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PD-97309A
HTA-SERIES HIGH RELIABILITY DC/DC CONVERTER
Description
The HTA Series of DC/DC converters is a family of 20W, single and dual output, high reliability devices designed to operate in extremely high temperature environments such as those encountered in oil exploration applications. Features include small size, low weight and high tolerance to environmental stresses such as wide temperature extremes, severe shock and vibration. All internal components are derated to meet the intended operating environment. Documentation including electrical stress and thermal analysis are available. The converters incorporate a fixed frequency single forward topology with magnetic feedback and internal EMI filter. All models include an external inhibit port and have an adjustable output voltage. They are enclosed in a hermetic 1.5" x 4.0" x 0.430" AlSi package and weigh less than 70grams. The package utilizes rugged ceramic feed-thru copper core pins and is sealed using parallel seam welding. Full environmental screening includes temperature cycling, constant acceleration, fine and gross leak, and burn-in. Nonscreened versions of the HTA converters are available for system development purposes. Variations in electrical specifications and screening to meet custom requirements can be accommodated.
200V Input, Single/Dual Output
Features
n 150 to 250V DC Input Range n Up to 20W Output Power n Single and Dual Output Models Include 3.3, 5, 12, 15, 5, 12 and 15V n Internal EMI Filter n Magnetically Coupled Feedback n High Efficiency - to 76% n -35C to +185C Operating Case Temperature Range n 10M @ 500VDC Isolation n Under-Voltage Lockout n Short Circuit and Overload Protection n Output Over Voltage Limiter n Adjustable Output Voltage n Synchronization Input and Output n External Inhibit n Low Weight, < 70grams
Applications
n Down Hole Exploration Tools The current limit point exhibits a slightly negative temperature coefficient to reduce the possibility of thermal runaway. An external Inhibit port is provided to control converter operation. The converter's operation is inhibited when this pin is pulled low. It is designed to be driven by an open collector logic device. The pin may be left open for normal operation and has a nominal open circuit voltage of 4.0V with respect to the Input Return (pin 2). The output voltage of all models can be adjusted using a single external resistor.
Circuit Description
The HTA series of converters utilize a single-ended forward topology with resonant reset. The nominal switching frequency is 500KHz. Electrical isolation and tight output regulation are achieved through the use of a magnetically coupled feedback. Voltage feed-forward with duty factor limiting provides high line rejection and protection against output over voltage in the event of an internal control loop failure. This mechanism limits the maximum output voltage to approximately 20% over the nominal regardless of the line voltage. Output current is limited under any load fault condition to approximately 125% of rated load at maximum operating case temperature. An overload condition causes the converter output to behave like a constant current source with the output voltage dropping below nominal. The converter will resume normal operation when the load current is reduced below the current limit point. This protects the converter from both overload and short circuit conditions.
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03/03/09
HTA-SERIES
Absolute Maximum Ratings
Input voltage range Output power Lead temperature Operating case temperature Storage temperature -0.5Vdc to +300Vdc Internally limited -35C to +185C -55C to +185C
Maximum Operating Conditions
Input voltage range Output power 150Vdc to 250Vdc 0 to Max. Rated -35C to +185C
+300C for 10 seconds Operating temperature
Electrical Performance Characteristics
Parameter Input Voltage Output voltage ( Vout ) HTA2003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Output power ( POUT ) Output current ( IOUT ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Line regulation ( VRLINE ) Load regulation ( VRLOAD ) Cross regulation ( VRCROSS ) HTA20005D HTA20012D HTA20015D 1 1 1 1 1 1 1 2,3 2,3 2,3 2,3 2,3 2,3 2,3 1,2,3 Group A Subgroup Conditions -35C TC +185C VIN = 200V DC 5%, CL = 0 unless otherwise specified Limits Min 150 3.25 4.95 11.88 14.85 4.95 11.88 14.85 3.20 4.85 11.64 14.55 4.85 11.64 14.55 0 Nom 200 3.30 5.00 12.00 15.00 5.00 12.00 15.00 Max 250 3.35 5.05 12.12 15.15 5.05 12.12 15.15 V IOUT = 100% rated load Note 4 3.40 5.15 12.36 15.45 5.15 12.36 15.45 20 W Unit V
IOUT = 100% rated load Note 4
VIN = 150, 200, 250 Volts, Note 2
1,2,3
VIN = 150, 200, 250 Volts, Note 2
Either Output, Note 3 Either Output, Note 3 Either Output, Note 3 1,2,3 1,2,3 VIN = 150, 200, 250 Volts IOUT = 0, 50%, 100% rated, Note 4 IOUT = 0, 50%, 100% rated, Note 4 VIN = 150, 200, 250 Volts VIN = 150, 200, 250 Volts Duals only, Note 5
