PRM® Regulator PRM48BF480T400B00 S C NRTL US High Efficiency Remote Sense PRM Converter FEATURES DESCRIPTION ® • 3.61 MHrs MTBF (MIL-HDBK-217Plus Parts Count) TYPICAL APPLICATIONS • • • • • • ® The VI Chip PRM Regulator is a high efficiency converter, operating from a 38 to 55 Vdc input to generate a regulated 5 to 55 Vdc output. The ZVS buck – boost topology enables high switching frequency (~1 MHz) operation with high conversion efficiency. High switching frequency reduces the size of reactive 3 components enabling power density up to 1,360 W/in . • 45 V (38 to 55), non-isolated ZVS buck-boost regulator • 5 to 55 V adjustable output range • Building block for high efficiency DC-DC systems 2 • 400W output power in 1.1 in footprint • 97% typical efficiency, at full load 3 3 • 1,360 W/in (83 W/cm ) Power Density • Enables a 48 V to 1.5 V, 230 A isolated, regulated 2 2 solution with total footprint of 3.3 in (21 cm ) • Flexible “Remote Sense” architecture optimizes regulation / feedback loop design to fit application requirements • Current feedback signal allows dynamic adjustment of current limit setpoint High Efficiency Server Processor and Memory Power High Density ATE System DC-DC Power Telecom NPU and ASIC Core Power LED Drivers High Density Power Supply DC-DC Rail Outputs Non-isolated Power Converters The full VI Chip package is compatible with standard pick-and-place and surface mount assembly processes with a planar thermal interface area and superior thermal conductivity. In a Factorized Power Architecture™ system, the ® PRM48BF480T400B00 and downstream VTM current multiplier minimize distribution and conversion losses in a high power solution. An external control loop and current sensor maintain regulation and enable flexibility both in the design of voltage and current compensation loops to control of output voltages and currents. 48 V to 1.5 V, 230A Voltage Regulator Voltage Control Feedback Enable/ Disable Voltage Reference PC PR +IN TM TM PC +OUT +IN PRM Regulator 38 to 55 Vdc Input -IN IF RE -IN VC Current Sense Constant Vc PRM® Regulator +OUT1 +OUT2 VTM Current Multiplier -OUT SG VC TM PC +IN -OUT1 -OUT2 +OUT1 +OUT2 TM VTM Current Multiplier -IN VC Rev 1.1 800 927.9474 -OUT1 -OUT2 Load PRM48BF480T400B00 1.0 ABSOLUTE MAXIMUM RATINGS The ABSOLUTE MAXIMUM ratings below are stress ratings only. Operation at or beyond these maximum ratings can cause permanent damage to device. Electrical specifications do not apply when operating beyond rated operating conditions. All voltages are specified relative to SG unless otherwise noted. Positive pin current represents current flowing out of the pin. PR ……………………………………………………………………….. PC ……………………………………………………………………….. TM ……………………………………………………………………….. +IN to –IN …………………………………………………………………………… VS ……………………………………………………………………….. SG …………………………………………………………………………… IF …………………………………………………………………………… RE …………………………………………………………………………… VC to –OUT +OUT to –OUT Output Current Operating Analog IC Junction Temperature Storage Temperature ……………………………………………………………………….. …………………………………………………………………………… …………………………………………………………………………… …………………………………………………………………………… …………………………………………………………………………… Min -0.3 -0.3 -0.3 -1 -0.5 -0.5 -0.3 -0.5 -1 -40 -40 Max 10.5 ±10 5.7 ±10 5.7 ±1 62 10.5 ±100 ±100 5.7 5 18 ±1.8 62 ±11 125 125 Unit V mA V mA V mA V V mA mA V V V A V A ºC ºC 2.0 ELECTRICAL CHARACTERISTICS Specifications apply over all line and load conditions, TJ = 25 ºC and output voltage from 20V to 55V, unless otherwise noted. Boldface specifications apply over the temperature range of -40 ºC < TJ < 125 ºC (T-grade). Attribute POWER INPUT SPECIFICATION Input Voltage Range VIN Slew Rate No Load Power Dissipation Input Quiescent Current Input Current Input Capacitance (Internal) Input Capacitance (Internal) ESR POWER OUTPUT SPECIFICATION Output Voltage Range Output Current Output Power Symbol VIN dVIN/dt P NL I QC IIN_DC CIN_INT RCin V OUT I OUT P OUT TON TOFF + TON Output Turn-ON Delays Current Sharing Difference (exclusive of current limit) Efficiency Output Discharge current Output Voltage Ripple Output Inductance (Parasitic) Output Capacitance (Internal) Output Capacitance (Internal) ESR POWERTRAIN PROTECTIONS Input Undervoltage Turn-ON Input Undervoltage Turn-OFF Input Overvoltage Turn-ON Input Overvoltage Turn-OFF Overcurrent (IF) and Input Over/Undervoltage Blanking Time Output Overvoltage Threshold Thermal Shutdown Setpoint Overtemperature, Output Overvoltage and PC Shutdown Response Time Short Circuit Vout Threshold Short Circuit Vout Recovery Threshold Short Circuit Vpr Threshold Short Circuit Vpr Recovery Threshold Short Circuit Timeout Short Circuit Recovery Time Output Power Limit PRM® Regulator IOUT_SHARE η I OD V OUT_PP LOUT_PAR COUT_INT RCout VIN_UVLO+ VIN_UVLOVIN_OVLO+ VIN_OVLOTBLANK V OUT_OVLO+ TJ_OTP TPROT V SC_VOUT V SC_VOUTR V SC_VPR V SC_VPRR TSC TSCR P PROT Conditions / Notes Min 38 0.001 0 < VIN < 18 V PC HIGH, VIN = 45 V PC LOW, VIN = 45 V IOUT = 8.33A, VIN = 38 V, V OUT = 48 V Effective value, V IN = 45 V (see Fig. 20) Typ Max Unit 45 55 1000 4 8.5 11.0 V V/ms W mA A µF mΩ 55 8.33 400 V A W µs ms ±10 % ±24 % 2.4 4.5 10.9 4 1.5 5 See Fig.16, SOA See Fig.16, SOA From PC pin release to V OUT, VIN pre-applied and TOFF already expired From VIN applied to V OUT, PC floating Equal input, output and PR voltage at full load; VIN = 45 V, V OUT = 48 V Equal input, output and PR voltage at full load; Over line and trim, with 25°C < TC < 100°C but negligible part-part temp mismatch Equal input, output and PR voltage at full load; Over line and trim, with 25°C < TC < 100°C and <= 75°C part-part temp. mismatch (worst case) Nominal line, full load, V OUT = 48V 50% load and V OUT = 48 V; over temperature >50% load; over temperature