ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 1 of 29
Member of the Family
Applications
• Low voltage, high density systems with
Interm ediate Bus Ar c hitec tur es (IBA)
• Point-of-load regulators for high performance
DSP, FPGA, ASIC, and microprocessors
• Desktops, servers, and portable computing
• Broadban d, net work ing, opt ic al, and
communications systems
Benefits
• Integrates digital power conversion with
intelligent power management
• Eliminates the need for external power
management components
• Completely programmable via industry-standard
I2C communication bus
• One part that covers all applications
• Reduces board space, system cost and
complexity, and time to market
Features
• RoHS lead free and lead-solder-exempt products are
available
• Wide input voltage range: 8V–14V
• High continuous output current: 60A
• Programmable output voltage range: 0.5V–2.75V
• Efficiency greater than 92%
• Active digital current share
• Single-wire serial communication bus for frequency
synchronization, programming, and monitoring
• Real time voltage, current, and temperature
measurements, monitoring, and reporting
• Optimal voltage positioning with programmable slope
of the VI line
• Overcurr ent, ov ervo lta ge, u nderv olt ag e, and
overtemperature protections with programmable
thresholds and types
• Programmable fixed switching frequency 0.5-1.0MHz
• Programmable turn-on and turn-off delays
• Programmable turn-on and turn-off voltage slew rates
with tracking protection
• Programmable feedback loop compensation
• Power Good signal with programmable limits
• Programmable fault management
• Start up into the load pre-biased up to 100%
• Current sink capability
• Industry standard size through-hole single-in-line
package: 2.4”x0.55”
• Low height of 1.1”
• Wide operating temperature range: 0 to 70ºC
• UL 60950-1/CS A 22.2 No. 60950-1-07 Second
Edition, IEC 60950-1: 2005, and EN 60950-1:2006
Description
Power-One’s point-of-load converters are recommended for use with regulate d bus converters in an Intermediate
Bus Architecture (IBA). The ZY8160 is an intelligent, fully programmable multiphase step-down point-of-load DC-
DC module integrating digital power conversion and intelligent power management. When used with ZM7300
Series Digital Power Managers, the ZY8160 completely eliminates the need for external components for
sequencing, tracking, protection, monitoring, and reporting. All parameters of the ZY8160 are programmable via
the industry-standard I2C communication bus and can be changed by a user at any time during product
development and service.
Reference Documents:
• ZM7300G Series Digital Power Manager. Data Sheet
• ZM7300 Digital Power Manager Programming Manual
• Power-One I2C Graphical User Interface Program
• ZM00056-KIT USB to I2C Adapter Kit. User Man ual
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 2 of 29
1. Orderin g Information
ZY 81 60 y – zz
Product
family:
Z-One
Module
Series:
Server Class
Intelligent POL
Converter
Output
Current:
60A
RoHS compliance:
No suffix - RoHS compliant
with Pb solder exemption1
G - RoHS compliant for all
six substances
Dash
Packaging Option2:
R1 – 30 pc Tray
Q1 – 1 pc sample for
evaluation only
______________________________________
1 The solder exemption refers to all the rest rict ed materials except l ead in solder. These materi als are Cadmium (Cd), Hexavalent chromium
(Cr6+), Mercury (Hg), P ol ybromi nated biphenyl s (PBB), Polybrominated diphenylethers (PBDE), and Lead (Pb) used anywhere except in
solder.
2 Packaging opti on is used only for ordering and not included in the part number printed on the POL converter label.
3 Z-One evaluation board is available in onl y one configurati on: ZM7300-KIT-HKS.
Example: ZY8160G-R1: A 30-piece tray of RoHS compliant POL converters. Each POL converter is labeled
ZY8160G.
2. A b solute Maximum Ratings
Stresses in excess of the absolute maximum ratings may cause performance degradation, adversely affect long-
term reliability, and cause permanent damage to the converter.
Parameter Conditions/Description Min Max Units
Operating Temperature Contr ol ler cas e temper atur e 0 100 °C
Input Voltage 250ms Transient 15 VDC
3. Environmen tal and Mechanical Specifications
Parameter Conditions/Description Min Nom Max Units
Ambient Temperature Range 0 70 °C
Storage Temperature (Ts) -55 125 °C
Weight 33 grams
Operating Vibration
(sinusoidal)
Frequency Range
Magnitude
Sweep Rate
Repetitions in each axis (Min-Max-Min Sweep)
5
0.5
1
2
500
Hz
G
oct/min
sweeps
Non-Operating Shock
(half sine)
Acceleration
Duration
Number of shocks in each axis
50
11
10
G
ms
MTBF Calculated Per Telcordia Technologies SR-332 18.5 MHrs
Peak Reflow Temperature ZY8160 220 °C
Peak Reflow Temperature ZY8160G 245 260 °C
Lead Plating ZY8160 and ZY8160G 100% Matte Tin
Moisture Sensitivity Level
per JEDEC J-STD-020C ZY8160
ZY8160G 2
3
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 3 of 29
4. Electrical Specifications
Specificat ions appl y at the input vo ltage f rom 8V to 14V, output load f rom 0 to 60A, am bient tem perature f rom 0°C
to 70°C, output capacitance consisting of 110µF ceramic and 220µF tantalum, and default performance
parameters settings unless otherwise noted.
4.1 Input Specifications
Parameter Conditions/Description Min Nom Max Units
Input voltage (VIN) Refer to Figure 1 8 14 VDC
Input Current (at no load) VIN=12V 29 mADC
Maximum Input Current VIN=8V, VOUT=2.1V 17.5 ADC
4.2 Output Specifications
Parameter Conditions/Description Min Nom Max Units
Output Voltage Range (VOUT) Programmable
1
0.5
Default (no pr ogra mm ing)
0.5 2.75
VDC
VDC
Output Voltage Setpoint Accuracy VIN=12V, IOUT=0.5*IOUT MAX,
FSW=500kHz, room temperature ±1.2% or 10mV whichever is
greater %VO.SET
Output Current (IOUT) VIN MIN to VIN MAX -402 60 ADC
Line Regulation VIN MIN to VIN MAX ±0.5 %VOUT
Load Regulation 0 to IOUT MAX ±0.5 %VOUT
Dynamic Regulation
Peak Deviation
Settling Time
50% - 75% load step, Slew rate 1A/µs
COUT=660µF, FSW=1MHz
to 10% of peak deviation
100
35
mV
µ
s
Output Voltage Peak-to-Peak
Ripple and Noise
BW=20MHz
Full Load
VIN=12V, VOUT=0.75V
VIN=12V, VOUT=1.0V
VIN=12V, VOUT=1.8V
VIN=12V, VOUT=2.5V
15
20
25
30
mV
mV
mV
mV
Efficiency
FSW=500kHz
Full Load
Room temperature
VIN=12V, VOUT=0.5V
VIN=12V, VOUT=0.75V
VIN=12V, VOUT=1.0V
VIN=12V, VOUT=1.2V
VIN=12V, VOUT=1.5V
VIN=12V, VOUT=1.8V
VIN=12V, VOUT=2.5V
78.8
82.3
85.5
87.4
89.3
90.6
92.5
%
%
%
%
%
%
%
Temperature Coefficient VIN=12V, VOUT =2.5V, IOUT=0.5*IOUT MAX 50 ppm/°C
Switching Frequency
(3 phases combined) Default
Programmab le, 250 kHz steps
500 500
1,000 kHz
kHz
Duty Cycle Default
Programmable, 0.5% steps
0 33
33 %
%
1 ZY8160 is a step -down converter, t hus t he output volt age is always lower than the input voltage as show in Figure 1.
2 At the negative output current (bus terminator mode) efficiency of the ZY8160 degrades resulting in increased internal power dissipation.
