LTC7860 High Efficiency Switching Surge Stopper Features Description High Efficiency VOUT Clamp Stops High Voltage Input Surges nn SWITCH-ON Mode 100% Duty Cycle for Normal Operation nn PROTECTIVE PWM Mode for Transients and Faults nn V Pin to SGND Range: 3.5V to 60V IN nn External Input Voltage is Extendable to 200V+ nn Adjustable Output Voltage Clamp nn Adjustable Output Overcurrent Protection nn Power Inductor Improves Input EMI in Normal Operation nn Programmable Fault Timer nn Adjustable Soft-Start for Input Inrush Current Limiting nn 4.5% Retry Duty Cycle During Faults nn Adjustable Switching Frequency: 50kHz to 850kHz nn Optional Reverse Input Voltage Protection nn Available in Thermally Enhanced 12-lead MSOP Package The LTC(R)7860 high efficiency surge stopper protects loads from high voltage transients. High efficiency permits higher currents and smaller solution sizes. During an input overvoltage event, such as a load dump in vehicles, the LTC7860 controls the gate of an external MOSFET to act as a switching DC/DC regulator (PROTECTIVE PWM mode). This operation regulates the output voltage to a safe level, allowing the loads to operate through the input over-voltage event. During normal operation (SWITCHON mode), the LTC7860 turns on the external MOSFET continuously, passing the input voltage through to the output. An internal comparator limits the voltage across the current sense resistor and regulates the maximum output current to protect against overcurrent faults. nn Applications Industrial and Automotive Power Telecom Power nn Vehicle Power Including ISO7637 nn Military Power Including MIL1275 nn nn L, LT, LTC, LTM, OPTI-LOOP, Linear Technology, Burst Mode and the Linear logo are registered trademarks and Hot Swap is a trademark of Linear Technology Corporation. All other trademarks are the property of their respective owners. Protected by U.S. Patents including 5731694. An adjustable timer limits the time that the LTC7860 can spend in overvoltage or overcurrent regulation. When the timer expires, the external MOSFET is turned off until the LTC7860 restarts after a cool down period. By strictly limiting the time in PROTECTIVE PWM Mode when the power loss is high, the components and thermal design can be optimized for normal operation and safely operate through high voltage input surges and/or overcurrent faults. An additional PMOS can be added for reverse battery protection. Typical Application VIN 60V MAX 12V NOM 3.5V MIN VOUT 18V MAX 12V NOM 3.5V MIN 5A 6.8H 12m 10F PROTECTIVE PWM: VOUT Clamped to 18V During a VIN Surge GATE VFBN SENSE VIN 60V INPUT SURGE CAP 10F LTC7860 TMR 22F 0.1F 10k 680pF VIN 10V/DIV VFB FREQ 0.47F 1M RUN SGND PGND VOUT 10V/DIV 18V ADJUSTABLE CLAMP VTMR 1V/DIV 48.7k SS ITH CTMR = 22F 0.1F 100ms/DIV 7860 TA01b 7860 TA01a 7860f For more information www.linear.com/LTC7860 1 LTC7860 Absolute Maximum Ratings Pin Configuration (Notes 1, 2) Input Supply Voltage (VIN).......................... -0.3V to 65V VIN-VSENSE Voltage....................................... -0.3V to 6V VIN-VCAP Voltage......................................... -0.3V to 10V RUN Voltage............................................... -0.3V to 65V VFBN, TMR Voltages...................................... -0.3V to 6V SS, ITH, FREQ, VFB Voltages......................... -0.3V to 5V Operating Junction Temperature Range (Notes 3, 4)......................................... -55C to 150C Storage Temperature Range................... -65C to 150C Lead Temperature (Soldering, 10 sec) MSOP Package.................................................. 300C TOP VIEW TMR FREQ SGND SS VFB ITH 1 2 3 4 5 6 13 PGND 12 11 10 9 8 7 GATE VIN SENSE CAP RUN VFBN MSE PACKAGE 12-LEAD PLASTIC MSOP TJMAX = 150C, JA = 40C/W, JC = 10C/W EXPOSED PAD (PIN 13) IS PGND, MUST BE SOLDERED TO PCB Order Information LEAD FREE FINISH TAPE AND REEL PART MARKING* PACKAGE DESCRIPTION TEMPERATURE RANGE LTC7860EMSE#PBF LTC7860EMSE#TRPBF 7860 12-Lead Plastic MSOP -40C to 125C LTC7860IMSE#PBF LTC7860IMSE#TRPBF 7860 12-Lead Plastic MSOP -40C to 125C LTC7860HMSE#PBF LTC7860HMSE#TRPBF 7860 12-Lead Plastic MSOP -40C to 150C LTC7860MPMSE#PBF LTC7860MPMSE#TRPBF 7860 12-Lead Plastic MSOP -55C to 150C Consult LTC Marketing for parts specified with wider operating temperature ranges. *The temperature grade is identified by a label on the shipping container. Consult LTC Marketing for information on non-standard lead based finish parts. For more information on lead free part marking, go to: http://www.linear.com/leadfree/ For more information on tape and reel specifications, go to: http://www.linear.com/tapeandreel/ 2 7860f For more information www.linear.com/LTC7860 LTC7860 Electrical Characteristics The l denotes the specifications which apply over the specified operating junction temperature range, otherwise specifications are at TA = 25C. (Note 3) VIN = 12V, unless otherwise noted. SYMBOL PARAMETER CONDITIONS MIN TYP MAX UNITS Input Supply VIN Input Voltage Operating Range 3.5 VUVLO Undervoltage Lockout (VIN-VCAP) Ramping Up Threshold (VIN-VCAP) Ramping Down Threshold Hysteresis IQ Input DC Supply Current FREQ = 0V, VFB = 0.83V (No Load) Shutdown Supply Current RUN = 0V l l 3.25 3.00 60 V 3.50 3.25 0.25 3.8 3.50 V V V 0.77 1.2 mA 7 12 A 0.800 0.809 V 0.005 %/V Output Sensing VREG Regulated Feedback Voltage VREG = (VFB - VFBN) VITH = 1.2V (Note 4) Feedback Voltage Line Regulation VIN = 3.8V to 60V (Note 4) Feedback Voltage Load Regulation VITH = 0.6V to 1.8V (Note 4) VITH = 1.2V, IITH = 5A (Note 4) l 0.791 -0.005 -0.1 -0.015 0.1 1.8 % gm(EA) Error Amplifier Transconductance IFB Feedback Input Bias Current -50 -10 50 mS nA IFBN Feedback Negative Input Bias Current -50 -10 50 nA 85 95 103 mV 0.1 2 A 1.26 1.32 V Current Sensing VILIM Current Limit Threshold (VIN-VSENSE) VFB = 0.77V ISENSE SENSE Pin Input Current VSENSE = VIN l Start-Up and Shutdown VRUN RUN Pin Enable Threshold VRUN Rising l 1.22 RUN Pin Hysteresis Soft-Start Pin Charging Current VSS = 0V ITPU TMR Pull-Up Current TMR = 1.1V, VFB = 0.83V ITPDR TMR Pull-Down Current Restart TMR = 1.1V, VFB = 0.77V ITPDC TMR Pull-Down Current Cool Down TMR = 1.1V, VFB = 0.77V VGTH TMR Gate Off Threshold VFB = 0.77V VFB = 0.77V ISS 150 mV 10 A Fault Timer l -35 -30 -25 40 A A 1.0 1.3 1.6 A l 1.25 1.29 1.35 V l 37 VRTH TMR Restart Threshold TSETI(1F) TMR Set Time Initial for Fault Detection for 1F (TSETI = VGTH/ITPU) 240 TSETR(1F) TMR Set Time Repeat for Fault Detection for 1F (TSETI = (VGTH - VRTH)/ITPU) 32 ms/F TRSTC(1F) TMR Restart Cool Down Time for 1F (TRSTC = (VGTH - VRTH)/ITPDC) 732 ms/F DTYTSTR TMR Restart Duty Cycle in a Sustained Fault (DTYTSTR = TSETR/TRSTC) l 3.5 44 4.5 mV 50 5.5 ms/F % Switching Frequency 7860f For more information www.linear.com/LTC7860 3 LTC7860 Electrical Characteristics The l denotes the specifications which apply over the specified operating junction temperature range, otherwise specifications are at TA = 25C. (Note 3) VIN = 12V, unless otherwise noted. SYMBOL PARAMETER CONDITIONS MIN TYP MAX UNITS Programmable Switching Frequency RFREQ = 24.9k RFREQ = 64.9k RFREQ = 105k 375 105 440 810 505 kHz kHz kHz Low Switching Frequency FREQ = 0V 320 350 380 kHz 485 535 585 kHz High Switching Frequency FREQ = Open fFOLD Foldback Frequency as Percentage of Programmable Frequency VFB = 0V, FREQ = 0V tON(MIN) Minimum On-Time 18 % 220 ns Gate Driver VCAP Gate Bias LDO Output Voltage (VIN-VCAP) IGATE = 0mA RUP Gate Pull-Up Resistance Gate High 2 RDN Gate Pull-Down Resistance Gate Low 0.9 Note 1: Stresses beyond those listed under Absolute Maximum Ratings may cause permanent damage to the device. Exposure to any Absolute Maximum Rating condition for extended periods may affect device reliability and lifetime. Note 2: The junction temperature (TJ in C) is calculated from the ambient temperature (TA in C) and power dissipation (PD in Watts) as follows: TJ = TA + (PD * JA) where JA (in C/W) is the package thermal impedance provided in the Pin Configuration section for the corresponding package. Note 3: The LTC7860 is tested under pulsed load conditions such that TJ TA. The LTC7860E is guaranteed to meet performance specifications from 0C to 85C operating junction temperature range. The LTC7860E specifications over the -40C to 125C operating junction temperature range are assured by design, characterization and correlation with 4 l 7.6 8.0 8.5 V statistical process controls. The LTC7860I is guaranteed to meet performance specifications over the -40C to 125C operating junction temperature range, the LTC7860H is guaranteed over the -40C to 150C operating junction temperature range, and the LTC7860MP is guaranteed and tested over the full -55C to 150C operating junction temperature range. High junction temperatures degrade operating lifetimes; operating lifetime is derated for junction temperatures greater than 125C. The maximum ambient temperature consistent with these specifications is determined by specific operating conditions in conjunction with board layout, the rated package thermal impedance and other environmental factors. Note 4: The LTC7860 is tested in a feedback loop that adjust VREG or (VFB - VFBN) to achieve a specified error amplifier output voltage (on ITH pin). 