Section 4.0 COUT_EXT = 0 F, IOUT = 8.33 A, VIN = 45 V, V OUT = 48 V, 20 MHz BW Frequency @ 1 MHz, Simulated J-Lead model Effective value, V OUT = 48 V (see Fig. 20) 20 18.02 96.0 94.0 90.0 Instantanous powertrain shutdown, latched after TBLANK Instantaneous, latched shutdown Instantaneous, latched shutdown; guaranteed by design, not production tested; V TM = 4.03V 35.75 33.56 57.24 58.44 37.13 59.91 V V V V 50 120 150 µs 55.25 130 56.57 59.04 V ºC 2 3.0 4.0 7.2 7.1 20 0.1 Short circuit fault latched after V SC_VOUT and V SC_VPR thresholds persist for this time 400 800 927.9474 1500 % % % % mA mV nH µF mΩ 31.97 55.91 Rev 1.1 ±35 96.8 0.5 960 1.9 4 1.5 Instantanous powertrain shutdown, latched after TBLANK 48 µs V V V V ms ms W PRM48BF480T400B00 3.0 SIGNAL CHARACTERISTICS Specifications apply over all line and load conditions, TJ = 25 ºC and Output Voltage from 20V to 55V, unless otherwise noted. Boldface specifications apply over the temperature range of -40 ºC < TJ < 125 ºC (T-grade). Primary Control PC • The PC pin enables and disables the PRM • In PRM array configurations, PC pins should be connected in order to synchronize startup. • It is a weak pull-down during any fault mode excluding short circuit. PC is a strong pull-down to SG if a short circuit fault is latched. Signal Type State Regular Operation Analog Output Startup Startup Digital Input / Output Standby Digital Output [Short Circuit Fault] Digital Output [All other Faults] Fault Fault Attribute PC Voltage PC Available Current IPC_OP PC Source Current IPC_EN Minimum Time to Start PC Enable Threshold PC Disable Threshold PC Resistance (External) PC Sink Current to SG PC Sink Current to ~1V Voltage Source VS • Intended to power feedback components and/or auxiliary circuits Signal Type State Attribute VS Voltage Regular VS Available Current Operation Analog Output VS Voltage Ripple Transition Symbol V PC VS Capacitance (External) VS Fault Response Time TOFF VPC_EN VPC_DIS RPC_EXT IPC_SC IPC_FAULT Conditions / Notes CVS_EXT TFR_VS Typ 5 Max 5.3 1.8 After TOFF 10.0 1.75 Resistance to SG required to disable the PRM Short circuit, PC voltage 1 V or above Tempature, over- and undervoltage, overcurrent Iout = 0A, Cvs_ext=0. Maximum specification includes powertrain operation in burst mode. 18.0 2.50 2.40 30.0 3.20 300 25 10 Conditions / Notes Min 8.55 5 Typ 9.00 100 From fault recognition to VS = 1.5 V Unit V mA 90 Section 5.0 Symbol V VS IVS VVS_PP Min 4.7 µA ms V V Ω mA µΑ Max 9.45 Unit V mA 400 mV 0.04 µF µs Unit 30 Reference Enable RE • RE signals successful startup and a powertrain that is ready for operation • Regulated, delayed voltage source intended to power the feedback circuit voltage reference and current monitor Signal Type State Attribute Symbol Regular Operation Analog Output Min Typ Max V RE 3.0 3.3 3.6 V RE Available Current RE Regulation RE Voltage Ripple PC to RE Delay RE Capacitance (External) I RE %RE VRE_PP TPC_RE CRE_EXT 8.0 across load and temperature in burst mode Fault detected 0.1 mA % mV µs µF VS to RE Delay TVS_RE VS = 8.1 V to RE high, V IN > VIN_UVLO- RE Voltage Transition State Analog Input Regular Operation Attribute PR Voltage Active Range PR Source Current PR Sink Current PR Resistance to SG 1 ms Symbol V PR IPR IPR_Low Conditions / Notes VPR ≤ 0.79V VPR > 0.79V Min 0.79 Typ Max 7.40 Unit V 2 mA 250 500 750 µA RPR 93.3 kΩ Current Feedback IF • A voltage proportional to the PRM output current must be supplied externally to the IF pin in order for the device to properly protect overcurrent events and to enable output current limit (clamp) • Overcurrent protection trip will cause instantaneous powertrain disable, latched after TBLANK Signal Type Analog Input ±2.5 100 100 Control Node PR • Modulator control node input • Sinks constant current when externally driven in active range • Sources current when pulled below active range Signal Type Conditions / Notes PRM® Regulator State Regular Operation Attribute Current Limit (clamp) Threshold Symbol VIF_IL Overcurrent Protection Threshold VIF_OC IF Input Impedance Current Limit Bandwidth Conditions / Notes VIN = 45 V; TJ = 25 °C Not Production Tested; Guaranted by Design; TJ = 25 °C RIF BW IL Rev 1.1 800 927.9474 Min 1.90 Typ 2.00 Max 2.10 2.58 2.69 2.80 2.11 2.13 2 2.15 Unit V kΩ kHz PRM48BF480T400B00 Temperature Monitor TM • The TM pin monitors the internal temperature of the PRM analog control IC. • "Power Good" flag to verify that the PRM is operating State Attribute Signal Type TM Voltage Symbol V TM Conditions / Notes Full temperature range Min 2.12 Typ Max 4.04 TM Voltage reference VTM_AMB TJ = 27 °C 2.94 3.00 3.06 TM Voltage Ripple TM Available Current VVS_PP I TM Analog Output Fault or Standby Digital Output [Fault Flag] TM Disabled Current Symbol ISG VTM Control VC • Pulsed voltage source used to power and synchronize downstream VTM • If not used, must be resistively terminated to -OUT Signal Type State Attribute VC Voltage Symbol VVC Analog Output Startup VC Available Current IVC VC duration TVC VC Slew Rate I TM_DIS Signal Ground SG • All control signals must be referenced to this pin, with the exception of VC • SG is internally connected to -IN and -OUT Signal Type State Attribute Analog Input / Output Any Maximum Allowable Current PRM® Regulator Powertrain in burst mode 200 dVC/dt mV/°C 10 DC state with TM Voltage +/- 0.5V. This is a high impedance state. RVC_EXT = 68Ω 0.0 V mV µA 100 ATM TM Gain Regular Operation Unit V mA Conditions / Notes Min -100 Typ Max 100 Unit mA Conditions / Notes Min 13 Typ Max Unit V 10 16 VC <=14 V, VIN > 20 V 200 7 RVC = 1k Ω Rev 1.1 800 927.9474 mA 20 ms V/ µs PRM48BF480T400B00 4.0 FUNCTIONAL BLOCK DIAGRAM +Vin Vcc Vcc 3.3V Linear Regulator Internal Vcc Regulator PC PR Vout Cin 