VDC to 5 VDC DCDC Converter that need to be verified by testing them: 1. When the TRACO converter first starts up its output is looking into a 99% reactive load. Recall that the main load on the TRACO Converter is the 6 DCDC Buck Converters that supply all of the actual operating voltages to the circuits on the DK Board. The input to each of these converters includes an LC Filter that has a 10 uH inductor and 4x 150 uFd Tantalum caps plus 4x 10 uFd Ceramic caps all 8 caps in parallel to Ground. These LC Filters go series resonant at about 2 kHz or at about a 0.5 msec period. There are 6 of these series resonant filters all in parallel basically shorting the TRACO output to Ground at the 2 kHz frequency and thus potentially causing a serious problem with its feedback servo loop. The Q of these filters at 2 kHz is about: 2 kHz x 2pi x 10 uH / 50 mOhm = about 2.5 This Q is low enough so that there will not be a significant noise peak at 2 kHz. The 50 mOhm is made up from about 41 mOhm DC copper resistance in the inductor winding, and a minimum of 10 mOhm in the 4 terminal current shunt series resistor. Note that there are other losses so the Q should actually be lower, e.g. the winding's AC copper resistance at 2 kHz, most of the current shunt resistors are actually 20 or 25 mOhm, and hysteresis losses in the inductor. For the first approximately 1 second of operation of the TRACO Converter it has very little Real load. After charging them it sees just the Reactive load of these 6 series LC Filters all connected to the TRACO's output in parallel. 2. When the DK board is operating the Real DC load on the TRACO Converter is expected to be about a steady 1.5 Amps from our circuits on the DK board. But there can be additional loads of approximately 1.5 Amps that could switch ON or OFF with fast transition times. Will these fast approximately 2x changes in real load current upset the TRACO Converter when it also has the large reactive load from the LC Filters on it ? Needs to be verified. In the following tests with scope shots labeled: traco_... or linear_... the following loads were used: - Always connected to the output of the supply is: 4x LC Filters of 600 uFd Tantalum in series with 10 uH 2x LC Filters of 1000 uFd Aluminum in series with 10 uH All 6 of these are in parallel across the supply's output. - Sometimes a DC load of 1 Amp is used: this is 2x 10 Ohm power resistors in parallel. - Sometimes a dynamic load of about 1.3 Amps is used: this is a 3.8 Ohm power resistor in the drain of an IRF540ZPBF power FET that is turned ON & OFF by a bipolar square wave from an HP function generator. Startup testing was done both with and without the 1 Amp DC load also connected to the supply's output. Dynamic testing was done both with and without the 1 Amp DC load also connected to the supply's output. The Linear supply (Power-One 5V 12 Amp) is used only with the initial testing of DK board SN #0. So far both the TRACO and the Linear supply look stable at start up and with a sharp load change.