7860f For more information www.linear.com/LTC7860 LTC7860 Typical Performance Characteristics Frequency Over Input Voltage 600 FREQ = OPEN 550 500 f (kHz) 500 f (kHz) 120 FREQUENCY FOLDBACK (%) FREQ = OPEN 550 450 450 400 400 FREQ = 0V 350 0 20 10 30 VIN (V) FREQ = 0V 350 40 50 300 -75 60 -25 25 75 125 TEMPERATURE (C) GATE Bias LDO (VIN - VCAP) Load Regulation 0.1 -0.1 -0.2 -2.0 -0.3 -2.5 -0.4 -3.0 -3.5 20 0 200 400 VFB (mV) 600 800 Current Sense Voltage Over ITH Voltage 90 80 70 60 50 40 30 20 10 0 0 5 10 IGATE (mA) 15 -0.5 20 0 5 10 IGATE (mA) 15 7860 G22 SS PULL-UP CURRENT (A) 98 96 94 92 25 75 125 TEMPERATURE (C) 175 0 0.4 0.8 1.2 ITH VOLTAGE (V) 1.6 TMR Pull-UP Current Over Temperature -25.0 VSS = 0V 12 10 8 6 -75 -25 2 7860 G24 TMR PULL-UP CURRENT (A) 14 -25 20 SS Pin Pull-Up Current Over Temperature 100 90 -75 -10 7860 G23 Current Sense Voltage Over Temperature CURRENT LIMIT SENSE VOLTAGE (mV) 40 100 CURRENT SENSE VOLTAGE (mV) 0.0 -1.5 60 7860 G21 VIN = 5V (VIN - VCAP) DROPOUT (V) (VIN - VCAP) REGULATION (%) 0.0 -1.0 80 0 175 GATE Bias LDO (VIN - VCAP) Dropout Behavior -0.5 100 7860 G20 7860 G19 0.5 Frequency Foldback % Over Feedback Voltage Frequency Over Temperature 600 300 TA = 25C, unless otherwise noted. 25 75 125 TEMPERATURE (C) 175 -27.5 -30.0 -32.5 -35.0 -75 -50 -25 0 25 50 75 100 125 150 175 TEMPERATURE (C) 7860 G27 7860 G25 7860 G26 7860f For more information www.linear.com/LTC7860 5 LTC7860 Pin Functions TMR (Pin 1): Programmable Fault Timer. The TMR function monitors the time spent in PROTECTIVE PWM mode and provides fault control. During a fault, a 30A (ITPU) current pulls up the TMR pin. If the fault clears before the 1.29V TMR Gate Off Threshold (VGTH) is reached, a 40A current (ITPDR) resets the TMR pin to ground. The gate turns off and shuts down when VGTH is reached. In shutdown, a 1.3A (ITPDC) current pulls TMR down to a 240mV TMR Restart Threshold (VRTH) allowing a cool down period before restart. FREQ (Pin 2): Switching Frequency Setpoint Input. The switching frequency is programmed by an external setpoint resistor RFREQ connected between the FREQ pin and signal ground. An internal 20A current source creates a voltage across the external setpoint resistor to set the internal oscillator frequency. Alternatively, this pin can be driven directly by a DC voltage to set the oscillator frequency. Grounding selects a fixed operating frequency of 350kHz. Floating selects a fixed operating frequency of 535kHz. SGND (Pin 3): Ground Reference for Small-Signal Analog Component (Signal Ground). Signal ground should be used as the common ground for all small-signal analog inputs and compensation components. Connect the signal ground to the power ground (ground reference for power components) only at one point using a single PCB trace. SS (Pin 4): Soft-Start and External Tracking Input. The LTC7860 regulates the feedback voltage to the smaller of 0.8V or the voltage on the SS pin. An internal 10A pull-up current source is connected to this pin. A capacitor to ground at this pin sets the ramp time to the final regulated output voltage. VFB (Pin 5): Output Feedback Sense. A resistor divider from the regulated output point to this pin sets the output voltage. The LTC7860 will nominally regulate VFB to the internal reference value of 0.8V. If VFB is less than 0.4V, the switching frequency will linearly decrease and fold back to about one-fifth of the internal oscillator frequency to reduce the minimum duty cycle. 6 ITH (Pin 6): Current Control Threshold and Controller Compensation Point. This pin is the output of the error amplifier and the switching regulator's compensation point. The voltage ranges from 0V to 2.9V, with 0.8V corresponding to zero sense voltage (zero current). VFBN (Pin 7): Feedback Input for an Inverting Feedback Option. Connect VFBN to the center of a resistor divider between the output and VFB. The VFBN threshold is 0V. To defeat the inverting amplifier and use Non-Inverting feedback option, tie VFBN > 2V. VFBN can be tied to FREQ if FREQ is floated and a 535kHz fixed operating frequency is selected. The minimum suggested value of the feedback resistor between VFB and VFBN for Inverting Feedback Option is 10K. RUN (Pin 8): Run Control Input. A RUN voltage above the 1.26V threshold enables normal operation, while a voltage below the threshold shuts down the controller. An internal 0.4A current source pulls the RUN pin up to about 3.3V. The RUN pin can be connected to an external power supply up to 60V. CAP (Pin 9): Gate Driver (-) Supply. A low ESR ceramic bypass capacitor of at least 0.47F or 10X the effective CMILLER of the P-channel power MOSFET, is required from VIN to this pin to serve as a bypass capacitor for the internal regulator. To ensure stable low noise operation, the bypass capacitor should be placed adjacent to the VIN and CAP pins and connected using the same PCB metal layer. SENSE (Pin 10): Current Sense Input. A sense resistor, RSENSE, from the VIN pin to the SENSE pin sets the maximum current limit. The peak inductor current limit is equal to 95mV/RSENSE. For accuracy, it is important that the VIN pin and the SENSE pin route directly to the current sense resistor and make a Kelvin (4-wire) connection. VIN (Pin 11): Chip Power Supply. A minimum bypass capacitor of 0.1F is required from the VIN pin to power ground. For best performance use a low ESR ceramic capacitor placed near the VIN pin. 7860f For more information www.linear.com/LTC7860 LTC7860 Pin Functions GATE (Pin 12): Gate Drive Output for External P-Channel MOSFET. The gate driver bias supply voltage (VIN-VCAP) is regulated to 8V when VIN is greater than 8V. The gate driver is disabled when (VIN-VCAP) is less than 3.5V (typical), 3.8V maximum in start-up and 3.25V (typical) 3.5V maximum in normal operation. PGND (Exposed Pad Pin 13): Ground Reference for Power Components (Power Ground). The PGND exposed pad must be soldered to the circuit board for electrical contact and for rated thermal performance of the package. Connect signal ground to power ground only at one point using a single PCB trace. FUNCTIONAL Diagram VIN UVLO + - 0.4A RUN 1.26V CIN VIN 3.25V RSENSE SENSE RUN + - - LOGIC CONTROL DRV MP HIGH CURRENT PATH Q S R R SGND GATE VOUT COUT CCAP IN LDO OUT VIN - 8V PLL SYSTEM FREQ - 20A VCO RFREQ ICMP CAP + + 10A + + - GATE OFF VGTH 1.29V TMR CTMR ITPDC 1.3A ITPDR 40A VRTH 0.24V + - - + EA (Gm = 1.8mS) FAULT TIMER LOGIC 0.8V EN CSS 0.5A VFBN RZ1 RFB2 VFB COOL DOWN NORMAL OPERATION VIN Z1 + ITPU 30A SS - SLOPE COMPENSATION RFB1 PGND ITH 7860 FD RITH CITH1 7860f For more information www.linear.com/LTC7860 7 LTC7860 Operation High Efficiency Switching Surge Stopper Overview The LTC7860 is designed for use as a high efficiency switching surge stopper and/or input inrush current limiter. Normal operation for the LTC7860 is in "dropout" or SWITCH-ON mode. The LTC7860 switches during start-up or in response to either an input over-voltage or output short-circuit event (PROTECTIVE PWM mode). If the time spent switching exceeds the time programmed by the timer the LTC7860 will shut down. A high efficiency surge stopper or input inrush current limiter can be thought of as a pre-regulator. As an example of a MIL1275 application, the input voltage connects to a 28V vehicle power bus. The 28V power bus can go as high as 100V with a surge profile lasting up to 500mS. The output must be pre-regulated or limited to 34V maximum and can go as low as 12V during engine cranking. The LTC7860 limits the voltage seen at the output and protects any load connected to the 28V bus from potentially destructive voltage levels. The LTC7860 timer limits the time spent switching where excessive and thermally destructive power loss can occur. For both a linear surge stopper such as the LTC4363 and the LTC7860 switching surge stopper, the power loss increases significantly once regulation begins. In a linear surge stopper, the power loss is the power loss of the regulating MOSFET. In a high efficiency surge stopper or switching surge stopper, internal power loss is determined by conversion efficiency. A switching surge stopper will allow higher output current and power levels than a comparable linear solution by virtue of reduced power loss. In a switching surge stopper the internal surge power loss can increase by as much as 10 times the normal power loss. If the time spent in PWM mode regulation is limited, the operating power can be pushed beyond what can be achieved in steady state operation. This is precisely the same concept as utilized in linear surge stoppers but extended to a switching supply. The use of the timer improves reliability and reduces component size when compared to a continuous solution. By limiting the time in 8 regulation when the power loss is high, the components and thermal design can be optimized for normal operation