Therefore maximum all owable negati ve c urrent is l imited to 40A.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 4 of 29
1.5
1.0
Vo
[V]
14.011.08.0 Vi [V]
0.5
2.5
2.0
3.0
9.0 10.0 12.0 13.0
2.75
9.6
2.1
10.5
Figure 1. Output Voltage as a Function of Input Voltage
4.3 Protection Specifications
Parameter Conditions/Description Min Nom Max Units
Output Overcurrent Protection
Type Default
Programmable Non-Latching, 130ms period
Latching/Non-Latching
Threshold Default
Programmab le in 11 steps
40 140
140 %IOUT
%IOUT
Threshold Accuracy -25 25 %IOCP.SET
Output Overvoltage Protection
Type Default
Programmable Non-Latching, 130ms period
Latching/Non-Latching
Threshold Default
Programmab le in 10% step s
1101 130
130 %VO.SET
%VO.SET
Threshold Accuracy Measured at VO.SET=2.5V -2 2 %VOVP.SET
Delay From instant when threshold is exceeded until
the turn-off command is generated 6 μs
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 5 of 29
Output Undervoltage Protection
Type Default
Programmable Non-Latching, 130ms period
Latching/Non-Latching
Threshold Default
Programmable in 5% steps
75 75
90 %VO.SET
%VO.SET
Threshold Accuracy Measured at VO.SET=2.5V -2 2 %VUVP.SET
Delay From instant when threshold is exceeded until
the turn-off co mm and is gener ated 6 μs
Overtemperature Protection
Type Default
Programmable Non-Latching, 130ms period
Latching/Non-Latching
Turn Off Threshold Temperature is increasing 120 °C
Turn On Threshold
Temperature is decreasing after the module was
shut down by OTP
110 °C
Threshold Accuracy -5 5 °C
Delay
From instant when the controller juncti on
temperature reaches the OTP threshold until the
turn-off command is generate d
2 ms
Tracking Protection (when Enabled)
Type Default
Programmable Disabled
Latching/Non-Latching, 130ms period
Threshold Enabled during output voltage ramping up ±250 mVDC
Threshold Accuracy -50 50 mVDC
Delay From instant when threshold is exceeded until
the turn-off co mm and is gener ated 6 μs
Overtemperature Warning
Threshold Always enabled, reported in Status register 120 °C
Threshold Accuracy -5 5 °C
Hysteresis 3 °C
Delay
From instant when threshold is exceeded until
the warning signal is generated
6 μs
Power Good Signal (PGOOD pin)
Logic
V
OUT
is inside the PG window
VOUT is outside the PG window
High
Low
N/A
Lower Threshold Default
Programmable in 5% steps
90 90
95 %VO.SET
%VO.SET
Upper Threshold 110 %VO.SET
Delay
From instant when threshold is exceeded until
status of PG signal changes
6 μs
Threshold Accuracy Measured at VO.SET=2.5V -2 2 %VO.SET
___________________
1 Minimum OVP threshol d is 1.0V
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 6 of 29
4.4 Feature Specifications
Parameter Conditions/Description Min Nom Max Units
Current Sha re
Type Active, Single Line
Current Share Accuracy IOUT MIN≥20%*IOUT NOM ±20 %IOUT
Interleave
Interleave (Phase Shift) Default
Programmab le in 11.25
°
steps
0 0
348.75 Degree
degree
Sequencing
Turn ON Delay Default
Programmable in 1ms steps
0
0
255
ms
ms
Turn OFF Delay Default
Programmable in 1ms steps
0
0
63
ms
ms
Tracking
Turn ON Slew Rate
Default
Programmab le in 7 steps
0.1
0.1
8.33
1
V/ms
V/ms
Turn OFF Slew Rate
Default
Programmab le in 7 steps
-0.1
-0.1
-8.33
1
V/ms
V/ms
Optimal Voltage Positioning
Load Regulation Default
Programmab le in 7 steps
0
0
1.3
mV/A
mV/A
Feedback Loop Compensation
Zero1 (Effects phase lead and
increases gain in mid-band)
Programmable 0.05 50 kHz
Zero 2 (Effects pha se lead an d
increases gain in mid-band)
Programmable 0.05 50 kHz
Pole 1 (Integrator Pole, effects
loop gain)
Programmable 0.05 50 kHz
Pole 2 (Effects phase lag and
limits gain in mid-band)
Programmable 1 1000 kHz
Pole 3 (High frequen cy low- pass
filter to limit PWM noise)
Programmable 1 1000 kHz
Monitoring
Voltage Monitoring Accuracy 1 LSB=22mV -1%VOUT
– 1 LSB 1%VOUT
+ 1 LSB mV
Current Monitoring Accuracy 20%IOUT NOM <IOUT≤IOUT NOM 20 20 %IOUT
Temperature Monitoring Accuracy Junction temperature of POL controller -5 +5 °C
Remote Voltage Sense (+VS and –VS pins)2
Voltage Drop Compensation Between +VS and VOUT 300 mV
Voltage Drop Compensation Between -VS and PGND 100 mV
___________________
1 Achieving fast slew rates under spec ific line and l oad conditions may require feedback loop adjustment
2 If the voltage sense outputs are connect ed remotely, i t is rec ommended to place a 0. 01-0.1μF c eramic capacitor bet ween +VS and –VS pins
as close to the POL converter as possible. The capacitor improves noise immunity of the POL converter.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 7 of 29
4.5 Signal Specifications
Parameter Conditions/Description Min Nom Max Units
VDD Internal supply voltage 3.15 3.3 3.45 V
SYNC/DAT A Line (SD pin)
ViL_sd LO W level input voltage -0.5 0.3 x VDD V
ViH_sd HIGH level input voltage 0.75 x
VDD
VDD + 0.5 V
Vhyst_sd Hysteresis of input Schmitt trigger
0.25 x
VDD
0.45 x
VDD
V
VoL LOW level sink current @ 0.5V 14 60 mA
Tr_sd Maximum allowed rise time 10/90%VDD 300 ns
Cnode_sd Added node capacitance 5 10 pF
Ipu_sd Pull-up current sour ce at Vsd= 0V 0.3 1.0 mA
Freq_sd Clock frequency of external SD line 475 525 kHz
Tsynq Sync pulse duration 22 28
% of clock
cycle
T0 Data=0 pulse duration 72 78
% of clock
cycle
ADDR0…ADDR4 Inputs
ViL_x LOW level input voltage -0.5 0.3 x VDD V
ViH_x HIGH level input voltage 0.7 x VDD VDD+0.5 V
Vhyst_x Hysteresis of input Schmitt trigger 0.1 x VDD 0.3 x VDD V
RdnL_ADDR External pull down resistance
ADDRX forced low
10 kOhm
Power Good and OK Inputs/Outputs
Iup_PG Pull-up current sour ce inp ut forced low PG 25 110 μA
Iup_OK Pull-up current sour ce inp ut forced low OK 175 725 μA
ViL_x LOW level input voltage -0.5 0.3 x VDD V
ViH_x HIGH level input voltage 0.7 x VDD VDD+0.5 V
Vhyst_x Hysteresis of input Schmitt trigger 0.1 x VDD 0.3 x VDD V
IoL LOW level sink current at 0.5V 4 20 mA
Current Sha re Bus (CS pin)
Iup_CS Pull-up current source at VCS = 0V 0.84 3.1 mA
ViL_CS LOW level input volta ge -0.5 0.3 x VDD V
ViH_CS HIGH level input voltage 0.75 x
VDD
VDD+0.5 V
Vhyst_CS Hysteresis of input Schmitt trigger
0.25 x
VDD
0.45 x
VDD
V
IoL LOW level sink current at 0.5V 14 60 mA
Tr_CS Maximum allowed ris e time 10/90% VDD 100 ns
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 8 of 29
5. Typical Performance Characteristics
5.1 Efficiency Curves
75
80
85
90
95
010 20 30 40 50 60
Output Current, A
Efficiency, %
Vo=0.75V Vo=1.0V Vo=1.2V
Vo=1.8V Vo=2.5V
Figure 2. Efficiency vs. Load. Vin=9.6V, Fsw=500kHz
75
80
85
90
95
010 20 30 40 50 60
Output Current, A
Efficiency, %
Vo=0.75V Vo=1.0V Vo=1.2V
Vo=1.8V Vo=2.5V
Figure 3. Efficiency vs. Load. Vin=12V, Fsw=500kHz
75
80
85
90
95
0.5 11.5 22.5
Output Voltage, V
Efficiency, %
Vin=9.6V Vin=12V
Figure 4. Efficiency vs. Output Voltage, I out=60A,
Fsw=500kHz
75
80
85
90
95
8 9 10 11 12 13 14
Inpu t Vol t age, V
Efficiency, %
Vo=0.5V Vo=1.8V Vo=2.5V
Figure 5. Efficiency vs. Input Voltage. Iout=60A, Fsw =500kHz
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 9 of 29
82
84
86
88
90
92
94
500 750 1000
Switching Frequency, kHz
Efficiency, %
Vo=1V Vo=1.8V Vo=2.5V
Figure 6. Efficiency vs. Switching Frequency. Vin=12V,
Iout=60A
5.2 Turn-On Characteristics
Figure 7. Tracking Turn -On. Rising Slew Rate is
Programmed at 0.5V/ms.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
Figure 8. Turn-On with Different Rising Slew Rates.
