PT4500 Series 20-W 24-V Input Isolated DC/DC Converter SLTS153B - JUNE 2000 - REVISED OCTOBER 2002 Features • Input Voltage Range: 18V to 40V • 20W Rated • Output Voltages: 1.2V to 15V • 82% Efficiency • 1500 VDC Isolation • Low Profile (8.5 mm) • Adjustable Output Voltage • • • • • On/Off Control Differential Remote Sense Short Circuit Protection Over Temperature Shutdown Space Saving Package: 1.0 sq. in. PCB Area (Suffix N) • 4×106 Hrs MTBF Description Ordering Information The PT4500 Excalibur™ power modules are a series of isolated DC/DC converters housed a new space-saving copper case. The series includes a number of standard output voltages ranging from as low as 1.2VDC to 15VDC, each adjustable by up to 10% of nominal. The modules are ideal for Telecom, Industrial, Computer, and other distributed power applications that require input-to-output isolation. Using multiple modules, system designers can implement a complete custom power supply solution. The flexibility of full isolation also allows the input or output to be configured for negative voltage operation. The PT4500 series is electrically equivalent to the popular PT4140 series and requires no additional components for proper operation. PT4501H PT4502H PT4503H PT4504H PT4506H PT4507H PT4508H PT4509H = = = = = = = = 3.3V/5A 5.0V/4A 12V/1.6A 15V/1.3A 1.5V/5A 1.8V/5A 2.5V/5A 1.2V/5A Pin-Out Information (16.5W) Remote On/Off 2 –Vin 3 –Vin 4 +Vin 5 +Vin 6 Remote Sense (–) 7 –Vout PT Series Suffix (PT1234x ) 8 –Vout Case/Pin Configuration Package Code 9 +Vout 10 +Vout (ELJ) (ELK) (ELL) 11 Remote Sense (+) 12 Vout Adjust * (7.5W) (9W) (12.5W) (6W) Order Suffix N A C Vertical Horizontal SMD (Reference the applicable package code drawing for the dimensions and PC board layout) Remote Sense (+) 11 4, 5 –VIN 2, 3 9, 10 +V OUT 7, 8 –VOUT PT4500 1 Remote On/Off Function 1 Standard Application +V IN Pin 12 LOAD 6 Remote Sense (–) Q1 BSS138 For technical support and more information, see inside back cover or visit www.ti.com VOAdj * * For further information, see application notes. PT4500 Series 20-W 24-V Input Isolated DC/DC Converter Specifications SLTS153B - JUNE 2000 - REVISED OCTOBER 2002 (Unless otherwise stated, Ta =25°C, V in =24V, Cout =0µF, and Io =Io max) Characteristic Symbol Output Current Io Conditions Over Vin range Input Voltage Range Set Point Voltage Tolerance Temperature Variation Line Regulation Load Regulation Vin Vo tol Regtemp Regline Regload Over Io Range Total Output Voltage Variation ∆Votot Includes set-point, line, load, –40° ≤Ta ≤ +85°C Efficiency η –40° ≤Ta ≤ +85°C, Io =Iomin Over Vin range Over Io range Min Vo = 15V Vo = 12V Vo =5.0V Vo ≤ 3.3V Vo ≥5.0V Vo ≤3.3V Vo = 15V Vo = 12V Vo =5.0V Vo =3.3V Vo =1.8V Vo =1.5V Vo =1.2V Vo ≥ 5.0V Vo ≤ 3.3V Vo Ripple (pk-pk) Vr 20MHz bandwidth Transient Response ttr 0.1A/µs load step, 50% to 100% Iomax Vo over/undershoot Vo ≥ 5.0V Vo ≤ 3.3V Vin =18V, ∆Vo = –1% ∆Vtr Current Limit Threshold Output Voltage Adjust Switching Frequency Ilim Vo adj ƒs Under-Voltage Lockout Remote On/Off (Pin 1) High-Level Input Voltage Low-Level Input Voltage Low-Level Input Current UVLO VIH VIL IIL Standby Input Current Internal Input Capacitance External Output Capacitance Isolation Voltage Capacitance Resistance Operating Temperature Range Solder Reflow Temperature Storage Temperature Reliability Iin standby Cin Cout Mechanical Shock — Mechanical Vibration — Weight Flammability — — Ta Treflow Ts MTBF Over Vin range Vo ≥ 5.0V Vo ≤ 3.3V Referenced to –Vin (pin 2) pins 1 & 2 connected Input–output/input–case Input to output Input to output Over Vin range Surface temperature of module pins or case — Per Bellcore TR-332 50% stress, Ta =40°C, ground benign Per Mil-Std-883D, method 2002.3, 