and safely operate through high voltage input surges and/ or overcurrent faults. In a switching surge stopper the insertion loss in normal operation or SWITCH-ON mode is the primary consideration and not efficiency in switching. The LTC7860 circuit must operate without damage during a surge or fault event. The Switching Surge Stopper is effectively a wire in normal operation where the insertion loss is determined by multiplying the input current by the effective resistance. LTC7860 Main Control Loop The LTC7860 uses a peak current-mode control architecture to regulate the output in a step-down DC/ DC switching regulator. The VFB input is compared to an internal reference by a transconductance error amplifier (EA). The internal reference can be either a fixed 0.8V reference VREF or the voltage input on the SS pin. In normal operation VFB regulates to the internal 0.8V reference voltage. In soft-start, when the SS pin voltage is less than the internal 0.8V reference voltage, VFB will regulate to the SS pin voltage. The error amplifier output connects to the ITH (current [I] threshold [TH]) pin. The voltage level on the ITH pin is then summed with a slope compensation ramp to create the peak inductor current set point. The peak inductor current is measured through a sense resistor, RSENSE, placed across the VIN and SENSE pins. The resultant differential voltage from VIN to SENSE is proportional to the inductor current and is compared to the peak inductor current setpoint. During normal operation the P-channel power MOSFET is turned on when the clock leading edge sets the SR latch through the S input. The P-channel MOSFET is turned off through the SR latch R input when the differential voltage from VIN to SENSE is greater than the peak inductor current setpoint and the current comparator, ICMP, trips high. 7860f For more information www.linear.com/LTC7860 LTC7860 Operation Power CAP and VIN Undervoltage Lockout (UVLO) Power for the P-channel MOSFET gate driver is derived from the CAP pin. The CAP pin is regulated to 8V below VIN in order to provide efficient P-channel operation. The power for the VCAP supply comes from an internal LDO, which regulates the VIN-CAP differential voltage. A minimum capacitance of 0.47F (low ESR ceramic) is required between VIN and CAP to assure stability. For VIN 8V, the LDO will be in dropout and the CAP voltage will be at ground, i.e., the VIN-CAP differential voltage will equal VIN. If VIN-CAP is less than 3.25V (typical), the LTC7860 enters a UVLO state where the GATE is prevented from switching and most internal circuitry is shut down. In order to exit UVLO, the VIN-CAP voltage would have to exceed 3.5V (typical). Shutdown and Soft-Start When the RUN pin is below 0.7V, the controller and most internal circuits are disabled. In this micropower shutdown state, the LTC7860 draws only 7A. Releasing the RUN pin allows a small internal pull-up current to pull the RUN pin above 1.26V and enable the controller. The RUN pin can be pulled up to an external supply of up to 60V or driven directly by logic levels. The start-up of the output voltage VOUT is controlled by the voltage on the SS pin. When the voltage on the SS pin is less than the 0.8V internal reference, the VFB pin is regulated to the voltage on the SS pin. This allows the SS pin to be used to program a soft-start by connecting an external capacitor from the SS pin to signal ground. An internal 10A pull-up current charges this capacitor, creating a voltage ramp on the SS pin. As the SS voltage rises from 0V to 0.8V, the output voltage VOUT rises smoothly from zero to its final value. The SS time must be sufficiently less than the TMR set time to avert a timer shutdown in startup or fault recovery. If the slew rate of the SS pin is greater than 1.2V/ms, the output will track an internal soft-start ramp instead of the SS pin. The internal soft-start will guarantee a smooth start-up of the output under all conditions, including in the case of a short-circuit recovery where the output voltage will recover from near ground. Frequency Selection The switching frequency of the LTC7860 can be selected using the FREQ pin. The FREQ pin can be tied to signal ground, floated, or programmed through an external resistor. Tying FREQ pin to signal ground selects 350kHz, while floating selects 535kHz. Placing a resistor between FREQ pin and signal ground allows the frequency to be programmed between 50kHz and 850kHz. Refer to the chart in the Application section for switching frequency versus resistor values. Fault Protection In the event of an output short-circuit or overcurrent condition that causes the output voltage to drop significantly while in current limit, the LTC7860 operating frequency will fold back. Anytime the output feedback VFB voltage is less than 50% of the 0.8V internal reference (i.e., 0.4V), frequency foldback is active. The frequency will continue to drop as VFB drops until reaching a minimum foldback frequency of about 18% of the setpoint frequency. Frequency foldback is designed, in combination with peak current limit, to limit current in start-up and short-circuit conditions. Setting the foldback frequency as a percentage of operating frequency assures that start-up characteristics scale appropriately with operating frequency. 7860f For more information www.linear.com/LTC7860 9 LTC7860 Applications Information The LTC7860 is a high efficiency switching surge stopper which provides input voltage surge protection, input inrush current limiting and output short protection. High Efficiency Switching permits high output current capability and small solution size. During an input overvoltage event, such as a load dump in vehicles, the LTC7860 controls the gate of an external MOSFET to act as a switching DC/DC regulator (PROTECTIVE PWM mode). This operation regulates the output voltage to a safe level, allowing the loads to operate through the input over-voltage event. During normal operation (SWITCH-ON mode), the LTC7860 turns on the external MOSFET continuously, passing the input voltage through to the output. An internal comparator limits the voltage across the current sense resistor and regulates the maximum output current to protect against over current faults. Output Voltage Programming The LTC7860 is highly flexible and offers application options to address a variety of input and output voltage ranges. These options are best divided into two categories. The first category is operation at or below VIN = 60V. The second category is operation above 60V. The LTC7860 input and output voltage operation in the second category depends only on external components and can be reliably extended up to 200V. Operation for VIN of 60V and BELOW For operation at VIN of 60V and BELOW, the output voltage is programmed by connecting a feedback resistor divider from the output to the VFB pin as shown in Figure 1a. The front page application is an example of this configuration. The output voltage in steady state operation is set by the feedback resistors RFB2 and RFB1 according to the equation: R VOUT = 0.8V * 1+ FB1 RFB2 Great care should be taken to route the VFB line away from noise sources, such as the inductor or the GATE signal that drives the external P MOSFET. The best practice is to locate resistors RFB2 and RFB1 and capacitor CFF local 10 to the LTC7860 to keep the VFB trace short and without VIAS. The planes for VOUT and GND are then routed to the desired regulation point. Detailed layout suggestions are discussed in the Layout sections later in the data sheet. The feed-forward capacitor CFF is added to improve transient response. VOUT LTC7860 RZ1 RFB2 CFF VFB VFBN PGND SGND RFB1 Z1 7860 F01a Figure 1a. Switching Surge Stopper for VIN Operation of 60V and BELOW (VFBN > 2V) Operation for VIN ABOVE 60V For operation at VIN = 60V, a floating ground must be created by a bootstrapped shunt regulator such as a Zener or similar element. To establish shunt DC bias to the LTC7860, connect the floating ground to the LTC7860 PGND and SGND pins. The Zener voltage or Shunt DC bias limit is typically 12V to minimize internal power dissipation but can be extended up to 60V. The VIN Operational Input voltage ranges for these applications are limited only by external components and can reliably extend to 200V and beyond. There are two feedback options for operation above 60V which are Inverting and Non-Inverting Feedback. The Inverting Feedback Option uses fewer components with slightly reduced accuracy (Figure 1b). The Non- Inverting Feedback Option uses additional components but with better accuracy (Figure 1c). It has the additional advantage of reducing VIN quiescent current in normal operation. Inverting Feedback Option In the Inverting Feedback Option for VIN ABOVE 60V, the voltage is programmed by connecting a feedback resistor divider from the output to ground as shown in Figure 1b. VOUT is divided down and the voltage presented to the gate of QFB. The gate voltage is then translated into a signal current by QFB and RFB3 