Rising Slew Rates are Programmed as follows: V1-
and V2-0.5V/ms, V3 -0.2V/ms.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
Figure 9. Turn On with Sequencing and Tracking. Rising Slew
Rate Programmed at 0.5V/ms , V 1 an d V2 delays are
programmed at 5ms.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 10 of 29
Figure 10. Turn On into Prebiased Loa d. V1 and V2 are
Prebiased b y V3 via a Diode.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
5.3 Turn-Off Characteristics
Figure 11. Tracking Turn-Off. Falling Slew Rate is
Programmed at 0.5V/ms.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
Figure 12. Turn-Off with Tracking and Sequencing. Falling
Slew Rate is Programmed at 0.5V/ms.
Vin=12V, Ch1 – V1, Ch2 – V2, Ch3 – V3
5.4 Transient Respon se
The picture below shows the deviation of the output
voltage in response to the 50-75-50% step load at
1A/μs. In all tests the ZY8160 converters had the
switching frequency of 1MHz and a total of 660μF
ceramic and tantalum capacitors connected across
the output pins. Bandwidth of the feedback loop was
programmed for faster transient response.
Figure 13. Vin=12V, Vout=1.8V
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 11 of 29
5.5 Thermal Derating Curves
20
30
40
50
60
25 35 45 55 65 75
Ambient Temperature, C
Load Current , A
0 LFM
100 LFM (0.5 m/s)
200 LFM (1 m/s)
300 LFM (1.5 m/s)
400 LFM (2 m/s)
500 LFM (2.5 m/s)
Figure 14. Thermal Derating Curves. Vin=12V, Vout=2.5V, Fsw=500kHz
20
30
40
50
60
25 35 45 55 65 75
Ambient Temperature, C
Load Current , A
0 LFM
100 LFM (0.5 m/s)
200 LFM (1 m/s)
300 LFM (1.5 m/s)
400 LFM (2 m/s)
500 LFM (2.5 m/s)
Figure 15. Thermal Derating Curves. Vin=12V, Vout=2.5V, Fsw=1,000kHz
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 12 of 29
6. Typical Application
ZM73XX
6 25 57 6042
8 9 26 38 43 58
4HRES_N
PG0
PG1
PG2
PG3
EN0
EN1
EN2
EN3 50
55
7
5
49
51
52
54
61 LCK_N
56
SD
OKD
OKC
OKB
OKA
53
20
13
11
16 ACFAIL_N
18 RES_N
CB
FE_EN 17
23
30 SDA
27 SCL
45 ADDR2
46 ADDR1
47 ADDR0
48 IBVS
44 AREF
36 INT3_N
37 INT2_N
40 INT1_N
41 INT0_N TMS
TCK
TDO
TDI 34
33
31
32
IBV
+3.3V
SDA
SCL
47k
10k
R3R4
10n 10n
100n 100n 100n 100n
ZY8160
SDOK VIN
VDD VDD VDD VDD VDD
VSSVSS VSS VSS VSS VSS
Intermediate Voltage Bus
IR
10k
63
VIN
GND
GND
GND
GND
GND
GND
VS-
VS+
VOUT
VOUT
VOUT
VOUT
12
13
7
8
11
18
20
22
24
17
19
21
23
10
22µ 22µ 22µ 47µ 220µ
14
15
16
1
9ADDR0
ADDR1
ADDR2
ADDR3
ADDR4
CSPG
364 5
+V
OUT
-V
OUT
10µ 10µ 22µ22µ
Connect to other
Z-One® POL
Converters
Connect CS pin to
other ZY8160 to
enable current share Low ESR Ceramic
Capacitors To Keep
The Input Voltage
Ripple ≤2% Of V
IN
Tantalum Capacitors
Are Not Required, If
Inductance Of Input
Source <0.1µH
1.5mΩ1.5mΩ125mΩ125mΩ
Low ESR Ceramic And
Tantalum Capacitors
Figure 16. Block Diagram of Typical Multi ple Output Application with Digital Power Manager and I2C Interface
The schematic of a typical application of ZY8160 point-of-load converters (POL) is shown in Figure 16. The
system includes a ZM7300 series Digital Power Manager (DPM), a ZY8160 POL, and may include additional
ZY8160 POLs and other Z-One® series POLs . All POLs are connected to the D PM and to each ot her via a single-
wire SD (s ync/data) line. The line pr ovides s ynchroniz ation of al l POLs to the m aster c lock gener ated by the DPM
and simultaneously performs data transfer between POLs and the DPM. Each POL has a unique 5-bit address
programmed by grounding respective address pins. To enable the current share, CS pins of POLs connected in
parallel are interconnected.
In addition to the SD li ne, OK pins of the POLs ar e connec ted to the r especti ve OK pins of the DPM. A num ber of
POLs connected to the same OK pin of the DPM forms a group. Grouping of POLs enables users to program,
control, and monitor multiple POLs simultaneously and execute advanced fault management schemes.
The type, value, and the number of output capacitors shown in the schematic are required to meet the
specifications published in the data sheet. However, ZY8160 POLs are fully operational with diff erent parameters
of output capacitors. The feedback loop compensation may need to be adjusted to optimize performance of the
POLs for specific parameters of the output capacitors.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 13 of 29
7. Pin Assignments and Descr iption
Pin
Name Pin
Number Pin
Type Buffer
Type Pin Description Notes
OK 3 I/O PU Fault/Status Condition Connect to OK pi n of other Z-POL and/or DPM.
Leave floating, if not used
SD 5 I/O PU Sync/Data Li ne Connect to SD pin of DPM
PGOOD 4 I/O PU Power Good
CS 6 I/O PU Current Share
Connect to CS pin of other Z-POLs connected in
parallel
ADDR4 16 I PU POL Address Bit 4 Tie to GND for 0 or leave floating for 1
ADDR3 15 I PU POL Address Bit 3 Tie to GND for 0 or leave floating for 1
ADDR2 14 I PU POL Address Bit 2 Tie to GND for 0 or leave floating for 1
ADDR1 9 I PU POL Address Bit 1 Tie to GND for 0 or leave floating for 1
ADDR0 1 I PU POL Address Bit 0 Tie to GND for 0 or leave floating for 1
-VS 10 I A Negative Voltage Sense Connect to the negative point close to the load
+VS 11 I A Positive Voltage Sense Connect to the positive point close to the load
VOUT 18, 20,
22,24
P Output Voltage
GND
7, 8, 17,
19, 21,
23
P Power Ground
VIN 12, 13 P Input Voltage
Legend: I=input, O=output, I/O=input/output, P=power, A=anal og, P U=i nternal pul l -up
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 14 of 29
8. Programmable Features
Performance parameters of ZY8160 POL converters
can be programmed via the industry standard I2C
communication bus without replacing any
components or re wiring PCB tr aces . Each p aram eter
has a default value stored in the volatile memory
registers detaile d in Table 1. T he setup regist ers 00h
through 14h are programmed at the system power-
up. When the user programs new performance
parameters, the values in the registers are
overwritten. Upon removal of the input voltage, the
default values are restored.
