PD-97309A HTA-SERIES HIGH RELIABILITY DC/DC CONVERTER 200V Input, Single/Dual Output Description The HTA Series of DC/DC converters is a family of 20W, single and dual output, high reliability devices designed to operate in extremely high temperature environments such as those encountered in oil exploration applications. Features include small size, low weight and high tolerance to environmental stresses such as wide temperature extremes, severe shock and vibration. All internal components are derated to meet the intended operating environment. Documentation including electrical stress and thermal analysis are available. The converters incorporate a fixed frequency single forward topology with magnetic feedback and internal EMI filter. All models include an external inhibit port and have an adjustable output voltage. They are enclosed in a hermetic 1.5" x 4.0" x 0.430" AlSi package and weigh less than 70grams. The package utilizes rugged ceramic feed-thru copper core pins and is sealed using parallel seam welding. Full environmental screening includes temperature cycling, constant acceleration, fine and gross leak, and burn-in. Nonscreened versions of the HTA converters are available for system development purposes. Variations in electrical specifications and screening to meet custom requirements can be accommodated. Features n 150 to 250V DC Input Range n Up to 20W Output Power n Single and Dual Output Models Include 3.3, 5, 12, 15, ±5, ±12 and ±15V n Internal EMI Filter n Magnetically Coupled Feedback n High Efficiency - to 76% n -35°C to +185°C Operating Case Temperature Range n 10MΩ @ 500VDC Isolation n Under-Voltage Lockout n Short Circuit and Overload Protection n Output Over Voltage Limiter n Adjustable Output Voltage n Synchronization Input and Output n External Inhibit n Low Weight, < 70grams Applications Circuit Description n Down Hole Exploration Tools The HTA series of converters utilize a single-ended forward topology with resonant reset. The nominal switching frequency is 500KHz. Electrical isolation and tight output regulation are achieved through the use of a magnetically coupled feedback. Voltage feed-forward with duty factor limiting provides high line rejection and protection against output over voltage in the event of an internal control loop failure. This mechanism limits the maximum output voltage to approximately 20% over the nominal regardless of the line voltage. The current limit point exhibits a slightly negative temperature coefficient to reduce the possibility of thermal runaway. Output current is limited under any load fault condition to approximately 125% of rated load at maximum operating case temperature. An overload condition causes the converter output to behave like a constant current source with the output voltage dropping below nominal. The converter will resume normal operation when the load current is reduced below the current limit point. This protects the converter from both overload and short circuit conditions. www.irf.com An external Inhibit port is provided to control converter operation. The converter’s operation is inhibited when this pin is pulled low. It is designed to be driven by an open collector logic device. The pin may be left open for normal operation and has a nominal open circuit voltage of 4.0V with respect to the Input Return (pin 2). The output voltage of all models can be adjusted using a single external resistor. 1 03/03/09 HTA-SERIES Absolute Maximum Ratings Maximum Operating Conditions Input voltage range -0.5Vdc to +300Vdc Input voltage range 150Vdc to 250Vdc Output power Internally limited Output power 0 to Max. Rated Lead temperature +300°C for 10 seconds Operating temperature Operating case temperature -35°C to +185°C Storage temperature -55°C to +185°C -35°C to +185°C Electrical Performance Characteristics Parameter Group A Subgroup Conditions -35°C ≤ TC ≤ +185°C VIN = 200V DC ± 5%, CL = 0 unless otherwise specified Input Voltage Output voltage ( Vout ) HTA2003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D 1 1 1 1 1 1 1 IOUT = 100% rated load Note 4 Limits Min Nom Max Unit 150 200 250 V 3.25 4.95 11.88 14.85 ±4.95 ±11.88 ±14.85 3.30 5.00 12.00 15.00 ±5.00 ±12.00 ±15.00 3.35 5.05 12.12 15.15 ±5.05 ±12.12 ±15.15 V HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Output power ( POUT ) Output current ( IOUT ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D 2,3 2,3 2,3 2,3 2,3 2,3 2,3 IOUT = 100% rated load Note 4 3.20 4.85 11.64 14.55 ±4.85 ±11.64 ±14.55 3.40 5.15 12.36 15.45 ±5.15 ±12.36 ±15.45 1,2,3 VIN = 150, 200, 250 Volts, Note 2 0 20 W 1,2,3 VIN = 150, 200, 250 Volts, Note 2 6.10 4.00 1.67 1.33 3.20 1.34 1.06 A Either Output, Note 3 Either Output, Note 3 Either Output, Note 3 0 0 0 0 0 0 0 Line regulation ( VRLINE ) 1,2,3 VIN = 150, 200, 250 Volts IOUT = 0, 50%, 100% rated, Note 4 -0.5 +0.5 % Load regulation ( VRLOAD ) 1,2,3 IOUT = 0, 50%, 100% rated, Note 4 VIN = 150, 200, 250 Volts -1.0 +1.0 % 1,2,3 VIN = 150, 200, 250 Volts Duals only, Note 5 -5.0 -3.0 -3.0 5.0 3.0 3.0 % Cross regulation ( VRCROSS ) HTA20005D HTA20012D HTA20015D For Notes to Electrical Performance Characteristics, refer to page 5 2 www.irf.com HTA-SERIES Electrical Performance Characteristics Parameter Input current, no load ( IIN ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Input current inhibited Output ripple ( VRIP ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Switching frequency ( FS ) ( continued ) Group A Subgroup Conditions -35°C ≤ TC ≤ +185°C VIN = 200V DC ± 5%, CL = 0 unless otherwise specified 1,3 Limits Max Unit IOUT = 0, Pin 4 open 20 mA 2 IOUT = 0, Pin 4 open 30 mA 1,2,3 Pin 4 shorted to pin 2 5.0 mA 1,3 VIN = 150, 200, 250 Volts IOUT = 100% rated load Notes 4, 6 50 50 70 80 80 80 80 mV p-p 25 25 35 40 40 40 40 mV p-p 650 KHz 2 Min Nom VIN = 150, 200, 250 Volts IOUT = 100% rated load Notes 4, 6 1,2,3 Sync. Input (Pin 4) open 500 550 1 IOUT = 100% rated load Note 4 70 75 76 76 75 76 76 74 78 79 79 78 79 79 HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D 2 IOUT = 100% rated load Note 4 65 70 71 71 70 71 71 HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D 3 IOUT = 100% rated load Note 4 68 73 74 74 73 73 73 Efficiency ( EFF ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D For Notes to Electrical Performance Characteristics, refer to page 5 www.irf.com % 3 HTA-SERIES Electrical Performance Characteristics Parameter Under Voltage Lockout Turn-on ( input voltage rising ) Turn-off ( input voltage decreasing ) Synchronization Frequency Range Pulse Amplitude, High Pulse Amplitude, Low Pulse Rise Time Pulse Duty Cycle Group A Subgroup 1,2,3 ( continued ) Conditions -35°C ≤ TC ≤ +185°C VIN = 200V DC ± 5%, CL = 0 unless otherwise specified Min Nom No load, Full load Notes 1, 4 Unit 146 V Note 1 500 2.0 -0.5 20 Transient Recovery Specification Max 119 1,2,3 1,2,3 1,2,3 1,2,3 Limits 650 10 0.8 100 80 KHz V V ns % Notes 4, 10, 11, 12 Transient Load Response Half to Full Load 4,5,6 Overshoot Recovery Time 10 300 % µs Transient Load Response Full to Half Load 4,5,6 Overshoot Recovery Time 10 450 % µs Transient Load Response 10% to Half Load 4,5,6 Overshoot Recovery Time 15 300 % µs Transient Load Response Half to 10% Load 4,5,6 Overshoot Recovery Time 15 450 % µs 1,2,3 Note 1 -0.5 5.0 100 50 V µA V 115 105 130 175 150 220 % 30 W 10 200 % ms 2200 1000 180 120 500 90 60 µF Enable Input ( Inhibit Function ) open circuit voltage drive current ( sink ) voltage range Current Limit Point Expressed as a percentage of full rated load current 1 2 3 VOUT = 90% of Nominal, Note 4 Power dissipation, load fault ( PD ) 1,2,3 Short Circuit, Overload, Note 8 4,5,6 No Load, Full Load Notes 4, 9 Turn-on Response Overshoot ( VOS) Turn-on Delay (TDLY ) Capacitive Load ( CL ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D 1 3.0 2.0 IOUT = 100% rated load No effect on DC performance Notes 1, 4, 7 Each output on duals Line Rejection 1 Isolation 1 MIL-STD-461, CS101 30Hz to 50KHz, Notes 1, 4 Input to Output or Any Pin to Case except pin 3, test @ 500VDC Device Weight 40 50 dB 100 MΩ 70 g For Notes to Electrical Performance Characteristics, refer to page 5 4 www.irf.com HTA-SERIES Notes for Electrical Performance Characteristics Table 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Parameter is tested as part of design characterization or after design changes. Thereafter, parameter shall be guaranteed to the limits specified. Parameter verified during line and load regulation tests. Output load current must be distributed such that at least 20% of the total load current is being provided by one of the outputs. Load current split equally between outputs on dual output models. Cross regulation is measured with 20% rated load on output under