1mS, half-sine, mounted to a fixture Mil-Std-883D, Method 2007.2 Suffix N 20-2000Hz, soldered Suffix A, C — Materials meet UL 94V-0 PT4500 SERIES Typ Max Units 0.1 (1) 0.1 (1) 0.1 (1) 0.1 (1) 18 — — — — — — — — — 24 ±1 ±0.5 ±0.2 ±0.4 ±13 1.3 1.6 4 5 40 ±1.5 — ±1 ±1 ±33 (2) — ±2 ±3 (2) — — — — — — — — — — — — — — 600 800 — 86 83 82 79 67 65 59 0.5 15 100 ±3 ±150 200 ±10 650 850 16.5 — — — — — — — — — — — — — — 700 900 — 2.5 –0.2 — — — 0 1500 — 10 –40 — –40 — — –10 7 0.5 — — 1100 — — — — Open (3) 0.8 – 10 — 220 (4) — — — 85 (5) 215 (6) 125 µA mA µF µF V pF MΩ °C °C °C 4 — — 106 Hrs — 500 — G’s — — — 20 (7) 20 (7) 23 — — — G’s A (2) VDC %Vo %Vo %Vo %Vo mV %Vo % %Vo mVpp µs %Vo mV %Iomax % kHz V V grams Notes: (1) The DC/DC converter will operate at no load with reduced specifications. (2) For optimum voltage accuracy the ‘Remote Sense (+)’ and ‘Remote Sense (–)’ pins must be connected to +Vout and –V out respectively. (3) The Remote On/Off control (pin 1) has an internal pull-up. If pin 1 is left open the PT4500 will operate when input power is applied. A small lowleakage (<100nA) MOSFET must be used to control this input. The open-circuit voltage is less than 10V. See application notes for further information. (4) External output capacitance is not required for proper operation. Capacitamce may be added to improve the response to load transients. The maximum total capacitance (including the load circuit) must not exceed 220µF, and the combined ESR of must not be less than 100mΩ. (5) See Safe Operating Area curves or contact the factory for the appropriate derating. (6) During solder reflow of SMD package version do not elevate the module case, pins, or internal component temperatures above a peak of 215°C. For further guidance refer to the application note, “Reflow Soldering Requirements for Plug-in Power Surface Mount Products,” (SLTA051). (7) The case pins on the through-hole package types (suffixes N & A) must be soldered. For more information see the applicable package outline drawing. For technical support and more information, see inside back cover or visit www.ti.com Typical Characteristics PT4500 Series 20-W 24-V Input Isolated DC/DC Converter PT4501, 3.3 VDC SLTS153B - JUNE 2000 - REVISED OCTOBER 2002 PT4502, 5 VDC (See Note A) Efficiency vs Output Current 70 18.0V 24.0V 30.0V 36.0V 60 90 80 VIN 70 18.0V 24.0V 30.0V 36.0V 60 50 1 2 3 4 5 Ripple vs Output Current 1 3 4 0 VIN 30 36.0V 30.0V 24.0V 18.0V 20 10 VIN 30 36.0V 30.0V 24.0V 18.0V 20 4 5 1 Iout (A) 2 3 0.4 0.8 2 Power Dissipation vs Output Current 2 1 0 3 4 36.0V 30.0V 24.0V 18.0V 3 0 5 5 VIN 4 1 VIN 4 18.0V 24.0V 30.0V 36.0V 3 2 1 0 0 1 Iout (A) 2 3 4 0 0.4 0.8 Iout (A) 60 50 40 30 20 90 80 Airflow 70 300LFM 200LFM 100LFM Nat conv 60 50 40 30 5 80 Airflow 70 300LFM 200LFM 100LFM Nat conv 60 50 40 30 20 20 4 Ambient Temperature (°C) 300LFM 200LFM 100LFM Nat conv Ambient Temperature (°C) Airflow 70 1.6 Safe Operating Area, Vin =24V (See Note B) 90 80 1.2 Iout (A) Safe Operating Area, Vin =24V (See Note B) Safe Operating Area, Vin =24V (See Note B) 90 1.6 6 Pd - Watts 3 Pd - Watts 36.0V 30.0V 24.0V 18.0V 1.2 Iout (A) 5 Iout (A) 20 0 VIN 4 3 36.0V 30.0V 24.0V 18.0V Power Dissipation vs Output Current 5 2 30 4 6 1 VIN Iout (A) Power Dissipation vs Output Current 0 40 0 0 6 1.6 10 0 3 1.2 Ripple vs Output Current 40 0 2 0.8 50 10 1 0.4 Iout (A) Ripple - mV 40 0 18.0V 24.0V 30.0V 36.0V Ripple vs Output Current Ripple - mV Ripple - mV 2 50 2 70 Iout (A) 50 1 VIN 50 0 Iout (A) 0 80 60 50 0 Pd - Watts Efficiency - % VIN Efficiency - % Efficiency - % 90 80 (See Note A) Efficiency vs Output Current Efficiency vs Output Current 90 Ambient Temperature (°C) PT4503, 12 VDC (See Note A) 0 1 2 3 4 Iout (A) 0 0.3 0.6 Note A: Characteristic data