Table 1. ZY8160 Memory Registers
Register Content Address
PC1
Protection Conf i guration 1
00h
PC2
Protection Conf i guration 2
01h
PC3
Protection Conf i guration 3
02h
DON
Turn-On Delay
05h
DOF
Turn-Off Delay
06h
TC
Tracking Configuration
03h
INT
Interleave Configuration and
Frequency Selection
04h
RUN
RUN Regis ter
15h
ST
Status Register
16h
VOS
Output Voltage Setpoint
07h
CLS
Current Limit Setpoint
08h
DCL
Duty Cyc l e Limit
09h
B1
Dig Controller Denominator z-1
Coefficient
0Ah
B2 Dig Controller Denominator z
-2
Coefficient
0Bh
B3 Dig Controller Denominator z
-3
Coefficient
0Ch
C0L
Dig Controller Numerator z0
Coefficient, Low Byte
0Dh
C0H
Dig Controller Numerator z0
Coefficient, High Byte
0Eh
C1L
Dig Controller Numerator z-1
Coefficient, Low Byte
0Fh
C1H Dig Controller Numerator z
-1
Coefficient, High Byte
10h
C2L Dig Controll er Numerator z
-2
Coefficient, Low Byte
11h
C2H
Dig Controller Numerator z-2
Coefficient, High Byte
12h
C3L
Dig Controller Numerator z-3
Coefficient, High Byte
13h
C3H
Dig Controller Numerator z-3
Coefficient, Low Byte
14h
VOM
Output Voltage Monitoring
17h
IOM
Output Current Monitoring
18h
TMP
Temperature Monitoring
19h
ZY8160 converters can be programmed using the
Graphical User Interface or directly via the I2C bus by
using high and low level commands as described in
the ”ZM7300 Digital Power Manager Programming
Manual”.
ZY8160 parameters can be reprogrammed at any
time during the s ystem operation and service except
for the digital filter coefficients, the switching
frequency and the duty cycle limit, that can only be
changed when the PO L output is turned off.
8.1 Output Voltage
The output voltage can be programmed in the POL
Output Conf iguration windo w shown in the Figure 17
or directly via the I2C bus by writing into the VOS
register shown in Figure 18.
Figure 17. Output Confi gura tio n Window
Figure 18. Output Voltage Setpoi nt Register VOS
VOS7
VOS6
VOS5
VOS4
VOS2
VOS1
VOS0
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
Bit 7:0
VOS[7:0]
, Output voltage setting
00h: corresponds to 0.5000V
01h: corresponds to 0.5125V
…
77h: corresponds to 1.9875V
78h: corresponds to 2.0000V
79h: corresponds to 2.025V
…
…
96h: corresponds to 2.750V
VOS3
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 15 of 29
8.1.1 Output Voltage Setpoint
The output voltage programming range is from 0.5V
to 2.75V. To improve the resolution of the output
voltage settings, the voltage range is divided into
sub-ranges as shown in Table 2.
Table 2. Output Volta ge Adjustment Resolution
VOUT MIN, V VOUT MAX, V Resolution, mV
0.500 2.000 12.5
2.025 2.75 25
8.1.2 Output Voltage Margining
If the output voltage needs to be varied by a certain
percentage, the margining function can be utilized.
The margining can be programmed in the POL
Output Configuration window or directly via the I2C
bus using high level commands as described in the
‘”DPM Programming Manual”.
In order t o properl y m argin POLs that are c onnected
in parallel, th e POLs must be m embers of one of the
Parallel Buses. Refer to the DPM Configure Devices
window shown in Figure 45.
8.1.3 Optimal Voltage P o sitioning
Optimal voltage positioning increases the voltage
regulation window by properly positioning the output
voltage setpoint. Positioning is determined by the
load regulation that can be programmed in the GUI
Output Configuration window shown in Figure 17 or
directly via the I2C bus by writing into the CLS
register shown in Figure 28.
Figure 19 illustrates optimal voltage positioning
concept. If no load regulation is programmed, the
headroom (voltage differential between the output
voltage setpoint and a regulation limit) is
approximately half of the voltage regulation window.
When load regulation is programmed, the output
voltage will decrease as the output current
increases, so the VI characteristic will have a
negative slope. Therefore, by properly selecting the
operating point, it is possible to increase the
headroom as shown in the picture.
Upper Regulation
Limit
Lower Regulation
Limit
Light
Load
V
OUT
I
OUT
VI Curve Without
Load Regulation
VI Curve With
Load Regulation
Heavy
Load
Headroom without
Load Regulation
Operating
Point
Headroom with
Load Regulation
Figure 19. Concept of Optimal Volt a g e Po s itioning
Increased headroom allows tolerating larger voltage
deviations. For example, the step load change from
light to heavy load will cause the output voltage to
drop. If the optim al voltage posit ioning is utili zed, the
output voltage will stay within the regulation window.
Otherwise, the output voltage will drop below the
lower regulation limit. To compensate for the voltage
drop external output capacitance will need to be
added, thus increasing cost and complexity of the
system.
The effect of optimal voltage positioning is shown in
Figure 20 and Figure 21. In this case, switching
output load causes large peak-to-peak deviation of
the output voltage. By programming load regulation,
the peak to peak deviation is dramatically reduced.
Figure 20. Transi ent Resp o nse without Optimal Voltage
Positioning
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 16 of 29
Figure 21. Transient Response with Optimal Voltage
Positioning
8.2 Sequencing and Trac king
Turn-on delay, turn-off delay, and rising and falling
output voltage slew rates can be programmed in the
GUI Sequencing/Tracking window shown in Figure
22 or direct ly via th e I2C bus by writing into the DO N,
DOF, and TC registers, respectively. The registers
are shown in Figure 23, Figure 24, and Figure 26.
Figure 22. Sequencing Window
8.2.1 Turn-On Delay
Turn-on delay is defined as an interval from the
application of the Turn-On comm and until the output
voltage starts ramping up.
DON7
DON6
DON5
DON4
DON2
DON1
DON0
Bit 7
Bit 0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
Bit 7:0 DON[7:0]: Turn-on delay time
00h: corresponds to 0ms delay after turn-on command has occurred
…
FFh: corresponds to 255ms delay after turn-on command has occurred
DON3
Figure 23. Turn-On Delay Register DON
8.2.2 Turn-Off Delay
---
---
DOF5
DOF4
DOF2
DOF1
DOF0
Bit 7
Bit 0
U
U
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
Bit 7:6 Unimplemented, read as ‘0’
Bit 5:0 DOF[5:0]: Turn- o f f delay time
00h: corresponds to 0ms delay after turn-off command has occurred
…
3Fh: corresponds to 63ms delay after turn-off command has occurred
DOF3
Figure 24. Turn-Off Delay Register DOF
Turn-off delay is defined as an interval from the
application of the Turn-Off command until the output
voltage reaches zero (if the falling slew rate is
programmed) or until both high side and low side
switches are turned off (if the slew rate is not
programmed). T herefore, for the slew rate controlled
turn-off the r amp-down time is i nclu ded in the tur n-off
delay as shown in Figure 25.
Turn-Off
Command
Internal
ramp-down
command
VOUT
User programmed turn-off delay, TDF
Calculated
delay TD
Time
Ramp-down time, TF
Falling slew
rate dVF/dT
Figure 25. Relationship between Turn-Off Delay and Falling
Slew Rate
As it can be seen from the figure, the internally
calculated delay TD is determined by the equation
below.
dT
dV
V
TT
F
OUT
DFD
−=
,
For proper operation TD shall be greater than zero.
The appropriate value of the turn-off delay needs to
be programmed to satisfy the condition.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 17 of 29
If the falling slew rate control is not utilized, the turn-
off delay only determines an interval from the
application of the Turn-Off command until both high
side and low side switches are turned off. In this
case, the output voltage ramp-down process is
determined by load parameters.
