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MP1591
2A, 32V, 330KHz Step-Down Converter
The Future of Analog IC Technology
DESCRIPTION
The MP1591 is a high voltage step-down converter ideal for automotive power adapter battery chargers. Its wide 6.5V to 32V input voltage range covers the automotive battery's requirements and it achieves 2A continuous output for quick charge capability. Current mode operation provides fast transient response and eases loop stabilization. Fault protection includes cycle-by-cycle current limiting and thermal shutdown. In shutdown mode, the converter draws only 20A of supply current. The MP1591 requires a minimum number of readily available external components to complete a 2A step-down DC to DC converter solution.
FEATURES
* * * * * * * * * * * * * * * * * * Wide 6.5V to 32V Input Operating Range 34V Absolute Maximum Input 2A Output Current 120m Internal Power MOSFET Switch Stable with Low ESR Output Ceramic Capacitors Up to 95% Efficiency 20A Shutdown Mode Fixed 330KHz Frequency Thermal Shutdown Cycle-by-Cycle Over Current Protection Output Adjustable From 1.23V to 21V Under Voltage Lockout Reference Voltage Output Available in 8-Pin SOIC Packages Automotive Power Adapters PDA and Cellular Phone Battery Chargers Distributed Power Systems Automotive Aftermarket Electronics
APPLICATIONS
EVALUATION BOARD REFERENCE
Board Number EV0020 Dimensions 2.1"X x 1.4"Y x 0.5"Z
"MPS" and "The Future of Analog IC Technology" are Registered Trademarks of Monolithic Power Systems, Inc.
TYPICAL APPLICATION
INPUT 6.5V to 32V C2 10nF
Efficiency vs Load Current
100 90 VOUT=5V VOUT=3.3V
2
1
OFF ON OPEN NOT USED
7
EN
EFFICIENCY (%)
IN
BS 3 SW
8
MP1591
REF GND 4 FB COMP 6 5
D1
OUTPUT 2.5V 2A
80 70 60 50 40 30 20 0
C3 OPEN
C4 4.7nF
VIN=12V 0.5 1 1.5 LOAD CURRENT (A) 2
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
PACKAGE REFERENCE
TOP VIEW
BS IN SW GND 1 2 3 4 8 7 6 5 REF EN COMP FB
ABSOLUTE MAXIMUM RATINGS (1)
IN Supply Voltage........................ -0.3V to +34V SW Voltage............................. -1V to VIN + 0.3V BS Voltage ....................VSW - 0.3V to VSW + 6V All Other Pins................................. -0.3V to +6V Junction Temperature...............................150C Lead Temperature ....................................260C Storage Temperature ..............-65C to +150C
Recommended Operating Conditions
(2)
EXPOSED PAD ON BACKSIDE (SOIC8N ONLY) CONNECT TO PIN 4
Input Voltage ................................... 6.5V to 32V Operating Temperature .............-40C to +85C
Thermal Resistance
Temperature -40C to +85C -40C to +85C
(3)
Part Number* MP1591DN MP1591DS *
Package SOIC8E SOIC8
SOIC8 (w/ Exposed Pad) ....... 50 ...... 10... C/W SOIC8..................................... 90 ...... 45... C/W
Notes: 1) Exceeding these ratings may damage the device. 2) The device is not guaranteed to function outside of its operating conditions. 3) Measured on approximately 1" square of 1 oz copper.
JA
JC
For Tape & Reel, add suffix -Z (eg. MP1591DN-Z) For RoHS Compliant Packaging, add suffix -LF (eg. MP1591DN-LF-Z)
ELECTRICAL CHARACTERISTICS
VIN = 12V, TA = +25C, unless otherwise noted.
Parameter Shutdown Supply Current Supply Current Feedback Voltage Error Amplifier Voltage Gain Error Amplifier Transconductance High-Side Switch On Resistance Low-Side Switch On Resistance (4) High-Side Switch Leakage Current Current Limit (5) Current Sense to COMP Transconductance Oscillation Frequency Short Circuit Oscillation Frequency Maximum Duty Cycle (4) Minimum Duty Cycle (4) EN Shutdown Threshold Voltage Enable Pull-Up Current EN UVLO Threshold EN UVLO Threshold Hysteresis
(4)
Symbol Condition VEN = 0V VEN = 5V, VFB = 1.4V 6.5V VIN 32V, VCOMP < 2V IC = 10A
Min
Typ 20 1.0 1.230 400 700 120 8.5 0 3.6 3.5
Max 35 1.2 1.258 1100
Units A mA V V/V A/V m A A A/V
1.202 500
VEN = 0V, VSW = 0V 2.5
10 4.9
280 VFB = 0V VFB = 1.0V VFB = 1.5V 0.8 VEN = 0V VEN Rising 2.4
330 35 90 1.2 1.8 2.6 250
380
0 1.6 2.8
KHz KHz % % V A V mV
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
ELECTRICAL CHARACTERISTICS (continued)
VIN = 12V, TA = +25C, unless otherwise noted.