test while changing the load on the other output from 20% to 80% of rated. Guaranteed for a D.C. to 20MHz bandwidth. Tested using a 20KHz to 10MHz bandwidth using the circuit on page 6. Capacitive load may be any value from 0 to the maximum limit without compromising dc performance. A capacitive load in excess of the maximum limit may interfere with the proper operation of the converter’s overload protection, causing erratic behavior during turn-on. Overload power dissipation is defined as the device power dissipation with the load set such that VOUT = 90% of nominal. Turn-on delay time from either a step application of input power or a logic low to a logic high transition on the inhibit pin (pin 4) to the point where VOUT = 90% of nominal. Transient recovery time is from the change in load condition until the output is within 3% of the nominal output voltage. Recovery time is measured from initiation of the transient to where VOUT has returned to within ±1% of VOUT at 50% load. Load transient time ≥ 10µs. Fig I. Circuit for Measuring Output Ripple Voltage 50 Ω 50 Ω Coax 1 µF Oscilliscope or Equivalent with 10 MHz Bandwidth. Multiply readings by 2. 0.1 µF + Vout 50 Ω Termination DUT Return RL for IRATED www.irf.com 5 HTA-SERIES Fig II. Block Diagram - Single Output D C INP UT IM P UT FILTE R 1 E NA B LE 4 CA S E 3 INP U T RE TU RN 2 OU TP UT FILTE R PR IM A R Y BI AS S UP P LY CU R RE N T S E NS E 7 + OU TPU T 8 OU TPU T R ETU RN DRIVE R E R ROR AMP & RE F SE N SE A M P LIFIE R SY N C. IN PU T 6 S Y N C. O UTP U T 5 11 TRIM 12 N/ C 10 +S E N SE 9 -S EN S E C ON TRO L V FB Fig III. Block Diagram - Dual Output DC INP UT EN AB LE CA SE 1 4 IM P UT F ILT ER O U TP UT F ILT ER P RIM A RY B IAS SU PP LY C URR EN T S E NS E O U TP UT F ILT ER 3 7 +O UT PU T 8 O UT P UT RE T URN 9 -O UT P UT D R IV ER INP U T R ET UR N 2 E RRO R A MP & RE F S YN C. IN PU T 6 S YN C. O UT P UT 5 6 10 T RIM 11 N/C 12 N/C CO N TR O L VFB www.irf.com HTA-SERIES Technical Notes: Remote Sensing Output Voltage Adjust - Single Output Models This feature is available only for single output models. Connection of the + Sense and - Sense leads at a remotely located load permits compensation for resistive voltage drop between the converter output and the load when they are physically separated by a significant distance. This connection allows regulation to the placard voltage at the point of application. When the remote sensing features is not used, the sense leads should be connected to their respective output terminals at the converter. A combination of the compensation voltage drop and output voltage adjustment (described below in the ‘Output Voltage Adjustment’ section) is limited to 10% of the nominal output voltage. In addition to permitting close voltage regulation of remotely located loads, it is possible to utilize the converter sense pins to incrementally increase the output voltage. The increased output voltage is limited to 10% maximum. The adjustments made possible by this method are intended as a means to “trim” the output to a voltage setting for certain design application, but are not intended to create an adjustable output converter. These output voltage setting variations are obtained by connecting a resistor with an appropriate value between the +Sense and -Sense pins while connecting the -Sense pin to the Output Return pin as shown in Fig IV below. The resistance value for a desired output voltage can be determined by use of the equation presented below. Inhibiting Converter Output As an alternative to application and removal of the DC voltage to the input, the user can control the converter output by providing TTL compatible, positive logic signal to Enable pin (pin 4) and to Input Return (pin 2). Enable signal is internally pulled “high” so that when not used, an open connection on the Enable pin permits normal converter operation. When its use is desired, a logical “low” on this port will shut the converter down. Synchronization of Multiple Converters When operating multiple converters, system requirements often may require operation of the converters at a common frequency. To accommodate this requirement, the HTA series of converters provide both a synchronization input and output. The Sync Input port permits synchronization of a HTA connverter to any compatible external frequency source operating between 500KHz and 650KHz. This