8.2.3 Rising and Falling Sl ew Rates
The output voltage tracking is accomplished by
programming the rising and falling slew rates of the
output voltage. To achieve programmed slew rates,
the output volta ge is being c hanged in 12.5mV steps
where duration of each step determines the slew
rate. For example, ramping up a 1.0V output with a
slew rate of 0.5V/ms will require 80 s teps duration of
25μs each.
Duration of each voltage step is calculated by
dividing the m as ter clock frequenc y genera ted b y the
DPM. Since all POLs in the s ystem are s ynchronize d
to the master clock, the matching of voltage slew
rates of dif f erent out puts is ver y ac cur ate as it ca n be
seen in Figure 7 and Figure 11.
During the turn on process, a POL not only delivers
current required by the load (ILOAD), but also charges
the load capacitance. The charging current can be
determined from the equation below:
dt
dV
CI R
LOADCHG ×=
Where, CLOAD is load capacitance, dVR/dt is rising
voltage slew rate, and ICHG is charging current.
When selecting the rising slew rate, a user needs to
ensure that
OCPCHGLOAD III <+
Where IOCP is the overcurrent protection threshold of
the ZY8160. If the condition is not met, then the
overcurrent protection will be triggered during the
turn-on process. To avoid this, dVR/dt and the
overcurrent protection threshold should be
programmed to meet the condition above.
Figure 26. Tracking Configuration Register TC
8.3 Protection
ZY8160 Ser ies c on verter s have a c omprehens ive s et
of programmable protection functions. The set
includes the output over- and undervoltage
protection, overcurrent protection, overtemperature
protection, tracking protection, overtemperature
warning, and Power Good signal. Status of
protection functions is stored in the ST register
shown in Figure 27.
Figure 27. Protection Status Register ST
Thresholds of overcurrent, over- and undervoltage
protections, and Power Good limits can be
programmed in the POL Output Configuration
window or directly via the I2C bus by writing into the
---
R2
R1
R0
F2
F1
F0
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
U
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-0
R/W-1
Bit 7
Unimplemented
, read as ‘0’
Bit 6:4
R[2:0]
: Value of Vo rising slope
0: corresponds to 0.1V/ms (default)
1: corresponds to 0.2V/ms
2: corresponds to 0.5V/ms
3: corresponds to 1.0V/ms
4: corresponds to 2.0V/ms
5: corresponds to 5.0V/ms
6: corresponds to 8.3V/ms
7: corresponds to 8.3V/ms
Bit 3
SC
, Slew rate control at turn-off
0: Slew rate control is disabled
1: Slew rate control is enabled
Bit 2:0
F[2:0]
: Value of Vo falling slope
0: corresponds to -0.1V/ms (default)
1: corresponds to -0.2V/ms
2: corresponds to -0.5V/ms
3: corresp
onds to -1.0V/ms
4: corresponds to -2.0V/ms
5: corresponds to -5.0V/ms
6: corresponds to –8.3V/ms
7: corresponds to –8.3V/ms
SC
TP
PG
TR
OT
UV
OV
PV
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R-1
R-0
R-1
R-1
R-1
R-1
R-1
R-1
Bit 7
TP
: Tem perature Warning
Bit 6
PG
: Power Good Warning
Bit 5
TR
: Tracking Fault
Bit 4
OT
: Overtemperature Fault
Bit 3
OC
: Overcurrent Fault
Bit 2
UV
: Undervoltage Fault
Bit 1
OV
: Overvol tage Error
Bit 0
PV
: Phase Voltage Error (Not Active)
Note:
- An activated warning/fault/error is encoded as ‘0’
OC
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 18 of 29
CLS and PC2 registers shown in Figure 28 and
Figure 29.
LR2
LR1
LR0
TCE
CLS2
CLS1
CLS0
Bit 7
Bit 0
R = Readable bit
W = Writable bit
U = Unimplemented bit,
read as ‘0’
- n = Value at POR reset
R/W-0
R/W-0
R/W-0
R/W-1
R/W-0
R/W-1
R/W-1
R/W-1
Bit 7:5 LR[2:0], Load regulation configuration
000: 0 V/A/Ohm
001: 0.39 V/A/Ohm
010: 0.78 V/A/Ohm
011: 1.18 V/A/Ohm
100: 1.57 V/A/Ohm
101: 1.96 V/A/Ohm
110: 2.35 V/A/Ohm
111: 2.75 V/A/Ohm
Bit 4 TCE, Temperature compensation enable
0: disabled
1: enabled
Bit 3:0 CLS[3:0], Current limit setting
0h: corresponds to 37%
1h: corresponds to 47%
…
Bh: corresponds to 140%
Values higher than Bh are translated to Bh (140%)
CLS3
Figure 28. Current Limit Setpoint Register CLS
Figure 29. Protection Configuration Register P C2
Note that the overvoltage and undervoltage
protection thresholds and Power Good limits are
defined as percentages of the output voltage.
Therefore, the absolute levels of the thresholds
change when the output voltage setpoint is changed
either by output voltage adjustment or by margining.
In addition, a user can change type of protections
(latching or non-latching) or disable certain
protections. These settings are programmed in the
POL Fault management window shown in Figure 30
or directl y via the I2C by writing into t he PC1 register
shown in Figure 31.
Figure 30. Fault management window
Figure 31. Protection Configuration Register P C1
If the non-latching protection is selected, a POL will
attempt to restart every 130ms until the condition
that triggered the protection is removed. When
restarting, the output voltages follow tracking and
sequencing settings.
If the latching t ype is select ed, a POL wil l turn of f and
stay off. The POL can be turned on after 130ms, if
the condition that caused the fault is removed and
the respective bit in the ST register was cleared, or
the Turn On command was recycled, or the input
voltage was recycled.
TRE
PVE
TRP
OTP
UVP
OVP
PVP
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R/W-0
R/W-1
R/W-0
R/W-0
R/W-0
R/W-1
R/W-1
R/W-0
Bit 7
TRE
: Tracking fault enable
1 = enabled
0 = disabled
Bit 6
PVE
: Phase voltage error enable
1 = enabled
0 = disabled
Bit 5
TRP
: Tracking fault protection
1 = latching
0 = non latching
Bit 4
OTP
: Overtemperature protection configuration
1 = latching
0 = non latching
Bit 3
OCP
: Overcurrent protection configuration
1 = latching
0 = non latching
Bit 2
UVP
: Undervoltage protection configuration
1 = latching
0 = non latching
Bit 1
OVP
: Overvoltage protection configuration
1 = latching
0 = non latching
Bit 0
PVP
: Phase Voltage Protection (Not Active)
1 = latching
0 = non latching
OCP
---
---
---
PGLL
OVPL0
UVPL1
UVPL0
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
U
U
U
R/W-0
R/W-0
R/W-0
R/W-0
R/W-1
Bit 7:5
Unimplemented
, read as ‘0’
Bit 4
PGLL
: Set Power Good Low Level
1 = 95% of Vo
0 = 90% of Vo (Default)
Bit 3:2
OVPL[1:0]
: Set Over Voltage Protection
Level
00 = 110% of Vo
01 = 120% of Vo
10 = 130% of Vo (Default)
11 = 130% of
Vo
Bit 1:0
UVPL[1:0]
: Set Under Voltage Protection Level
00 = 75% of Vo (Default)
01 = 80% of Vo
10 = 85% of Vo
11 = 90% of Vo
OVPL1
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 19 of 29
All protection functions can be classified into three
groups based on their effect on system operation:
warnings, faults, and errors.
8.3.1 Warnings
This group includes Overtemperature Warning and
Power Good Signal. Warnings do not turn off POLs
but rather set status bits which can be noted by the
DPM and be transmitted to a host controller via the
I2C bus.