0 0 0 0 0 0 0 -0.5 -1.0 -5.0 -3.0 -3.0
6.10 4.00 1.67 1.33 3.20 1.34 1.06 +0.5 +1.0 5.0 3.0 3.0
A
% %
1,2,3
%
For Notes to Electrical Performance Characteristics, refer to page 5
2
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HTA-SERIES
Electrical Performance Characteristics
Group A Subgroup 1,3
( continued )
Limits Min Nom Max 20 Unit mA
Parameter Input current, no load ( IIN ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Input current inhibited Output ripple ( VRIP ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Switching frequency ( FS ) Efficiency ( EFF ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D
Conditions -35C TC +185C VIN = 200V DC 5%, CL = 0 unless otherwise specified IOUT = 0, Pin 4 open
2
IOUT = 0, Pin 4 open
30
mA
1,2,3 1,3
Pin 4 shorted to pin 2 VIN = 150, 200, 250 Volts IOUT = 100% rated load Notes 4, 6
5.0 50 50 70 80 80 80 80 25 25 35 40 40 40 40 500 70 75 76 76 75 76 76 65 70 71 71 70 71 71 68 73 74 74 73 73 73 550 74 78 79 79 78 79 79 650
mA
mV p-p
2
VIN = 150, 200, 250 Volts IOUT = 100% rated load Notes 4, 6
mV p-p
1,2,3 1
Sync. Input (Pin 4) open IOUT = 100% rated load Note 4
KHz
2
IOUT = 100% rated load Note 4
%
3
IOUT = 100% rated load Note 4
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For Notes to Electrical Performance Characteristics, refer to page 5
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HTA-SERIES
Electrical Performance Characteristics
Group A Subgroup 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3
( continued )
Limits Min Nom Max 146 V 119 Unit
Parameter Under Voltage Lockout Turn-on ( input voltage rising ) Turn-off ( input voltage decreasing ) Synchronization Frequency Range Pulse Amplitude, High Pulse Amplitude, Low Pulse Rise Time Pulse Duty Cycle Transient Recovery Specification Transient Load Response Half to Full Load Transient Load Response Full to Half Load Transient Load Response 10% to Half Load Transient Load Response Half to 10% Load Enable Input ( Inhibit Function ) open circuit voltage drive current ( sink ) voltage range Current Limit Point Expressed as a percentage of full rated load current Power dissipation, load fault ( PD ) Turn-on Response Overshoot ( VOS) Turn-on Delay (TDLY ) Capacitive Load ( CL ) HTA20003R3S HTA20005S HTA20012S HTA20015S HTA20005D HTA20012D HTA20015D Line Rejection Isolation Device Weight
Conditions -35C TC +185C VIN = 200V DC 5%, CL = 0 unless otherwise specified No load, Full load Notes 1, 4
Note 1
500 2.0 -0.5 20
650 10 0.8 100 80
KHz V V ns %
Notes 4, 10, 11, 12 4,5,6 4,5,6 4,5,6 4,5,6 Overshoot Recovery Time Overshoot Recovery Time Overshoot Recovery Time Overshoot Recovery Time Note 1 3.0 -0.5 1 2 3 1,2,3 115 105 130 10 300 10 450 15 300 15 450 5.0 100 50 175 150 220 30 10 200 2200 1000 180 120 500 90 60 40 100 70 50 % s % s % s % s V A V
1,2,3
VOUT = 90% of Nominal, Note 4
%
Short Circuit, Overload, Note 8 No Load, Full Load Notes 4, 9 IOUT = 100% rated load No effect on DC performance Notes 1, 4, 7 Each output on duals
W % ms
4,5,6 1
2.0
F
1 1
MIL-STD-461, CS101 30Hz to 50KHz, Notes 1, 4 Input to Output or Any Pin to Case except pin 3, test @ 500VDC
dB M g
For Notes to Electrical Performance Characteristics, refer to page 5
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HTA-SERIES
Notes for Electrical Performance Characteristics Table
1. 2. 3. 4. 5. 6. 7. Parameter is tested as part of design characterization or after design changes. Thereafter, parameter shall be guaranteed to the limits specified. Parameter verified during line and load regulation tests. Output load current must be distributed such that at least 20% of the total load current is being provided by one of the outputs. Load current split equally between outputs on dual output models. Cross regulation is measured with 20% rated load on output under test while changing the load on the other output from 20% to 80% of rated. Guaranteed for a D.C. to 20MHz bandwidth. Tested using a 20KHz to 10MHz bandwidth using the circuit on page 6. Capacitive load may be any value from 0 to the maximum limit without compromising dc performance. A capacitive load in excess of the maximum limit may interfere with the proper operation of the converter's overload protection, causing erratic behavior during turn-on. Overload power dissipation is defined as the device power dissipation with the load set such that VOUT = 90% of nominal. Turn-on delay time from either a step application of input power or a logic low to a logic high transition on the inhibit pin (pin 4) to the point where VOUT = 90% of nominal. Transient recovery time is from the change in load condition until the output is within 3% of the nominal output voltage. Recovery time is measured from initiation of the transient to where VOUT has returned to within 1% of VOUT at 50% load. Load transient time 10s.
