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78M6618 PDU1 Evaluation Board User Manual November 2011 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time. M a x i m I n t e g r a t e d P r o d u c t s , 1 2 0 S a n G a b r i e l D r iv e , S u n n y v a le , C A 9 4 0 8 6 4 0 8- 7 3 7 - 7 6 0 0 2011 Maxim Integrated Products Maxim is a registered trademark of Maxim Integrated Products. UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Table of Contents 1 Introduction.................................................................................................................................... 5 1.1 Package Contents................................................................................................................. 5 1.2 System Requirements........................................................................................................... 5 1.3 Safety and ESD Notes .......................................................................................................... 6 1.4 Firmware Demo Code Introduction ........................................................................................ 6 1.5 Testing the Evaluation Board Prior to Shipping...................................................................... 6 2 Installation ..................................................................................................................................... 7 2.1 USB Connection and Driver Installation................................................................................. 8 2.2 Connecting the External DC Supply ...................................................................................... 8 2.3 Confirm COM Port Mapping .................................................................................................. 9 2.4 Verify Serial Connection to the PC ...................................................................................... 10 2.5 Connect the AC Source and Load ....................................................................................... 12 3 Circuit Description and Theory of Operation ............................................................................. 13 3.1 78M6618 ............................................................................................................................ 13 3.2 Voltage Regulators ............................................................................................................. 13 3.3 Input Signal Conditioning .................................................................................................... 14 3.4 Relay Control ...................................................................................................................... 14 3.5 Theory of Operation ............................................................................................................ 14 3.5.1 78M6618 Operation ................................................................................................... 14 3.5.2 Voltage and Current Measurement ............................................................................ 14 4 In-Circuit Emulator (ICE) Adaptor ............................................................................................... 17 5 Schematics, Bill of Materials, and PCB Layouts ........................................................................ 18 5.1 78M6618 PDU1 Evaluation Board Schematics .................................................................... 18 5.2 78M6618 PDU1 Evaluation Board Bill of Materials .............................................................. 22 5.3 78M6618 PDU1 Evaluation Board PCB Layouts.................................................................. 25 6 Ordering Information ................................................................................................................... 26 7 Contact Information ..................................................................................................................... 26 Appendix A - 78M6618 PDU1 Board with CTs .................................................................................... 27 A.1 78M6618 PDU-CT Evaluation Board ................................................................................... 27 A.2 78M6618 PDU-CT Evaluation Board Schematics ................................................................ 28 A.3 78M6618 PDU-CT Evaluation Board Bill of Materials .......................................................... 32 A.4 78M6618 PDU-CT Evaluation Board PCB Layouts.............................................................. 34 Appendix B – 78M6618 PDU1 Version 1 (Single-Ended Shunt) ......................................................... 36 Revision History .................................................................................................................................. 37 Rev 3 3 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 Figures Figure 1: 78M6618 PDU1 Connections .................................................................................................... 7 Figure 2: Serial Port Verification Screen................................................................................................. 12 Figure 3: Differential PDU Block Diagram............................................................................................... 13 Figure 4: PCB Parasitic Resistance ....................................................................................................... 15 Figure 5: Differential Amplifier and Current Sense Resistor .................................................................... 15 Figure 6: Detail View of Differential Amplifiers ........................................................................................ 16 Figure 7: ICE Adaptor ............................................................................................................................ 17 Figure 8: 78M6618 ICE Adaptor Attachment .......................................................................................... 17 Figure 9: 78M6618 PDU1 Evaluation Board Electrical Schematic (1 of 4)............................................... 18 Figure 10: 78M6618 PDU1 Evaluation Board Electrical Schematic (2 of 4)............................................. 19 Figure 11: 78M6618 PDU1 Evaluation Board Electrical Schematic (3 of 4)............................................. 20 Figure 12: 78M6618 PDU1 Evaluation Board Electrical Schematic (4 of 4)............................................. 21 Figure 13: 78M6618 PDU1 Evaluation Board PCB Top View ................................................................. 25 Figure 14: 78M6618 PDU1 Evaluation Board PCB Power View.............................................................. 25 Figure 15: 78M6618 PDU1 Evaluation Board PCB GND View................................................................ 25 Figure 16: 78M6618 PDU1 Evaluation Board PCB Bottom View ............................................................ 25 Figure 17: 78M6618 PDU-CT Evaluation Board ..................................................................................... 27 Figure 18: 78M6618 PDU-CT Evaluation Board Electrical Schematic (1 of 4) ......................................... 