3.3V 16V 9V Cout Q3 Q1 +Vout -Vout Q4 Q2 Output Discharge 8.2V PR +Vout L uC 8051 RE -Vin (OD) Modulator PR 93.3kW Vcc 100uA 2.5mA Min SET Q CLR TOFF delay S VTM Vc Start up pulse 14V VC 10ms Fault Logic Instant latch R Enable Q Var. Vclamp 0.5mA RE Latch after 120us RE 3.3V R 3V Vin (OV, UV) Vout (OV) 5V 2mA max Vs 9V 0.01uF Enable PC 10uA VPC_EN TM PC 3 V @ 27°C PRM® Regulator Temperature dependent voltage source Overtemperature Protection Current Limit Overcurrent Protection Rev 1.1 800 927.9474 VIF_IL IF Vref (130°C ) SG VIF_OC PRM48BF480T400B00 5.0 HIGH LEVEL FUNCTIONAL STATE DIAGRAM Conditions that cause state transitions are shown along arrows. Sub-sequence activities listed inside the state bubbles. Application of Vin PC HIGH and Toff expiry Toff Timeout PC: 90uA to HIGH Powertrain Stopped STANDBY SEQUENCE PC: 10uA to LOW TBLNK STARTUP SEQUENCE PC: 1.8mA to HIGH Overtemp or Output OVP PC HIGH and Ton expiry Fault removed expiry Ton timeout; VC Pulse; Powertrain Active Delayed RE BLANKING PC: 1.8mA to HIGH TBLNK Timeout Powertrain Paused Input OVP, Input UVP, or OverCurrent Prot SUSTAINED OPERATION PC: 1.8mA to HIGH Powertrain Active Short Circuit: Vout < VSC_Vout and Vpr > VSC_Vpr PC falling edge Vout < 1 V And TSCR expiry Short Removed: Vout > VSC_VOUTR or Vpr < VSC_VPR_R TSC expiry OUTPUT DISCHARGE PC: pulsed 25mA drive LOW TSCR Timeout Powertrain Stopped IOD Output Discharge PRM® Regulator Rev 1.1 800 927.9474 SHORT CIRCUIT PC: 1.8mA to HIGH TSC Timeout Powertrain Active PC falling edge PRM48BF480T400B00 6.0 TIMING DIAGRAMS Module Inputs are shown in blue; Module Outputs are shown in brown; Timing diagrams assumes the following: Single PRM (no array) VS powers error amplifier RE powers voltage reference and output current transducer IOUT is sensed, scaled, and fed back to IF pin such that IF = 2.00 V at full load 2 1 Start up with 1.2V/ms < dVIN/dt < maximum 3 4 Input OV recovery Quick OC Input OV (t<TBLNK) 5 6 PC disable PC release 7 8 Full load Load release and applied Output OV (slow f/b) VIN OV TOFF TON UV 18 V Vpr_max Input TBLNK PR Vpr_min t < TBLNK VIF_OC IF VIF_IL Input / Output PC Vpc TOFF TON TOFF TPROT TBLNK Vpc_en VC Vvc TVC VOUT TPROT OV 1V Output RE TVS_RE TPC_RE Vre_amb TBLNK Vvs_amb VS TM OT Vtm_amb PRM® Regulator Rev 1.1 800 927.9474 TPC_RE TPC_RE PRM48BF480T400B00 9 Start up with minimum < dVIN/dt < 1.2V/ms TOFF VIN OV 10 Output short (Output Short fault circuit conditions satisfied) (Output Short fault timer expired) 11 12 13 Output Power limit Protection Current limit event Input UV UV 18 V Input TBLNK Vpr_max PR Vpr_min VIF_OC IF VIF_IL TSC Output TSCR+TOFF PC Vpc Vpc_en VC Vvc VOUT OV Input / Output <TBLNK Vsc_vpr 1V RE Vre_amb Vvs_amb VS TM OT Vtm_amb PRM® Regulator Rev 1.1 800 927.9474 PRM48BF480T400B00 7.0 APPLICATIONS CHARACTERISTICS The following figures present typical performance at TC = 25ºC, unless otherwise noted. See associated figures for general trend data. No Load Power Dissipation vs. Line Module Enabled - Nominal VOUT 6 No Load Power Dissipation vs. Line Module Disabled, PC=Low 1 5 0.8 4 0.6 3 0.4 2 0.2 1 0 38 40 42 44 46 48 50 52 0 54 38 40 42 44 Input Voltage [V] -40 ºC TCASE: 25 ºC 46 48 50 52 54 Input Voltage [V] 100 ºC -40 ºC TCASE: 25 ºC 100 ºC Figure 1 - No load power dissipation vs. VIN, module enabled Figure 2 - No load power dissipation vs. VIN, module disabled Efficiency & Power Dissipation VOUT = 20 V TCASE = -40 ºC 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 16 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 Efficiency & Power Dissipation VOUT = 48 V TCASE = -40 ºC 9 14 12 10 8 6 4 2 0 1 2 3 Load Current [A] VIN: 38 45 55 38 4 5 6 7 8 9 Load Current [A] 45 55 Figure 3 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 20 V, TCASE = -40ºC PRM® Regulator 16 VIN: 38 45 55 38 45 55 Figure 4 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 48 V, TCASE = -40ºC Rev 1.1 800 927.9474 PRM48BF480T400B00 Efficiency & Power Dissipation VOUT = 55 V TCASE = -40 ºC 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 18 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 16 14 12 10 8 6 4 0 1 2 3 4 5 6 7 8 Efficiency & Power Dissipation VOUT = 20 V TCASE = 25 ºC 9 14 12 10 8 6 4 2 0 1 2 3 Load Current [A] 38 VIN: 45 55 16 4 5 6 7 8 9 Load Current [A] 38 45 55 Figure 5 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 55 V, TCASE = -40ºC 38 VIN: 45 55 38 45 55 Figure 6 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 20 V, TCASE = 25ºC Efficiency & Power Dissipation VOUT = 48 V TCASE = 25 ºC 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 16 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 Efficiency & Power Dissipation VOUT = 55 V TCASE = 25 ºC 9 16 14 12 10 8 6 4 0 1 2 3 Load Current [A] 38 VIN: 45 55 18 4 5 6 7 8 9 Load Current [A] 38 45 55 Figure 7 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 48 V, TCASE = 25ºC 38 VIN: 45 55 38 45 55 Figure 8 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 55 V, TCASE = 25ºC Efficiency & Power Dissipation VOUT = 20 V TCASE = 100 ºC 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 16 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 8 Efficiency & Power Dissipation VOUT = 48 V TCASE = 100 ºC 9 14 12 10 8 6 4 2 0 1 2 3 Load Current [A] VIN: 38 45 55 38 4 5 6 7 8 9 Load Current [A] 45 55 Figure 9 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 20 V, TCASE = 100ºC PRM® Regulator 16 VIN: 38 45 55 38 45 55 Figure 10 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 48 V, TCASE = 100ºC Rev 1.1 800 927.9474 PRM48BF480T400B00 VPR vs. Case Temperature VIN = 45 V; VOUT = 48 V Efficiency & Power Dissipation VOUT = 55 V TCASE = 100 ºC 98 96 94 92 90 88 86 84 82 80 78 76 74 72 70 18 16 6 14 12 5 4.5 6 1 2 