has been developed from actual products tested at 25°C. This data is considered typical data for the Converter. Note B: SOA curves represent the conditions at which internal components are at or below the manufacturer’s maximum operating temperatures For technical support and more information, see inside back cover or visit www.ti.com 0.9 Iout (A) 1.2 1.5 Application Notes PT4500/PT4520 Series Operating Features and System Considerations for the PT4500/PT4520 DC/DC Converters Output Current Limit The PT4500 and PT4520 series of DC/DC converters incorporate an output current limit. This protects both the module and upstream source against load faults. Applying a load, in excess of the current limit threshold, will simply cause the output voltage to drop. The output current remains limited, but continues to flow in the fault. The drop in output voltage will vary according to the severity of the fault. Applying a short circuit to the output will result in an output voltage of zero, and the fault current will be limited to a value slightly higher than the current limit threshold. Upon the removal of the load fault, the output voltage of the module will fully recover to its normal regulated output voltage. Primary-Secondary Isolation The PT4500 and PT4520 series of DC/DC converters incorporate electrical isolation between the input terminals (primary) and the output terminals (secondary). All converters are production tested to a withstand voltage of 1500VDC. The isolation complies with UL60950 and EN60950, and the requirements for operational isolation. This allows the converter to be configured for either a positive or negative input voltage source. Output Voltage Adjustment The output voltage is typcially adjustable over a range of ±10% of nominal. Consult the separate application note, “Ajusting the Output Voltage of the PT4500/PT4520 Series of Isolated DC/DC Converters.” Turn-On Time The typical turn-on time is typically 35 milliseconds at Vin =48V. This is from application of input power, or the removal of a low-voltage signal from the Remote On/Off (pin 1). This includes about about 5–10ms of delay time before the output voltage begins to rise. Turn-on time will vary slightly with input voltage, output load, and the total amount of capacitance connected to the output. Input Current Limiting The converter is not internally fused. For safety and overall system protection, the maximum input current to the converter must be limited. Active or passive current limiting can be used. Passive current limiting can be a fast acting fuse. A 125-V fuse, rated no more than 5A, is recommended. Active current limiting can be implemented with a current limited “Hot-Swap” controller. Thermal Considerations Airflow may be necessary to ensure that the module can supply the desired load current in environments with elevated ambient temperatures. The required airflow rate may be determined from the Safe Operating Area (SOA) thermal derating curves. These are provided in the “Typical Characteristics” section of the converter specifications. Remote On/Off Function The output voltage from the converter can be turned off from the primary side using the Remote On/Off control (pin 1). Consult the separate application note, “Using the Remote On/Off Function on the PT4500/PT4520 Series of Isolated DC/DC Converters.” Under-Voltage Lock-Out The Under-Voltage Lock-Out (UVLO) circuit prevents operation of the converter whenever the input voltage to the module is insufficient to maintain output regulation. Below the UVLO threshold the module is off and the Remote On/Off control (pin 1) is inoperative. Table 1-2 gives the applicable UVLO thresholds. Table 1-2; UVLO Thresholds Series UVLO Threshold Vin Range PT4520 