and sent to the LTC7860 Floating Ground Inverting Feedback Pin VFBN. The resistor RFB4 7860f For more information www.linear.com/LTC7860 LTC7860 Applications Information VIN VIN VIN LTC7860 VFB Z1 RFB4 CFB4 VOUT PGND SGND RFB2 QFB CFF QFBM2 QFBM1 VOUT RFB2 RFB4 CFF QFB 7860 F01c PGND SGND 7860 F01b RFB3 RFB3 RFB1 FLOATING GND RFB1 Figure 1b. Switching Surge Stopper for VIN Operation ABOVE 60V with Inverting Feedback translates the signal current proportional to VOUT into a feedback voltage between VFB and VFBN. The voltage at VFBN is the input of an inverting amplifier and is nominally equal to the Floating Ground. The output voltage in steady state operation is set by the feedback resistors according to the equation: R R VOUT = 0.8V * FB3 + VGSQFB * 1+ FB2 RFB4 RFB1 The shunt DC bias or Zener and floating ground permits the drain current of QFB to be translated to a differential feedback voltage VFB - VFBN independent of the value of VIN. RFB4 should be greater than 10k to avoid VFB pin output current limitations. The integrator capacitor, CFB4, should be sized to ensure the negative sense amplifier gain rolls off and limits high frequency gain peaking in the DC/DC control loop. The integrator capacitor pole can be safely set to be two times the switching frequency without affecting the DC/DC phase margin according to the following equation. It is highly recommended that CFB4 be used in most applications. CFB4 = Z2 RFBM1 VIN LTC7860 VFBN VFB Z1 VFBN FLOATING GND RFBM2 RZ2 1 (2 * * 2 * RFB4 * FREQSW ) Great care should be taken to route the VFB and VFB lines away from noise sources, such as the inductor or the GATE signal that drives the external P MOSFET. Figure 1c. Switching Surge Stopper with VIN Operation ABOVE 60V with Non-Inverting Feedback Non-Inverting Feedback Option In the Non-Inverting Feedback Option for VIN ABOVE 60V, the voltage is programmed by connecting a feedback resistor divider from the output to ground as shown in Figure 1c. VOUT is divided down and the voltage presented to the base of QFB. The base voltage is then translated into a signal current by QFB and RFB3 and sent to PNP mirror QFBM1, RFBM1, QFBM2 and RFBM2. In the Non-Inverting Option, the internal inverting amplifier must be defeated by tying VFBN greater than 2V. In Figure 1c, RZ2 and Z2 are used to tie VFBN high where Z2 is chosen greater than 2V but less than 6V. VFBN may also be tied to the FREQ pin when the pin is floated and a fixed 535kHz switching frequency is selected. Choosing a fixed 535kHz in the Non-Inverting option can simplify the PCB design and reduce component count. For the Non-Inverting Option, an NPN is used for QFB, which results in greater accuracy. The resistor RFB4 translates the signal current proportional to VOUT into a feedback voltage applied directly to the VFB pin. The VFBN pin is tied high and the inverting amplifier is defeated. The output voltage in steady state operation is set by the feedback resistors according to the equation: R R VOUT = 0.8V * FB3 + VBEQFB * 1+ FB2 RFB4 RFB1 7860f For more information www.linear.com/LTC7860 11 LTC7860 Applications Information Switching Frequency The choice of operating frequency is a trade-off between efficiency and component size. Lowering the operating frequency improves efficiency by reducing MOSFET switching losses but requires larger inductance and/or capacitance to maintain low output ripple voltage. Conversely, raising the operating frequency degrades efficiency but reduces component size.The switching frequency and resulting switching power loss are of secondary concern. It is generally recommended to go with as high a switching frequency as practical so as to limit the overall solution size. The free-running switching frequency can be programmed from 50kHz to 850kHz by connecting a resistor from FREQ pin to signal ground. The resulting switching frequency as a function of resistance on the FREQ pin is shown in Figure 2. 1000 800 FREQUENCY (kHz) Current Sensing and Current Limit Programming The LTC7860 senses the inductor current through a current sense resistor, RSENSE, placed across the VIN and SENSE pins. The voltage across the resistor, VSENSE, is proportional to inductor current and in normal operation is compared to the peak inductor current setpoint. An inductor current limit condition is detected when VSENSE exceeds 95mV. When the current limit threshold is exceeded, the P-channel MOSFET is immediately turned off by pulling the GATE voltage to VIN regardless of the controller input. The peak inductor current limit is equal to: 900 95mV IL(PEAK) RSENSE 700 600 500 This inductor current limit would translate to an output current limit based on the inductor ripple and duty factor: 400 300 200 100 0 Select an inductor with a saturation current rating sufficient to cover peak current during a full load input transient or output over load. Powder core inductors are typically a good choice as they tend to be small and have good saturation characteristics. 15 25 35 45 55 65 75 85 95 105 115 125 FREQ PIN RESISTOR (k) 3863 F02 Figure 2. Switching Frequency vs Resistor on FREQ pin Inductor Selection A reasonable starting point for ripple current is 70% of IOUT(MAX) at maximum VIN. The largest ripple current occurs at the highest VIN. To guarantee that the ripple current does not exceed a specified maximum, the inductance should be chosen according to: 95mV IL IOUT(LIMIT) = - RSENSE 2 The SENSE pin is a high impedance input with a maximum leakage of 2A. Since the LTC7860 is a peak current mode controller, noise on the SENSE pin can create pulse width jitter. Careful attention must be paid to the layout of RSENSE. To ensure the integrity of the current sense signal, VSENSE, the traces from VIN and SENSE pins should be short and run together as a differential pair and Kelvin (4-wire) connected across RSENSE (Figure 3). VOUT VOUT L= 1- f * I L(MAX) VIN(MAX) 12 7860f For more information www.linear.com/LTC7860 LTC7860 Applications Information VIN VIN LTC7860 SENSE OPTIONAL FILTERING CF RSENSE RF MP 7860 F03 Figure 3. Inductor Current Sensing The LTC7860 has internal filtering of the current sense voltage which should be adequate in most applications. However, adding a provision for an external filter offers added flexibility and noise immunity, should it be necessary. The filter can be created by placing a resistor from the RSENSE resistor to the SENSE pin and a capacitor across the VIN and SENSE pins. It is important that the VIN plane be a clean low inductance connection with minimal PCB via's. The maximum output current in SWITCH-ON mode is greater than the maximum current in PROTECTIVE PWM mode by one half the ripple current. The SWITCH-ON mode power path components must be designed to support the maximum power seen at the non-switching current limit setting. Power MOSFET Selection The LTC7860 drives a P-channel power MOSFET that serves as the main switch for the nonsynchronous inverting converter. Important P-channel power MOSFET parameters include drain-to-source breakdown voltage, on-resistance RDS(ON), threshold voltage VGS(TH), and the MOSFET's thermal resistance JC(MOSFET) and JA(MOSFET). The drain-to-source breakdown voltage must meet the following condition: BVDSS > VIN(MAX) The most important parameter for selection of the PMOS switch (after voltage rating) is RDS(ON). This will determine PMOS loss during SWITCH-ON operation. The gate driver bias voltage VIN-VCAP is set by an internal LDO regulator. In normal operation, the CAP pin will be regulated to 8V below VIN. A minimum 0.47F capacitor is required across the VIN and CAP pins to ensure LDO stability. If required, additional capacitance can be added to accommodate higher gate currents without voltage droop. In shutdown and Burst Mode operation, the CAP LDO is turned off. In the event of CAP leakage to ground, the CAP voltage is limited to 9V by a weak internal clamp from VIN to CAP. As a result, a minimum 10V VGS rated MOSFET is required. Diode Selection When the P-channel MOSFET is turned off, a commutating diode carries the inductor current. This diode is only used during switching and does not conduct in SWITCH-ON mode. The average forward diode current is described as: IF(AVG) = IOUT * (1 - D) The worst-case condition for diode conduction is a short circuit condition where the diode must handle the maximum current as the P-channel MOSFET's duty factor approaches 0%. The diode therefore must be chosen carefully to meet worstcase voltage and current requirements. A good practice is to choose a diode that has a forward current rating higher than IOUT(MAX). The diode reverse breakdown voltage must meet the following condition: VR > VIN(MAX) CIN and COUT Selection (Buck Mode) The input capacitance, CIN, is required to filter the square wave current through the P-channel MOSFET. Use a low ESR capacitor sized to handle the maximum RMS current: ICIN(RMS) = IOUT(MAX) * VOUT VIN * -1 VIN VOUT 7860f For more information www.linear.com/LTC7860 13 LTC7860 Applications Information The