3 4 5 6 7 8 4.70 38 VIN: 45 55 38 45 -40 9 -20 0 20 Figure 11 – Total efficiency and power dissipation vs. VIN and IOUT, VOUT = 55 V, TCASE = 100ºC 40 60 Temperature [ºC] IOUT: 55 4.70 Load Current [A] 6.04 4.52 4 4 0 6.20 5.5 8 6.16 10 6.5 80 4.17 100 8.33 Figure 12 – Typical control node voltage vs. TCASE, IOUT; VIN = 45 V, VOUT = 48 V Powertrain switching frequency and periodic output charge vs. input voltage - Full load 1025 36 fsw 1000 32 975 28 950 24 925 20 900 16 875 12 µC 850 8 825 4 0 800 38 40 42 44 46 48 50 52 54 56 Input Voltage [V] Powertrain switching frequency and periodic input charge vs. input voltage - Full load 1025 36 fsw 1000 32 975 28 950 24 925 20 900 16 875 12 µC 850 8 0 800 38 40 42 44 46 48 50 52 54 4 825 55 20 48 55 55 20 8.33 80 0 10 15 20 25 30 Current 35 40 45 50 Power Figure 16 – DC Output Safe Operating Area Rev 1.1 800 927.9474 160 5 48 240 4.17 0.00 320 6.25 2.08 400 Output Voltage [V] 20 48 DC Safe Operating Area 10.42 56 Figure 15 – Powertrain switching frequency and periodic input charge vs. VIN, VOUT; IOUT = 8.33 A PRM® Regulator 48 Input Voltage [V] VOUT 20 Figure 14 – Powertrain switching frequency and periodic output charge vs. VIN, VOUT; IOUT = 8.33 A = 30ºC, VIN = 45 V, VOUT = 48 V, IOUT = 8.33 A, no external capacitance. 55 VOUT Figure 13 – Typical output voltage ripple waveform, TCASE 55 60 PRM48BF480T400B00 DC modulator gain and powertrain equivalent output resistance vs. output current - VOUT = 55V DC modulator gain and powertrain equivalent output resistance vs. output current - VOUT = 20V 10 14 20 200 12 16 10 14 12 8 10 6 6 4 250 8 Gpr 6 150 4 2 Gpr 8 100 0 req_out 50 -2 18 -4 1 2 3 4 5 6 7 8 2 2 0 0 req_out 4 0 9 0 1 2 3 Output Current [A] VIN: 38 45 4 5 6 7 8 9 Output Current [A] 55 38 45 55 VIN: Figure 17 – Powertrain characteristics vs. IOUT; Resistive load, VOUT = 55 V, various VIN 38 45 55 38 45 55 Figure 18 – Powertrain characteristics vs. IOUT; Resistive load, VOUT = 20 V, various VIN DC modulator gain and powertrain equivalent output resistance vs. output current - VOUT = 48V 12 Effective internal input (CIN_INT) and output (COUT_INT) capacitance vs. applied voltage 90 Gpr 10 9 80 8 7 7 6 6 5 5 4 4 3 3 2 2 10 1 1 0 0 Input Capacitance F] 70 8 60 6 50 4 40 30 2 req_out 20 0 -2 0 1 2 3 4 5 6 7 8 0 0 9 5 10 15 20 Output Current [A] VIN: 38 45 55 38 9 8 45 25 30 35 Voltage [V] 55 Cin Figure 19 – Powertrain characteristics vs. IOUT; Resistive load, VOUT = 48 V, various VIN 40 45 50 55 Cout Figure 20 – Effective internal input capacitance vs. voltage – ceramic type and output Outpu Pow [W 400 360 320 280 240 200 160 120 80 40 0 2.5 Powertrain equivalent input resistance vs. output current - V OUT = 55V Output Power vs. VPR VIN = 45V, VOUT = 48V, TC=25ºC 16 14 12 10 8 6 4 2 3.0 7.0 3.5 4.0 4.5 5.0 5.5 6.0 0 6.5 0 PR Voltage [V] Figure 21 – Output Power vs. VPR; VIN = 45 V, VOUT = 48 V, TCASE = 25ºC PRM® Regulator 2 3 4 5 6 7 8 9 Output Current [A] VIN: 1 38 45 55 Figure 22 – Magnitude of powertrain dynamic input impedance vs. VIN, IOUT; VOUT = 55 V Rev 1.1 800 927.9474 PRM48BF480T400B00 Powertrain equivalent input resistance vs. output current - VOUT = 20V Powertrain equivalent input resistance vs. output current - VOUT = 48V 90 20 80 18 70 16 14 60 12 50 10 40 8 30 6 20 4 10 2 0 0 0 1 2 3 4 5 6 7 8 0 9 1 2 Output Current [A] VIN: 38 45 3 4 5 6 7 8 9 Output Current [A] 55 VIN: Figure 23 – Magnitude of powertrain dynamic input impedance vs. VIN, IOUT; VOUT = 20 V 38 45 55 Figure 24 – Magnitude of powertrain dynamic input impedance vs. VIN, IOUT; VOUT = 48 V 8.0 GENERAL CHARACTERISTICS Specifications apply over all line and load conditions, TJ = 25 ºC and Output Voltage from 20V to 55V, unless otherwise noted. Boldface specifications apply over the temperature range of -40 ºC < TJ < 125 ºC (T-grade). Attribute MECHANICAL Length Symbol Width Height Lead Finish Max Unit 32.3 / [1.27] 32.5 / [1.28] 32.8 / [1.29] mm / [in] 21.8 / [0.86] 22.0 / [0.87] 22.3 / [0.88] mm / [in] 6.48 / [0.255] 6.73 / [0.265] 6.98 / [0.275] mm / [in] 3 3 4.81 / [0.29] cm / [in ] No Heatsink W 15 Nickel Palladium Gold THERMAL Operating Junction Temperature Operating Case Temperature Thermal Capacity ASSEMBLY Peak Compressive Force Applied to Case (Z-axis) Storage Temperature Typ L Vol Weight Min W H Volume Conditions / Notes TJ TC g 0.51 0.02 0.003 2.03 0.15 0.051 -40 -40 125 100 µm ºC ºC Ws/ºC 10 TST -40 ESD Rating 6 5.41 125 Supported by J-Lead only Human Body Model, "JEDEC JESD 22-A114C.01" 1000 Charged Device Model, "JEDEC JESD 22-C101D" 400 lbs lbs / in 2 ºC V SOLDERING Peak Temperature During Reflow MSL 4 (Datecode 1528 and later) Maximum Time Above [217] ºC Peak Heating Rate During Reflow Peak Cooling Rate Post Reflow 1.5 2.5 245 ºC 150 2 3 s ºC / s ºC / s RELIABILITY AND AGENCY APPROVALS MTBF Agency Approvals / Standards PRM® Regulator Telcordia Issue 2 - Method I Case 1; Ground Benign, Controlled MIL-HDBK-217Plus Parts Count - 25C Ground Benign, Stationary, Indoors / Computer Profile C TUV US CE Mark ROHS 6 of 6 Rev 1.1 800 927.9474 5.28 3.61 MHrs MHrs PRM48BF480T400B00 9.0 PRODUCT OUTLINE DRAWING AND RECOMMENDED PCB FOOTPRINT PRM® Regulator Rev 1.1 800 927.9474 PRM48BF480T400B00 PRODUCT DETAILS AND DESIGN GUIDELINES 9.1 minimum load. Figure 25 shows a reference AC smallsignal model. Control pins description and characteristics Control node (PR) is the input to the control node which determines the powertrain timing and ultimately the module output power (Figure 21). An internal 0.5 mA current sink is always active. The bi-directional buffer between PR and the control node has two states. In normal operation, PR will be above the 0.79 V switching threshold, and will drive the control node through the buffer. An internal 