8.3.1.1 Overtemperature Warning
The Overtemperature Warning is generated when
temperature of the controller exceeds 120°C. The
Overtemperature Warning changes the PT bit of the
status register ST to 0 and sends the signal to the
DPM. Re porting is enabled in th e POL Conf iguration
Faults window or directly via the I2C by writing into
the PC3 register shown in Figure 33. When the
temperature falls below 117°C, the PT bit is cleared
and the Overtemperature Warning is removed.
8.3.1.2 Power Good
Power G oo d is an op en collec tor out p ut t hat is pu lled
low, if the output voltage is outside of the Power
Good window. The window is formed by the Power
Good High threshold that is equal to 110% of the
output voltage and the Power Good Low threshold
that can be programmed at 90 or 95% of the output
voltage.
The Po wer Good protec tion is on ly enabled after the
output volta ge reaches its stead y state lev el. The PG
pin is pulled low during transitions of the output
voltage from one level to other as shown in Figure
32.
The Power Good W arning pulls the Power Good pin
low and c hanges the PG bit of the status register ST
to 0. It sends the signal to the DPM, if the reporting is
enabled. When the output voltage returns within the
Power Good window, the PG pin is pulled high, the
PG bit is cleared and the Power Good Warning is
removed. The Power Good pin can also be pulled
low by an external circuit to initiate the Power Good
Warning.
Note: T o retrieve status informati on, Stat us Monitoring in the DPM
Configure Devices window should be enabled (refer to
Digital Power Manager Data Sheet). The DPM will retrieve
the status information from each POL on a continuous
basis.
8.3.2 Faults
This group includes overcurrent, overtemperature,
undervoltage, and tracking protections. Triggering
any protection in this group will turn off the POL.
8.3.2.1 Ov ercurrent Protection
Overcurrent protection is active whenever the output
voltage of the POL exceeds the pre-bias voltage (if
any). When the output current reaches the OC
threshold, t he ou tput vo ltage w ill start d ecr easing. As
soon as the output voltage decreases below the
undervoltage protection threshold, the OC fault
signal is ge nerated, th e POL turns off and the OC bit
in the register ST is changed to 0. Both high side and
low side switches of the POL are turned off instantly
(fast turn-off).
The temperature compensation is added to keep the
OC threshold approximately constant at
temper atures abo ve r oom tem perature. Note that the
temperature compensation can be disabled in the
POL Output Configuration window or directly via the
I2C by writing into the CLS register. However, it is
recommended to keep the temperature
compensation enabled.
8.3.2.2 Undervoltage Protection
The undervoltage protection is only active during
steady state operation of the POL to prevent
nuisance tripping. If the output voltage decreases
below the U V threshold and ther e is no OC fault, the
UV fault signal is generated, the POL turns off, and
the UV bit in the register ST is changed to 0. The
output voltage is ramped down according to
sequencing and tracking settings (regular turn-off).
8.3.2.3 Overtemperature Protection
Overtemperature protection is active whenever the
POL is powered up. If temperature of the controller
exceeds 120°C, the OT fault is gener ated, PO L turns
off , and the OT bit in the regis ter ST is c hanged to 0.
The output voltage is ramped down according to
sequencing and tracking settings (regular turn-off).
If non-latching OTP is programmed, the POL will
restart as soon as the temperature of the controller
decreases below the Overtemperature Warning
threshold of 110°C.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 20 of 29
8.3.2.4 Tracking Protection
Tracking protection is active only when the output
voltage is ramping up. The purp ose of the protection
is to ensure that the voltage differential between
multiple rails being trac ked does not excee d 250mV.
This protection eliminates the need for external
clamping diodes between different voltage rails
which are frequently recommended by ASIC
manufacturers.
When the tracking protection is enabled, the POL
continuously compares actual value of the output
voltage to its programmed value as defined by the
output voltage and its rising slew rate. If absolute
value of the difference exceeds 250mV, the tracking
fault signal is generated, the POL turns off, and the
TR bit in the register ST is changed to 0. Both high
side and low side switches of the POL ar e turned off
instantly (fast turn-off).
The tracking protection can be disabled, if it
contradicts requirements of a particular system (for
example turning into high capacitive load where
rising slew rate is not important). It can be disabled
in the POL Configuration Faults window or directly
via the I2C bus by writing into the PC1 register.
Figure 32. Protecti ons Enab le C onditions
8.3.3 Errors
The group includes overvoltage protection and the
phase voltage error. The phase voltage error is not
availab le in ZY8160.
8.3.3.1 Overvoltage Protection
The overvoltage protection is active whenever the
output voltage of the POL exceeds the pre-bias
voltage (if any). If the output voltage exceeds the
overvoltage protection threshold, the overvoltage
error signal is generated, the POL turns off, and the
OV bit in the register ST is changed to 0. The high
side swit ch is t urned off ins tant l y, an d simultaneous ly
the low side switch is turned on to ensure reliable
protection of sensitive loads. The low side switch
provides low impedance path to quickly dissipate
energy stored in the output filter and achieve
effective voltage limitation.
The OV thr eshold can be program med fr om 110% to
130% of the output voltage setpoint, but not lower
than 1.0V.
8.3.4 Faults and Errors Propagation
The feature adds flexibility to the fault management
scheme by giving users control over propagation of
fault signals within and outside of the system. The
propagation means that a fault in one POL can be
programmed to turn off other POLs and devices in
the system, even if they are not directly affected by
the fault.
OVP Thres hold
Output Vo ltage
Time
Vo
1.0V
Enable command
0
1
OCP enabled
0
1
prebiased output
OTP
continuously enabled
OVP Thres hold
OVP Thres hold
UVP Threshold
UVP Threshold
UVP Threshold
PG Low Threshold
PG Low Threshold
PG Low Threshold
PG High=110%VOUT
PG High=110%VOUT
PG High=110%VOUT
Output Vo ltage
Output Vo ltage
Power Good
Signal
1
0
Tracking
Thresholds
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 21 of 29
8.3.4.1 Grouping of POLs
Z-Series PO Ls can be arranged i n several gr oups to
simplify fault management. A group of POLs is
defined as a number of POLs with interconnected
OK pins. A group can include from 1 to 32 POLs. If
fault propagation within a group is desired, the
propagat ion b it n eeds t o be chec ked in the G UI Fault
Management Window. The parameters can also be
programmed directly via the I2C bus by writing into
the PC3 register shown in Figure 33.
When propagation is enabled, the faulty POL pulls its
OK pin low. A low OK line initiates turn-off of other
POLs in the group.
Figure 33. Protection Configuration Register P C3
In addition, the OK lines can be connected to the
DPM to facilitate propagation of faults and errors
between groups. One DPM can control up to 4
independent groups. To enable fault propagation
between groups, the respective bit needs to be
checked in the DPM Faults / Group Fault
Propagation window shown in Figure 34.
Figure 34. DPM Fault Propagat i on Window
In this case low OK line will signal DPM to pull other
OK lines low to initiate shutdown of other POLs as
programmed in the DPM Faults / Group Fault
Propagation window. If an error is propagated, the
DPM can a lso generat e com mands to turn of f a f ront
end (a DC-DC converter generating the intermediate
bus voltage) and trigger an optional crowbar
protection to accelerate removal of the IBV voltage.
8.3.4.2 Propagation Pro cess
Propagation of a fault (OCP, UVP, OTP, and TRP)
initiates regular turn-off of other POLs. The faulty
POL in this case performs either the regular or the
fast turn-off depending on a specific fault as
described in section 8.3.2.
Propagation of an error initiates fast turn-off of other
POLs. The faulty POL performs the fast turn-off and
turns on its low side switch.
Example of the fault propagation is shown in Figure
35 - Figure 36. In this three-output system (refer to
the block diagram in Figure 16), the POL powering
the output V3 (Ch 1 in the picture) encounters the
undervoltage fault after the turn-on. When the fault
propagation is not enabled, the POL turns off and
generates the UV fault signal. Because the UV fault
triggers the regular turn off, the POL meets its turn-
off delay and falling slew rate settings during the
turn-ff process as shown in Figure 35. Since the UV
fault is programmed to be non-latching, the POL will
attempt to restart every 130ms, repeating the
process described above until the condition causing
the undervoltage is removed.