formula has a maximum at VIN = 2VOUT, where ICIN(RMS) = IOUT(MAX)/2. This simple worst-case condition is commonly used for design because even significant deviations do not offer much relief. Note that ripple current ratings from capacitor manufacturers are often based on only 2000 hours of life. Ripple currents will only be applied during PROTECTIVE PWM operation, so de-rating requirements are minimal. The selection of COUT is primarily determined by the ESR required to minimize voltage ripple and load step transients. The VOUT is approximately bounded by: 1 VOUT I L ESR + 8 * f *COUT Soft-start is enabled by connecting a capacitor from the SS pin to ground. An internal 10A current source charges the capacitor, providing a linear ramping voltage at the SS pin that causes VOUT to rise smoothly from 0V to its final value. The total soft-start time will be approximately: t SS = CSS * 0.8V 10A Short-Circuit Faults: Current Limit and Foldback Since IL increases with input voltage, the output ripple is highest at maximum input voltage. Typically, once the ESR requirement is satisfied, the capacitance is adequate for filtering and has the necessary RMS current rating. Multiple capacitors placed in parallel may be needed to meet the ESR and RMS current handling requirements. Dry tantalum, specialty polymer, aluminum electrolytic and ceramic capacitors are all available in surface mount packages. Specialty polymer capacitors offer very low ESR but have lower specific capacitance than other types. Tantalum capacitors have the highest specific capacitance, but it is important to only use types that have been surge tested for use in switching power supplies. Aluminum electrolytic capacitors have significantly higher ESR, but can be used in cost-sensitive applications provided that consideration is given to ripple current ratings and longterm reliability. Ceramic capacitors have excellent low ESR characteristics but can have a high voltage coefficient and audible piezoelectric effects. External Soft-Start Start-up characteristics are controlled by the voltage on the SS pin. When the voltage on the SS pin is less than the internal 0.8V reference, the LTC7860 regulates the VFB pin voltage to the voltage on the SS pin. When the SS pin is greater than the internal 0.8V reference, the VFB pin voltage regulates to the 0.8V internal reference. The SS pin is used to program an external soft-start function. The 14 primary function of the external SOFT START feature for a Switching Surge Stopper is as an inrush current limiter in startup and fault recovery. The inductor current limit is inherently set in a current mode controller by the maximum sense voltage and RSENSE. In the LTC7860, the maximum sense voltage is 95mV, measured across the inductor sense resistor, RSENSE, placed across the VIN and SENSE pins. The output current limit is approximately: 95mV IL ILIMIT(MIN) = - RSENSE 2 The current limit must be chosen to ensure that ILIMIT(MIN) > IOUT(MAX) under all operating conditions. Short-circuit fault protection is assured by the combination of current limit and frequency foldback. When the output feedback voltage, VFB, drops below 0.4V, the operating frequency, f, will fold back to a minimum value of 0.18 * f when VFB reaches 0V. Both current limit and frequency foldback are active in all modes of operation. In a shortcircuit fault condition, the output current is first limited by current limit and then further reduced by folding back the operating frequency as the short becomes more severe. The worst-case fault condition occurs when VOUT is shorted to ground. Short-Circuit Recovery and Internal Soft-Start An internal soft-start feature guarantees a maximum positive output voltage slew rate in all operational cases. In a short-circuit recovery condition for example, the output recovery rate is limited by the internal soft-start so that 7860f For more information www.linear.com/LTC7860 LTC7860 VIN VOUT INTERNAL SOFT-START INDUCED START-UP (NO EXTERNAL SOFT-START CAPACITOR) ~650s TIME VOLTAGE (4a) VOUT SHORT-CIRCUIT INTERNAL SOFT-START INDUCED RECOVERY TIME 7860 F05 (4b) Figure 4. Internal Soft-Start (4a) Allows Soft-Start without an External Soft-Start Capacitor and Allows Soft Recovery from (4b) a Short-Circuit output voltage overshoot and excessive inductor current buildup is prevented. The internal soft-start voltage and the external SS pin operate independently. The output will track the lower of the two voltages. The slew rate of the internal soft-start voltage is roughly 1.2V/ms, which translates to a total soft-start time of 650s. If the slew rate of the SS pin is greater than 1.2V/ms the output will track the internal softstart ramp. To assure robust fault recovery, the internal soft-start feature is active in all operational cases. If a short-circuit condition occurs which causes the output to drop significantly, the internal soft-start will assure a soft recovery when the fault condition is removed. The internal soft-start assures a clean soft ramp-up from any fault condition that causes the output to droop, guaranteeing a maximum ramp rate in soft-start, short-circuit fault release. Figure 4 illustrates how internal soft-start controls the output ramp-up rate under varying scenarios. VIN Undervoltage Lockout (UVLO) nificantly, the LTC7860 is guaranteed to operate down to a VIN of 3.5V over the full temperature range. The implications of both the UVLO rising and UVLO falling specifications must be carefully considered for low VIN operation. The UVLO threshold with VIN rising is typically 3.5V (with a maximum of 3.8V) and UVLO falling is typically 3.25V (with a maximum of 3.5V). The operating input voltage range of the LTC7860 is guaranteed to be 3.5V to 60V over temperature, but the initial VIN ramp must exceed 3.8V to guarantee start-up. For example, Figure 5 illustrates LTC7860 operation when an automotive battery droops during a cold crank condition. The typical automotive battery voltage is 12V to 14.4V, which is more than enough headroom above 3.8V for the LTC7860 to start up. Onboard electronics which are powered by a DC/DC regulator require a minimum supply voltage for seamless operation during the cold crank condition, and the battery may droop close to these minimum supply requirements during a cold crank. The DC/DC regulator should not exacerbate the situation by having excessive voltage drop between the already suppressed battery voltage input and the output of the regulator which powers these electronics. As seen in Figure 5, the LTC7860's 100% duty cycle capability allows low dropout from the battery to the output. The drop from VIN to VOUT is determined by the output Load current multiplied by the total series resistance of the switching surge stopper. The 3.5V guaranteed UVLO assures sufficient margin for continuous, uninterrupted operation in extreme cold crank battery drooping conditions. However, additional input capacitance or slower soft start-up time may be required at low VIN (e.g. 3.5V to 4.5V) in order to limit VIN droop caused by inrush currents, especially if the input source has a sufficiently large output impedance. VBATTERY 12V VOLTAGE VOLTAGE Applications Information VOUT 5V The LTC7860 is designed to accommodate applications requiring widely varying power input voltages from 3.5V to 60V. To accommodate the cases where VIN drops sig- LTC7860's 100% DUTY CYCLE CAPABILITY ALLOWS VOUT TO RIDE VIN WITHOUT SIGNIFICANT DROP-OUT TIME 7860 F06 Figure 5. Typical Automotive Cold Crank 7860f For more information www.linear.com/LTC7860 15 LTC7860 Applications Information Minimum On-Time Considerations The minimum on-time, tON(MIN), is the smallest time duration that the LTC7860 is capable of turning on the power MOSFET, and is typically 220ns. It is determined by internal timing delays and the gate charge required to turn on the MOSFET. Low duty cycle applications may approach this minimum on-time limit, so care should be taken to ensure that: tON(MIN) < VOUT VIN(MAX) * f If the duty cycle falls below what can be accommodated by the minimum on-time, the controller will skip cycles. However, the output voltage will continue to regulate. Thermal Considerations The sustained or static power loss in SWITCH-ON operation must be limited so as to ensure suitable maximum component temperatures during all normal operating conditions. The temperature rise of a Switching Surge Stopper is best measured empirically. Power Loss for the SWITCH-ON power paths is I2RSW-ON and may be calculated according to the equation below. I2RSW-ON = I2 * (RSENSE + RDS(ON) + RINDUCTOR) The dynamic or transient power loss in PROTECTIVE PWM operation is of concern with respect to component temperature rise and is principally managed by the timer function which sets a maximum time in this mode. Thermal mass and thermal resistance play key roles in determining the peak temperatures of components at the point in time when the timer cycles off and shuts down. Worst-case operation for a single fault shorted output is typically