28 Figure 19: 78M6618 PDU-CT Evaluation Board Electrical Schematic (2 of 4) ......................................... 29 Figure 20: 78M6618 PDU-CT Evaluation Board Electrical Schematic (3 of 4) ......................................... 30 Figure 21: 78M6618 PDU-CT Evaluation Board Electrical Schematic (4 of 4) ......................................... 31 Figure 22: 78M6618 PDU-CT Evaluation Board PCB Top View.............................................................. 34 Figure 23: 78M6618 PDU-CT Evaluation Board PCB Bottom View......................................................... 35 Tables Table 1: COM Port Setup Parameters.................................................................................................... 10 Table 2: 78M6618 PDU1 Evaluation Board Bill of Materials ................................................................... 22 Table 3: 78M6618 PDU-CT Evaluation Board Bill of Materials................................................................ 32 4 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual 1 Introduction The Teridian™ 78M6618 PDU1 evaluation board is an example of a low-cost power distribution unit (PDU) utilizing the 78M6618 system-on-chip (SoC). The 78M6618 monitors the AC line voltage and eight load currents, and controls switching of eight internal load relays. The embedded firmware calculates the RMS line voltage and RMS load currents, watts, VAs, VARs, and power factor. The real-time data is transmitted to a PC via a USB interface for display in a Windows®-based graphical user interface (GUI). The 78M6618 UART interface is used as the communications link to an on-board isolated USB interface IC. Included with the 78M6618 PDU1 is a Windows-based GUI for simplified access to the following measurement data and controls: • • • • • • • • RMS voltage and current Real, apparent, and reactive power and power factor Accumulated energy usage and expense tracking Line frequency Minimum and peak parameter tracking Alarm indicators Programmable alarm thresholds Internal load relay (16A) control This document describes the evaluation board with “78M6618 PDU1_DIFF” imprinted on the board. This board is a complete replacement for (and obsoletes) the earlier 78M6618 PDU1 evaluation board. Refer to the GUI User Guide for information about the GUI. 1.1 Package Contents The 78M6618 PDU1 evaluation kit includes: • • • • 78M6618 PDU1_DIFF evaluation board Universal AC to 12 V DC power supply with international plug adapters ICE Adaptor board USB A/B cable 1.2 System Requirements The 78M6618 PDU1 GUI requires use of a PC with the following features: • • PC (1 GHz, 1 GB) with Microsoft Windows 7, Windows XP® or Win2000, equipped with USB port Minimum 1024 x 768 video display resolution Teridian is a trademark of Maxim Integrated Products, Inc. Windows and Windows XP are registered trademarks of Microsoft Corp. Rev 3 5 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 1.3 Safety and ESD Notes EXERCISE CAUTION WHEN LIVE AC VOLTAGES ARE PRESENT! Standard ESD precautions must be taken when handling electronic equipment. The 78M6618 PDU1 contains ESD protected interfaces. Do not connect test equipment, ICE emulators or external development boards directly to the 78M6618 hardware. Damage to the 78M6618 PDU1 and external equipment will occur due to the 78M6618’s “high side” reference topology. The 78M6618’s V3P3 (i.e., “high side”) is connected directly to Neutral (Earth Ground) and the ground is 3.3V below neutral, creating a ground reference disparity with any properly grounded external equipment. Also, reversing the line and neutral connections at the inlet would place the board’s ground reference at the AC line voltage. Always use the isolated USB interface for connecting to a PC. Contact the factory for instructions on connecting other types of test equipment. The board components and firmware settings are designed to operate with the following nominal AC electrical ranges: Voltage Current Line Frequency 110-240 VAC 20A Max 46-64 Hz 1.4 Firmware Demo Code Introduction The Firmware Demo Code provides the following features: • • Basic energy measurement data such as Watts, Volts, current, VAR, VA, phase angle, power factor, accumulated energy, frequency, date/time, and various alarm statuses. Control of alarm thresholds, calibration coefficients, temperature compensation, etc. There are two means to facilitate performance evaluation between the user at the PC host and the firmware code in the 78M6618 PDU1 evaluation board: • The graphical user interface (GUI). For information about the GUI, refer to the GUI User Guide. • The Command Line Interface (CLI) via HyperTerminal or comparable terminal emulator on a different operating system. For information about the CLI, see the Firmware Description Document. The 78M6618 PDU1 evaluation board is shipped with demonstration code loaded in the 78M6618 device and included on the CD. The code revision can be verified by entering the command >i via the command line interface. Firmware for the Demo Unit can be updated using either the Teridian TFP2 or an in-circuit emulator such as Signum Systems ADM51 (www.signum.com). 1.5 Testing the Evaluation Board Prior to Shipping Before every 78M6618 PDU1 evaluation board is shipped, the following procedures have been performed at the factory: • • 6 Full Calibration – Precise energy source equipment is used to calibrate the current and voltage. The temperature is also calibrated at the same time. Accuracy Test – This “bench” level test ensures the energy measurement accuracy is within +/-0.5%. Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual 2 Installation Figure 1 shows the basic connections to the 78M6618 PDU1 Evaluation Board. DC power is supplied to the PDU1 through the DC power jack (J48). The USB cable provides an electrically isolated communications link between the host PC and the PDU1 as well as power to the USB controller on the Evaluation Board. The AC input to the PDU is connected via the terminal block J4. The PDU1 has eight outlets that connect to the loads to be measured. Screw terminals are provided to make the line and neutral connections to the loads. AC Inlet (J4) DC Power Plug (J48) Outlet 5 Outlet 7 Connect the USB Port (J47) to the Host PC Outlet 8 Outlet 6 Outlet 3 Outlet 4 Outlet 1 Outlet 2 Figure 1: 78M6618 PDU1 Connections Rev 3 7 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 2.1 USB Connection and Driver Installation This evaluation kit includes an isolated USB interface for serial communications with a PC. The FTDI USB controller IC FT232R performs the USB functions. The FTDI Windows driver presents a virtual COM port for enabling serial communications. Control of the 78M6618-PDU-1 can be managed using either a terminal emulation program or using the supplied Windows Dashboard GUI. The FTDI Windows driver is a certified driver for Windows 2000 and XP. Because the USB interface is USB powered, the USB driver installation can be completed with no other DC power supplied to the evaluation board. 1. Connect a USB AB cable between the host PC and the evaluation board. 