input signal should be referenced to the Input Return and have a 10% to 90% duty cycle. Compatibility requires transition times less than100ns, maximum low level of +0.8V and a minimum high level of +2.0V. The Sync Output of another converter which has been designated as the master oscillator provides a convenient frequency source for this mode of operation. When external synchronization is not required, the Sync In pin should be left unconnected thereby permitting the converter to operate at its own internally set frequency. ⎧ ⎫ VNOM ⎬ Radj = 100 • ⎨ ⎩VOUT - VNOM -.025 ⎭ Where VNOM = device nominal output voltage, and VOUT = desired output voltage Finding a resistor value for a particular output voltage, is simply a matter of substituting the desired output voltage and the nominal device voltage into the equation and solving for the corresponding resistor value. Under no circumstance should RADJ be less than 500Ω. Fig IV. Connection for VOUT Adjustment N/C Trim HTA200XXS + Sense RADJ - Sense Output Return + Output To Load The sync output signal is a continuous pulse train set at 550 ± 50KHz, with a duty cycle of 15 ± 5.0%. This signal is referenced to the Input Return and has been tailored to be compatible with the HTA Sync Input port. Transition times are less than 100ns and the low level output impedance is less than 50Ω. This signal is active when the DC input voltage is within the specified operating range and the converter is not inhibited. This output has adequate drive reserve to synchronize at least five additional converters. www.irf.com 7 HTA-SERIES Examination of the equation relating output voltage and resistor value reveals a special benefit of the circuit topology utilized for remote sensing of output voltage in the HTA200XXS series of converters. It is apparent that as the resistance increases, the output voltage approaches the nominal set value of the device. In fact the calculated limiting value of output voltage as the adjusting resistor becomes very large, is ≈ 25mV above nominal device voltage. The consequence is that if the +sense connection is unintentionally broken, an HTA200XXS has a fail-safe output voltage of Vout + 25mV, where the 25mV is independent of the nominal output voltage. It can be further demonstrated that in the event of both the +Sense and -Sense connections being broken, the output will be limited to Vout + 440mV. This 440mV is also essentially constant independent of the nominal output voltage. While operation in this condition is not damaging to the device, not all performance parameters will be met. Output Voltage Adjust - Dual Output Models By use of the Trim pin (10), the magnitude of output voltages can be adjusted over a limited range in either a positive or negative direction. Connecting a resistor between the trim pin and either the output return or the positive output will raise or lower the magnitude of output voltages. The span of output voltage adjustment is restricted to the limits shown in Table I. Table 1. Output Voltage Trim Values and Limits HTA20005D HTA20012D VOUT VOUT RADJ RADJ HTA20015D VOUT RADJ 5.5 0 12.5 0 15.5 0 5.4 12.5K 12.4 47.5K 15.4 62.5K 5.3 33.3K 12.3 127K 15.3 167K 5.2 75K 12.2 285K 15.2 375K 5.1 200K 12.1 760K 15.1 1.0M 5.0 ∞ 12.0 ∞ 15.0 ∞ 4.9 190K 11.7 975K 14.6 1.2M 4.8 65K 11.3 288K 14.0 325K 4.7 23K 10.8 72.9K 13.5 117K 4.6 4.583 2.5K 0 10.6 10.417 29.9K 0 13.0 12.917 12.5K 0 8 Note that the nominal magnitude of output voltage resides in the middle of the table and the corresponding resistor value is set to ∞. To set the magnitude greater than nominal, the adjust resistor is connected to output return. To set the magnitude less than nominal, the adjust resistor is connected to the +Output. (Refer to Fig V.) Fig V. Connection for VOUT Adjustment N/C Trim HTA200XXD - Output + Output ADJ + N/C Output Return Connect R RADJ To Loads to + to increase, - to decrease For output voltage settings that are within the limits, but between those listed in Table I, it is suggested that the resistor values be determined empirically by selection or by use of a variable resistor. The determined value can then be replaced with a good quality fixed resistor for permanent installation. When use of this adjust feature is elected, the user should be aware that the temperature performance of the converter output voltage will be affected by the temperature