Parameter Thermal Shutdown
(4)
Symbol Condition IREF = 0 IREF = 0 to 1mA IREF = 100A, VIN = 6.5 to 32V
Min
Typ 160 5.0 100 30
Max
Units C V mV mV
REF Voltage REF Load Regulation (4) REF Line Regulation (4)
Notes: 4) These parameters are guaranteed by design, not production tested. 5) Equivalent output current = 1.5A 50% Duty Cycle 2.0A 50% Duty Cycle Assumes ripple current = 30% of load current. Slope compensation changes current limit.
PIN FUNCTIONS
Pin # 1 2 Name Description BS IN High-Side Gate Drive Boost Input. BS supplies the drive for the high-side N-Channel MOSFET switch. Connect a 10nF or greater capacitor from SW to BS to power the high-side switch. Power Input. IN supplies the power to the IC, as well as the step-down converter switches. Drive IN with a 6.5V to 32V power source. Bypass IN to GND with a suitably large capacitor to eliminate noise on the input to the IC. See Input Capacitor. Power Switching Output. SW is the switching node that supplies power to the output. Connect the output LC filter from SW to the output load. Note that a capacitor is required from SW to BS to power the high-side switch. Ground. For the MP1591DN, connect the Exposed Pad to pin 4. Feedback Input. FB senses the output voltage to regulate that voltage. Drive FB with a resistive voltage divider from the output voltage. The feedback threshold is 1.230V. See Setting the Output Voltage.
3
SW
4 5
GND FB
6
COMP Compensation Node. COMP is used to compensate the regulation control loop. Connect a series RC network from COMP to GND to compensate the regulation control loop. In some cases, an additional capacitor from COMP to GND is required. See Compensation. EN REF Enable/UVLO. A voltage greater than 2.8V enables operation. For complete low current shutdown the EN pin voltage needs to be less than 800mV. Reference Output. REF is the 5V reference voltage output. It can supply up to 1mA to external circuitry. If used, bypass REF to GND with 10nF or greater capacitor. Leave REF unconnected if not used.
7 8
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
OPERATION
The MP1591 is a current mode step-down regulator. It regulates input voltages from 6.5V to 32V down to an output voltage as low as 1.230V and is able to supply up to 2A of load current. The MP1591 uses current-mode control to regulate the output voltage. The output voltage is measured at FB through a resistive voltage divider and amplified through the internal error amplifier. The output current of the transconductance error amplifier is presented at COMP where a network compensates the regulation control system. The voltage at COMP is compared to the switch current measured internally to control the output voltage. The converter uses an internal N-Channel MOSFET switch to step-down the input voltage to the regulated output voltage. Since the MOSFET requires a gate voltage greater than the input voltage, a boost capacitor connected between SW and BS drives the gate. The capacitor is internally charged while SW is low. An internal 10 switch from SW to GND is used to insure that SW is pulled to GND when the switch is off to fully charge the BS capacitor
IN 2 REF 8 5V INTERNAL REGULATORS OSCILLATOR SLOPE COMP CLK CURRENT SENSE AMPLIFIER + -M1
35/330KHz +
1 Q Q
BS
+
S R
1.2V EN 7
--
SHUTDOWN COMPARATOR LOCKOUT COMPARATOR
--
CURRENT COMPARATOR
3 M2
SW
-2.60V/ 2.35V
1.8V + THERMAL PROTECTION ERROR AMPLIFIER 4 GND
+
--
FREQUENCY FOLDBACK COMPARATOR
--
0.7V 1.230V
+
5 FB
6 COMP
Figure 1--Functional Block Diagram
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
APPLICATION INFORMATION
COMPONENT SELECTION
Setting the Output Voltage The output voltage is set using a resistive voltage divider from the output voltage to FB. The voltage divider divides the output voltage down by the ratio:
VFB = VOUT x R2 (R1 + R2)
The inductance value can be calculated by the equation:
L1 = VOUT x ( VIN - VOUT ) ( VIN x f x I)
Where VIN is the input voltage, f is the switching frequency and I is the peak-to-peak inductor ripple current. Table 1 lists a number of suitable inductors from various manufacturers.
Table 1--Inductor Selection Guide Package Dimensions (mm) Vendor/ Core Core Model Type Material W L H Sumida CR75 CDH74 Open Open Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite 7.0 7.3 5.5 5.5 6.7 7.8 8.0 5.7 5.7 6.7 5.5 5.2 5.5 5.5 3.0
Where VFB is the feedback voltage and VOUT is the output voltage. Thus the output voltage is:
VOUT = 1.230 x (R1 + R2) R2
A typical value for R2 can be as high as 100k, but 10k is recommended. Using that value, R1 is determined by:
R1 8.18 x ( VOUT - 1.230 )
CDRH5D28 Shielded CDRH5D28 Shielded CDRH6D28 Shielded CDRH104R Shielded Toko D53LC Type A D75C D104C D10FL Coilcraft DO3308 DO3316 Open Open Shielded Shielded Shielded Open
For example, for a 3.3V output voltage, R2 is 10k, and R1 is 17k. Inductor (L1) The inductor is required to supply constant current to the output load while being driven by the switched input voltage. A larger value inductor results in less ripple current that results in lower output ripple voltage. However, the larger value inductor has a larger physical size, higher series resistance, and/or lower saturation current. Choose an inductor that does not saturate under the worst-case load conditions. A good rule to use for determining the inductance is to allow the peak-to-peak ripple current in the inductor to be approximately 30% of the maximum load current that the IC can provide. Also, make sure that the peak inductor current (the load current plus half the peak-to-peak inductor ripple current) is below the 2.3A minimum current limit.