2. Upon attaching the 78M6618-PDU-1 to the PC, the Found New Hardware Wizard automatically launches and installs the appropriate driver files. If your PC does not find the FTDI driver files on its local hard disk drive, locate and reference the FTDI USB Driver and Utilities subdirectory on the CD. The FT232R controller is powered from the USB cable and is active even when no AC power is applied to the 78M6618-PDU-1. Note: If an older FTDI driver has been previously installed, it is recommended to remove the older version before installing this newer FTDI driver. Execute the ftdiClean.exe utility from the FTDI USB Driver and Utilities subdirectory. For FTDI driver support on other operating systems, please check FTDI’s website at (http://www.ftdichip.com/FTDrivers.htm). 2.2 Connecting the External DC Supply An external DC supply is provided for operation of the evaluation board. Follow these steps to connect the 78M6618 PDU1 with the external DC supply: 1. Select the appropriate plug for the AC adapter and snap it into place. 2. Connect the DC cable of the 12V AC adapter to J48. 3. Plug the AC adapter into an appropriate outlet. 8 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual 2.3 Confirm COM Port Mapping 1. Launch the Control Panel and click on the System icon. 2. The System Properties screen appears. Click on the Hardware tab. Click on Device Manager. Under Ports (COM & LPT), look for the USB Serial Port assignment. 3. Take note of the COM port assignment for the USB Serial Port. PDU-1 COM Port: Rev 3 9 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 2.4 Verify Serial Connection to the PC After connecting the USB cable from the 78M6618-PDU-1 to the host PC and powering the PDU board with the 12VDC adapter, start the HyperTerminal application (or another suitable communication program) to create a session using the communication parameters shown in Table 1. The firmware installed in your board may use a different COM port setup than what is shown here. Refer to the Firmware Description Document provided with your board for the correct setup for your firmware. Table 1: COM Port Setup Parameters Setup Parameter 78M6618 Port speed (baud) 38400 Data bits Parity Stop bits Flow control 8 None 1 None HyperTerminal can be found in Windows by selecting Start All Programs Accessories Communications HyperTerminal. The connection parameters are configured by selecting File Properties. The New Connection Properties menu appears. Select COM Port Select the appropriate COM port and click Configure. The COMn Properties menu appears. 10 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Note that port parameters can only be adjusted when the connection is not active. It may be necessary to click the Disconnect Button (shown below) to disconnect the port. When the terminal emulation program has connected to the correct USB COM port, verify operation of the PDU by pressing the “Enter” key on the PC. The evaluation board should respond with a “>” prompt. You should also be able to identify the firmware version programmed into your board If communication is not established with the evaluation board, check the following: 1. Make sure that 12VDC is supplied to the board through J48. 2. Make sure that the terminal emulation program is using the correct COM port. 3. Check the serial port configuration against the configuration given in the Firmware Description Document. Rev 3 11 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 Disconnect Figure 2: Serial Port Verification Screen FTDI COM Port Trouble-Shooting If the FTDI device driver did not install properly, there would be no assigned COM port number for the FTDI controller. Repeat the USB Driver Installation, see Section 2.1. Microsoft Windows may associate a Ball Point device to the FTDI USB controller. When this occurs a FTDI device COM port assignment is available via HyperTerminal but there is no communications data. Verify if a Ball Point device has been added to the “Human Interface Devices” via the Device manager. Refer to Section 2.3 for access to the Device Manager. If a Ball Point device exists, delete it and unplug and replug the evaluation board’s USB cable. 2.5 Connect the AC Source and Load Connect the desired AC source to the terminal block J4. Be sure to observe the correct connections for line and neutral as they are designated on the silk screen. Terminal block J4 accepts bare wires size 24AWG to 10AWG. Be sure to select wire gauge appropriate to the total load to be applied to the board, and make sure that the screws are tightened for good electrical connection and wire retention. The loads to be controlled and metered are connected to the screw terminals J7-J22 that are located on the bottom edge of the board. These terminals can accept bare wire, or spade terminals or ring terminals that are capable of accepting a 6-32 screw. The individual terminals are rated to carry a maximum current of 15A. As with the AC inlet connection, be sure to observe proper connection to the AC line (labeled Outlet n) and AC neutral. 12 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual 3 Circuit Description and Theory of Operation Figure 3 shows a block diagram of the PDU1 Evaluation Board. For simplicity, only one of the 8 identical channels is shown. AC NEUTRAL Voltage Sense Resistors AC LINE Low Pass Filter V3P3 V input DIO +12VDC 78M6618 I Input +12V V6P6 Series Regulators Current Sense Resostor Differential Amplifier + Relay Driver - V3P3 GND Low Pass Filter 12VDC Return LOAD (One of 8 channels) Figure 3: Differential PDU Block Diagram The main functional blocks of the evaluation board are the 78M6618 energy measurement SoC, voltage regulators, input signal conditioning, and relay control. 3.1 78M6618 The 78M6618 is a highly integrated IC for energy monitoring and measurement. The key features of the 78M6618 include: • A 21-bit delta sigma analog to digital converter (ADC) with 10 multiplexed analog inputs • • A 32-bit digital signal processor core (Compute Engine, or CE) An 8-bit microprocessor core • • • 128 Kbytes flash memory 32,768 kHz oscillator Up to 19 general-purpose digital I/O pins (DIO). For detailed information on the 78M6618, refer to the 78M6618 Data Sheet. 3.2 Voltage Regulators The evaluation board is powered by an external 12VDC source. The on-board relays for switching power to the 8 outlets are powered directly from the 12V supply. Linear regulators are used to provide the 3.3V supply for the 78M6618 and external logic and a 6.6V supply for the operational amplifiers that are used to amplify the voltage from the current sense resistors. Rev 3 13 78M6618 PDU1 Evaluation Board User Manual 3.3 UM_6618_022 Input Signal Conditioning Input signal conditioning includes the voltage divider used to reduce the AC line voltage to a level that can be measured by the 78M6618, the differential amplifiers that are used to remove common-mode voltage from the input signals to the ADC current channels, and the low-pass filters that block high-frequency signal content from the ADC inputs. 3.4 Relay Control Power to each of the 12 outlets on the board is switched by a relay. The relays are individually controlled by digital I/O (DIO) lines from the 78M6618. Do to the type of relay driver circuit used on this board, the firmware Relay Config register (0x0210) is set equal to 2. This inverts the relay driver input polarity. 