PT5540 Series 12-W 5-V Input Step-Up (Boost) Integrated Switching Regulator SLTS175 FEBRUARY 2003 Features • Input Voltage: 5V • 84% Efficiency • Industrial Temperature Range: –40°C to +85°C • Under-Voltage Lockout • Soft Start Description Ordering Information The PT5540 Excalibur™ power modules are a series of integrated switching regulators (ISRs) that provide a boost-voltage function. They are designed for use with +5V bus systems that require an additional higher voltage rail. The modules are rated 12W and produce a fixed output voltage over the full industrial temperature range of -40°C to +85°C. The series includes the common output voltages, +12V and +15V. Applications include PCI cards, audio circuits, and battery operated instruments. The PT5540 series is packaged in a 3-pin thermally efficient copper case. The case is solderable, has a small footprint, and can accommodate both through-hole and surface mount pin configurations. The PT5540 series is offered as a next generation replacement to the popular PT5040 series. The PT5540 has a lower operating temperature range and improved start-up characteristics. PT5541H PT5542H PT5544H PT5545H PT5546H PT5548H • Small Footprint: 0.94in × 0.35in (Vertical package) • Solderable Copper Case • Surface Mountable • IPC Lead Free 2 Pin-Out Information = +12 Volts = +15 Volts = + 8 Volts = + 9 Volts = +10 Volts = +12.6 Volts Pin Function 1 Vin 2 GND 3 Vo PT Series Suffix (PT1234 x ) Case/Pin Configuration Vertical Horizontal SMD Order Suffix N A C Package Code (EFN) (EFP) (EFQ) (Reference the applicable package code drawing for the dimensions and PC board layout) Standard Application + CIN 100µF 1 PT5540 2 COM +VO 3 COUT 100µF + +VIN COM CIN = Required 100µF electrolytic COUT = Required 100µF electrolytic (not to exceed 560µF) For technical support and more information, see inside back cover or visit www.ti.com PT5540 Series 12-W 5-V Input Step-Up (Boost) Integrated Switching Regulator Specifications (Unless otherwise stated, Ta =25°C, Vin =5V, Cin =100µF, Cout =100µF, and Io =Iomax) Characteristics Symbols Output Current Io Input Voltage Range Vin Set-Point Voltage Tolerance Temperature Variation Line Regulation Load Regulation Total Output Variation Vo tol ∆Regtemp ∆Regline ∆Regload ∆Regtot Efficiency η Vo Ripple (pk-pk) Transient Response Under-Voltage Lockout Start-up Current Switching Frequency External Capacitance Operating Temperature Range Storage Temperature Mechanical Shock Vr ttr ∆Vtr UVLO Iinstart ƒo Cin Cout Ta Ts Mechanical Vibration Weight Flammability Notes: (1) (2) (3) (4) (5) (6) SLTS175 FEBRUARY 2003 — — Conditions Over Vin range Over Io range –40°C <Ta < +85°C, Io =Iomin Over Vin range Over Io range Includes set-point, line, load, –40°C ≤ T a ≤ +85°C Io =75% of Iomax Min PT5541/8 PT5542 PT5544 PT5545 PT5546 Vo >10V Vo ≤10V PT5541/8 PT5542 PT5544 PT5545 PT5546 20MHz bandwidth 1A/µs load step, 50% of I o max V o over/undershoot Vin increasing Hysterisis On start up, Cout =560uF Over Vin and Io ranges Over Vin range — Per Mil-STD-883D, Method 2002.3 , 1 msec, Half Sine, mounted to a fixture Per Mil-STD-883D, Method 2007.2, 20-2000 Hz, Soldered in a PC board — Materials meet UL 94V-0 0.1 (1) 0.1 0.1 0.1 0.1 4.5 4.5 — — — — PT5540 SERIES Typ Max — — — — — Units — — ±0.5 — — 1 0.75 1.75 1.5 1.3 9 (Vo–1) ±2 — ±0.5 ±0.5 V — ±3 — %Vo — — — — — — — — — 0.1 — 300 100 (3) 100 (3) –40 (4) -40 — 84 84 86 86 86 2 150 1 4.3 0.2 Iin + 0.5 350 — — — — 500 — — — — — 5 — 3 — — — 400 — 560 +85 (5) +125 — — — 20 (6) 6.5 — — A %Vo %Vo %Vo %Vo % % Vo µSec % Vo V A kHz µF °C °C G’s G’s grams The ISR will operate down to no load with reduced specifications. Boost topology ISRs are not short circuit protected. The PT5540 Series requires a 100µF electrolytic or tantalum capacitor at both the input and output for proper operation in all applications. For operation below 0°C, the output capacitor C2 must have stable characteristics. Use either a low ESR tantalum or Oscon® capacitor. See SOA curves or consult factory for the appropriate derating. 