DC259 DESCRIPTION Demo Board DC259A provides an isolated 3.3V or 5Vout at 10A from a 36 to 72VDC source. The DC259A’s small size (2.4in x 2.3in x 0.5in) and industry standard pin-out allows rapid evaluation in new or existing designs. Gerber files are available upon request. Synchronous output rectifiers result in high-efficiency (89% typical) operation, eliminating the need for a heat sink in many applications *. Standard PCB and transformer technology reduces manufacturing cost. Input under-voltage lockout, remote on/off, output voltage trim, over-voltage protection and current limit are included. QUICK START GUIDE DC259A comes configured for 5V operation. For 3.3V operation, separate the control and power board by gently rocking and pulling the boards apart. Locate JP1 and JP2 which are located on the top side of the control board (the side facing the bottom of the unit) near the left edge of the large rectangular hole in the board. See Figure 1. JP1 and JP2 share a common resistor pad. Carefully remove the 0 ohm jumper from the center/JP2 position and install into the center/JP1 position (if the 0 ohm jumper is damaged, replace with a small section of wire). Next locate and remove JP3 (0 ohm jumper) which is located on the bottom, left side of the control board near the output Connect wire jumpers from J6 (+Sense) to J5 (+Vout) and from J8 (-Sense) to J9 (-Vout). See Figure 2. There is no minimum load requirement. Connect a DVM and 0-10A variable test load (electronic load box or power resistors) with series current meter between J5 (+Vout) and J9 (-Vout). Connect a 36 to 72VDC / 2A power supply and DVM between J4 (+Vin) and J1 (-Vin). See SETUP for details. The shut-down circuitry is referenced to the primary. The unit can be shut down by connecting J3 (ON) to J1 (-Vin). *Based on 190 lfm airflow, 50C ambient (110C PCB) temperature. See Thermal Measurements section. BOARD PHOTO 1 DC259 SETUP JP3 JP1, JP2 Figure 1. Location of JP1, JP2 and JP3 which select between 5 and 3.3V operation. 3 6 -7 2 V D C POW ER SUPPLY + + DVM A - + A - + - - + + 0 -1 0 A LOAD DVM Figure 2. Test Setup. Pin Assignments. 2 DC259 PERFORMANCE SUMMARY Input Voltage 36 to 72VDC (100Vmax) Input Current (min) 72Vin, on/off=low 15mA Input Current 72Vin, 5V/0Aout 50mA typ Input Current (max) 36Vin, 5V/10Aout 1.6A 36Vin, 5V/12Aout 2A 36Vin, output shorted. Input current = 2Apk, 4ms switching bursts. <10mAavg 36Vin, 5V/10Aout, start-up 2.2Apk 36Vin, 3.3V/10Aout, start-up 2Apk Input Ripple 48Vin, 5V/10Aout, source C = 39uF 0.6Ap-p Conducter Emissions EN55022, CISPR-A, FCC part 15 (Consult Factory for