3.5 Theory of Operation Before describing the operation of the PDU, it may be helpful to make note of some of the characteristics of the 78M6618 and the board design. 1. The reference for the 78M6618’s ADC is its positive power supply (V3P3), not ground. 2. The 78M6618’s 3.3V power supply is directly connected to the neutral side of the AC power source. As a result, the 78M6618’s ground reference is actually 3.3V below the AC neutral. 3.5.1 78M6618 Operation The analog multiplexer at the front end of the delta-sigma ADC sequentially presents the signals at the 10 analog input pins to the ADC, which converts them to digital words which are presented to the 32-bit compute engine (CE). The CE performs filtering and calculates RMS voltage and current, line frequency, real power and reactive power. The CE transfers its results to the 80515 MPU at the end of each accumulation interval. The accumulation interval, which is the period over which RMS voltage, current and power are calculated, is determined by the firmware loaded into the 78M6618’s internal flash, and may be between 200 milliseconds and 1 second. The 80515 MPU performs some scaling of the CE results, calculates some additional values, and manages the communication with an external host via its integrated UART. The MPU also controls the operation of the CE. 3.5.2 Voltage and Current Measurement As previously described, the reference voltage for the 78M6618 ADC is 3.3V. The valid input range for the ADC is 3.3V ±250 mV. A 250 mV signal corresponds to full scale on the ADC. A voltage divider is used to scale the line voltage to the ±250 mV range of the ADC. The voltage divider consists of 2 1 MΩ resistors and one 750 Ω resistor. The ADC measures the voltage across the 750Ω resistor, which is 0.0375% of the line voltage. With this ratio, the ADC can measure line voltages up to 667VPEAK, which corresponds to a sinusoidal voltage input of ~471 VRMS. An RC low-pass filter at the input to the ADC limits the frequency content of the input signal to around 4,500 Hz. The PDU uses current sense resistors, also known as shunt resistors, to sense the current flowing in the neutral or return of each outlet. The value of the current sense resistor is selected to scale the voltage drop across the resistor to the input range of the ADC. The sense resistors must also have low resistance values in order to keep voltage drop and power dissipation to acceptable levels. The 78M6618’s ADC has single ended inputs referenced to V3P3. The PCB traces that are used for the line and neutral buses on the PDU board have resistances that are of the same magnitude or greater than that of the acceptable shunts. This parasitic resistance appears between the reference end of the sense resistors and the ADCs reference point, as illustrated by Figure 4. If the sense resistors are corrected directly to the ADC inputs as shown in Figure 5, it is impossible to separate the voltage across the sense resistors from the voltage across the parasitic resistance in the PCB. Because of this, current flowing in one outlet will affect the voltage at the ADC current measurement inputs for other channels, resulting in channel-to-channel crosstalk. To eliminate this problem, differential amplifiers are used between the current sense resistors and the ADC current measurement inputs, as shown in Figure 5. The differential amplifier is biased to provide an output centered at 3.3V, and rejects the voltage drop due to the PCB resistance, which appears as common mode voltage at the amplifier inputs, so that the signal presented at the ADC input is 14 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual due only to the voltage drop across the current sense resistor. An additional advantage of using the differential amplifier is that it is possible to use lower value sense resistors by increasing the gain of the differential amplifier. The PDU evaluation board uses 500 µΩ sense resistors, with an amplifier gain of 10. With this configuration, a peak current of 50A results in full-scale input to the ADC. This allows the PDU to measure 16A loads with a crest factor slightly greater than 3. ADC Reference Neutral Runknown 78M6618 Runknown Runknown Rshunt Rshunt Runknown Rshunt Rshunt AC Load Load Load Load Current Sense Inputs Line Figure 4: PCB Parasitic Resistance AC Return from load V6P6 Load Current Differential Amplifier - AC Neutral + Current Sense Resostor To LPF and ADC Input GND Figure 5: Differential Amplifier and Current Sense Resistor The layout of the feedback networks for the differential amplifiers is critical to provide true differential operation and to avoid noise pickup due to the high voltages and currents present on the PDU1 board. Figure 6 shows a detail view of the current sense resistors, the dual op amp, and their feedback networks. Rev 3 15 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 Figure 6: Detail View of Differential Amplifiers The op amps and their feedback networks are laid out to minimize the interconnect distance between the current sense resistors and the op amp inputs. They are also located above a V3P3 plane to minimize electrical noise pickup. For more detailed information on PCB layout, refer to the application note Designing a Differential Power Distribution Unit Using the 78M6618. 16 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual 4 In-Circuit Emulator (ICE) Adaptor The 78M6618’s firmware (stored in internal flash memory) can be updated to accommodate program enhancements. Use the Signum ADM51 or the Teridian TFP2 to download new firmware to the 78M6618. The supplied ICE Adaptor is required to interface the flat ribbon cable (provided with the ADM51 or TFP2) to the 78M6618 evaluation board. Figure 7: ICE Adaptor Figure 3 shows how to attach the ICE Adaptor to the 78M6618 evaluation board. Please make note of the orientation of the ICE Adaptor as to how it attaches to the 78M6618 evaluation board (V3P3 ICE Adaptor pin connects to the +V Evaluation Board pin). Figure 8: 78M6618 ICE Adaptor Attachment Disconnect the 78M6618 evaluation board from live AC voltages before connecting the ADM51 or TFP2. An Earth ground disparity and high AC voltages are present on the 78M6618 evaluation board when it is connected to the AC outlet. Equipment damage to the 78M6618, ADM51/TFP2 and attached PC may occur when live AC voltages are present on the 78M6618 evaluation board. Refer to the 78M661x Safety Precautions Applications Note for additional information. It is recommended to always use the supplied flat ribbon cable. Do not use discrete wires in place of the flat ribbon. Poor signal integrity will cause flash memory programming errors. Additional adaptors and flat ribbon cables can be ordered through Maxim. Rev 3 17 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 5 Schematics, Bill of Materials, and PCB Layouts This section includes the schematics, bill of materials and PCB layouts for the 78M6618 PDU1 evaluation board. 