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 PT5540 Series 12-W 5-V Input Step-Up (Boost) Integrated Switching Regulator SLTS175 FEBRUARY 2003 PT5541, 12VDC (See Note A) Efficiency vs Output Current VIN 9.0V 7.0V 5.0V 70 9.0V 8.0V 7.0V 6.0V 5.0V 80 70 60 0.2 0.4 0.6 0.8 1 60 50 0 0.15 0.3 Iout (A) 0.45 0.6 0 0.75 Ripple vs Output Current Ripple vs Output Current 150 100 Ripple - mV 5.0V 6.0V 7.0V 8.0V 9.0V 200 VIN 5.0V 6.0V 7.0V 8.0V 9.0V 160 120 50 80 0.8 1 100 0 0 0.15 0.3 0.45 0.6 0.75 0 Power Dissipation vs Output Current Power Dissipation vs Output Current 1.5 1 0.5 5.0V 6.0V 7.0V 8.0V 9.0V 1.5 1 0.8 1 0.15 0.3 0.45 0.6 0.75 0.3 0.6 Airflow 70 200LFM 120LFM 60LFM Nat Conv 60 50 40 30 0.8 1 1.2 1.5 Safe Operating Area; Vin =5V (See Note B) 90 Airflow 70 200LFM 120LFM 60LFM Nat Conv 60 50 40 30 20 20 0.9 Iout (A) Ambient Temperature (°C) 80 Ambient Temperature (°C) 90 80 Iout (A) 0 Safe Operating Area; Vin =5V (See Note B) 90 0.6 1 Iout (A) Safe Operating Area; Vin =5V (See Note B) 0.4 5.0V 6.0V 7.0V 8.0V 1.5 0 0 Iout (A) 0.2 VIN 0.5 0 0.6 1.5 2 0.5 0 1.2 Power Dissipation vs Output Current VIN 2 Pd - Watts 5.0V 6.0V 7.0V 8.0V 9.0V 0.9 2.5 Pd - Watts VIN 2 0 0.6 Iout (A) 2.5 0.4 0.3 Iout (A) 2.5 0.2 5.0V 6.0V 7.0V 8.0V 50 Iout (A) 0 VIN 150 0 0.6 1.5 200 40 0 1.2 Ripple vs Output Current 200 VIN 0.9 250 Ripple - mV 250 0.4 0.6 Iout (A) 240 0.2 0.3 Iout (A) 300 0 8.0V 7.0V 6.0V 5.0V 70 50 0 VIN 80 60 50 Ripple - mV 90 Efficiency - % 80 Efficiency - % 90 VIN Efficiency - % 100 100 90 Pd - Watts Efficiency vs Output Current Efficiency vs Output Current 100 Ambient Temperature (°C) PT5545, 9VDC (See Note A) PT5542, 15VDC (See Note A) 80 Airflow 70 200LFM 120LFM 60LFM Nat Conv 60 50 40 30 20 0 0.15 0.3 0.45 0.6 0.75 Iout (A) 0 0.3 0.6 0.9 Iout (A) Note A: Characteristic data has been developed from actual products tested at 25°C. This data is considered typical data for the ISR. Note B: SOA curves represent operating conditions at which internal components are at or below manufacturer’s maximum rated operating temperatures. For technical support and more information, see inside back cover or visit www.ti.com 1.2 1.5 Application Notes PT5540 Series Capacitor Recommendations for the PT5540 Boost Regulator Regulator Series Input Capacitors: The minimum input capacitance required is 100µF, with a 200-mA(rms) ripple current rating and 150mΩ typical equivalent series resistance (ESR). Electrolytic capacitors have marginal ripple performance at frequencies greater than 400kHz but have excellent low-frequency transient response. Above the ripple frequency, ceramic capacitors are necessary to improve the transient response and reduce any high frequency noise components apparent during higher current excursions. Preferred ESR type capacitor part numbers are identified in Table 2-1. Output Capacitor: The recommended output capacitance is determined by 0.5-A(rms) ripple current rating and 100µF minimum capacitance. The maximum output capacitance is 560µF. Ripple current and >50mΩ ESR value are the major considerations, along with temperature, when designing with different types of capacitors. Tantalum capacitors have a recommended minimum voltage rating of 2 × (the maximum DC voltage + AC ripple). This is necessary to insure reliability for input voltage bus applications. Tantalum Capacitors (Optional Input Capacitors) Tantalum type capacitors can be used for the input bus but only the AVX TPS, Sprague 593D/594/595, or Kemet T495/T510 series. These capacitors are recommended over many other tantalum types due to their higher rated surge, power dissipation, and ripple current capability. As a caution the TAJ series by AVX is not recommended. This series has considerably higher ESR, reduced power dissipation, and lower ripple current capability. The TAJ series is less reliable than the AVX TPS series when determining power dissipation capability. Tantalum or Oscon® types are recommended for applications where ambient temperatures fall below 0°C. Do not use tantalum capacitors on the output bus. Capacitor Table Table 1 identifies the characteristics of capacitors from a number of vendors with acceptable ESR and ripple current ratings. The number of capacitors required at both the input and output buses is identified for each capacitor type. This is not an extensive capacitor list. Capacitors from other vendors are available with comparable specifications. Those listed are for guidance. The RMS ripple current rating and ESR (Equivalent Series Resistance at 100kHz) are critical parameters necessary to insure both optimum regulator performance and long capacitor life. Table 1: Input/Output Capacitors Capacitor Vendor/ Series Panasonic FC (Radial) (Surface Mtg).............. Capacitor Characteristics Quantity Working Voltage Value(µF) (ESR) Equivalent Series Resistance 105°C Maximum Ripple Current(Irms) Physical