8. 9. 10. 11. 12.
Fig I. Circuit for Measuring Output Ripple Voltage
50 50 Coax 1 F Oscilliscope or Equivalent with 10 MHz Bandwidth. Multiply readings by 2. 50 Termination
0.1 F
+ Vout
DUT
Return
RL for IRATED
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HTA-SERIES
Fig II. Block Diagram - Single Output
D C INP UT 1 IM P UT FILTE R
OU TP UT FILTE R
7
+ OU TPU T
E NA B LE
4
PR IM A R Y BI AS S UP P LY
CU R RE N T S E NS E
8
OU TPU T R ETU RN
CA S E
3
DRIVE R
INP U T RE TU RN
2
11
E R ROR AMP & RE F
TRIM
12 10 9
N/ C +S E N SE -S EN S E
SE N SE A M P LIFIE R SY N C. IN PU T S Y N C. O UTP U T 6
C ON TRO L V FB
5
Fig III. Block Diagram - Dual Output
DC INP UT
1
IM P UT F ILT ER
O U TP UT F ILT ER
7
+O UT PU T
EN AB LE
4
P RIM A RY B IAS SU PP LY
C URR EN T S E NS E
8
O UT P UT RE T URN
CA SE
3
D R IV ER
O U TP UT F ILT ER
9
-O UT P UT
INP U T R ET UR N
2
10
E RRO R A MP & RE F
T RIM
11 12
N/C N/C
S YN C. IN PU T S YN C. O UT P UT
6
CO N TR O L VFB
5
6
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HTA-SERIES Technical Notes:
Remote Sensing
This feature is available only for single output models. Connection of the + Sense and - Sense leads at a remotely located load permits compensation for resistive voltage drop between the converter output and the load when they are physically separated by a significant distance. This connection allows regulation to the placard voltage at the point of application. When the remote sensing features is not used, the sense leads should be connected to their respective output terminals at the converter. A combination of the compensation voltage drop and output voltage adjustment (described below in the `Output Voltage Adjustment' section) is limited to 10% of the nominal output voltage.
Output Voltage Adjust - Single Output Models
In addition to permitting close voltage regulation of remotely located loads, it is possible to utilize the converter sense pins to incrementally increase the output voltage. The increased output voltage is limited to 10% maximum. The adjustments made possible by this method are intended as a means to "trim" the output to a voltage setting for certain design application, but are not intended to create an adjustable output converter. These output voltage setting variations are obtained by connecting a resistor with an appropriate value between the +Sense and -Sense pins while connecting the -Sense pin to the Output Return pin as shown in Fig IV below. The resistance value for a desired output voltage can be determined by use of the equation presented below.
Inhibiting Converter Output
As an alternative to application and removal of the DC voltage to the input, the user can control the converter output by providing TTL compatible, positive logic signal to Enable pin (pin 4) and to Input Return (pin 2). Enable signal is internally pulled "high" so that when not used, an open connection on the Enable pin permits normal converter operation. When its use is desired, a logical "low" on this port will shut the converter down.
VNOM Radj = 100 * VOUT - VNOM -.025
Where VNOM = device nominal output voltage, and VOUT = desired output voltage
Finding a resistor value for a particular output voltage, is simply a matter of substituting the desired output voltage and the nominal device voltage into the equation and solving for the corresponding resistor value. Under no circumstance should RADJ be less than 500.