5.1 78M6618 PDU1 Evaluation Board Schematics . V3P3 V3P3 51 To Relay s LINE 2,3 NEUTRAL 2,3 C2 10uF 25V 1812 DigiKey 478-1762-1-ND V2P5 V3P3A VREF External wire to J2 center point V1 Green CON1 1 EGND V1 R2 2K 0603 53 EGNDV 52 XIN 66 R3 20.0K 1% 0603 GND C7 33pF 0603 VA VB R1 16.9K 1% 0603 XIN 1 LINEV V3P3 C8 1000pF 0603 R7 750 0.1% 0603 U1-1 78M6618-68QFN QFN68 Y1 32.768KHz CM200S 535-9166-1-ND XOUT 68 GND 4 R9 R8 1M 0.1% 1M 0.1% 1206W 1206W MS 660-RN732BTTD1004B25 J3 C6 1000pF 0603 C4 NC 0603 C5 100pF 0603 GNDA1 NEUTRAL White 63 +/-250mVpp +/-178mVrms R4 750 0.1% 0603 C3 0.1uF 0603 GND GNDA2 1 2 VREF IA IB IC ID IE IF IG IH 50 R5 R6 1M 0.1% 1M 0.1% 1206W 1206W MS 660-RN732BTTD1004B25 62 XOUT C9 9pF 0603 65 Black terminal block A98275-ND 61 60 59 58 57 56 55 54 OUTCUR1 OUTCUR3 OUTCUR5 OUTCUR7 OUTCUR2 OUTCUR4 OUTCUR6 OUTCUR8 V3P3 LINE J4 V2P5 GND GND 2 2 3 3 2 2 3 3 48 C1 0.1uF 0603 + GND All things ref erenced to V3P3 f or 78M6618 V3P3 connected to NEUTRAL f or Saf ety due to SMA GND shield +12VDC Note: SMA GND shield is -3.3V relativ e to Neutral (Earth GND) U10 3 DigiKey 160-1181-6-ND MS 502-RAPC712X RAPC712A 5VEXT C15 0.1uF 0603 R106 11K J48 OUT GND 2 78L33 D9 Red LED 1 2 3 12 VDC Input IN U11 C13 220uF 25V lo imp UUDB MS 647-UUD1E221MNL Ty co 640454-2 3 + C12 1uF 20V 1206P IN OUT GND 2 78L33 1 MT2 MT3 MT4 MT5 LOGO1 LOGO2 1 1 V6P6 C36 1uF 0603 C35 + 10uF 25V 1812 DigiKey 478-1762-1-ND V3P3 connected to NEUTRAL 1 C14 1uF 0603 GND MT1 3.3V above Neutral (V3P3) + C30 10uF 25V 1812 DigiKey 478-1762-1-ND 3.3V below Neutral TERIDIAN SEMICONDUCTOR CORP. Title x MT6 Warning V3P3 TERIDIAN GND Power Distribution Unit 8 Outlet Dif f erential Current Single Phase Size B Document Number Date: Tuesday , May 10, 2011 Rev Sheet 1 of 4 Figure 9: 78M6618 PDU1 Evaluation Board Electrical Schematic (1 of 4) 18 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual . LINE 1,3 LINE 1,3 NEUTRAL 1,3 R16 2K 0603 NEUTRAL +12VDC +12VDC 1 Neutral1/White J14 CON4 STERM MS 534-8191 1 2 3 4 1 8 R79 7.5K 0603 R81 .0005 2512P MS 66-ULR25R006FLFTR OUTLET2 J52 CON1 4 1 2 1 2 7 8 3 4 RL2 16A 12V SPDT Low Prof ile ALZ 255-1446-ND R80 75K 0603U4A R78 7.5K 0603 Q11 NUD3112/SOT V6P6 MAX4494/SO 3 + 2 C18 1000pF 0603 - R77 75K 0603 R25 750 0603 GND CON1 1 R29 .0005 2512P MS 66-ULR25R006FLFTR Neutral3/White R83 7.5K 0603 Egnd/Green 6 R82 V3P3 C48 75K 0603 RLY 4 J55 Line/Black Neutral/White Egnd/Green CON1 1 RL4 16A 12V SPDT Low Prof ile ALZ 255-1446-ND J56 CON1 1 Neutral4/White .0005 RELAY 3 V6P6 0.1UF 0603 MAX4494/SO 3 + R86 75K 0603 Q13 NUD3112/SOT RELAY 4 R31 10K 0603 4 V3P3 C20 1000pF 0603 C40 .047uF 0603 OUTCUR4 1 - 1 +12VDC U5A GND R87 7.5K 0603 OUTCUR3 GND 2 R34 LED, Green D4 LED V6P6 2512P MS 66-ULR25R006FLFTR C39 .047uF 0603 OUTCUR3 R32 2K 0603 4 R26 10K 0603 GND C19 1000pF 0603 0603 750 R30 0.1UF 7 0603 - 1 Q12 NUD3112/SOT V3P3 NEUTRAL U5B 0603 75K R89 0603 7.5K R88 OUTLET4 C46 4 1 2 OUTLET3 J54 GND R85 75K 0603 MAX4494/SO 5 + 8 3 4 1 R84 7.5K 0603 8 Neutral/White CON1 7 8 5 6 Line/Black OUTCUR2 +12VDC LED RL3 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 4 R21 10K 0603 GND R27 2K D3 0603 RLY 3 J53 RELAY 2 C38 .047uF 0603 OUTCUR2 1 1 0603 2K R22 D2 LED 0.1UF 0603 Neutral2/White Egnd/Green OUTCUR1 +12VDC V6P6 V3P3 V3P3 C37 .047uF 0603 R20 750 0603 4 Neutral/White 1 - 4 J13 CON4 STERM MS 534-8191 1 2 3 4 J51 CON1 1 2 J12 CON4 STERM MS 534-8191 1 2 3 4 R73 75K 0603 RLY 2 Line/Black 0.1UF 0603 7 C47 5 6 J11 CON4 STERM MS 534-8191 1 2 3 4 6 R74 7.5K 0603 Egnd/Green 7 8 J10 CON4 STERM MS 534-8191 1 2 3 4 MAX4494/SO 5 + C17 1000pF 0603 OUTCUR1 U4B 4 R17 10K 0603 GND C45 0603 2512P MS 66-ULR25R006FLFTR 3 4 J9 CON4 STERM MS 534-8191 1 2 3 4 GND R76 75K R75 7.5K 0603 R19 .0005 J50 CON1 RL1 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 8 Neutral/White OUTLET1 7 8 3 4 5 6 Line/Black 1 5 6 J8 CON4 STERM MS 534-8191 1 2 3 4 J49 CON1 RELAY 1 Q10 LED NUD3112/SOT NUD3112LT1GOSCT-ND GND J7 CON4 STERM MS 534-8191 1 2 3 4 V3P3 DigiKey 475-1409-1-ND LED, Green D1 OUTCUR4 1 R35 750 0603 TERIDIAN SEMICONDUCTOR CORP. Title Power Distribution Unit 8 Outlet Dif f erential Current Single Phase Size B Document Number Date: Tuesday , May 10, 2011 Rev Sheet 2 of 4 Figure 10: 78M6618 PDU1 Evaluation Board Electrical Schematic (2 of 4) Rev 3 19 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 . V6P6 LINE 1,2 LINE 1,2 NEUTRAL 1,3 +12VDC J15 CON4 STERM MS 534-8191 1 2 3 4 1,3 GND J16 CON4 STERM MS 534-8191 1 2 3 4 Line/Black NC R107 NC R114 NC R108 NC R111 NC R109 NC R112 NC R110 NC R113 NEUTRAL NEUTRAL 0603 2K R37 RLY 5 LED 1 2512P MS 66-ULR25R006FLFTR J58 CON1 1 R39 Neutral1/White 0603 7.5K R91 Egnd/Green 75K 0603 GND MAX4494/SO 5 6 + C49 V3P3 0603 75K R90 V6P6 0.1UF 0603 CON1 1 J22 CON4 STERM MS 534-8191 1 2 3 4 R44 .0005 2512P MS 66-ULR25R006FLFTR R97 0603 75K MAX4494/SO 3 2 Neutral1/White 0603 7.5K R94 Egnd/Green R40 750 0603 GND OUTCUR6 Q16 NUD3112/SOT D7 Neutral/White CON1 OUTLET7 CON1 1 0603 7.5K R103 Neutral1/White U7B 4 1 2 7 8 3 4 1 J62 R49 .0005 2512P MS 66-ULR25R006FLFTR R105 GND 75K C52 0603 0603 0.1UF NEUTRAL MAX4494/SO 5 0603 75K R102 V3P3 Egnd/Green + 0603 2K R52 Neutral/White Egnd/Green OUTLET8 J64 CON1 1 Neutral1/White OUTCUR7 OUTCUR7 .0005 2512P MS 66-ULR25R006FLFTR GND 2 R99 75K C24 1000pF 0603 U7A 4 C44 .047uF 0603 OUTCUR8 1 - R55 750 0603 GND R98 7.5K RELAY 8 R51 10K 0603 V6P6 MAX4494/SO 3 + R54 1 D8 R101 0603 75K 7.5K R100 0603 4 C43 .047uF 0603 Q17 NUD3112/SOT RL8 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 8 Line/Black 1 1 2 5 6 J63 RELAY 7 LED LED, Green V6P6 0.1UF 0603 RLY 8 CON1 C23 1000pF 0603 0603 750 R50 7 6 C50 - 8 Line/Black R104 7.5K 0603 1 R46 10K 0603 GND RL7 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 4 LED RLY 7 J61 RELAY 6 C42 .047uF 0603 OUTCUR6 0603 2K R47 1 R41 10K 0603 GND R45 750 0603 0603 75K R95 OUTCUR5 C22 1000pF 0603 1 - C41 .047uF 0603 Q15 NUD3112/SOT D6 U6A + 4 LED V6P6 4 J21 CON4 STERM MS 534-8191 1 2 3 4 1 2 J60 R96 7.5K 0603 RELAY 5 R36 10K 0603 V3P3 0603 2K R42 4 Neutral/White RL6 16A 12V SPDT Low Prof ile ALZ 255-1446-ND OUTLET6 3 4 J20 CON4 STERM MS 534-8191 1 2 3 4 V3P3 NUD3112LT1GOSCT-ND C21 1000pF 0603 OUTCUR5 U6B C51 0603 0.1UF 7 8 3 4 5 6 Line/Black 1 7 8 J59 CON1 7 8 J19 CON4 STERM MS 534-8191 1 2 3 4 Q14 NUD3112/SOT NEUTRAL R93 4 1 2 OUTLET5 R92 7.5K 0603 8 3 4 5 6 Neutral/White CON1 7 8 J57 5 6 J18 CON4 STERM MS 534-8191 1 2 3 4 LED, Green DigiKey 475-1409-1-ND NEUTRAL GND RL5 16A 12V SPDT Low Prof ile ALZ 255-1446-ND RLY 6 J17 CON4 STERM MS 534-8191 1 2 3 4 GND D5 OUTCUR8 1 TERIDIAN SEMICONDUCTOR CORP. Title Power Distribution Unit 8 Outlet Dif f erential Current Single Phase Size B Document Number Date: Wednesday , May 11, 2011 Rev Sheet 3 of 4 Figure 11: 78M6618 PDU1 Evaluation Board Electrical Schematic (3 of 4) 20 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual . V3P3 NEUTRAL USBDM USBDP C31 4.7uF 1206P 16 15 8 19 24 RXD TXD USBDM USBDP NC1 RESETB RTS CTS DTR DSR DCD RI NC2 CBUS0 CBUS1 CBUS2 CBUS3 CBUS4 1.5M A/B White Cable Mouser 571-1487588-2 C32 0.1uF 0603 OSCI OSCO 3V3OUT 25 7 18 21 26 17 AGND GND1 GND2 GND3 TEST 27 28 5 1 1 2 3 4 USBTX USBRX 3 11 2 9 10 6 23 22 13 14 12 V2 V1 VOA VIA VIB VOB ND1 G2 TP1 TP TPWW TP2 C33 TP 0.1uF TPWW 0603 GND J39 DEBUG SIP100P4 U2 28-LD SSOP 768-1007-1-ND 28-SSOP 1 10 6 7 46 R71 0 0603 R72 0 0603 GND V3P3 UTX URX 19 20 21 26 27 30 31 32 33 34 35 17 18 GND USBGND U2 internal 3.3V LDO can source upto 50ma 1 8 7 6 5 1 2 3 4 9 11 DIO16 DIO19 DIO43 DIO5 DIO4 DIO3 DIO1 DIO2 DIO18 DIO17 no connect no connect no connect SMBRXD SMBCLOCK SMBTXLOB SMBCKHDB SMBALTRB no connect no connect CE SLE SDATA SREAD SCLK