Size(mm) Input Bus Output Bus Vendor Part Number 35V 25V 35V 100 330 100 0.117Ω 0.090Ω 0.150Ω 555mA 755mA 670mA 8x11.5 10×12.5 10x10.2 1 1 1 1 1 1 EEUFC1V101 EEUFC1E331 EEVFC1V101P FC/FK (Surface Mtg) 35V 100 0160Ω 600mA 8x10.2 1 1 EEVFK1V101P United Chemi-con LXZ/LXV Series MVY (Surface Mtg) 35V 25V 25V 150 220 330 0.120Ω 0.120Ω 0.150Ω 555mA 555mA 670mA 8x12 8x12 10×10.3 1 1 1 1 1 1 LXZ35VB151M8X12LL LXZ25VB221M8X12LL MVY25VC331M10X10TP Nichicon PM Series 35V 25V 120 180 0.150Ω 0.150Ω 555mA 555mA 10x12.5 10x12.5 1 1 1 1 UPM1V121MPH6 UPM1E181MPH6 NX 16V 150 0.026Ω 3300mA 10x8 1 N/R (1) PNX1C151MCR1GS Os-con: SP SVP (surface Mount) 20V 20V 120 100 0.024Ω 0.024Ω 3100mA 3320mA 8x10.5 8x12 1 1 N/R (1) N/R (1) 20SP120M(No Vout) 20SVP100M (No Vout) AVX Tantalum TPS (Surface Mtgt) 16V 20V 100 100 0.125Ω 0.200Ω >1149mA >1118mA 7.3L ×5.7W ×4.1H 1 1 N/R (1) N/R (1) TPSE107M016R0125(No Vout) TPSV107M016R0200 (No Vout) Kemet Tantalum T520/T495 Series (Surface Mount) 10V 10V 100 100 0.080Ω 0.100Ω 1700mA >100mA 4.3W ×7.3L ×4.0H 1 1 N/R (1) N/R (1) T520D107M010AS(No Vout) T495X107M010AS(No Vout) Sprague Tantalum 594D Series (Surface Mount) 16V 100 0.075Ω 1410mA 7.2L ×6W ×4.1H 1 N/R (1) 594D107X0016D2T (1) N/R –Not recommended. The surge and normal voltage rating does not meet the minimum operating limits. For technical support and more information, see inside back cover or visit www.ti.com Application Notes PT5540 Series Features and System Considerations for the PT5540 Series of Boost ISRs Boost Regulator Topology and Characteristics Figure 1-1 shows a block diagram of the boost regulator circuit, which is representative of the PT5540 ISR series. Note that when the MOSFET switch is off, the output regulator is connected directly to the input via an inductor and schottky diode. Thus with the MOSFET switch inactive, the output voltage merely tracks the input voltage, less the forward voltage drop of the diode. Figure 1-1; Boost Regulator Block Diagram Inductor VIN Schottky Diode V OUT Soft-Start Power Up When the input source voltage rises above the UVLO threshold voltage the regulator will initiate a soft-start power up. The soft-start circuitry introduces a short time delay and slows the rate at which the output rises to full regulation voltage. Figure 1-2 shows the power-up characteristic of a PT5542 (15V) regulator. After the application of the input voltage, Vin, there is a delay of approximately 100ms before the output voltage rises above the input voltage. This delay provides more time for a slow rising input source to reach the minimum operating voltage of 4.5V. The waveforms of Figure 1-2 were measured with a 5Vdc input voltage and 0.5-Adc constant current load. Fiigure 1-2; Typical Power Up Waveforms for the PT5542 MOSFET Switch Output Capacitor Vo (5V/Div) PWM Control Vin (5V/Div) COM One of the characteristic of a boost regulator is that its input current is always higher than its output current. For example, a 12-W rated 5V to 12V boost regulator, operating at 80% efficiency, will demand 15W of input power. Thus a 1-A load on the regulator’s output will correlate to 3-A of input current from its source. And any fall (droop) in the input voltage will corrspondingly result in the input current rising further. The input current demanded by a boost regulator is therefore high, making it important that the regulator be connected to a low impedance source. Under-Voltage Lockout (UVLO) The PT5540 series of boost regulators incorporate an input under-voltage lockout (UVLO). The UVLO prevents operation of the regulator until the input voltage is above the UVLO threshold (see data sheet specifications). This prevents the regulator from drawing a high startup current during power up, and minimizes the current drain from the input source during low input voltage conditions. Note: Below the UVLO threshold, the regulator’s internal MOSFET is merely held ‘off ’, disabling its boost function. Under this condition the regulator will still produce an output voltage. This is the input voltage less the forward voltage drop of the internal schottky diode. Iin (1A/Div) HORIZ SCALE: 40ms/Div Input Source Requirements As the input current is much higher than the output load current, boost regulators are sensitive to source voltage impedance. This is especially during power up when a regulator attempts to start at too low an input voltage. The UVLO built into the PT5540 series reduces the input current