Emissions Data) Class A Output Voltage Jumper selectable 5V or 3.3V Trim Range User selectable (R40) Start-up Time 36Vin, 5V/10Aout, output voltage up 90ms Overshoot Turn-on 72Vin, 5V/0Aout 0% Turn-on 72Vin, 3.3V/0Aout 10% Undershoot Turn-off none Output Ripple 48Vin, 5V/10Aout, measured across C16, 20MHz BW 70mVp-p typ 48Vin, 5V/10Aout, measured across C16, 350MHz BW 120mVp-p typ 48Vin, 3.3V/10Aout, measured across C16, 20MHz BW 60mVp-p typ 48Vin, 3.3V/10Aout, measured across C16, 350MHz BW 110mVp-p typ Input Current (start) Min Load Transient Response 0A 48Vin, 5Vout/5 to 10A step +/-50mV, t = 1ms 48Vin, 3.3Vout/5 to 10A step +/-30mV, t = 1ms 48Vin, 5V/10Aout 89% 48Vin, 3.3V/10Aout 86% Operating Temperature PCB temperature (see Thermal Performance Section) 0 to 110C Isolation Voltage Input to output 1500VDC Input/output to case 1000VDC Switching Frequency Fixed, nominal 130KHz Agency Approval Designed to meet EN60950, UL1950 Efficiency 3 DC259 TYPICAL PERFORMANCE CHARACTERISTICS 50mV/DIV 50mV/DIV 50mV/DIV 50mV/DIV 2us/DIV Figure 3. 3.3V/10A Output Ripple with 48Vin. (Top trace = 350MHz BW, bottom trace = 20MHz BW) 50mV/DIV 2us/DIV Figure 4. 5V/10A Output Ripple with 48Vin. (Top trace = 350MHz BW, bottom trace = 20MHz BW) 50mV/DIV 1ms/DIV Figure 5. 3.3V Output Response, 5A to 10A current step (48Vin). 2ms/DIV Figure 6. 5V Output Response, 5A to 10A current step (48Vin). 4 43 46 51 48Vin 72Vin 5V/8A 36Vin U1 pin 15 (pgnd) 34 35 32 5V/10A 190lfm 48 50 46 5V/10A w/HS 72Vin 48Vin 36Vin 58 56 46 5V/8A 66 72Vin L2 between foil & core 60 73 70 70 5V/10A 83 76 81 5V/10A 52 50 45 5V/10A 190lfm 50 46 47 5V/10A 190lfm 60 55 51 5V/10A w/HS 62 60 55 5V/10A w/HS 60 72Vin 63 44 54 58 36Vin 48Vin 72Vin 5V/8A 60 48Vin 72Vin HS side of board behind Q6 59 36Vin 5V/8A 58 Q6 54 48Vin 5V/8A 36Vin T1 between wire & core Temperature Rise above 22C ambient Board Mounted Horizontally, 4 OZ Cu (2 OZ internal) (lfm = linear feet per minute, HS = Thermalloy P6515B Heat Sink) 60 54 59 5V/10A 60 48Vin 5V/8A 36Vin Q3 73 70 74 5V/10A 83 83 81 5V/10A 78 75 78 5V/10A 46 46 46 5V/10A 190lfm 58 56 46 46 45 5V/10A w/HS 63 60 55 5V/10A w/HS 5V/10A 190lfm 50 62 63 61 5V/10A w/HS 50 50 50 5V/10A 190lfm DC259 THERMAL MEASUREMENTS 5 1 J3 ON + 3 D23 C26 68uF 20V R34 100k 1 1 1 Q8 D5 C13 4.7uF D18 1 R37 12.1k 1% Q12 2 3 D15 R27 10k 2 3 D11 M M SZ5240BT1 Q10 3 3 2 3 C25 0.1uF R26 5.36k 1% 1 1 3 D9 D3 M M SZ5246BT1 R21 20.5k 1% J2 CA SE R43 3.9k 1 8 3 4 R12 61.9k 1% R14 62k R49 62k R11 1.5K IN1 V CC1 IN2 GND2 2 7 5 6 C19 2.2uF GND1 OUT 1 OUT 2 V CC2 U1 LTC1693-1 R10 1.5K L3 14 13 17 P RN/S HD 12VI N R39 4.53k 1% U3 LT1 339 