INT DATAIO DATACLK GND GND CSN TRXCE PWRUP MISO SCK DR MOSI CD TXEN no connect SDI CLK SDO CSZ SDA SCL J66 37 38 DIO4 DIO5 V3P3 CON2 1 2 ERXTX/SEG9 ETCLK/SEG10 ERST/SEG11 ICEE CKTEST/SEG19 TMUXOUT TX RX DIO2 DIO1 5 64 16 40 42 43 44 45 29 22 23 24 14 15 41 28 DIO3 DIO16 DIO17 DIO18 DIO19 DIO43 TEST POINT RELAY 8 RELAY 7 RELAY 6 RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1 TP7 TP SEG0 SEG1 SEG2 SEG7 SEG8 SEG12 SEG14 SEG15 SEG16 SEG17 SEG18 TPWW TP6 TP TPWW R15 470 0603 J40 SPI1 DIP100P10 1 3 5 7 9 2 4 6 8 10 V3P3 OPTX/DIO2 OPRX/DIO1 WPULSE/DIO6/SEG26 3 TEST PCLK PSDI PSDO PCSZ 39 DIO6 R60 470 0603 Internal slav e SPI controller CLK SDI SDO CSZ GND DigiKey 160-1181-6-ND D12 Red LED LED, Red V3P3 R61 10K 0603 67 GNDD1 ADI TX/RX data interf ace 8 25 12 13 LED, Grn LED D11 R62 470 0603 PCLK PSDI PSDO PCSZ COM0 COM1 U1-2 78M6618-68QFN QFN68 3 3 3 3 2 2 2 2 V3P3 PCLK/SEG3 PSDI/SEG6 PSDO/SEG4 PCSZ/SEG5 1 2 LED, Y el READY TPWW D10 TP5 TP 1 DIO3 DIO7/SEG27 DIO8/SEG28 DIO9/SEG29 DIO10/SEG30 DIO11/SEG31 DIO13/SEG33 DIO14/SEG34 DIO15/SEG35 DIO16/SEG36 DIO17/SEG37 DIO18/SEG38 DIO19/SEG39 DIO43/SEG63 ACTIVE DigiKey 160-1184-1-ND TP4 J67 CON2 I2C Master f or EEPROM 1 R58 330 0603 U3 R59 ADUM3201 10K ADUM3201 ADUM3201ARZ-ND 0603 Alternate bit-bang SPI interf ace 1 1 2 3 4 5 6 V3P3 VCCIO VCC PacketPower 2 1 J47 USB-B MS 806-KUSBVX-BSIN-W USBBV 4 20 OneNet DigiKey 475-1409-1-ND 4 2 1 36 ICEEN C29 1000pF 0603 GND USB3V USB5V ICE inputs become LCD seg driv ers when ICEE low RXTX TCLK ERST Must use isolated USB hub SDCK/DIO4/SEG24 SDATA/DIO5/SEG25 SM Bus 1 1 2 3 4 5 6 RESET Reset Switch EVQ-PJX05M Panasonic 1K 1K 1000pF V3P3 J38 ICE SIP100P6 49 VBAT GND Optional SW1 R56 R57 C28 GND V3P3D GND C25 0.1uF 0603 C26 0.1uF 0603 47 C27 1uF 0603 810-C1608X5R1C105M V3P3SYS 1,2 J37 Pins SM Bus Address TP3 Wh SIP100P2 Pulse Output GND TERIDIAN SEMICONDUCTOR CORP. Title GND Power Distribution Unit 8 Outlet Dif f erential Current Single Phase Size B Document Number Date: Tuesday , May 10, 2011 Rev Sheet 4 of 4 Figure 12: 78M6618 PDU1 Evaluation Board Electrical Schematic (4 of 4) Rev 3 21 78M6618 PDU1 Evaluation Board User Manual 5.2 UM_6618_022 78M6618 PDU1 Evaluation Board Bill of Materials Table 2: 78M6618 PDU1 Evaluation Board Bill of Materials Item Qty Reference C1,C3,C15,C25,C26,C32,C33, C45,C46,C47,C48,C49,C50, C51,C52 C2,C30,C35 C4 C5 Part PCB Footprint Digi-Key MS - Mouser Part Number Manufacturer RoHS 0.1µF 0603 399-5089-1-ND C0603C104K5RACTU KEMET Yes 10µF 25V 100pF 2312 0603 0603 399-3734-1-ND DNP 445-1281-1-ND T491C106K025AT — C1608C0G1H101J KEMET — TDK Corporation 1000pF 0603 445-1298-1-ND C1608X7R2A102K TDK Corporation C0603C330J5GACTU C1608C0G1H090C CC1206KKX7R8BB10 5 KEMET TDK Corporation Yes — Yes Yes Yes Yes Yes Yageo Yes UUD1E221MNL1GS Nichicon Yes 1 15 2 3 4 3 1 1 5 11 C6,C8,C17,C18,C19,C20,C21, C22,C23,C24,C29 6 7 1 1 C7 C9 33pF 9pF 0603 0603 399-1055-1-ND 445-5046-1-ND 8 1 C12 1µF 25V 1206 311-1356-1-ND 9 1 C13 220µF 25V lo imp SMD 493-2278-1-ND 10 3 C14,C27,C36 1µF (0603) 0603 490-3897-1-ND 11 1 4.7µF 1206 399-4630-1-ND (1206) 12 8 C31 C37,C38,C39,C40,C41,C42, C43,C44 .047µF 0603 490-1567-1-ND 13 9 D1,D2,D3,D4,D5,D6,D7,D8,D11 Green LED 0603 14 2 D9,D12 Red LED 15 1 16 17 17 1 18 16 D10 J3,J49,J50,J51,J52,J53,J54, J55,J56,J57,J58,J59,J60,J61, J62,J63,J64 J4 J7,J8,J9,J10,J11,J12,J13,J14, J15,J16,J17,J18,J19,J20,J21, J22 19 1 20 1 22 GRM188R61E105KA1 2D T491A475M025AT GRM188F51H473ZA0 1D Murata Yes KEMET Yes Murata Yes 475-1409-1-ND LG Q971-KN-1 OSRAM Opto Semiconductors Yes 0603 160-1181-6-ND LTST-C190CKT Lite-On Inc. Yes Yellow LED 0603 160-1184-1-ND LTST-C190YKT Lite-On Inc. Yes CON1 Through Hole DNP — — — TERM BLOCK Through Hole A98275-ND 796740-2 TE Connectivity Yes CON4 Through Hole MS 534-8191 8191 Keystone Electronics Yes J38 ICE Through Hole S1011E-36-ND PBC36SAAN J39 DEBUG Through Hole S1011E-36-ND PBC36SAAN Sullins Connector Solutions Sullins Connector Solutions Yes Yes Rev 3 UM_6618_022 Item Qty 78M6618 PDU1 Evaluation Board User Manual Reference Part PCB Footprint Digi-Key MS - Mouser Part Number Manufacturer RoHS S2011E-36-ND PBC36DAAN Sullins Connector Solutions Yes 806-KUSBVX-BS1N-B Kycon Yes RAPC712X Switchcraft Sullins Connector Solutions Yes 21 1 J40 SPI1 Through Hole 22 1 J47 USB-B Through Hole 23 1 J48 RAPC712A Through Hole MS 806-KUSBVXBS1N-B MS 502-RAPC712X 24 2 J66,J67 CON2 Through Hole S1011E-36-ND PBC36SAAN 25 2 LOGO1,LOGO2 Logo Silkscreen — — — — 26 5 TP1,TP2,TP5,TP6,TP7 TP Through Hole S1011E-36-ND PBC36SAAN Sullins Connector Solutions Yes 27 8 Q10,Q11,Q12,Q13,Q14,Q15,Q 16,Q17 SOT-23-3 NUD3112LT1GOSCTND NUD3112LT1G ON Semiconductor Yes 28 8 Through Hole 255-1446-ND ALZ12F12 Panasonic Yes 29 1 0603 P16.9KHCT-ND ERJ-3EKF1692V Panasonic Yes 30 9 2K 0603 P2.0KGCT-ND ERJ-3GEYJ202V Panasonic Yes 31 32 1 2 RL1,RL2,RL3,RL4,RL5,RL6,RL 7,RL8 R1 R2,R16,R22,R27,R32,R37,R42, R47,R52 R3 R4,R7 20.0K 1% 750 0.1% 0603 0603 ERJ-3EKF2002V ERA-3YEB751V Panasonic Panasonic Yes Yes 33 4 R5,R6,R8,R9 1M 0.1% 1206 RN732BTTD1004B25 KOA Speer Yes 34 3 470 0603 ERJ-3GEYJ471V Panasonic Yes 35 10 R15,R60,R62 R17,R21,R26,R31,R36,R41,R4 6,R51,R59,R61 P20.0KHCT-ND P750YCT-ND MS 660RN732BTTD1004B25 P470GCT-ND 10K 0603 P10.0KHCT-ND ERJ-3EKF1002V Panasonic Yes 36 8 0.0005 2512 MS 66ULRB2R0005FLFSLT ULRB22512R0005FL FSLT IRC Yes 37 8 750 0603 P750GCT-ND ERJ-3GEY0R00V Panasonic Yes 38 39 1 2 330 0 0603 0603 P330HCT-ND P0.0GCT-ND ERJ-3EKF3300V ERJ-3GEY0R00V Panasonic Panasonic Yes Yes 40 16 75K 0603 RG16P75.0KBCT-ND RG1608P-753-B-T5 Susumu Yes Rev 3 R19,R29,R34,R39,R44,R49,R5 4,R81 R20,R25,R30,R35,R40,R45,R5 0,R55 R58 R71,R72 R73,R76,R77,R80,R82,R85, R86,R89,R90,R93,R95,R97, R99,R101,R102,R105 INDCT LOAD/RELAY DRVR 16A 12V SPDT Low Profile 16.9K 1% Yes 23 78M6618 PDU1 Evaluation Board User Manual Item Qty Reference R74,R75,R78,R79,R83,R84, R87,R88,R91,R92,R94,R96, R98,R100,R103,R104 UM_6618_022 Part PCB Footprint Digi-Key MS - Mouser Part Number Manufacturer RoHS 7.5k 0603 RG16P7.5KBCT-ND RG1608P-752-B-T5 Susumu Yes 11K 0603 P11KGCT-ND ERJ-3GEYJ113V Panasonic Yes 2.5k 0603 DNP — — — 41 16 42 1 43 8 44 1 TP3 Wh Through Hole S1011E-36-ND PBC36SAAN 45 1 TP4 TEST POINT Through Hole S1011E-36-ND PBC36SAAN 46 47 48 1 1 1 U1 U2 U3 78M6618-68QFN FTDI 28-SSOP ADUM3201 68-QFN 28-SSOP 8-SOIC — 768-1007-1-ND ADUM3201ARZ-ND — FT232RL-REEL ADUM3201ARZ 49 4 U4,U5,U6,U7 OP AMP 8-SOIC LM2904MXCT-nd LM2904MX 50 2 U10,U11 78L33 SOT-89-3 497-1200-1-ND L78L33ACUTR 51 1 Y1 32.768KHz 4-SOJ 535-9166-1-ND ABS25-32.768KHZ-T 52 6 MT1,MT2,MT3,MT4,MT5,MT6 STANDOFFS Through Hole MS 534-1809 1809 53 6 standoff bumpers RUBBER N/A MS 534-720 720 54 12 # 4 screws for stand offs Screws Through Hole H346 PMS 440 0050 PH 24 R106 R107,R108,R109,R110,R111, R112,R113,R114 Sullins Connector Solutions Sullins Connector Solutions Maxim FTDI Analog Devices ROHM Semiconductor STMicroelectronics Abracon Corporation Keystone Electronics Keystone Electronics B&F Fastener Supply Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Rev 3 UM_6612_016 5.3 78M6618 PDU1 Evaluation Board User Manual 78M6618 PDU1 Evaluation Board PCB Layouts Figure 13: 78M6618 PDU1 Evaluation Board PCB Top View Figure 14: 78M6618 PDU1 Evaluation Board PCB Power View Figure 15: 78M6618 PDU1 Evaluation Board PCB GND View Figure 16: 78M6618 PDU1 Evaluation Board PCB Bottom View Rev 3 25 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 6 Ordering Information Part Description Order Number 78M6618 PDU1 Evaluation Board 78M6618-PDU-1 7 Contact Information For more information about Maxim products or to check the availability of the 78M6618, contact technical support at www.maxim-ic.com/support. 