PTM
PGM
TRP
OTP
UVP
OVP
PVP
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R/W-0
R/W-0
R/W-1
R/W-1
R/W-1
R/W-1
R/W-1
R/W-1
Bit 7
PTM
: Temperature warning Message
1 = enabled
0 = disabled
Bit 6
PGM
: Power good message
1 = enabled
0 = disabled
Bit 5
TRP
: Tracking fault propagation
1 = enabled
0 = disabled
Bit 4
OTP
: Overtemperature fault propagation
1 = enabled
0 = disabled
Bit 3
OCP
: Overcurrent fault propagation
1 = enabled
0 = disabled
Bit 2
UVP
: Undervoltage fault propagation
1 = enabled
0 = disabled
Bit 1
OVP
: Overvoltage err or propagation
1 = enabled
0 = disabled
Bit 0
PVP
: Phase voltage error propagation (Not Active)
1 = enabled
0 = disabled
OCP
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 22 of 29
If the fault propagation between groups is enabled,
the POL p owering t he outp ut V3 pulls its OK line lo w
and the DPM propagates the signal to the POL
powering the output V1 that belongs to other group.
The POL power ing the out put V 1 (Ch3 in t he pictur e)
executes the regular turn-off. Since both V1 and V3
have the same dela y and slew rate sett ings the y will
continue to turn off and on synchronously every
130ms as shown in Figure 36 until the condition
causing the undervoltage is removed. The POL
powering the output V2 continues to ramp up until it
reaches its steady state level.
130ms is the interval from the instant of time when
the output voltage ramps down to zero until the
output voltage starts to ramp up again. Therefore,
the 130ms hiccup interval is guaranteed regardless
of the turn-off delay setting.
Figure 35. Turn-On into UVP on V3. The UV Fault Is
Programmed To Be Non-Latching. Ch1 – V3 (Group
C), Ch2 – V2, Ch3 – V1 (Group A)
Figure 36. Turn-On into UVP on V3. The UV Fault Is
Programmed To Be Non-Latching and Propagate
From Group C to Group A. Ch1 – V3 (Group C),
Ch2 – V2, Ch3 – V1 (Group A)
Summary of protections, their parameters and
features are shown in Table 3
Table 3. Summar y of Protections Parameters and Features
Code Name Type When Active Turn
Off Low Side
Switch Propagation Disable
PT
Temperature
Warning
Warning
Whenever V
IN
is applied
No
N/A
Readable by
DPM
No
PG
Power Good
Warning
During steady state
No
N/A
Readable by
DPM
No
TR
Tracking
Fault
During ramp up
Fast
Off
Regular turn off
Yes
OT Overtemperature Fault Whenever VIN is applied Regular Off R egular turn of f No
OC
Overcurrent
Fault
When V
OUT
exceeds prebias
Fast
Off
Regular turn off
No
UV Undervoltage Fault During steady state Regular Off Regular turn off No
OV
Overvoltage
Error
When V
OUT
exceeds prebias
Fast
On
Fast turn off
No
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 23 of 29
8.4 PWM Parameters
Z-Series POLs utilize the di gital PWM c ontroller . The
controller enables users to program most of the
PWM performance parameters, such as switching
frequency, interleave, duty cycle, and feedback loop
compensation.
8.4.1 Switching Frequency
The switching frequency can be programmed in the
PWM sub window in the POL Configuration
Com pensation window sho wn in Figure 37 or directl y
via the I2C bus by writ ing into the I NT r egister shown
in Figure 38. No t e t hat the c ontent of the regis ter c an
be changed only when the POL is turned off.
Switching actions of all POLs connected to the SD
line are synchronized to the master clock generated
by the DPM. Eac h POL is e qui ppe d with a PL L an d a
frequency divider so they can operate at multiples
(including fractional) of the master clock frequency
as programmed by a user. The POL converters can
operate at 500kHz, 750kHz, and 1MHz. Although
synchronized, switching frequencies of different
POLs are independent of each other. It is
permissible to mix POLs operating at different
frequencies in one system. It allows optimizing
efficiency and trans ient response of each POL in the
system individually.
Figure 37. POL Controller Compensation Window
Figure 38. Interleave Configuration Register I NT
8.4.2 Interleave
Interleave is defined as a phase delay between the
synchronizing slope of the master clock on the SD
pin and PWM signal of a P OL. The in terl eave ca n be
programmed in the PWM section of the POL
Controller Compensation window or directly via the
I2C bus by writing into the INT register.
Every POL generates switching noise. If no
interleave is programmed, all POLs in the system
switch simultaneously and noise reflected to the
input source from all POLs is added together as
shown in Figure 39.
Figure 39. Input Voltage Noise, No Inter leav e
FRQ2
FRQ1
FRQ0
INT4
INT2
INT1
INT0
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R/W-0
R/W-0
R/W-0
R/W-0
1)
R/W-0
1)
R/W-0
1)
R/W-0
1)
R/W-0
1)
Bit 7:5
FRQ[2:0]
: PWM Frequency Selection
000: 500kHz
001: 750kHz
010: 1000kHz
Bit 4:0
INT[4:0]
: Interleave position
00h: Ton starts with 0.0° Phase lag to SD Line
01h: Ton starts with 11.25° Phase lag to SD Line
02h: Ton starts with 22.50° Phase lag to SD Line
…
1Fh: Ton starts with 348.75° Phase lag to SD Line
1)
Initial value depends on the state of the Interleave Mode (
IM
) Input:
IM=Open:
At POR reset the
5 corresponding ADDRESS bits are loaded
IM=Low:
At POR reset a 0 is loaded
INT3
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 24 of 29
Figure 40 shows the i nput voltage noise of th e thr ee-
output system with programmed interleave. Instead
of all three POLs switching at the same time as in
the previous example, the POLs V1, V2, and V3
switch at 67.5°, 180°, and 303.75°, respectively.
Noise is spread evenly across the switching cycle
resulting in more than 1.5 times reduction. To
achieve s im ilar noise r educ tion without the interleave
will require the addition of an external LC filter.
Figure 40. Input Voltage Noise with Inte rlea ve
Similar noise reduction can be achieved on the
output of POLs connected in parallel. Figure 41 and
Figure 42 show the output noise of two POLs
connected in parallel without and with a 180°
interleave, respectively. Resulting noise reduction is
more than 2 times and is equivalent to doubling
switching frequency or adding extra capacitance on
the output of the POLs.
Figure 41. Output Voltage Noise, Full Load, No Interleave
Figure 42. Output Voltage Noise, Full Load, 180° Interleave
ZY8160 interleave is independent of the number of
POLs in a system and is fully programmable in
11.25° steps. It allows maximum output noise
reduction by intelligently spreading switching energy.
Note: Due to noise sensitivity issues that may occur in limited
cases, it is recommended to avoid phase lag settings of
112.5 and 123.75 degrees, otherwise false PG and/or OV
indications may occur.
8.4.3 Duty Cycle Limit
The ZY8160 is a step-dow n converter theref ore VOUT
is al ways les s than VIN. The r elati onship betw een t he
two parameters is characterized by the duty cycle
and can be estimated from the following equation:
MININ
OUT
V
V
DC
.
=
,
Where, DC is the duty cycle, VOUT is the required
maximum output voltage (including margining),
VIN.MIN is the minimum input voltage.
It is good prac tice to limit the m aximum duty cycle of
the PWM controller to a somewhat higher value
compared to the steady-state duty cycle as
expressed by the above equation. This will further
protect the output from excessive voltages. The dut y
cycle limit can be programmed in the PWM section
of the POL Controller Compensation window or
directly via the I2C bus by writing into the DCL
register shown in Figure 43.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 25 of 29
Figure 43. Duty Cycle Lim i t Register
8.4.4 ADC Saturation Feedforward
To speed up the PWM response in case of heavy
dynam ic loads, the d uty c ycle c an b e forc ed eith er t o
0 or the duty cycle limit depending on the polarity of
the transient. This function is equivalent to having
two comparators defining a window around the
output voltage setpoint. When an error signal is
inside the window, it will produce gradual duty cycle
change proportional to the error signal. If the error
signal goes outside the window (usu ally due to large
output cur rent s teps ) , the dut y c ycle wil l chan ge to its
limit in one switching cycle. In most cases this will
significantly improve transient response of the
controller, reducing amount of required external
capacitance.