DO 1608C-105 R24 130 R25 470 R28 1 2 R29 10 27k D20 D17 3 M M SZ5242BT1 Q7 NDT 410EL R38 143k 1% 1 R13 47k 1 HEADE R 6 C31 1uF C27 2.2nF C28 2.2nF C29 0.1uF R8 10 1 R15 47 3 V FB C30 4700pF BG 9 16 3 2 3 2 1 D2 M URS 120 Q2 FM M T 718 D4 1 1 D22 BAT54 R41 2.4k R31 3.3 1 3 D13 BAS21 1 470 D6 M M SZ5242BT1 R16 3 1/2W Q3 1 IRF1310NS 3 Q4 R9 FM M T 718 0.025 2 1 D1 M URS 120 1 D16 D19 BAS21 BAS21 C14 2.2uF S Y NC 1 J1 -Vin 5VRE F 2 1 1 2 3 4 5 6 CT 3 2 P13 S L/ ADJ 4 C2 1.5uF 100V C11 2200pF 250V IA V G 5 J4 +Vin VRE F 10 S OCK ET6 8 1 2 2 3 C4 1.5uF 100V S GND 3 1 C3 1.5uF 100V 15 6 5 4 3 2 1 20 P GND J13 19 TG SS 6 V BO OS T 18 TS 11 1 2 C12 0.1uF P10 -6 P10 -10 P10 -7 P10 -8 C21 0.1uF JP2 0 JP1 0 D7 BAT54 3 1 J10-12 J10-2 J10-4 J10-5 J10-3 P10 -12 P10 -2 P10 -4 P10 -5 P10 -3 7 S ENSE + 3 1 12 S ENSE VC 4 4 3 J10-6 J10-10 J10-7 J10-8 3 1 2 J10-11 J10-9 J10-1 NC 5 6 7 8 5 6 7 R44 100k R32 470 IS O1 M OC207 2 1 3 4 C1 2.2nF 250V 1 Q13 C23 0.1uF 2 3 1 D21 M M SZ5231BT1 R23 4.7k C17 1000pF R20 4.7k C15 1000pF R19 470 C9 1nF 100V R2 10 R46 1k R47 100 1 COLL C22 0.22uF D14 BAT54 R22 470 D10 BAT54 Q5 SUD30N04 C10 1000pF 100V R7 10 Not e: Unless noted: Al l caps 25V . Al l resisto rs 0.1W, 5% . Al l di odes FMM D914 All NP Ns FMM T 3904TA All PNPs FMM T 3906TA 10 11 12 7 8 9 T2 Coi ltroni cs CTX02-14678 5 2 1 4 3 6 T1 Coi ltroni cs CTX02-14675 4 3 10 4 3 8 P10 -11 P10 -9 P10 -1 Q1 IRF1310NS 1 2 3 1 3 1 J11-1 4 1 3 8 1 Q6 SUD30N04 C6 8 GND1 GND2 R33 1k OUT 1 IN1 OUT 2 V CC2 U2 LTC1693-1 V CC1 IN2 3 REF U4 LT1 431 2 7 5 6 R48 100 R45 9.31k 1% JP3 0 R36 3.01k 1% R30 100 D8 BAS21 3 1 D12 BAS21 1 C34 C8 R42 4.42k 1% C24 0.01uF R40 T BD R35 1k C20 4.7uF + C35 + P9 -Vout P5 +Vo ut C16 33uF 10V J9 -Vout J8 -Sense J7 Tri m J6 +Se nse J5 +Vo ut C36 150pF (opti onal ) 1kV L4 DO 1608C-105 + + C33 C7 + + + C5 C5 to C8, C33 to C35 330uF, 10V + L2 2.4uH CE PH149-2R4M C G ND-F 6 R1 2 G ND-S C18 2200pF 250V 4 RT OP RMID 5 1 2 4 3 J11-2 J11-4 J11-3 J11-8 P11 -2 P11 -4 P11 -3 P11 -8 7 COMP P11 -1 3 V+ J11-5 J11-6 J11-7 P11 -5 P11 -6 P11 -7 L1 DO 1608C-472 DC259 SCHEMATIC DIAGRAM 6 DC259 PARTS LIST REFERENCE DESIGNATOR QUANTITY PART NUMBER DESCRIPTIONN VENDOR TELEPHONE C36 1/OPT GRM43X7R151KXKVAL CAP CER X7R 150pF 1kV 20% 1808 OPTION MuRata 814-237-1431 C9,C10 2 12061C102MAT1A CAP CER X7R 1000pF 100V 20% 1206 Avx 843-946-0362 C15,C17 2 06035C102MAT1A CAP CER X7R 1000pF 50V 20% 0603 Avx 843-946-0362 C27,C28 2 06035C222MAT1A CAP CER X7R 2200pF 50V 20% 0603 C1,C11,C18 3 GHM3035X7R222K-GC CAP CER X7R 2200pF 250V 10% C30 1 06035C472MAT1A C24 1 06035C103MAT1A C21,C25 2 C12,C23,C29 C22 Avx 843-946-0362 MuRata 