Synchronization of Multiple Converters
When operating multiple converters, system requirements often may require operation of the converters at a common frequency. To accommodate this requirement, the HTA series of converters provide both a synchronization input and output. The Sync Input port permits synchronization of a HTA connverter to any compatible external frequency source operating between 500KHz and 650KHz. This input signal should be referenced to the Input Return and have a 10% to 90% duty cycle. Compatibility requires transition times less than100ns, maximum low level of +0.8V and a minimum high level of +2.0V. The Sync Output of another converter which has been designated as the master oscillator provides a convenient frequency source for this mode of operation. When external synchronization is not required, the Sync In pin should be left unconnected thereby permitting the converter to operate at its own internally set frequency. The sync output signal is a continuous pulse train set at 550 50KHz, with a duty cycle of 15 5.0%. This signal is referenced to the Input Return and has been tailored to be compatible with the HTA Sync Input port. Transition times are less than 100ns and the low level output impedance is less than 50. This signal is active when the DC input voltage is within the specified operating range and the converter is not inhibited. This output has adequate drive reserve to synchronize at least five additional converters.
Fig IV. Connection for VOUT Adjustment
N/C Trim
HTA200XXS
+ Sense - Sense
RADJ
Output Return + Output
To Load
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HTA-SERIES
Examination of the equation relating output voltage and resistor value reveals a special benefit of the circuit topology utilized for remote sensing of output voltage in the HTA200XXS series of converters. It is apparent that as the resistance increases, the output voltage approaches the nominal set value of the device. In fact the calculated limiting value of output voltage as the adjusting resistor becomes very large, is 25mV above nominal device voltage. The consequence is that if the +sense connection is unintentionally broken, an HTA200XXS has a fail-safe output voltage of Vout + 25mV, where the 25mV is independent of the nominal output voltage. It can be further demonstrated that in the event of both the +Sense and -Sense connections being broken, the output will be limited to Vout + 440mV. This 440mV is also essentially constant independent of the nominal output voltage. While operation in this condition is not damaging to the device, not all performance parameters will be met. Note that the nominal magnitude of output voltage resides in the middle of the table and the corresponding resistor value is set to . To set the magnitude greater than nominal, the adjust resistor is connected to output return. To set the magnitude less than nominal, the adjust resistor is connected to the +Output. (Refer to Fig V.)
Fig V. Connection for VOUT Adjustment
N/C Trim
RADJ
+
HTA200XXD
N/C - Output
Output Return + Output
To Loads
Output Voltage Adjust - Dual Output Models
By use of the Trim pin (10), the magnitude of output voltages can be adjusted over a limited range in either a positive or negative direction. Connecting a resistor between the trim pin and either the output return or the positive output will raise or lower the magnitude of output voltages. The span of output voltage adjustment is restricted to the limits shown in Table I.
Connect R
ADJ
to + to increase, - to decrease
For output voltage settings that are within the limits, but between those listed in Table I, it is suggested that the resistor values be determined empirically by selection or by use of a variable resistor. The determined value can then be replaced with a good quality fixed resistor for permanent installation. When use of this adjust feature is elected, the user should be aware that the temperature performance of the converter output voltage will be affected by the temperature performance of the resistor selected as the adjustment element and therefore, is advised to employ resistors with a very small temperature coefficient of resistance.
Table 1. Output Voltage Trim Values and Limits
HTA20005D VOUT 5.5 5.4 5.3 5.2 5.1 5.0 4.9 4.8 4.7 4.6 4.583 RADJ 0 12.5K 33.3K 75K 200K 190K 65K 23K 2.5K 0
HTA20012D VOUT 12.5 12.4 12.3 12.2 12.1 12.0 11.7 11.3 10.8 10.6 10.417 RADJ 0 47.5K 127K 285K 760K 975K 288K 72.9K 29.9K 0
HTA20015D VOUT 15.5 15.4 15.3 15.2 15.1 15.0 14.6 14.0 13.5 13.0 12.917 RADJ 0 62.5K 167K 375K 1.0M 1.2M 325K 117K 12.5K 0
8
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HTA-SERIES Application Notes:
DC-DC converters constructed with aluminium-silicon (ALSi) controlled expansion alloy benefit from low mass, high thermal conductivity, and CTE match to substrates mounted in them. The one disadvantage over traditional cold rolled steel packages (CRS) however is that the ALSi material is more brittle than the CRS. For this reason, it is important to avoid using a thermal pad or gasket. The HTA-Series DC-DC converter requires 8-32 size screws and #8 flat washers. The minimum recommended mouting surface flatness is 0.002" per inch. The Procedure for mounting the converter is as follows: 1. Check all surfaces for foreign material, burrs, or anything that may interfere with the different parts.