with the input voltage in the high normal operating range and the output shorted. For this condition, the catch diode is typically the hottest component, as it conducts nearly all the peak current at a high duty cycle. Worst-case operation for a single fault input voltage surge is with the input at the maximum expected input voltage or 16 profile at the maximum operational load current. An input voltage surge and output short is a double fault and may not be required. Specific fault testing and design margin is determined by system requirements. Thermal evaluation and timer setting can be most easily done empirically by observing key component temperatures dynamically in various fault conditions. Observe peak temperatures with an instrument with sufficient bandwidth to track temperatures, such as an infrared (IR) camera. One with video capability is ideal. Set a maximum temperature rise goal based on component maximum junction temperature ratings, maximum expected ambient temperature, and allowed junction to case temperature rise. Start at lower input voltages and/ or shorter TMR timer settings and increase after empirical system verification and measurement. OPTI-LOOP(R) Compensation OPTI-LOOP compensation, through the availability of the ITH pin, allows the transient response to be optimized for a wide range of loads and output capacitors. The ITH pin not only allows optimization of the control loop behavior but also provides a test point for the regulator 's DC-coupled and AC-filtered closed-loop response. The DC step, rise time and settling at this test point truly reflects the closedloop response. Assuming a predominantly second order system, phase margin and/or damping factor can be estimated using the percentage of overshoot seen at this pin. The bandwidth can also be estimated by examining the rise time at this pin. The ITH series RITH-CITH1 filter sets the dominant polezero loop compensation. Additionally, a small capacitor placed from the ITH pin to signal ground, CITH2, may be required to attenuate high frequency noise. The values can be modified to optimize transient response once the final PCB layout is done and the particular output capacitor type and value have been determined. The output capacitors need to be selected because their various types and values determine the loop feedback gain and phase. An output 7860f For more information www.linear.com/LTC7860 LTC7860 Applications Information current pulse of 20% to 100% of full load current having a rise time of 1s to 10s will produce output voltage and ITH pin waveforms that will give a sense of the overall loop stability without breaking the feedback loop. The general goal of OPTI-LOOP compensation is to realize a fast but stable ITH response with minimal output droop due to the load step. For a detailed explanation of OPTI-LOOP compensation, refer to Application Note 76. fault timer The LTC7860 is a Switching Surge Stopper. The LTC7860 switches only during startup, during an overcurrent fault and during an input overvoltage surge (PROTECTIVE PWM operation). The primary function of a surge stopper is to limit the output to a programmed maximum voltage during an input voltage surge. Limiting the output voltage "Surge Stops" the input voltage surge and prevents it from propagating to the system and potentially causing damage. The Switching Surge Stopper external components are optimized to minimize total line resistance in normal operation or SWITCH-ON mode rather than overload operation. The fault timer limits the switching time during an overload. The fault timer is programmed to allow the Switching Surge Stopper to operate below a safe peak temperature with the PWM power losses in startup, in a current limit fault or in an input voltage surge. Since the device shuts down before reaching thermal equilibrium, the power rating can be significantly increased over continuous operation. The fault timer saves system cost and size by allowing component selections to be determined by normal or SWITCH-ON mode rather than Protective PWM operating mode. The timer indirectly limits the peak Switching Surge Stopper temperatures by limiting the total time spent in higher power loss PROTECTIVE PWM operating mode. reverses before reaching the fault set Gate Off threshold or VGTH the TMR pin reverses and pulls to ground by ITPDR. Please reference Figure 6, Timer (TMR) Functional Diagram. When the TMR pin exceeds VGTH, a fault is detected and the PMOS Gate is turned off and is held off for a cool down time. Once VGTH threshold is reached, the pull down current source ITPDC pulls down the TMR until reaching the TMR Reset Threshold or VRTH. The time the PMOS gate is shutdown after VGTH is reached until the fault is reset is called the cool down time. Once the fault is reset, the TMR pin will either pull-down to ground if the fault condition has been cleared or pulled up to VGTH if the fault is present. In the case of a persistent fault caused by a short circuit, TMR will continuously retry and shutdown. Programming the Fault Timer The TMR Initial Set Time for Fault Detection (TSETI) is the total time allowed in PWM Regulation before the PMOS Gate is turned off and shutdown. The constant TSETI(1F) is measured and can be used to calculate TSETI. The constant includes extension (1F) to indicate that the time is for a 1F capacitor and needs to be scaled by CTMR in F's. TSETI can be calculated using the equations below: TSET1 = CTMR * VGTH ITPU TSET1 = CTMR * TSET(1F) GATE OFF ITPU 30A VGTH 1.29V TMR CTMR VRTH 0.24V ITPDC 1.3A Fault Timer Functionality In normal operation the TMR pin voltage is held at ground by the current source TMR Pull-Down Reset ITPDR. When switching is detected, the TMR Pull-Up current or ITPU pulls up the TMR pin. If the fault is removed and the TMR ITPDR 40A + - + - FAULT TIMER LOGIC COOL DOWN NORMAL OPERATION 7860 F07 Figure 6. Timer (TMR) Functional Diagram 7860f For more information www.linear.com/LTC7860 17 LTC7860 Applications Information The TMR Reset Cool Down Time is TRSTC and is the total time allowed for the system to cool down before the PMOS Gate is turned on again after a fault. The constant TRSTC(1F) is measured and can be used to calculate TRSTC. The constant includes extension (1F) to indicate that the time is for a 1F capacitor and needs to be scaled by CTMR in F's. TRSTC can be calculated using the equations below: TRSTC = CTMR * VGTH - VRTH ITPDC TRSTC = CTMR * TRSTC(1F) TSETI determines how long the switcher is allowed to switch before shutting down. TRSTC determines how long the switcher cools down before the PMOS Gate can be turned on again. For a single fault exceeding TSET1, that shuts down the Switching Surge Stopper, it will restart after the TMR Reset Cooldown period (TRSTC). In the case of a sustained fault the TMR pin rises after the cool down period expires. In a sustained fault, the TMR pin will pull up from the VRTH threshold. The TMR Set Time Repeat after cool down is TSETR. The constant TSETR(1F) is measured and can be used to calculate TSETR. The constant includes extension (1F) to indicate that the value is for a 1F capacitor and needs to be scaled by CTMR in F's. TSETR can be calculated using the equations below: TSETR V -V = CTMR * GTH RTH ITPU In a sustained fault, the Switching Surge Stopper will continuously start, shutdown, cool down and restart at a fixed duty factor. The TMR Reset duty cycle in a sustained fault is DTYTSTR. DTYTSTR is measured and is calculated according to the equation below. 18 TSETR TRSTC A Switching Surge Stopper can be designed for performance in normal operation or SWITCH-ON mode. Its components and thermal design are optimized for normal operation and safely operate through high voltage input surges and/or overcurrent faults. Transient operation due to surges and other faults can be survived because the time in regulation is strictly limited when power loss is high. The principle design criterion in normal operation is the total resistance from VIN to VOUT with the resulting power loss and thermal considerations. As a design example, take an application with the following specifications: VIN = 8V to 14V DC with an input voltage transient of 60V and a decay constant of 500ms, VOUT < 18V, with a continuous output load current rating of 5A. We choose a P-channel MOSFET with the appropriate BVDSS and ID rating. In this example a good choice is the Vishay Si7461DP (BVDSS = 60V, RDS(ON) = 11.5m (typ), 120 = 1.6). The expected power dissipation from the P-channel in normal operation or SWITCH-ON mode can be calculated at TJ = 120C for VIN at 12V and IOUT equal to 5A. PPMOS = IOUT2 * RDS(ON) = 5A2 * 14.5m (1.6) = 580mW Next, set the inductor value to give 70% ripple current at maximum VIN = 60V. 17.2V 17.2V L= 1- = 6.5H 540kHz * (0.7 * 5A) 60V TSETR = CTMR * TSET(1F) DTYTSTR = Design Example Select 6.8H as the nearest standard value. A good choice for this application is the Coilcraft XAL6060-682ME, with a DCR value of 19m. The resulting ripple current is: 17.2V 17.2V IRIPPLE = 1- = 3.33A 540kHz * 6.8H 60V 7860f For more information www.linear.com/LTC7860 LTC7860 Applications Information The output voltage is programmed according to: R VOUT = 0.8V * 1+ FB2 RFB1 If RFB2 is chosen at 1M, then RFB1 is 48.7k. The FREQ pin is floated in order to program the switching frequency to 540kHz. The on-time required at 60V to generate 17.2V output can be calculated as: tON = VOUT 17.2V = = 531ns VIN * f 60V * 540kHz 95mV 3.33 - = 6.25A 12m 2 The total SWITCH-ON resistance RSW-ON from VIN to VOUT is: RSW-ON = 12m + 11.5m * (1.6) + 19m = 49.4m Set the RSENSE resistor value to ensure the converter can deliver a maximum output current of 5.0A during an input surge with sufficient margin to account for component variations and worst-case RSENSE data sheet tolerance. 