814-237-1431 CAP CER X7R 4700pF 50V 20% 0603 Avx 843-946-0362 CAP CER X7R 0.01uF 50V 20% 0603 Avx 843-946-0362 12065C104MAT1A CAP CER X7R 0.1uF 50V 20% 1206 Avx 843-946-0362 3 0603YC104MAT1A CAP CER X7R 0.1uF 16V 20% 0603 Avx 843-946-0362 1 0603ZC224MAT1A CAP CER X7R 0.22uF 10V 20% 0603 Avx 843-946-0362 C31 1 TMK316BJ105ML CAP CER X7R 1uF 16V 20% 1206 Taiyo Yuden 800-348-2496 C2,C3,C4 3 VJ1825Y155MXB CAP CER X7R 1.5uF 100V 20% 1825 Vitramon 203-268-6261 C14,C19 2 EMK316BJ225ML CAP CER X5R 2.2uF 16V 20% 1206 Taiyo Yuden 800-348-2496 C13,C20 2 EMK325BJ475MN CAP CER X5R C16 1 TAJB336M010R0375 CAP TANT. 4.7uF 16V 20% 1210 33uF 10V 20% 3528 Taiyo Yuden 800-348-2496 Avx 207-282-5111 C26 1 TPSE686M020R0125 CAP TANT 68uF 20V 20% 7343H Avx 207-282-5111 C5 to C8, 7 T510X3371010AS CAP TANT 330uF 10V 20% 7343H Kemet 864-963-6300 D1,D2 2 MURS120T3 DIODE ULTRAFAST 200V 1A SMB On Semiconductor 800-282-9855 D4,D5,D9,D15, 7 FMMD914 DIODE SWITCHING 70V 0.2A 4ns SOT-23 Zetex 516-543-7100 D3 1 MMSZ5246B-7 DIODE ZENER 16V 0.5W 5% SOD-123 Vishay 408-241-4588 D6,D17 2 MMSZ5242B-7 DIODE ZENER 12V 0.5W 5% SOD-123 Vishay 408-241-4588 D11 1 MMSZ5240B-7 DIODE ZENER 10V 0.5W SOD-123 Vishay 408-241-4588 D21 1 MMSZ5231B-7 DIODE ZENER 5.1V 0.5W SOD-123 Vishay 408-241-4588 D7,D10,D14,D22 4 BAT54TA DIODE SCHOTTKY 30V 200mA SOT-23 Zetex 516-543-7100 D8,D13,D12, 5 BAS21TA DIODE SWITCHING 200V 0.2A 50ns SOT-23 Zetex 516-543-7100 ISO1 1 MOC207 OPTOCOUPLER 100-200 2500VRMS SO8 QT Optoelectronics 408-720-1440 L1 1 DO1608C-472 INDUCTOR 4.7uH 20% 0.090ohms 1.5A Coilcraft 847-639-6400 L2 1 CEPH149-2R4MC INDUCTOR 2.4uH Sumida 847-956-0667 L3,L4 2 Coilcraft DO1608C-105 INDUCTOR 1.0mH 20% 13.8ohms 0.1A Coilcraft 847-639-6400 Q1,Q3 2 IRF1310NS MOSFET N-CHNL 100V 0.036ohms D2-PAK IR 310-322-3331 C33 to C35 D18,D20,D23 D16,D19 Q5,Q6 2 SUD30N04-10 MOSFET N-CHNL 40V 0.01ohms D-PAK Siliconix 800-554-5565 Q7 1 NDT410EL MOSFET N-CHNL 100V 0.25ohms SOT-223 Fairchild 408-822-2126 Q2,Q4 2 FMMT718TA TRAN PNP 20V 1.5A HIGH CURR SOT-23 Zetex 516-543-7100 Q8,Q12,Q13 3 FMMT3904TA TRAN NPN 40V 0.2A GEN PURPOSE SOT-23 Zetex 516-543-7100 Q10 1 FMMT3906TA TRAN PNP 40V 0.2A GEN PURPOSE SOT-23 Zetex 516-543-7100 R9 1 WSL 2110 0.025 1% RES CHIP 2110 0.025 1% 1/2W 2110 Dale 605-665-9301 R10,R11 2 CR18-152JM RES CHIP 1206 Tad 714-255-9123 1.5k 5% 1/8W 7 DC259 PARTS LIST R36 1 CR16-3011FM RES CHIP 0603 3.01k 1% Tad 800-508-1521 R42 1 CR16-4421FM RES CHIP 0603 4.42k 1% Tad 800-508-1521 R39 1 CR16-4531FM RES CHIP 0603 4.53k 1% Tad 800-508-1521 R26 1 CR16-5361FM RES CHIP 0603 5.36k 1% Tad 800-508-1521 R45 1 CR16-9311FM RES CHIP 0603 9.31k 1% Tad 