2. Place the converter on the mounting surface and line it up with mounting holes. 3. Install screws using appropriate washers and tighten by hand (~ 4 in.oz) in the sequence shown below in the diagram. . 4. Tighten the screws with appropriate torque driver using a controlled torque of up to 20-24 in.lb in the sequence as shown in the diagram.
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HTA-SERIES
Efficiency Curves for HTA20003R3S
Fig VI. 25C Efficiency vs. Output Loading
90 80 70 60 Efficiency % 50 40 30 20 10 0 0 1 2 3 4 5 6 7 Output Load (A) 150 Vin 200 Vin 250 Vin
Fig VII. 185C Efficiency vs. Output Loading
90 80 70 60 Efficicency % 50 40 30 20 10 0 0 1 2 3 4 5 6 7 Output Load (A) 150 Vin 200 Vin 250 Vin
10
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Efficiency Curve for HTA20003R3S
Fig VIII. Efficiency vs. Temperature
75 74 73 72 Efficiency % 71 150 Vin 70 69 68 67 66 65 0 20 40 60 80 100 120 140 160 180 200 Temperature C 200 Vin 250 Vin
Efficiency Curve for HTA20005S
Fig IX. 25C Efficiency vs. Output Loading
90% 80% 70% 60% Efficiency 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 Output Load (A) 150 Vin 200 Vin 250 Vin
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HTA-SERIES
Efficiency Curves for HTA20005S
Fig X. 185C Efficiency vs. Output Loading
90% 80% 70% 60% Efficiency 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 Output Load (A)
150 Vin 200 Vin 250 Vin
Fig XI. Efficiency vs. Temperature
85% 83% 81% 79% 77% 75% 73% 71% 69% 67% 65% 0 50 100
Tem perature C
Efficiency
150 Vin 200 Vin 250 Vin
150
200
12
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HTA-SERIES
Mechanical Diagram
0.245 O0.266
1 2 3 4 5 6 12 11 10 9 8 7
0.250
0.200 Typ. Non-cum.
1.500
1.100
1.000 Ref.
0.200 2.500 3.600 4.000 MAX.
Pin O 0.040
0.238 MAX. 0.430 Max. 0.075
NOTES: UNLESS OTHERWISE SPECIFIED, DIMENSIONAL TOLERANCE IS: 0.005"
Pin Designation (Single/Dual)
Pin # 1 2 3 4 5 6 7 8 9 10 11 12 Single DC Input Input Return Case Enable Sync. Output Sync. Input + Output Output Return - Sense + Sense Trim * N/C Dual DC Input Input Return Case Enable Sync. Output Sync. Input + Output Output Return - Output N/C Trim N/C
* Trim pin for Single Output models is reserved for future use. This pin must not be used or connected for any purpose.
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HTA-SERIES
Device Screening
Requirement MIL-STD-883 Method
2017 1014 1010 In accordance with device specification 2001 In accordance with device specification 1015 In accordance with device specification 1014 1014 2009
Condition
No Suffix
Qualilty)
/EM suffix
Evaluation) X X X (For info only) X Not required Not required Not required Not required 8 hours @ 185C X Not required X X
(Production (For Engineering -35C, +185C, 10 cycles 3000G for 1 minute 48 hrs @ 185C A2 C1 X X X X X X X X X X X X X
Internal Visual Seal (Laser Weld) Fine Leak Test (Unpressurized) Gross Leak Test (Unpressurized) Temperature Cycling Electrical Constant Acceleration Electrical Burn-in Final Electrical (Group A) Fine Leak Test Gross Leak Test External Visual
Part Numbering
HTA 200 05 S / EM Model Input Voltage
200 = 200V
EM = Engineering Model (evalulation purposes) Blank = No Suffix (production quality)
(Please refer to Device Screening Table for specific screening requirements)
Output Voltage
03R3 = 3.3V, 05 = 5V 12 = 12V, 15 = 15V
Output
S = Single D = Dual
WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 252-7105 IR SANTA CLARA: 2270 Martin Av., Santa Clara, California 95050, Tel: (408) 727-0500 Visit us at www.irf.com for sales contact information. Data and specifications subject to change without notice. 03/2009
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