performance of the resistor selected as the adjustment element and therefore, is advised to employ resistors with a very small temperature coefficient of resistance. www.irf.com HTA-SERIES Application Notes: DC-DC converters constructed with aluminium-silicon (ALSi) controlled expansion alloy benefit from low mass, high thermal conductivity, and CTE match to substrates mounted in them. The one disadvantage over traditional cold rolled steel packages (CRS) however is that the ALSi material is more brittle than the CRS. For this reason, it is important to avoid using a thermal pad or gasket. The HTA-Series DC-DC converter requires 8-32 size screws and #8 flat washers. The minimum recommended mouting surface flatness is 0.002” per inch. www.irf.com The Procedure for mounting the converter is as follows: 1. Check all surfaces for foreign material, burrs, or anything that may interfere with the different parts. 2. Place the converter on the mounting surface and line it up with mounting holes. 3. Install screws using appropriate washers and tighten by hand (~ 4 in.oz) in the sequence shown below in the diagram. . 4. Tighten the screws with appropriate torque driver using a controlled torque of up to 20-24 in.lb in the sequence as shown in the diagram. 9 HTA-SERIES Efficiency Curves for HTA20003R3S Fig VI. 25°C Efficiency vs. Output Loading 90 80 70 Efficiency % 60 50 150 Vin 200 Vin 250 Vin 40 30 20 10 0 0 1 2 3 4 5 6 7 Output Load (A) Fig VII. 185°C Efficiency vs. Output Loading 90 80 70 Efficicency % 60 50 150 Vin 200 Vin 250 Vin 40 30 20 10 0 0 1 2 3 4 5 6 7 Output Load (A) 10 www.irf.com HTA-SERIES Efficiency Curve for HTA20003R3S Fig VIII. Efficiency vs. Temperature 75 74 73 Efficiency % 72 71 150 Vin 200 Vin 70 250 Vin 69 68 67 66 65 0 20 40 60 80 100 120 140 160 180 200 Temperature C Efficiency Curve for HTA20005S Fig IX. 25°C Efficiency vs. Output Loading 90% 80% 70% Efficiency 60% 50% 150 Vin 200 Vin 40% 250 Vin 30% 20% 10% 0% 0 1 2 3 4 5 Output Load (A) www.irf.com 11 HTA-SERIES Efficiency Curves for HTA20005S Fig X. 185°C Efficiency vs. Output Loading 90% 80% 70% Efficiency 60% 50% 150 Vin 40% 200 Vin 250 Vin 30% 20% 10% 0% 0 1 2 3 4 5 Output Load (A) Efficiency Fig XI. Efficiency vs. Temperature 85% 83% 81% 79% 77% 75% 73% 71% 69% 67% 65% 150 Vin 200 Vin 250 Vin 0 50 100 150 200 Tem perature C 12 www.irf.com HTA-SERIES Mechanical Diagram 0.245 Ø0.266 1.500 1.100 1 12 2 11 3 10 4 9 5 8 6 7 0.250 0.200 Typ. Non-cum. 1.000 Ref. Pin Ø 0.040 0.200 2.500 3.600 4.000 MAX. 0.238 MAX. 0.430 Max. 0.075 NOTES: UNLESS OTHERWISE SPECIFIED, DIMENSIONAL TOLERANCE IS: 0.005" Pin Designation (Single/Dual) Pin # Single Dual 1 DC Input DC Input 2 Input Return Input Return 3 Case Case 4 Enable Enable 5 Sync. Output Sync. Output 6 Sync. Input Sync. Input 7 + Output + Output 8 Output Return Output Return 9 - Sense - Output 10 + Sense N/C 11 12 Trim * N/C Trim N/C * Trim pin for Single Output models is reserved for future use. This pin must not be used or connected for any purpose. www.irf.com 13 HTA-SERIES Device Screening Requirement MIL-STD-883 Method Condition No Suffix /EM suffix Internal Visual 2017 - Seal (Laser Weld) 1014 - X X Fine Leak Test (Unpressurized) - - X X (For info only) (Production (For Engineering Qualilty) Evaluation) X X Gross Leak Test (Unpressurized) - - X X Temperature Cycling 1010 -35°C, +185°C, 10 cycles X Not required - X Not required 3000G for 1 minute X Not required - X Not required 48 hrs @ 185°C X 8 hours @ 185°C - X X Not required In accordance with Electrical device specification Constant Acceleration 2001 In accordance with Electrical device specification Burn-in 1015 Final Electrical (Group A) In accordance with device specification Fine Leak Test 1014 A2 X Gross Leak Test 1014 C1 X X External Visual 2009 - X X Part Numbering HTA 200 05 S / EM EM = Engineering Model (evalulation purposes) Model Input Voltage Blank = No Suffix (production quality) 200 = 200V (Please refer to Device Screening Table for specific screening requirements) Output Voltage Output 03R3 = 3.3V, 05 = 5V 12 = 12V, 15 = 15V S = Single D = Dual WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105 IR SANTA CLARA: 2270 Martin Av., Santa Clara, California 95050, Tel: (408) 727-0500 Visit us at www.irf.com for sales contact information. Data and specifications subject to change without notice. 03/2009 14 www.irf.com