85mV = 12.1m 3.33A 1.05 * 5A + 2 The nearest standard value for RSENSE is 12m. The current limit in Normal Operation or SWITCH-ON mode is not reduced by the ripple current and is: ILIMIT(SURGE) = ILIMIT(SURGE) = RSW-ON = RSENSE + RDS(ON) + RINDUCTOR This on-time is larger than the LTC7860's minimum ontime with sufficient margin to prevent cycle skipping. RSENSE = The average output current limit during a surge is the Normal Operation current limit minus half the ripple current. The maximum current delivered during a surge will always be less than in Normal Operation or SWITCH-ON mode. 95mV = 7.9A 12m RSENSE power loss for normal operation and at current limit can be calculated according to the equations below. PRSENSE = IOUT2 * RSENSE = 5A2 * 12m = 300mW PRSENSE = IOUT2 * RSENSE = 7.9A2 * 12m = 750mW Select a 12m resistor capable of dissipating at least one watt. The total insertion loss in Normal Operation or SWITCHON mode can be calculated below. VDROP = IOUT * RSW-ON = 5A * 49.4m = 247mW The system will need to be designed to operate in this mode continuously. Temperature rise during a surge or fault operation will be limited by the timer. Choose an appropriate diode that will handle the power requirements during the surge or fault condition. The diode will never engage during normal operation or SWITCH-ON mode but only during a surge or fault. The PDS5100-13 Schottky diode is selected (VF(5A, 125C) = 0.60V) for this application. The continuous current rating of 5A is sufficient during the TMR limited PROTECTIVE PWM operation. The power dissipated during a surge or fault is. 17.2V PDIODE(SURGE) = 5A * 1- * 0.60V = 2.14W 60V A soft-start time of 8ms can be programmed through a 0.1F capacitor on the SS pin: CSS = 8ms * 10A = 0.1F 0.8V 7860f For more information www.linear.com/LTC7860 19 LTC7860 Applications Information A 700ms minimum time limit was chosen based on input surge specifications. We will calculate CTMR for the worst case using TSET(1F) minimum and allow for a 10% tolerance and a 10% variation in capacitance over temperature. We can calculate the required CTMR by using TSET(1F)MIN according to the equation below. CTMR = TSETIMIN TSET(1F)MIN * 1 700 1 * * = 21F 0.9 37 0.9 The nearest standard value for CTMR is 22F which results in the TMR Set Time Initial or TSETI values given by the equations below. We assume 10% tolerance for capacitors over temperature. TSETITYP = TSET(1F) * 22F = 44 * 22F = 968ms TSETIMIN = TSET(1F) * 22F = 37 * 22F * 0.90 = 732ms TSETIMAX = TSET(1F) * 22F = 50 * 22F * 1.1 = 1210ms Once TSET is tripped there will be a defined TMR Reset Cool Down Time TRSTCTYP. TRSTCTYP = TRSTC(1F) * 22F = 732 * 22F = 16.1s Loop compensation components on the ITH pin are chosen based on load step transient behavior (as described under OPTI-LOOP Compensation) and optimized for stability. Compensation is chosen to be 680pF and 10K. Gate Driver Component Placement, Layout and Routing It is important to follow recommended power supply PC board layout practices such as placing external power elements to minimize loop area and inductance in switching paths. Be careful to pay particular attention to gate driver component placement, layout and routing. We recommend a ceramic 0.47F 16V capacitor with a high quality dielectric such as X5R or X7R. Some high current applications with large Qg PMOS switches may benefit from an even larger CCAP capacitance. The effective CCAP capacitance should be greater than 0.1F minimum in all operating conditions. Operating voltage and temperature both decrease the rated capacitance to varying degrees depending on dielectric type. The LTC7860 is a PMOS controller with an internal gate driver and boot-strapped LDO that regulates the differential CAP voltage (VIN - VCAP) to 8V nominal. The CCAP capacitance needs to be large enough to assure stability and provide cycle-to-cycle current to the PMOS switch with minimum series inductance. Figure 7 shows the LTC7860 Generic Application Schematic which includes an optional current sense filter and series gate resistor. Figure 8 illustrates the recommended gate driver component placement, layout and routing of the GATE, VIN, SENSE and CAP pins and key gate driver components. It is recommended that the gate driver layout follow the example shown in Figure 8 to assure proper operation and long term reliability. The LTC7860 gate driver should connect to the external power elements in the following manner. First route the VIN pin using a single low impedance isolated trace to the positive RSENSE resistor PAD without connection to the VIN plane. The reason for this precaution is that the VIN pin is internally Kelvin connected to the current sense comparator, internal VIN power and the PMOS gate driver. 20 7860f For more information www.linear.com/LTC7860 LTC7860 Connecting the VIN pin to the VIN power plane adds noise and can result in jitter or instability. Figure 8 shows a single VIN trace from the positive RSENSE pad connected to CSF, CCAP, VIN pad and CINB. The total trace length to RSENSE should be minimized and the capacitors CCF, CCAP and CINB should be placed near the VIN pin of the LTC7860. CCAP should be placed near the VIN and CAP pins. Figure 8 shows CCAP placed adjacent to the VIN and CAP pins with SENSE routed between the pads. This is the recommended layout and results in the minimum parasitic inductance. The gate driver is capable of providing high peak current. Parasitic inductance in the gate drive and the series inductance between VIN to CAP can cause a voltage spike between VIN and CAP on each switching cycle. The voltage spike can result in electrical over-stress to the gate driver and can result in gate driver failures in extreme cases. It is recommended to follow the example shown in Figure 8 for the placement of CCAP as close as is practical. KELVIN CONNECT THE VIN PIN, CINB, CSF, CCAP CONNECTION TO RSENSE+, DO NOT CONNECT THIS TRACE TO THE VIN POWER PLANE. CINB VIN PLANE CCAP CSS The bypass capacitor CINB is used to locally filter the VIN supply. CINB should be tied to the VIN pin trace and to the PGND exposed pad. The CINB positive pad should connect to RSENSE positive though the VIN pin trace. The CINB ground trace should connect to the PGND exposed pad connection. VIN TMR CPITH ZRG CSF SRG SENSE SS CITH RITH RFREQ RSF RGATE GATE + RSENSE - Q1 LTC7860 ITH ROUTE VIN POWER PLANE TO THE POSITIVE POWER INPUT TO SENSE RESISTOR. DO NOT CONNECT THE VIN PIN TRACE. FREQ SGND VFBN PGND VFB 7860 F08 Figure 7. LTC7860 Generic Application Schematic with Optional Current Sense Filter and Series Gate Resistor RGATE resistor pads can be added with a 1 resistor to allow the damping resistor to be added later. The total length of the gate drive trace to the PMOS gate should be minimized and ideally be less than 1cm. In most cases with a good layout the RGATE resistor is not needed. The RGATE resistor should be located near the gate pin to reduce peak current through GATE and minimize reflected noise on the gate pin. The RSF and CSF pads can be added with a zero ohm resistor for RSF and CSF not populated. In most applications, external filtering is not needed. The current sense filter RSF and CSF can be added later if noise if demonstrated to be a problem. CAP RUN VIN CIN CINB TO Q1 GATE RGATE GATE CSF TO RSENSE+ VIN SENSE CAP CCAP RSF TO RSENSE- 7860 F09 Figure 8. LTC7860 Recommended Gate Driver PC Board Placement, Layout and Routing The Zener ZRG and Schottky SRG are recommended when driving large Power MOSFET's and should always be used in combination with RGATE equal to 1. We recommend using a 9.1V Zener in parallel with a Schottky diode when either the rise or fall time is measured to be greater than 30ns. The purpose of the diodes is to protect the internal multi-Amp gate driver against possible electrical over stress when switching the high capacitance power MOSFET Gate through an inductive gate trace at high current. 7860f For more information www.linear.com/LTC7860 21 LTC7860 Applications Information PC Board Layout Checklist When laying out the printed circuit board, the following checklist should be used to ensure proper operation of the LTC7860. 