26 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Appendix A - 78M6618 PDU1 Board with CTs This appendix includes the photograph, schematics, bill of materials, and layout images for a comparable 78M6618 PDU1 evaluation board using current transformers (CTs) in place of current shunt resistors. The information on this board is provided as reference only and is not available for purchase. A.1 78M6618 PDU-CT Evaluation Board Figure 17: 78M6618 PDU-CT Evaluation Board Rev 3 27 78M6618 PDU1 Evaluation Board User Manual A.2 UM_6618_022 78M6618 PDU-CT Evaluation Board Schematics . V3P3 V3P3 51 C1 10uF 25V 1812 DigiKey 478-1762-1-ND V3P3A V2P5 48 V2P5 62 VREF C2 0.1uF 0603 + GND GND VREF 61 60 59 58 57 56 55 54 OUTCUR1 OUTCUR2 OUTCUR3 OUTCUR4 OUTCUR5 OUTCUR6 OUTCUR7 OUTCUR8 IA IB IC ID IE IF IG IH V1 NEUTV 52 U1-1 78M6618-68QFN QFN68 1 1 2 3 J4 AC Inlet PX0580 MS 562-PX0580/PC 1 1 J2 CON1 SIPW2 J3 CON1 SIPW2 J6 CON1 SIPW2 Line/Black Neutral/White Egnd/Green J1 ACTERM K1287 MS 534-1287-ST 1 2 J5 ACTERM K1287 MS 534-1287-ST 1 2 J7 ACTERM K1287 MS 534-1287-ST 1 2 EGND Green LINE Black To Relay s Y1 32.768KHz CM200S 535-9166-1-ND XOUT 68 GND 4 XOUT C9 9pF 0603 GND J8 Weco Tst SIP100P2 EGND LINE +12VDC 2 NEUTRAL White 1 AC2 AC1 VR1 FSKS5-12V FSKS5 102-1471-ND NEUTRAL MT1 XIN 66 1 2 1 1 J83 CON1 SIP100P1 GNDA2 GNDA1 C8 1000pF 0603 MT13 J82 CON1 SIP100P1 XIN GND C7 33pF 0603 VA VB R3 20.0K 1% 0603 1 53 65 1 R7 750 0.1% 0603 LINEV 50 J85 CON1 SIP100P1 R8 R9 1M 0.1% 1M 0.1% 1206W 1206W MS 660-RN732BTTD1004B25 R1 16.9K 1% 0603 C5 100pF 0603 GND +12V GND 5 4 C10 0.1uF 0603 J9 Weco Tst RAPC712A MS 502-RAPC712 + 3 2 1 C11 220uF 25V lo imp UUDB MS 647-UUD1E221MNL 3 VIN C12 1uF 20V 1206P GND TAB GND 1 C6 1000pF 0603 V3P3 R2 2K 0603 V1 63 VOUT VR2 +3.3V 500mA MS 511-LD1117S33C SOT223 V3P3 4 2 1 J84 CON1 SIP100P1 R4 750 0.1% 0603 C4 NC 0603 GND +/-250mVpp +/-178mVrms R5 R6 1M 0.1% 1M 0.1% 1206W 1206W MS 660-RN732BTTD1004B25 C3 0.1uF 0603 GND C14 1uF 0603 V3P3 + C13 10uF 25V 1812 DigiKey 478-1762-1-ND GND MT2 MS 561-PS500A MS 561-PS500A MT4 MT3 MT7 MT6 MS 561-PS500A MT11 MS 561-PS500A LOGO4 MS 561-PS500A MS 561-PS500A MT5 MT8 MT9 MS 561-PS500A MT12 MS 561-PS500A LOGO5 1 1 LOGO6 LOGO3 LOGO1 LOGO2 1 1 1 1 MT10 MT14 MT15 MT16 TERIDIAN SEMICONDUCTOR CORP. Warning TERIDIAN Title Power Distribution Unit 8 Outlet Single Phase with CTs Size B Document Number PDUCTV1 Date: Monday , March 01, 2010 Rev 1 Sheet 1 of 4 Figure 18: 78M6618 PDU-CT Evaluation Board Electrical Schematic (1 of 4) 28 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual . +12VDC LINE NEUTRAL EGND LINE R10 2K 0603 NEUTRAL LED, Green MS 604-WP1503GD 2 1 EGND RL1 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 1 2 3 J21 AC Outlet PX0675 MS 562-PX0675/PC 1 J20 ACTERM K1287 Line/Black MS 534-1287-ST J23 Neutral/White ACTERM K1287 MS 534-1287-ST J25 Egnd/Green ACTERM K1287 MS 534-1287-ST 1 1 J37 AC Outlet PX0675 MS 562-PX0675/PC 1 1 J35 ACTERM K1287 Line/Black MS 534-1287-ST J39 Neutral/White ACTERM K1287 MS 534-1287-ST J41 Egnd/Green ACTERM K1287 MS 534-1287-ST R12 4.99 1% 1210 MS 660-SR732ETTE4R99F 1 2 RL2 16A 12V SPDT Low Prof ile ALZ 255-1446-ND RELAY 2 2 1 1 2 +12VDC RLY 3 CT2 CT020P2A CT020P2A Oswell R17 4.99 1% 1210 MS 660-SR732ETTE4R99F OUTLET3 1 2 RL3 16A 12V SPDT Low Prof ile ALZ 255-1446-ND RELAY 3 +12VDC RLY 4 R22 4.99 1% 1210 MS 660-SR732ETTE4R99F OUTLET4 1 2 RL4 16A 12V SPDT Low Prof ile ALZ 255-1446-ND C17 1000pF 0603 OUTCUR3 OUTCUR3 R24 750 0603 J33 LED SIP100P2 V3P3 R26 1K 0603 Q4 NPN 500ma 30V SOT23T MS 512-MMBTA13 RELAY 4 R28 10K 0603 7 8 1 2 OUTCUR2 LED, Green MS 604-WP1503GD 2 1 1 2 OUTCUR2 V3P3 CT3 CT020P2A CT020P2A Oswell GND R25 2K 0603 C16 1000pF 0603 J26 LED SIP100P2 R23 10K 0603 7 8 1 2 OUTCUR1 R19 750 0603 R21 1K 0603 Q3 NPN 500ma 30V SOT23T MS 512-MMBTA13 OUTCUR1 V3P3 R18 10K 0603 R20 2K 0603 C15 1000pF 0603 J18 LED SIP100P2 GND 3 4 1 1 2 3 J36 CON1 SIPW2 J38 CON1 SIPW2 J40 CON1 SIPW2 CT1 CT020P2A CT020P2A Oswell R14 750 0603 R16 1K 0603 7 8 OUTLET2 5 6 1 2 3 J29 AC Outlet PX0675 MS 562-PX0675/PC J28 ACTERM K1287 Line/Black MS 534-1287-ST J31 Neutral/White ACTERM K1287 MS 534-1287-ST J34 Egnd/Green ACTERM K1287 MS 534-1287-ST R15 2K 0603 Q2 NPN 500ma 30V SOT23T MS 512-MMBTA13 1 2 3 4 1 J27 CON1 SIPW2 J30 CON1 SIPW2 J32 CON1 SIPW2 RELAY 1 +12VDC RLY 2 5 6 1 J19 CON1 SIPW2 J22 CON1 SIPW2 J24 CON1 SIPW2 V3P3 R13 10K 0603 2 1 1 2 3 4 1 1 2 1 2 V3P3 GND 5 6 1 OUTLET1 1 2 1 1 2 1 2 1 2 3 J14 AC Outlet PX0675 MS 562-PX0675/PC J12 ACTERM K1287 Line/Black MS 534-1287-ST J15 Neutral/White ACTERM K1287 MS 534-1287-ST J17 Egnd/Green ACTERM K1287 MS 534-1287-ST 1 2 1 J11 CON1 SIPW2 J13 CON1 SIPW2 J16 CON1 SIPW2 J10 LED SIP100P2 R11 1K 0603 Q1 NPN 500ma 30V SOT23T MS 512-MMBTA13 7 8 3 4 5 6 +12VDC RLY 1 CT4 CT020P2A CT020P2A Oswell R27 4.99 1% 1210 MS 660-SR732ETTE4R99F C18 1000pF 0603 OUTCUR4 OUTCUR4 R29 750 0603 GND 1 2 TERIDIAN SEMICONDUCTOR CORP. Title Power Distribution Unit 8 Outlet Single Phase with CTs Size B Document Number PDUCTV1 Date: Monday , March 01, 2010 Rev 1 Sheet 2 of 4 Figure 19: 78M6618 PDU-CT Evaluation Board Electrical Schematic (2 of 4) Rev 3 29 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 . +12VDC LINE NEUTRAL EGND LINE R30 2K 0603 NEUTRAL LED, Green MS 604-WP1503GD 2 1 EGND RL5 16A 12V SPDT Low Prof ile ALZ 255-1446-ND 1 2 J53 3 AC Outlet PX0675 MS 562-PX0675/PC 1 J52 ACTERM K1287 Line/Black MS 534-1287-ST J55 Neutral/White ACTERM K1287 MS 534-1287-ST Egnd/Green J58 ACTERM K1287 MS 534-1287-ST 1 1 1 2 RL6 16A 12V SPDT Low Prof ile ALZ 255-1446-ND J70 AC Outlet PX0675 MS 562-PX0675/PC 1 1 J67 ACTERM Line/Black K1287 MS 534-1287-ST J71 Neutral/White ACTERM K1287 MS 534-1287-ST J73 Egnd/Green ACTERM K1287 MS 534-1287-ST RELAY 6 2 1 1 2 +12VDC RLY 7 CT6 CT020P2A CT020P2A Oswell R37 4.99 1% 1210 MS 660-SR732ETTE4R99F OUTLET7 1 2 RL7 16A 12V SPDT Low Prof ile ALZ 255-1446-ND RELAY 7 +12VDC RLY 8 R42 4.99 1% 1210 MS 660-SR732ETTE4R99F OUTLET8 1 2 RL8 16A 12V SPDT Low Prof ile ALZ 255-1446-ND C21 1000pF 0603 OUTCUR7 OUTCUR7 R44 750 0603 J66 LED SIP100P2 V3P3 R46 1K 0603 Q8 NPN 500ma 30V SOT23T MS 512-MMBTA13 RELAY 8 R48 10K 0603 7 8 1 2 OUTCUR6 LED, Green MS 604-WP1503GD 2 1 1 2 OUTCUR6 V3P3 CT7 CT020P2A CT020P2A Oswell GND R45 2K 0603 C20 1000pF 0603 J57 LED SIP100P2 R43 10K 0603 7 8 1 2 OUTCUR5 R39 750 0603 R41 1K 0603 Q7 NPN 500ma 30V SOT23T MS 512-MMBTA13 OUTCUR5 V3P3 R38 10K 0603 R40 2K 0603 C19 1000pF 0603 J50 LED SIP100P2 GND 3 4 1 1 2 3 J68 CON1 SIPW2 J69 CON1 SIPW2 J72 CON1 SIPW2 R32 4.99 1% 1210 MS 660-SR732ETTE4R99F CT5 CT020P2A CT020P2A Oswell R34 750 0603 R36 1K 0603 7 8 OUTLET6 5 6 1 2 3 J61 AC Outlet PX0675 MS 562-PX0675/PC J60 ACTERM K1287 Line/Black MS 534-1287-ST J63 Neutral/White ACTERM K1287 MS 534-1287-ST Egnd/Green J65 ACTERM K1287 MS 534-1287-ST R35 2K 0603 Q6 NPN 500ma 30V SOT23T MS 512-MMBTA13 1 2 3 4 1 J59 CON1 SIPW2 J62 CON1 SIPW2 J64 CON1 SIPW2 RELAY 5 +12VDC RLY 6 5 6 1 J51 CON1 SIPW2 J54 CON1 