PT4500 36 – 75V 18 – 40V 31V Typical 16.5V Typical For technical support and more information, see inside back cover or visit www.ti.com Application Notes PT4500/4520 Series Adjusting the Output Voltage of the PT4500/ PT4520 Series of Isolated DC/DC Converters The factory pre-set output voltage of TI’s PT4500 and PT4520 series of isolated DC/DC converters may be adjusted within a nominal ±10% range. Adjustment is made from the secondary side of the regulator1 with a single external resistor. For the input voltage range specified in the data sheet Table 2-1 gives the allowable adjustment range for each model, as Vo (min) and Vo (max). 4. Never connect capacitors to Vo adjust. Any capacitance added to the Vo adjust control pin will affect the stability of the converter. The values of (R1) [adjust down], and R2 [adjust up], can also be calculated using the following formulas. Adjust Up: An increase in the output voltage is obtained by adding a resistor, R2 between Vo Adjust (pin 12), and –Vout (pin 7, 8). Adjust Down: Add a resistor (R1), between Vo Adjust (pin 12), and +Vout (pin 9, 10). Ko(Va – Vr) – Rs Vr (Vo – Va) kΩ R2 = Ko (Va – Vo) kΩ = = = = = – Rs Original output voltage Adjusted output voltage Reference voltage (Table 2-1) Multiplier constant (Table 2-1) Internal series resistance (Table 2-1) Figure 2-1 2. The maximum rated output power for this series is 20W. An increase in the output voltage may therefore require a corresponding reduction in the maximum output current (see Table 2-1). The revised maximum output current must be determined as follows. 20 Io(max) = A, Va = Where Vo Va Vr Ko Rs Refer to Figure 2-1 and Table 2-2 for both the placement and value of the required resistor, (R1) or R2. Notes: 1. The PT4500 and PT4520 series of DC/DC converters incorporate isolation between the ±Vin and ±Vo terminals. Adjustment of the output voltage is made to the regulation circuit on the secondary or output side of the converter. (R1) +V o + V in (R1) Adj Down 4, 5 +Vin +Vout 9,10 PT4500/4520 2, 3 or 5A, whichever is less. Where Va is the adjusted ouput voltage. –Vin Remote On/Off 1 –Vout 7, 8 V o (adj) R2 Adjust Up 12 –V in –V o 3. Use only a single 1% resistor in either the (R1) or R2 location. Place the resistor as close to the module as possible. Table 2-1 DC/DC CONVERTER ADJUSTMENT RANGE AND FORMULA PARAMETERS Series Pt # 48V Bus 24V Bus Max Current 2 Vo(nom) Va(min) Va(max) Vr Ω) Ko (V·kΩ Ω) Rs (kΩ PT4529 PT4509 5A 1.2 1.05 1.35 0.6125 34.66 150.0 PT4526 PT4506 5A 1.5 1.35 1.65 1.225 67.07 43.2 PT4527 PT4507 5A 1.8 1.62 1.98 1.225 69.7 110.0 PT4528 PT4508 5A 2.5 2.25 2.75 1.225 64.2 187.0 For technical support and more information, see inside back cover or visit www.ti.com PT4521 PT4501 5A 3.3 2.95 3.65 1.225 69.3 187.0 PT4522 PT4502 4A 5.0 4.5 5.5 2.5 125.2 187.0 PT4523 PT4503 1.6A 12.0 10.8 13.2 2.5 139.8 110.0 PT4524 PT4504 1.3A 15.0 13.5 16.5 2.5 137.6 90.9 Application Notes continued PT4500/4520 Series Table 2-2 DC/DC CONVERTER SERIES ADJUSTMENT RESISTOR VALUES Series Pt # 48V Bus 24V Bus Vo(nom) Va(req’d) 1.05 1.1 1.15 1.2 1.25 1.3 1.35 1.4 1.45 1.5 1.55 1.6 1.65 1.7 1.75 1.8 1.85 1.9 1.95 2.25 2.3 2.35 2.4 2.45 2.5 2.55 2.6 2.65 2.7 2.75 2.95 3.0 3.05 3.1 3.15 3.2 3.25 3.3 3.35 3.4 3.45 3.5 3.55 3.6 3.65 PT4529 PT4509 1.2Vdc PT4526 PT4506 1.5Vdc PT4527 PT4507 1.8Vdc PT4528 PT4508 2.5Vdc PT4521 PT4501 3.3Vdc PT4522 PT4502 5.0Vdc Va(req’d) (15.1)kΩ (126.0)kΩ (458.0)kΩ 543.0kΩ 197.0kΩ 81.1kΩ R1 = (Blue) 4.5 4.55 4.6 4.65 4.7 4.75 4.8 4.85 4.9 4.95 5.0 5.05 5.1 5.15 5.2 5.25 5.3 5.35 5.4 5.45 5.5 (2.8)kΩ (53.2)kΩ (204.0)kΩ 1.3MΩ 627.0kΩ 404.0kΩ (51.7)kΩ (161.0)kΩ (489.0)kΩ 1.28MΩ 587.0kΩ 355.0kΩ (26.5)kΩ (92.9)kΩ (203.0)kΩ (425.0)kΩ (1.09)MΩ 1.09MΩ 450.0kΩ 237.0kΩ 131.0kΩ 