7.4 V clamp determines the maximum output power that can be requested of the modulator. When PR falls below 0.79 V, the converter will stop switching. An internal circuit clamps the modulator input control node to 0.79 V, and a buffer will source up to 2.5 mA out of the pin at that clamp level. For this reason, the output impedance of the amplifier driving PR must be taken into account. A rail-to-rail operational amplifier with low output impedance is always recommended. The powertrain small signal (plant) response consists of a single pole determined by the load resistance, the powertrain equivalent output resistance, and the total output capacitance (internal and external to the module). Both the modulator gain and the equivalent output resistance vary as a function of line, load and output voltage, as shown in Figures 17, 18 and 19. As the load increases, the powertrain pole moves to higher frequency. As a result, the closed loop crossover frequency will be the highest at full load and lowest at Current feedback (IF) is the input for the module output overcurrent protection and current limit features (see functional block diagram in section 4.0). A voltage proportional to the powertrain output current must be applied to IF in order for overcurrent protection to operate properly. If the IF voltage exceeds the IF pin’s overcurrent protection threshold, the powertrain will stop switching. If the IF voltage falls below the overcurrent protection threshold within TBLANK time, then the powertrain will immediately resumes switching. Otherwise a fault is latched. The current limit threshold for the IF pin is set lower than the protection threshold. When the IF pin average voltage exceeds the current limit threshold, an internal integrator will activate a clamp amplifier which overrides the modulator input maximum level. This causes the powertrain to maintain a constant output current. The bandwidth of this current limit integrator is significantly slower than that of the PR control node input. Therefore this current limit can not be used in lieu of properly compensating the (external) PR control loop to avoid exceeding maximum current or power ratings for the device. If the IF pin is not driven, it must be resistively terminated to SG. A 1 kΩ resistor to SG is recommended in this case. + VIN CIN_INT rEQ_IN + VPR RPR IPR_Low VPR · GPR COUT_INT rEQ_OUT - Figure 25 – PRM48BF480T400B00 AC small signal model PRM® Regulator + Rev 1.1 800 927.9474 VOUT - PRM48BF480T400B00 Signal Ground (SG) pin provides a Kelvin connection to the PRM’s internal signal ground. It should be used as the reference for PR, TM, IF, and should return all PC, VS and RE pin currents. In array configurations with common ground control circuits, a series resistor (~1 Ω) is recommended in order to decouple power and signal current returns. VTM Control (VC) pin supplies an initial VCC voltage to downstream VTMs, enabling them and synchronizing their startup with the PRM. The VCC voltage is a pulse, typically 10 ms duration at 14 V. If VC is not loaded by a VTM, it must be terminated with a 1 kΩ resistor to –VOUT. Primary Control (PC) is both an input and an output. It can provide the following features: • Delayed start: upon application of voltage (>UVLO) to the module power input and after TOFF, the PC pin will source a constant 90 µA current. • Output disable: PC may be pulled down externally in order to disable the module. Pull down resistance should be less than 300 Ω to SG. • Fault detection flag: The PC 5 V voltage source is internally turned off when a fault condition is latched. Note that aside from the Short Circuit fault condition, PC does not have significant current sinking capability. Therefore in the case of an array of PRMs with interconnected PC pins, PC does not in general reflect the fault state of all PRMs. The common PC line will not disable neighboring modules when a fault is detected except for a latched Output Short Circuit fault. Conversely any unit in the array latching a Short Circuit fault will disable the array for TSCR. Temperature Monitor (TM) pin outputs a voltage proportional to the absolute temperature of the converter analog control IC. It can be used to accomplish the following functions: • Monitor the control IC temperature: The gain and setpoint of TM are such that the temperature, in Kelvin, of the PRM controller IC is equal to the voltage on the TM pin scaled by 100. (i.e. 3.0 V = 300 K = 27ºC). • Closed loop thermal management at the system level (e.g. variable speed fans or coolant flow) • Fault detection flag: The TM voltage source is turned off as soon as a fault is detected. For system monitoring purposes (microcontroller interface) faults are detected on falling edges of TM. 9.2 Control circuit requirements and design procedure The PRM48BF480T400B00 is an intelligent powertrain module designed to fully exploit external output voltage feedback and current sensing sub-circuits. These two external circuits are illustrated in Figure 26, which shows an example of the PRM in a standalone application with local voltage feedback and high side current sensing. In general, these circuits include a precision voltage reference, an operational amplifier which provides closed loop feedback compensation, and a high side current sense circuit which includes a shunt and current sense IC. Voltage Source (VS) pin outputs a gated (e.g. mirrors PC status), non-isolated, regulated 9 V, 5 mA voltage source. It can be used to power external control circuitry; it always leads RE. PRM® Regulator 9.2.1 Setting the output voltage level The output voltage setpoint is a function of the voltage reference and the output voltage sense ratio. With reference to Fig. 26, R1 and R2 form