during startup by disabling the boost function until the source voltage has almost reached the minimum operating voltage of 4.5V. However, the UVLO circuitry will also promptly switch off the regulator if this voltage sags as the input current rises. This is often described as a “hiccup” effect. The module may hiccup at power up due to a combination of two conditions. The input voltage is rising too slowly and its source impedance is not low enough. To ensure a clean power-up the output impedance of the input source should be less than 25mΩ. A higher input impedance can be tolerated if the input voltage rises promptly and regulates closer to the nominal input voltage of 5V. For technical support and more information, see inside back cover or visit www.ti.com Application Notes continued PT5540 Series Fault Protection Unlike a “Buck” or step-down regulator it is not possible to provide a boost regulator with short-circuit protection. As revealed in the block diagram of Figure 1-1, inhibiting the MOSFET switching action only disables the regulator’s boost function. Therefore under a severe output impedance fault the control circuit cannot disconnect the output from the input source. To prevent an output over-current or short-circuit fault from propagating to the input bus, a fuse or equivalent over-current protection is recommended at the input of the module. Whatever form of protection is selected, it is important to note that the impedance and/or voltage drop of the series element will add to the regulator’s minimum input voltage requirements. Power up may also be affected. The combination of an input surge current with an impedance in series with the regulator input may cause the input voltage to momentarily dip back below the UVLO threshold. Ensure that the fuse rating or input current limit threshold are designed with a generous margin. For technical support and more information, see inside back cover or visit www.ti.com IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, modifications, enhancements, improvements, and other changes to its products and services at any time and to discontinue any product or service without notice. Customers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All products are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. TI warrants performance of its hardware products to the specifications applicable at the time of sale in accordance with TI’s standard warranty. Testing and other quality control techniques are used to the extent TI deems necessary to support this warranty. Except where mandated by government requirements, testing of all parameters of each product is not necessarily performed. TI assumes no liability for applications assistance or customer product design. Customers are responsible for their products and applications using TI components. To minimize the risks associated with customer products and applications, customers should provide adequate design and operating safeguards. TI does not warrant or represent that any license, either express or implied, is granted under any TI patent right, copyright, mask work right, or other TI intellectual property right relating to any combination, machine, or process in which TI products or services are used. Information published by TI regarding third–party products or services does not constitute a license from TI to use such products or services or a warranty or endorsement thereof. Use of such information may require a license from a third party under the patents or other intellectual property of the third party, or a license from TI under the patents or other intellectual property of TI. Reproduction of information in TI data books or data sheets is permissible only if reproduction is without alteration and is accompanied by all associated warranties, conditions, limitations, and notices. Reproduction of this information with alteration is an unfair and deceptive business practice. TI is not responsible or liable for such altered documentation. Resale of TI products or services with statements different from or beyond the parameters stated by TI for that product or service voids all express and any implied warranties for the associated TI product or service and is an unfair and deceptive business practice. TI is not responsible or liable for any such statements. Mailing Address: Texas Instruments Post Office Box 655303 Dallas, Texas 75265 Copyright 2003, Texas Instruments Incorporated