1. Multilayer boards with dedicated ground layers are preferable for reduced noise and for heat sinking purposes. Use wide rails and/or entire planes for VIN, VOUT and GND for good filtering and minimal copper loss. If a ground layer is used, then it should be immediately below (and/or above) the routing layer for the power train components which consist of CIN, sense resistor, P-channel MOSFET, Schottky diode, inductor, and COUT. Flood unused areas of all layers with copper for better heat sinking. 2. Keep signal and power grounds separate except at the point where they are shorted together. Short the signal and power ground together only at a single point with a narrow PCB trace (or single via in a multilayer board). All power train components should be referenced to power ground and all small-signal components (e.g., CITH1, RFREQ, CSS etc.) should be referenced to the signal ground. 3. Place CIN, sense resistor, P-channel MOSFET, inductor, and primary COUT capacitors close together in one compact area. The junction connecting the drain of the Pchannel MOSFET, cathode of the Schottky, and (+) terminal of the inductor (this junction is commonly referred to as switch or phase node) should be compact but be large enough to handle the inductor currents without large copper losses. Place the sense resistor and source of P-channel MOSFET as close as possible to the (+) plate of the CIN capacitor(s) 22 that provides the bulk of the AC current (these are normally the ceramic capacitors), and connect the (-) terminal of the inductor as close as possible to the (-) terminal of the same CIN capacitor(s). The high dI/dt loop formed by CIN, the MOSFET, and the Schottky diode should have short leads and PCB trace lengths to minimize high frequency EMI and voltage stress from inductive ringing. The (+) terminal of the primary COUT capacitor(s) which filter the bulk of the inductor ripple current (these are normally the ceramic capacitors) should also be connected close to the (-) terminal of CIN. 4. Place Pins 7 to 12 facing the power train components. Keep high dV/dt signals on GATE and switch away from sensitive small-signal traces and components. 5. Place the sense resistor close to the (+) terminal of CIN and source of P-channel MOSFET. Use a Kelvin (4-wire) connection across the sense resistor and route the traces together as a differential pair into the VIN and SENSE pins. An optional RC filter could be placed near the VIN and SENSE pins to filter the current sense signal. 6. Place the feedback divider RFB1/2 as close as possible to the VFB and VFBN pins. The (-) terminal of the feedback divider should connect to the output regulation point and the (+) terminal of the feedback divider should connect to VFB. 7. Place the ceramic CCAP capacitor as close as possible to the VIN and CAP pins. This capacitor provides the gate discharging current for the power P-channel MOSFET. 8. Place small signal components as close to their respective pins as possible. This minimizes the possibility of PCB noise coupling into these pins. Give priority to VFB, ITH, and FREQ pins. 7860f For more information www.linear.com/LTC7860 LTC7860 Typical Applications 3.5V to 60V Input, 12V/18V Maximum 5A Output at 535kHz OPTIONAL REVERSE BATTERY PROTECTION L1 MP1 6.8H Si7461DP XAL6060-682ME RSENSE 12m ALT VIN 60V MAX OPT REV 12V NOM MP2 -60V MIN Si7461DP VIN 60V MAX 12V NOM 3.5V MIN CIN1 10F CSF 100pF VIN D1 PDS5100-13 RSF OPT CFF 3.9pF SENSE GATE VFBN VOUT 18V MAX 12V NOM 3.5V MIN 5A RFB2 1M COUT1 10F VFB FREQ CCAP1 0.47F RRUN1 100k CITH1 680pF 0.1F RITH1 10k CITH2 10pF RFB1 48.7k CAP TMR LTC7860 RUN SS ITH CTMR 22F CSS1 0.1F SGND PGND 7860 TA02a PROTECTIVE PWM: VOUT Clamped to 18V During a VIN Surge 60V INPUT SURGE PROTECTIVE PWM: VOUT Clamped for TMR Timer Set Initial (TSETI) PROTECTIVE PWM: VOUT Shutdown for TMR Reset Cool Down (TRSTC) CTMR = 22F CTMR = 22F CTMR = 22F 60V INPUT SURGE VIN 20V/DIV VIN 10V/DIV VOUT 10V/DIV 60V INPUT SURGE VOUT 20V/DIV 18V ADJUSTABLE CLAMP VIN 20V/DIV OUTPUT CLAMP VOUT 20V/DIV TSETI VTMR 1V/DIV VTMR 1V/DIV 100ms/DIV 7860 TA02b TMR TIME SET INITIAL (TSETI) 200ms/DIV 7860 TA02c VTMR 1V/DIV OUTPUT SHUTDOWN TRSTC TMR RESET COOL DOWN (TRSTC) 2s/DIV 7860 TA02d 7860f For more information www.linear.com/LTC7860 23 LTC7860 Typical Applications 8V to 100V Input, 28V Nominal/34V Maximum, 10A Output at 400kHz with Non-Inverting Feedback Option OPTIONAL REVERSE BATTERY PROTECTION ALT VIN 100V MAX 28V NOM -100V MIN RSENSE 7m MP2 OPT REV SUM90P10-19L VIN 100V MAX 28V NOM 8V MIN + CIN1 1F 250V x3 CIN2 OPT MP1 SUM90P10-19L RSENSE 100 RG 1 L1 33H 7443633300 D2 STPS30M100DJF + COUT1 150F VOUT 34V MAX 28V NOM 8V MIN 10A COUT2 10F 50V x3 CGATE 1000pF R1 100k D7 CM024L3 4.3V VIN VFBN CCAP 0.47F CIN3 0.1F RRUN 100k R5 100k CVIN1 0.1F D5 CMHZ5242B 12V RFREQ1 61.9k CITH1 3.3F RITH1 10k CSENSE 100pF R3 4.99k GATE SENSE PNP Q1 CAP PNP Q2 Q1, Q2 BC857BS VFB RUN LTC7860 RFB4 10k TMR SS FREQ ITH CTMR 22F CSS1 0.1F SGND PGND PBHV9215Z115 Q5 D4 CMHZ5242B 12V R4 4.99k RFB1 10k Q3 KST43 MN1 TN5325K1G RFB3 205k R2 1k RFB2 10k 7860 TA03a PROTECTIVE PWM: VOUT Clamped to 34V During a VIN Surge 100V INPUT SURGE VIN 25V/DIV VOUT 25V/DIV 34V ADJUSTABLE CLAMP VTMR 1V/DIV VTMR 1V/DIV 100ms/DIV 24 7860 TA03b PROTECTIVE PWM: VOUT Shutdown for TMR Reset Cool Down (TRSTC) CTMR = 22F CTMR = 22F VIN 20V/DIV VOUT 20V/DIV PROTECTIVE PWM: VOUT Clamped for TMR Timer Set Initial (TSETI) 100V INPUT SURGE VIN 25V/DIV VOUT 25V/DIV OUTPUT CLAMP TSETI VTMR 1V/DIV TMR TIME SET INITIAL (TSETI) 200ms/DIV CTMR = 22F 7860 TA03c 100V INPUT SURGE OUTPUT SHUTDOWN TRSTC TMR RESET COOL DOWN (TRSTC) 2s/DIV 7860 TA03c 7860f For more information www.linear.com/LTC7860 LTC7860 Package Description Please refer to http://www.linear.com/designtools/packaging/ for the most recent package drawings. MSE Package 12-Lead Plastic MSOP, Exposed Die Pad (Reference LTC DWG # 05-08-1666 Rev F) BOTTOM VIEW OF EXPOSED PAD OPTION 2.845 0.102 (.112 .004) 5.23 (.206) MIN 2.845 0.102 (.112 .004) 0.889 0.127 (.035 .005) 6 1 1.651 0.102 (.065 .004) 1.651 0.102 3.20 - 3.45 (.065 .004) (.126 - .136) 12 0.65 0.42 0.038 (.0256) (.0165 .0015) BSC TYP RECOMMENDED SOLDER PAD LAYOUT 0.254 (.010) 0.35 REF 4.039 0.102 (.159 .004) (NOTE 3) 0.12 REF DETAIL "B" CORNER TAIL IS PART OF DETAIL "B" THE LEADFRAME FEATURE. FOR REFERENCE ONLY 7 NO MEASUREMENT PURPOSE 0.406 0.076 (.016 .003) REF 12 11 10 9 8 7 DETAIL "A" 0 - 6 TYP 3.00 0.102 (.118 .004) (NOTE 4) 4.90 0.152 (.193 .006) GAUGE PLANE 0.53 0.152 (.021 .006) DETAIL "A" 1.10 (.043) MAX 0.18 (.007) SEATING PLANE 0.22 - 0.38 (.009 - .015) TYP 1 2 3 4 5 6 0.650 (.0256) BSC NOTE: 1. DIMENSIONS IN MILLIMETER/(INCH) 2. DRAWING NOT TO SCALE 3. DIMENSION DOES NOT INCLUDE MOLD FLASH, PROTRUSIONS OR GATE BURRS. MOLD FLASH, PROTRUSIONS OR GATE BURRS SHALL NOT EXCEED 0.152mm (.006") PER SIDE 4. DIMENSION DOES NOT INCLUDE INTERLEAD FLASH OR PROTRUSIONS. INTERLEAD FLASH OR PROTRUSIONS SHALL NOT EXCEED 0.152mm (.006") PER SIDE 5. LEAD COPLANARITY (BOTTOM OF LEADS AFTER FORMING) SHALL BE 0.102mm (.004") MAX 6. EXPOSED PAD DIMENSION DOES INCLUDE MOLD FLASH. MOLD FLASH ON E-PAD SHALL NOT EXCEED 0.254mm (.010") PER SIDE. 0.86 (.034) REF 0.1016 0.0508 (.004 .002) MSOP (MSE12) 0911 REV F 7860f Information furnished by Linear Technology Corporation is believed to be accurate and reliable. However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights. For more information www.linear.com/LTC7860 25 LTC7860 Typical Application 8V to 100V Input, 28V Nominal/34V Maximum, 10A Output at 400kHz with Inverting Feedback Option OPTIONAL REVERSE BATTERY PROTECTION RSENSE 7m MP2 ALT VIN 100V MAX OPT REV SUM90P10-19L 28V NOM VIN -100V MIN 100V MAX 28V NOM 8V MIN + CIN2 OPT CIN1 1F 250V x3 MP1 SUM90P10-19L RSF 100 CGATE 1000pF L2 33H 7443633300 D1 STPS30M100DJF + COUT1 10F 50V x3 COUT2 150F RG 1 VOUT 34V MAX 28V NOM 8V MIN 10A CSF 100pF VIN SENSE CCAP 0.47F CIN3 0.1F RRUN 100k R5 100k CVIN1 0.1F D6 CMHZ5242B 12V RFREQ 61.9k RITH1 10k CITH1 3.3nF VFB CAP RUN GATE CFB1 47pf LTC7860 VFBN TMR FREQ SGND PGND PBHV9215Z115 Q1 D3 CMHZ5242B 12V CTMR 22F SS ITH RFB4 10k CSS1 0.1F RFBN2 1M RFBN1 10k RFB1 10k MN2 TN5325K1G MN1 TN5325K1G R2 1k RFB3 191k RFB2 10k 7860 TA04 Related Parts PART NUMBER LT4356-1 DESCRIPTION High Voltage Surge Stopper COMMENTS 100V Overvoltage and Overcurrent Protection, Latch-Off and Auto-Retry Option LTC4364 LT4363 Surge Stopper with Ideal Diode High Voltage Surge Stopper 4V to 80V Operation; -40V Reverse Input, -20V Reverse Output Protection 100V Overvoltage and Overcurrent Protection, Latch-Off and Auto-Retry Options LTC4366-1, LTC4366-2 LTC3864 High Voltage Surge Stopper Low IQ, High Voltage Step-Down DC/DC Controller with 100% Duty Cycle Wide Operating Voltage Range: 9V to >500V Rugged Floating Topology Fixed Frequency 50kHz to 850kHz, 3.5V VIN 60V, 0.8V VOUT VIN, IQ = 40A, MSOP-12E, 3mm x 4mm DFN-12 26 Linear Technology Corporation 1630 McCarthy Blvd., Milpitas, CA 95035-7417 For more information www.linear.com/LTC7860 (408) 432-1900 FAX: (408) 434-0507 www.linear.com/LTC7860 7860f LT 0215 * PRINTED IN USA LINEAR TECHNOLOGY CORPORATION 2015