the output voltage sensing divider which provides the scaled output voltage to the negative input of the error amplifier; a dedicated reference IC provides the reference voltage to the positive input of the error amplifier. Under normal operation, the error amplifier will keep the voltages at the inverting and non-inverting inputs equal, and therefore the output voltage is defined by: VOUT = V ref ⋅ Reference Enable (RE) pin outputs a regulated 3.3 V, 8 mA voltage source. It is enabled only after successful startup of the PRM powertrain (see chapters 5.0 and 6.0.) RE is intended to power the output current transducer and also the voltage reference for the control loop. Powering the reference generator with RE helps provide a controlled startup, since the output voltage of the system is able to track the reference level as it comes up. The following design procedures refer to the circuit shown in Figure 26. R1 + R2 R2 Note that the component R1 will also factor into the compensation as described in a later section. It is important to apply proper slew rate to the reference voltage rise when the control loop is initially enabled. The recommended range for reference rise time is 1 ms to 9 ms. The lower rise time limit will ensure optimized modulator timing performance during startup, and to allow the current limit feature (through IF pin) to fully protect the device during power-up. The upper rise time limit is needed to guarantee a sufficient factorized bus voltage is provided to any downstream VTM input before the end of the VC pulse. Rev 1.1 800 927.9474 PRM48BF480T400B00 9.2.2 Setting the output current limit and overcurrent protection level Powertrain equivalent resistance rEQ: See Figures 17, 18, 19 Internal output capacitance: see Figure 20 External output capacitance value In the case of ceramic capacitors, the ESR can be considered low enough to push the associated zero well above the frequency of interest. Applications with high ESR capacitor may require a different type of compensation, or cascade control. The system poles and zeros of the closed loop can then be defined as follows: The current limit and overcurrent protection set points are linked, and scale together against the current sense shunt, and the gain of the current sense amplifier. The output of the current sense IC provides the IF voltage which has VIF_IL and VIF_OC thresholds for the two functions respectively. The set points are therefore defined by: V I IL = IF _ IL R ⋅G S Powertrain pole, assuming the external capacitor ESR can be neglected: CS and I OC = RCOUT _ EXT VIF _ OC RS ⋅ G CS 9.2.3 The compensation characteristics must be selected to meet these stability criteria. Refer to Figure 27 for a local sense, voltage-mode control example based on the configuration in Figure 26. In this example, it is assumed that the maximum crossover frequency (FCMAX) has been selected to occur between B and C. Type-2 compensation (Curve IJKL) is sufficient in this case. The following data must be gathered in order to proceed: Modulator Gain GPR: See Figures 17, 18, 19 FP ≈ · RLOAD 2 π⋅ rEQ _ OUT rEQ _ OUT + RLOAD 1 · (COUT INT + COUT Compensation G MB = 20 log R Mid-Band FZ1 = [1] R1 Zero: 1 [2] 2 π⋅ R 3 ⋅ C1 Compensation FP 2 = Gain: 3 Compensation 1) Phase Margin > 45º : for the closed loop response, the phase should be greater than 45º where the gain crosses 0dB. 2) Gain Margin > 10 dB : The closed loop gain should be lower than -10dB where the phase crosses 0º. 3) Gain Slope = -20 dB/decade : The closed loop gain should have a slope of -20 dB/decade at the crossover frequency. PRM® Regulator rEQ _ OUT + RLOAD Main pole frequency: Control loop compensation requirements In order to properly compensate the control loop, all components which contribute to the closed loop frequency response should be identified and understood. Figure 25 shows the AC small signal model for the module. Modulator DC gain GPR and powertrain equivalent resistance rEQ_OUT are shown. These modeling parameters will support a design cut-off frequency up to 50 kHz. Standard Bode analysis should be used for calculating the error amplifier compensation and analyzing the closed loop stability. The recommended stability criteria are as follows: rEQ _ OUT · RLOAD where GCS is the gain of the current sense amplifier. << Pole: 1 ⋅C 2 π⋅ R3 ⋅ C1 2 C1 + C2 and for FP2>>FZ1 (C1 + C2 ≈ C1): FP 2 ≈ Rev 1.1 800 927.9474 1 2π ⋅ R ⋅ C2 [3] EXT ) PRM48BF480T400B00 9.2.4 Midband (R1,R3): Gain Design 9.2.5 Compensation Zero Design (C1): With reference to Figure 27: curve EFG is the: maximum output voltage in the application minimum input voltage expected in the application minimum load in the application PRM open loop response, and is where the minimum crossover frequency FCMIN occurs. Based on stability criteria, the compensation must be in the mid-band at the minimum crossover frequency, therefore FCMIN will occur where EFG is equal and opposite of GMB. C1 can be selected using Equation [2] so that FZ1 occurs prior to FCMIN. With reference to Figure 27: curve ABC is the: minimum output voltage in the application maximum input voltage expected in the application maximum load PRM open loop response, and is where the maximum crossover frequency occurs. In order for the maximum crossover frequency to occur at the design choice FCMAX, the compensation gain must be equal and opposite of the powertrain gain at this frequency. For stability purposes, the compensation should be in the Mid-band (J-K) at the crossover. Using Equation [1], the mid-band gain can be selected appropriately. C2 C1 R3 + Vref R2 R1 F1 +IN VS RS +OUT P R TM PRM Regulator CIN_EXT CIN_INT COUT_EXT COUT_INT -IN IF RE SG -OUT Vref I sense IC Vref IC Figure 26 – Control