800-508-1521 R37 1 CR16-1212FM RES CHIP 0603 12.1k 1% Tad 800-508-1521 R21 1 CR16-2052FM RES CHIP 0603 20.5k 1% Tad 800-508-1521 R12 1 CR10-5622FM RES CHIP 0805 56.2k 1% Tad 800-508-1521 R38 1 CR16-1433FM RES CHIP 0603 143k 1% Tad 800-508-1521 R31 1 CR16-3R3JM RES CHIP 0603 3.3 5% Tad 800-508-1521 R1,R8,R28 3 CR16-100JM RES CHIP 0603 10 5% Tad 800-508-1521 R2,R7 2 CR18-100JM RES CHIP 1206 10 5% Tad 800-508-1521 R15 1 CR10-470JM RES CHIP 0805 47 5% Tad 800-508-1521 R47 1 CR16-101JM RES CHIP 0603 100 5% Tad 800-508-1521 R48,R30 2 CR18-101JM RES CHIP 1206 100 5% Tad 800-508-1521 R24 1 CR10-131JM RES CHIP 0805 130 5% Tad 800-508-1521 R16,R19,R22, 5 CR16-471JM RES CHIP 0603 470 5% Tad 800-508-1521 R33,R35,R46 3 CR16-102JM RES CHIP 0603 1k 5% Tad 800-508-1521 R41 1 CR16-242JM RES CHIP 0603 2.4k 5% Tad 800-508-1521 R43 1 CR16-392JM RES CHIP 0603 3.9k 5% Tad 800-508-1521 R20,R23 2 CR16-472JM RES CHIP 0603 4.7k 5% Tad 800-508-1521 R27 1 CR16-103JM RES CHIP 0603 10k 5% Tad 800-508-1521 R29 1 CR18-273JM RES CHIP 1206 27k 5% Tad 800-508-1521 R25,R32 R13 1 CR16-473JM RES CHIP 0603 47k 5% Tad 800-508-1521 R14,R49 2 CR18-623JM RES CHIP 1206 62k 5% Tad 800-508-1521 R34,R44 2 CR16-104JM RES CHIP 0603 100k 5% Tad 800-508-1521 R40 0 RES TBD RES CHIP 0603 Tad 800-508-1521 JP1,JP2,JP3 3 CR10-000M RES CHIP 0805 0ohm 5% Tad 800-508-1521 T1 1 CTX02-14675 TRANSFORMER CTX02-14675 Coiltronics 561-241-7876 T2 1 CTX02-14678 TRANSFORMER CTX02-14678 Coiltronics 561-241-7876 J5,J9 2 1640B RECEPTACLE 0.078-0.081 Keystone 718-956-8900 J1,J2,J3,J4, 7 1425-2 PIN 0.04 PC PIN Keystone 718-956-8900 J6,J7,J8 P5,P9 2 1213-680-6 PIN 0.08 X 0.68 high pin Zierick 800-882-8020 J10 1 SMM-106-02-F-D SOCKET 12PINS DOUBLE ROW SMT Samtec 800-726-8329 J11 1 SMM-104-02-F-D SOCKET 8PINS DOUBLE ROW SMT Samtec 800-726-8329 J13 1 SMM-106-02-F-S SOCKET 6 PINS SURFACE MOUNT Samtec 800-726-8329 P10 1 HTSM2205-12-G2 HEADER 12PINS SURFACE MOUNT Comm-Con 626-301-4200 P11 1 HTSM2205-08-G2 HEADER 8PINS SURFACE MOUNT Comm-Con 626-301-4200 P13 1 HTSM2805-06-G2 HEADER 6 PINS SURFACE MOUNT Comm-Con 626-301-4200 4 1636-440-A-0 STANDOFF 3/16 ROUND 4-40 X 7/16 RAF 203-888-2133 8 DC259 PARTS LIST 1 P6515B HEATSINK P6515B Thermalloy 972-243-4321 U1,U2 2 LT1693-1B IC LTC1693-1 8-LEAD SO8 Linear 408-432-1900 U3 1 LT1339CSW IC LT1339CSW 20-LEAD SOL-20 Linear 408-432-1900 U4 1 LT1431CS8 IC LT1431CS8 8-LEAD SO8 Linear 408-432-1900 1 DEMO BOARD DC259A PRINTED CIRCUIT BOARD Linear 408-432-1900 STENCIL Linear 408-432-1900 2 PCB LAYOUT AND FILM 9 DC259 PCB LAYOUT AND FILM 10 DC259 PCB LAYOUT AND FILM 11 DC259 PCB LAYOUT AND FILM 12 DC259 PCB FAB DRAWING 13