67.7kΩ PT4523 PT4503 12.0Vdc PT4524 PT4504 15.0Vdc Va(req’d) (12.6)kΩ (40.3)kΩ (75.0)kΩ (120.0)kΩ (179.0)kΩ (262.0)kΩ (387.0)kΩ (595.0)kΩ (1.01)MΩ 1.06MΩ 645.0kΩ 437.0kΩ 312.0kΩ 229.0kΩ 169.0kΩ 125.0kΩ 90.2kΩ 62.4kΩ 10.8 11.0 11.2 11.4 11.6 11.8 12.0 12.2 12.4 12.6 12.8 13.0 13.2 13.5 13.6 13.8 14.0 14.2 14.4 14.6 14.8 15.0 15.2 15.4 15.6 15.8 16.0 16.5 (276.0)kΩ (365.0)kΩ (497.0)kΩ (719.0)kΩ (1.16)MΩ 588.0kΩ 239.0kΩ 123.0kΩ 64.6kΩ 29.7kΩ 6.4kΩ (90.7)kΩ (146.0)kΩ (224.0)kΩ (341.0)kΩ (536.0)kΩ (926.0)kΩ (2.09.0)MΩ 1.19MΩ 502.0kΩ 272.0kΩ 158.0kΩ 88.7kΩ 42.7kΩ 9.9kΩ R2 = Black For technical support and more information, see inside back cover or visit www.ti.com (312.0)kΩ (345.0)kΩ (427.0)kΩ (542.0)kΩ (713.0)kΩ (1.0)MΩ (1.57)MΩ 597.0kΩ 253.0kΩ 138.0kΩ 81.0kΩ 46.6kΩ 0.8kΩ Application Notes PT4500/4520 Series Using the Remote On/Off Function on the PT4500/ PT4520 Series of Isolated DC/DC Converters For applications requiring output voltage on/off control, the PT4500/4520 series of DC/DC converters incorporate a remote on/off function. This function may be used in applications that require battery conservation, power-up/ shutdown sequencing, and/or to coordinate the power-up of the regulator for active in-rush current control. (See the related application note, SLTA021). This function is provided by the Remote On/Off control, pin1. If pin 1 is left open-circuit, the converter provides a regulated output whenever a valid source voltage3 is applied between +Vin(pin 4, 5), and –Vin (pin 2, 3). Connecting pin 1 to pin 2, or applying a low-level signal to pin 1 (with respect to –Vin), 1 will disable the regulator output 5. Table 3-1 provides details of the interface requirements for the Remote On/Off pin. Figure 3-1 shows how a discrete MOSFET (Q1), may be referenced to the negative input voltage rail and used with this control input. Table 3-1 Inhibit Control Requirements 1 Parameter Min Max Enable (VIH) 2.5V (Open Circuit) 4 Disable (VIL) –0.3V 0.8V Notes: 1. The on/off control uses -Vin (pin 1), on the primary side of the converter, as its ground reference. All voltages specified are with respect to -Vin. Figure 3-1 +V o 4, 5 + V in +Vin +Vout 9,10 PT4500/4520 2, 3 V GS –Vin Remote On/Off 1 –Vout V o (adj) 6 7, 8 –V o Q1 BSS138 Note 4 –V in Turn-On Time: The converter typically produces a fully regulated output voltage within 35ms after the removal of the low voltage signal from the Remote On/Off pin. Using the circuit of Figure 3-1, Figure 3-2 shows the output voltage and input current waveforms of a PT4521 after Q1 is turned off. The turn off of Q1 corresponds to the drop in Q1 Vgs voltage. The waveforms were measured with a 48Vdc input voltage, and 2.75-A resistive load. Figure 3-2 2. The on/off control internal circuitry is a high impedance 10µA current source. The open-circuit voltage may be as high as 8.3Vdc. Vout (2V/Div) 3. The PT4500/20 series incorporates an “Under-Voltage Lockout” (UVLO) function. The UVLO prevents operation of the converter when there is sufficient input voltage to support a regulated output. Below the UVLO threshold voltage, there is no output from the module and the Remote On/Off control is inoperative. Iin (0.2A/Div) 4. The Remote On/Off input of the PT4500/20 series must be controlled with a low-leakage (<100nA) opendrain MOSFET. Do not use a pull-up resistor. 5. When the converter output is disabled, the current drawn from the input supply is typically reduced to 8mA (16mA maximum). Q1 Vgs (10V/Div) HORIZ. SCALE: 5ms/Div 6. Keep the on/off transition to less than 1ms. This prevents erratic operation of the ISR, whereby the output voltage may drift un-regulated between 0V and the rated output during power-up. 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