circuit example PRM® Regulator Rev 1.1 800 927.9474 PRM48BF480T400B00 Open Loop Gain vs. Frequency 80 60 I Application's op-amp G·BW Compensation Gain 40 F E PRM Open Loop Min Load 20 B A PRM Open Loop Max Load J K L FCMIN 0 FCMAX -20 C -40 G Frequency, Log scale (y-intercept is application specific) Figure 27 – Reference asymptotic Bode plot for the considered system 9.2.6 High Frequency Pole Design (C2): Using Equation [3], C2 should be selected so that FP2 is at least one decade above FCMAX and prior to the gain bandwidth product of the operational amplifier (10 MHz for this example). For applications with a higher desired crossover frequency the use of a high gain bandwidth product amplifier may be necessary to ensure that the real pole can be set at least one decade above the maximum crossover frequency. based on the ratio of the “kick” to “droop” (as defined in Fig. 28). k Vout d 9.2.7 Verifying Stability: The preferred method for verifying stability is to use a network analyzer, measuring the closed loop response across various lines and load conditions. Iou t transient response can be used in order to estimate stability. Figure 28 illustrates an example of a load step response. Equation [4] can be used to predict the phase margin PRM® Regulator time time Figure 28 – load step response example and “droop” vs. “kick” definition Rev 1.1 800 927.9474 PRM48BF480T400B00 9.3 k2 ln m 100 d2 k + 2 ln d Burst Operation: Figure 20 provides the effective internal capacitance of the module. A conservative estimate of input and output peak-peak voltage ripple at nominal line and trim is provided by equation [5]: [4] ΔV = Mode QTO T CINT I FL ⋅ 0.4 f SW + CEXT [5] At light loads, the PRM will operate in a burst mode due to minimum timing constraints. An example burst operation waveform is illustrated in Figure 29. For very light loads, and also for higher input voltages, the minimum time power switching cycle from the powertrain will exceed the power required by the load. In this case the external error amplifier will periodically drive PR below the switching threshold in order to maintain regulation. Switching will cease momentarily until the error amplifier once again drives PR voltage above the threshold. QTOT is the total input (Fig. 15) or output (Fig. 14) charge per switching cycle at full load, while CINT is the module internal effective capacitance at the considered voltage (Fig. 20) and CEXT is the external effective capacitance at the considered voltage. 9.5 Input filter stability The PRM can provide very high dynamic transients. It is therefore very important to verify that the voltage supply source as well as the interconnecting line are stable and do not oscillate. For this purpose, the converter dynamic input impedance magnitude is provided in rEQ _ IN Figures 22, 23, 24. It is recommended to provide adequate design margin with respect to the stability conditions illustrated in 10.5.1 and 10.5.2 . 9.5.1 Inductive source and local, external input decoupling capacitance with negligible ESR (i.e.: ceramic type) Figure 29 – light load burst mode of operation Note that during the bursts of switching, the powertrain frequency is constant, but the number of pulses as well as the time between bursts is variable. The variability depends on many factors including input voltage, output voltages, load impedance, and external error amplifier output impedance. In burst mode, the gain of the PR input to the plant which is modeled in the previous sections is time varying. Therefore the small signal analysis can not be directly applied to burst mode operation. 9.4 Input and Output filter design Figures 14 and 15 provide the total input and output charge per cycle, as well as switching frequency, of the PRM at full load under various input and output voltages conditions. PRM® Regulator The voltage source impedance can be modeled as a series RlineLline circuit. The high performance ceramic decoupling capacitors will not significantly damp the network because of their low ESR; therefore in order to guarantee stability the following conditions must be verified: Rline > (C IN INT Rline << rEQ _ IN Lline )⋅ r +C IN EXT [6] EQ IN [7] It is critical that the line source impedance be at least an octave lower than the converter’s dynamic input resistance, [7]. However, Rline cannot be made arbitrarily low otherwise equation [6] is violated and the system will show instability, due to under-damped RLC input network. Rev 1.1 800 927.9474 PRM48BF480T400B00 9.5.2 Inductive source and local, external input decoupling capacitance with significant RCIN_EXT ESR (i.e.: electrolytic type) In order to simplify the analysis in this case, the voltage source impedance can be modeled as a simple inductor Lline. Note that the high performance ceramic capacitors CIN_INT within the PRM should be included in the external electrolytic capacitance value for this purpose. The stability criteria will be rEQ _ IN > RCIN _ EXT Lline < rEQ _ IN C IN _ EXT ⋅ RC IN _ EXT [8] 9.7 Input Fuse Recommendations A fuse should be incorporated at the input to each PRM, in series with the +IN pin. A 15 A or smaller input fuse ® 2® (Littelfuse NANO 451/453 Series, or equivalent) is required to safety agency conditions of acceptability. Always ascertain and observe the safety, regulatory, or other agency specifications that apply to your specific application. [9] Arrays Up to ten PRMs of the same type may be placed in parallel to expand the power capacity of the system. The following high-level guidelines must be followed in order for the resultant system to start up and operate properly, and to avoid overstress or exceeding any absolute maximum ratings. –IN pins of all PRMs must be connected together. Both inductance