Under certain circumstances, usually when the
maximum duty cycle limit significantly exceeds its
nominal value, the ADC saturation can lead to the
overcompensation of the output error. The
phenomenon manifests itself as low frequency
oscillations on the output of the POL. It can usually
be reduced or eliminated by disabling the ADC
saturation or l im iting the m axim um duty cycl e to 120-
140% of the calcu lated val ue. It is not rec omm ended
to use ADC saturation for output voltages higher
than 2.0V.
The ADC saturation feedforward can be
programmed in the PWM section of the DPM
Configuration Compensation window or directly via
the I2C bus by writing into the DCL register.
8.4.5 Feedback Loop Compensation
Feedback loop com pensation can be programm ed in
the POL Contro ller Compensation window by setting
frequency of poles and zeros of the transfer function.
The transfer function of the POL converter is shown
in Figure 44. It is a t hir d ord er f unc tion with t wo zer os
and three poles. Pole 1 is the integrator pole, Pole 2
is used in conjunction with Zero 1 and Zero 2 to
adjust the phase lead and limit the gain increase in
mid band. Pole 3 is used as a high frequency low-
pass filter to limit PWM noise.
Z1 P1 Z2 P2 P3
0.1 110 100 1000
Freq
[kHz]
Magnitude[dB]
10
20
30
40
50
0.1 110 100 1000
Freq
[kHz]
-90
-45
-135
-180
0
+45
Phase
[°]
P1: Pole 1
P2: Pole 3
P3: Pole 3
Z1: Zero 1
Z2: Zero 2
Figure 44. Trans fe r Functi on of PWM
Positions of poles and zeroes are determined by
coefficients of the digital filter. The filter is
characterized by four numerator coefficients (C0, C1,
C2, C3) and three denominator coefficients (B1, B2,
B3). The coefficients are automatically calculated
when desired frequency of poles and zeros is
entered in the PWM section of the POL Controller
Compensation window. The c oef ficients are s tor e d in
the C0H, C0L, C1H, C1L, C2H, C2L, C3H, C3L, B1,
B2, and B3 register s.
Note: The GUI automatically transforms zero and pole
frequencies into the digital filter coefficients. It is strongly
recommended to use the GUI to determine the filter
coefficients.
Programming feedback loop compensation allows
optimizing POL performance for various application
conditions. For example, increase in bandwidth can
significantly improve dynamic response.
8.5 Current Share
The POL converters are equipped with the digital
current s hare function. To activate t he current sh are,
DCL5
DCL4
DCL3
DCL2
DCL0
HI
LO
Bit 7
Bit 0
R
=
Readable bit
W
=
Writable bit
U
=
Unimplemented bit,
read as ‘0’
-
n
=
Value at POR reset
R/W
-
1
R/W
-
1
R/W
-
1
R/W
-
0
R/W
-
0
R/W
-
0
R/W
-
0
R/W
-
1
Bit 7:2
DCL[5:0]
, Duty
Cycle Limitation
00h:
0
01h:
1/192
…
3Fh:
63/192
Bit 1:
HI
, ADC high saturation feed
-
forward
0: disabled
1: enabled
Bit 0:
LO
, ADC low saturation feed
-
forward
0: disabled
1: enabled
DCL1
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 26 of 29
interconnect the CS pins of the POLs connected in
parallel. The digital signal transmitted over the CS
line sets output currents of all POLs to the same
level.
When POLs are connected in parallel, they must be
included in the same parallel bus in the DPM
Configure Devices window shown in Figure 45. In
this case, the GUI automatically copies parameters
of one POL onto all POLs connected to the parallel
bus. It makes it impossible to configure different
performance parameters for POLs connected in
parallel except for interleave and load regulation
settings that are independent. The interleave allows
to reduce and move the output noise of the
converters connected in parallel to higher
frequencies as shown in Figure 41 and Figure 42.
The load regulation allows controlling the current
share loop gai n in c ase of small signa l oscillations. It
is recommended to always add a small amount of
load regu lation to one of t he convert ers connec ted in
parallel to reduce loop gain and therefore improve
stability.
8.6 Performance Parameters Monitoring
The POL converters can monitor their own
performance parameters such as output voltage,
output current, and temperature.
The output voltage is measured at the output sense
pins, output current is measured using the ESR of
the output inductor and temperature is measured by
the therm al sensor built i nto the control ler IC. Output
current readings are adjusted based on temperature
readings to compensate for the change of ESR of
the inductor wit h temperature.
An 8-Bit Analog to Digital Converter (ADC) converts
the output voltage, output current, and temperature
into a digital signal to be transmitted via the serial
interface. The ADC allows a minimum sampling
frequency of 700 Hz for all three values.
Monitored parameters are stored in registers (VOM,
IOM, and TMON) that are continuously updated. If
the Retrieve Monitoring bits for Parametric (P-
Monitor) and Status (S-Monitor) in the DPM
Configure Devices window shown in Figure 45 are
checked, those registers are being copied into the
ring buffer located in the DPM. Contents of the ring
buffer can be displayed in the DPM Monitoring
window shown in Figure 46 or it can be read directl y
via the I2C bus using high and low level commands
as described in the ”ZM7300 Digital Power Manager
Programming Manual”.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 28 of 29
Figure 46. DPM Monitor ing Window
9. Safety
The ZY8160 POL converters do not provide
isolation from input to output. The input devices
powering ZY8160 must provide relevant isolation
requirements according to all IEC60950 based
standards. Nevertheless, if the system using the
converter needs to receive safety agency approval,
certain rules must be followed in the design of the
system. In particular, all of the creepage and
clearance requirements of the end-use safety
requirem ents must be obse r ved. These r equ irements
are included in UL60950 - CSA60950-00 and
EN60950, although specific applications may have
other or additional requirements.
The ZY8160 POL c onverte rs have no i nternal f use. If
required, the external fuse needs to be provided to
protect the converter from catastrophic failure. Refer
to the “Input Fuse Selection for DC/DC converters”
application note on www.power-one.com
for proper
selection of the input fuse. Both input traces and the
chassis ground trace (if applicable) must be capable
of conducting a current of 1.5 times the value of the
fuse with out openi ng. The f us e must not be pl ac ed in
the grounded in put line.
Abnormal and component failure tests were
conducted with the POL input protected by a fast-
acting 32V, 25A, fuse. If a fuse rated greater than
25A is used, additional testing may be required.
In order for the output of the ZY8160 POL converter
to be considered as SELV (Safety Extra Low
Voltage), according to all IEC60950 based
standards, the input to the POL needs to be supplied
by an isolated secondary source providing a SELV
also.
ZY8160 60A DC-DC Intelligent PO L
8V to 14V Input • 0.5V to 2.75 V Out put
Data Sheet
ZD-01674 Rev. 1.5, 5-May-2011 www.power-one.com Page 29 of 29
10. Mechanical Drawings
All Dimens ion s are in m m
Tolerances: XX.X: ±0.1 XX.XX: ±0.05
Figure 47. Mechanical Drawing
Figure 48. Recommended Footprint – Top View
Notes:
1. NUCLEA R AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical
components in life support systems, equipm ent us ed in hazardous environm ents , or nuclear c ontrol sys t ems without the express written
consent of the respective di visional pres i dent of Power-One, Inc.
2. TECHNICAL REVISIONS - The appearance of products, incl udi ng safety agenc y cert ifications pictured on labels, may change depending on
the date manufactured. Specifications are subject to change without notice.
I2C is a trademark of Philips Corporation.