SIPW2 J56 CON1 SIPW2 V3P3 R33 10K 0603 2 1 1 2 3 4 1 1 2 1 2 V3P3 GND 5 6 1 OUTLET5 1 2 1 1 2 1 2 1 2 3 J46 AC Outlet PX0675 MS 562-PX0675/PC J44 ACTERM K1287 Line/Black MS 534-1287-ST J47 Neutral/White ACTERM K1287 MS 534-1287-ST J49 Egnd/Green ACTERM K1287 MS 534-1287-ST 1 2 1 J43 CON1 SIPW2 J45 CON1 SIPW2 J48 CON1 SIPW2 J42 LED SIP100P2 R31 1K 0603 Q5 NPN 500ma 30V SOT23T MS 512-MMBTA13 7 8 3 4 5 6 +12VDC RLY 5 CT8 CT020P2A CT020P2A Oswell R47 4.99 1% 1210 MS 660-SR732ETTE4R99F C22 1000pF 0603 OUTCUR8 OUTCUR8 R49 750 0603 GND 1 2 TERIDIAN SEMICONDUCTOR CORP. Title Power Distribution Unit 8 Outlet Single Phase with CTs Size B Document Number PDUCTV1 Date: Monday , March 01, 2010 Rev 1 Sheet 3 of 4 Figure 20: 78M6618 PDU-CT Evaluation Board Electrical Schematic (3 of 4) 30 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual . V3P3 V3P3 1 2 3 4 5 6 Reset Switch EVQ-PJX05M Panasonic 1K 1K 1000pF R54 330 0603 GND C28 0.1uF V3P3 0603 GND USB5V USBDM USBDP 15 14 C29 4.7uF 1206P 18 5 12 13 25 29 23 1.5M A/B White Cable Mouser 571-1487588-2 27 28 16 RXD TXD USBDM USBDP RTS CTS DTR DSR DCD RI RESETB NC1 NC2 NC3 NC4 NC5 NC6 CBUS0 CBUS1 CBUS2 CBUS3 CBUS4 OSCI OSCO 3V3OUT 24 4 17 20 26 C30 0.1uF 0603 VCCIO VCC AGND GND1 GND2 GND3 TEST J78 USB-B MS 154-2442-E USBB 1 2 3 4 5 6 22 21 10 11 9 11 9 V3P3D 47 4 2 1 36 TP1 TP TPWW TP2 TP TPWW 1 1 10 6 7 46 2 30 32 8 31 6 7 3 37 38 R55 0 0603 J79 V3P3 DEBUG SIP100P4 1 2 3 4 GND U2 FT232QFN32 MS 895-FT232RQ FTQFN32 GND UTX URX R57 10K 0603 DIO2 DIO1 17 18 ERXTX/SEG9 ETCLK/SEG10 ERST/SEG11 ICEE DIO3 DIO7/SEG27 DIO8/SEG28 DIO9/SEG29 DIO10/SEG30 DIO11/SEG31 DIO13/SEG33 DIO14/SEG34 DIO15/SEG35 DIO16/SEG36 DIO17/SEG37 DIO18/SEG38 DIO19/SEG39 DIO43/SEG63 CKTEST/SEG19 TMUXOUT TX RX I2C Master f or EEPROM DIO16 DIO19 DIO43 DIO5 DIO4 DIO3 DIO1 DIO2 DIO18 DIO17 no connect no connect no connect SMBRXD SMBCLOCK SMBTXLOB SMBCKHDB SMBALTRB no connect no connect CE SLE SDATA SREAD SCLK INT DATAIO DATACLK GND GND CSN TRXCE PWRUP MISO SCK DR MOSI CD TXEN no connect SDI CLK SDO CSZ SDA SCL V3P3 16 40 42 43 44 45 29 22 23 24 14 15 41 28 1 2 1 2 R52 470 0603 R53 470 0603 J75 ACTIVE SIP100P2 MS 604-WP1503Y D LED, Y el DIO3 DIO16 DIO17 DIO18 DIO19 DIO43 V3P3 RELAY 8 RELAY 7 RELAY 6 RELAY 5 RELAY 4 RELAY 3 RELAY 2 RELAY 1 DIO16 DIO19 DIO43 DIO5 DIO4 DIO3 DIO1 DIO2 V3P3 PCLK PSDI PSDO PCSZ PCLK/SEG3 PSDI/SEG6 PSDO/SEG4 PCSZ/SEG5 8 25 12 13 PCLK PSDI PSDO PCSZ R58 470 0603 J81 FAULT SIP100P2 MS 604-WP1503ID LED, Red 3 67 U1-2 78M6618-68QFN QFN68 39 OneNet interf ace to ADF7025 DIO18 GND DIO6 V3P3 R63 10K 0603 1 3 5 7 9 2 4 6 8 10 Internal slav e SPI controller CLK SDI SDO CSZ GND V3P3 V3P3 WPULSE/DIO6/SEG26 DIO17 18 16 14 12 10 8 4 6 2 J80 SPI1 DIP100P10 COM0 COM1 OPTX/DIO2 OPRX/DIO1 17 15 13 11 9 7 5 3 1 J77 ONENET DIP100P18 SEG0 SEG1 SEG2 SEG7 SEG8 SEG12 SEG14 SEG15 SEG16 SEG17 SEG18 GND 5 64 Alternate bit-bang SPI interf ace J74 READY SIP100P2 MS 604-WP1503GD LED, Grn GNDD1 ADI TX/RX data interf ace 19 20 21 26 27 30 31 32 33 34 35 R56 0 0603 PacketPower DIO4 DIO5 GND GND 1 19 RESET SDCK/DIO4/SEG24 SDATA/DIO5/SEG25 V3P3 ICE inputs become LCD seg driv ers when ICEE low RXTX TCLK ERST ICEEN C27 1000pF 0603 49 VBAT RESET R51 0 0603 C26 NC 0603 OneNet 2 1 J76 ICE SIP100P6 SW1 NC EP11 GNDD2 Optional SW1 R56 R57 C28 GND V3P3SYS R50 NC 0603 C25 0.1uF 0603 C24 0.1uF 0603 GND SM Bus 2 1 C23 1uF 0603 810-C1608X5R1C105M GND J37 Pins SM Bus Address R59 NC 0603 R60 NC 0603 R61 NC 0603 R62 NC 0603 R64 NC 0603 R65 NC 0603 R66 NC 0603 R67 NC 0603 DIO16 DIO18 DIO19 DIO43 TP3 Wh SIP100P2 Pulse Output GND GND TERIDIAN SEMICONDUCTOR CORP. Title Power Distribution Unit 8 Outlet Single Phase with CTs Size B Document Number PDUCTV1 Date: Monday , March 01, 2010 Rev 1 Sheet 4 of 4 Figure 21: 78M6618 PDU-CT Evaluation Board Electrical Schematic (4 of 4) Rev 3 31 78M6618 PDU1 Evaluation Board User Manual A.3 UM_6618_022 78M6618 PDU-CT Evaluation Board Bill of Materials Table 3: 78M6618 PDU-CT Evaluation Board Bill of Materials Item Q Reference Part PCB Footprint Part Number 1 8 CT1,CT2,CT3,CT4,CT5,CT6,CT7,CT8 CT020P2A CT020P2A 582-1084-ND 2 2 C1,C13 10uF 25V 1812 478-1762-1-ND 3 7 C2,C3,C10,C24,C25,C28,C30 0.1uF 603 490-1519-1-ND 4 1 C5 100pF 603 445-1281-1-ND 5 11 C6,C8,C15,C16,C17,C18, C19,C20,C21,C22,C27 1000pF 603 445-1298-1-ND 6 1 C7 33pF 603 399-1055-1-ND 7 1 C9 9pF 603 445-5046-1-ND 8 1 C11 220uF 25V lo imp UUDB MS 647-UUD1E221MNL 9 1 C12 1uF 20V 1206P 445-1381-1-ND 10 2 C14,C23 1uF 603 445-1328-1-ND 11 1 C29 4.7uF 1206P 478-2396-1-ND 12 1 J4 AC Inlet PX0580 MS 161-PX0580/PC 13 1 J8 Weco Tst SIP100P2 S1011E-36-ND 14 1 J9 Weco Tst RAPC712A MS 502-RAPC712x 15 9 J10,J18,J26,J33,J42,J50,J57,J66,J74 LED,GREEN SIP100P2 MS 604-WP1503GD 16 8 J14,J21,J29,J37,J46,J53,J61,J70 AC Outlet PX0675 MS 161-PX0675/PC 17 1 J75 ACTIVE,YELLOW SIP100P2 MS 604-WP1503YD 18 1 J76 ICE SIP100P6 S1011E-36-ND 19 1 J77 ONENET DIP100P18 S2011E-36-ND 20 1 J78 USB-B USBB MS 154-2442-E 21 1 J79 DEBUG SIP100P4 S1011E-36-ND 22 1 J80 SPI1 DIP100P10 S2011E-36-ND 23 1 J81 FAULT,RED SIP100P2 MS 604-WP1503ID 24 8 MT1,MT2,MT3,MT4,MT5,MT6,MT11,MT12 TP MTGPS.PRT MS 561-PS500A 25 8 Q1,Q2,Q3,Q4,Q5,Q6,Q7,Q8 NPN 500ma 30V SOT23T MS 512-MMBTA13 26 8 RL1,RL2,RL3,RL4,RL5,RL6,RL7,RL8 16A 12V SPDT ALZ 255-1446-ND 32 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Item Q Reference Part PCB Footprint Part Number 27 1 R1 16.9K 1% 603 P16.9KHCT-ND 28 9 R2,R10,R15,R20,R25,R30,R35,R40,R45 2K 603 P2.0KGCT-ND 29 1 R3 20.0K 1% 603 P20.0KHCT-ND 30 2 R4,R7 750 0.1% 603 P750YCT-ND 31 4 R5,R6,R8,R9 1M 0.1% 1206W 32 8 R11,R16,R21,R26,R31,R36,R41,R46 1K 603 P1.00KHCT-ND 33 8 R12,R17,R22,R27,R32,R37,R42,R47 4.99 1% 1210 MS SR732ELTE4R99F 34 10 R13,R18,R23,R28,R33, R38,R43,R48,R57,R63 10K 603 P10.0KHCT-ND 35 8 R14,R19,R24,R29,R34, R39,R44,R49 750 5% 603 P750GCT-ND 36 3 R51,R55,R56 0 603 P0.0GCT-ND 37 3 R52,R53,R58 470 603 P470GCT-ND 38 1 R54 330 603 P330HCT-ND 39 1 TP3 Wh SIP100P2 S1011E-36-ND 40 1 U1 78M6618-IM/F QFN68 Maxim 41 1 U2 FT232QFN32 FTQFN32 MS 895-FT232RQ 42 1 VR1 FSKS5-12V FSKS5 102-1471-ND 43 1 VR2 +3.3V 500mA SOT223 497-1241-1-ND 44 1 Y1 32.768KHz CM200S 535-9166-1-ND Rev 3 33 78M6618 PDU1 Evaluation Board User Manual A.4 UM_6618_022 78M6618 PDU-CT Evaluation Board PCB Layouts Figure 22: 78M6618 PDU-CT Evaluation Board PCB Top View 34 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Figure 23: 78M6618 PDU-CT Evaluation Board PCB Bottom View Rev 3 35 78M6618 PDU1 Evaluation Board User Manual UM_6618_022 Appendix B – 78M6618 PDU1 Version 1 (Single-Ended Shunt) This appendix includes a photograph of the original 78M6618 PDU1 evaluation board using a single-ended shunt topology. The user documentation for this board is available by request. This board is no longer available for purchase. 36 Rev 3 UM_6618_022 78M6618 PDU1 Evaluation Board User Manual Revision History REVISION NUMBER REVISION DATE 1.0 3/10/2010 2.0 9/11 Changed the document to reflect the new board revision. Added Appendix B. 11/11 Removed “_DIFF” from “PDU1_DIFF” in all places except where referring to the board imprint. Deleted the NI RunTime, LabWindows, and Trouble-Shooting sections. These sections are no longer applicable. Corrected Table 1, COM Port Setup Parameters. Replaced Figure 2 with a new screenshot. 3 Rev 3 DESCRIPTION First publication. 37