and resistance from the common power source to each PRM should be minimized, and matched. Input voltage to all PRMs must be the same. Independent fuses for each PRM are recommended. PC pins must be connected together for synchronization and proper fault response. Reference supply to the control loop voltage reference and current sense circuitry must be enabled when all modules’ RE pins have reached their operational voltage levels. There must be one single external voltage control loop. The control loop must drive each PR pin relative to each module’s SG pin, and the local PR voltage must be the same across all modules. Each PRM must have its own local current shunt and current sense circuitry to drive its IF pin. The number of PRMs required to achieve a given array capacity must consider all sources of mismatch to avoid overstress of any PRM in the PRM® Regulator Please contact Vicor Applications for assistance. Equation [9] shows that if the aggregate ESR is too small – for example by using very high quality input capacitors (CIN_EXT) – the system will be under-damped and may even become destabilized. Again, an octave of design margin in satisfying [8] should be considered the minimum. 9.6 array. Imbalances in sharing are not only due to current sharing accuracy specifications, but also temperature differences among PRMs, Vin variations, and error terms in the buffering of the error amplifier output to the PR pins. Control loop compensation procedures above will hold for an array, in general, although many parameters must be scaled against the number of PRMs in the system. 9.8 Layout considerations Application Note AN:005 details board layout using VI Chip components. Additional consideration must be given to the external control circuit components. The current sense shunt signal voltage is highly sensitive to noise. As such, current sensing circuitry should be located close to the shunt to minimize the length of the sense signals. A Kelvined connection at the shunt is recommended for best results. The control signal from a remote voltage sense circuit to the PRM should be shielded. Avoid routing this, or other control signals directly underneath the PRM, if possible. Components that tie directly to the PRM should be located close to their respective pins. It is also critical that all control components be referenced to SG, and that SG not be tied to any other ground in the system, including –IN or –OUT of the PRM. Rev 1.1 800 927.9474 PRM48BF480T400B00 Warranty Vicor products are guaranteed for two years from date of shipment against defects in material or workmanship when in normal use and service. This warranty does not extend to products subjected to misuse, accident, or improper application or maintenance. Vicor shall not be liable for collateral or consequential damage. This warranty is extended to the original purchaser only. EXCEPT FOR THE FOREGOING EXPRESS WARRANTY, VICOR MAKES NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Vicor will repair or replace defective products in accordance with its own best judgment. For service under this warranty, the buyer must contact Vicor to obtain a Return Material Authorization (RMA) number and shipping instructions. Products returned without prior authorization will be returned to the buyer. The buyer will pay all charges incurred in returning the product to the factory. Vicor will pay all reshipment charges if the product was defective within the terms of this warranty. Information published by Vicor has been carefully checked and is believed to be accurate; however, no responsibility is assumed for inaccuracies. Vicor reserves the right to make changes to any products without further notice to improve reliability, function, or design. Vicor does not assume any liability arising out of the application or use of any product or circuit; neither does it convey any license under its patent rights nor the rights of others. Vicor general policy does not recommend the use of its components in life support applications wherein a failure or malfunction may directly threaten life or injury. Per Vicor Terms and Conditions of Sale, the user of Vicor components in life support applications assumes all risks of such use and indemnifies Vicor against all damages. Vicor’s comprehensive line of power solutions includes high density AC-DC and DC-DC modules and accessory components, fully configurable AC-DC and DC-DC power supplies, and complete custom power systems. Information furnished by Vicor is believed to be accurate and reliable. However, no responsibility is assumed by Vicor for its use. Vicor components are not designed to be used in applications, such as life support systems, wherein a failure or malfunction could result in injury or death. All sales are subject to Vicor’s Terms and Conditions of Sale, which are available upon request. Specifications are subject to change without notice. Intellectual Property Notice Vicor and its subsidiaries own Intellectual Property (including issued U.S. and Foreign Patents and pending patent applications) relating to the products described in this data sheet. Interested parties should contact Vicor's Intellectual Property Department. The products described on this data sheet are protected by the following U.S. Patents Numbers: 5,945,130; 6,403,009; 6,710,257; 6,911,848; 6,930,893; 6,934,166; 6,940,013; 6,969,909; 7,038,917; 7,145,186; 7,166,898; 7,187,263; 7,202,646; 7,361,844; D496,906; D505,114; D506,438; D509,472; and for use under 6,975,098 and 6,984,965. Vicor Corporation 25 Frontage Road Andover, MA, USA 01810 Tel: 800-735-6200 Fax: 978-475-6715 email Customer Service: [email protected] Technical Support: [email protected] PRM® Regulator Rev 1.1 800 927.9474