10.1 10.0 3.0 5.0 7.6 9.7 9.4 9.4 5.0 7.6 1.5 3.0 5.1 4.0
10.0 10.0 4.3
13.0 3.0 13.0 5.1
Input Capacitor (C1) The input current to the step-down converter is discontinuous, and so a capacitor is required to supply the AC current to the step-down converter while maintaining the DC input voltage. A low ESR capacitor is required to keep the noise at the IC to a minimum. Ceramic capacitors are preferred, but tantalum or low ESR electrolytic capacitors may also suffice.
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER The input capacitor value should be greater than 10F. The capacitor can be electrolytic, tantalum or ceramic. However, since it absorbs the input switching current it requires an adequate ripple current rating. Its RMS current rating should be greater than approximately 1/2 of the DC load current. For insuring stable operation C1 should be placed as close to the IC as possible. Alternately, a smaller high quality ceramic 0.1F capacitor may be placed closer to the IC and a larger capacitor placed farther away. If using this technique, it is recommended that the larger capacitor be a tantalum or electrolytic type. All ceramic capacitors should be placed close to the MP1591. Output Capacitor (C5) The output capacitor is required to maintain the DC output voltage. Low ESR capacitors are preferred to keep the output voltage ripple low. The characteristics of the output capacitor also affect the stability of the regulation control system. Ceramic, tantalum or low ESR electrolytic capacitors are recommended. In the case of ceramic capacitors, the impedance at the switching frequency is dominated by the capacitance, and so the output voltage ripple is mostly independent of the ESR. The output voltage ripple is estimated to be:
VRIPPLE f 1.4 x VIN x LC f SW
2
Output Rectifier Diode (D1) The output rectifier diode supplies the current to the inductor when the high-side switch is off. To reduce losses due to the diode forward voltage and recovery times, use a Schottky rectifier. Table 2 provides some recommended Schottky rectifiers based on the maximum input voltage and current rating.
Table 2--Diode Selection Guide
VIN (Max) 15V 20V 2A Load Current Part Vendor Number 30BQ15 4 B220 1 SK23 6 SR22 6 20BQ030 4 B230 1 SK23 6 SR23 3, 6 SS23 2, 3 21DQ04 4 MBRS240L 5 SK24 6 SS24 2, 3 3A Load Current Part Vendor Number B320 SK33 SS32 B330 B340L MBRD330 SK33 SS33 B340L MBRS340 SK34 SS34 1 1, 6 3 1 1 4, 5 1, 6 2, 3 1 4 1, 6 2, 3
30V
34V
Table 3 lists manufacturer's websites.
Table 3--Schottky Diode Manufacturers
# 1 2 3 4 5 6 Vendor Diodes, Inc. Fairchild Semiconductor General Semiconductor International Rectifier On Semiconductor Pan Jit International Web Site www.diodes.com www.fairchildsemi.com www.gensemi.com www.irf.com www.onsemi.com www.panjit.com.tw
Where VRIPPLE is the output ripple voltage, fLC is the resonant frequency of the LC filter, fSW is the switching frequency. In the case of tantalum or low-ESR electrolytic capacitors, the ESR dominates the impedance at the switching frequency, and so the output ripple is calculated as:
VRIPPLE I x R ESR
Choose a rectifier whose maximum reverse voltage rating is greater than the maximum input voltage, and whose current rating is greater than the maximum load current.
Where VRIPPLE is the output voltage ripple and RESR is the equivalent series resistance of the output capacitors.
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER Compensation The system stability is controlled through the COMP pin. COMP is the output of the internal transconductance error amplifier. A series capacitor-resistor combination sets a pole-zero combination to control the characteristics of the control system. The DC loop gain is:
A VDC = VREF x A VEA x G CS x R LOAD VOUT
The system crossover frequency fC, (the frequency where the loop gain drops to 1, or 0dB) is important. A good rule of thumb is to set the crossover frequency to approximately one tenth of the switching frequency. In this case, the switching frequency is 330KHz, so use a crossover frequency of 33KHz. Lower crossover frequencies result in slower response and worse transient load recovery. Higher crossover frequencies can result in instability. Choosing the Compensation Components The values of the compensation components given in Table 4 yield a stable control loop for the output voltage and given capacitor. Table 4--Compensation Values for Typical Output Voltage/Capacitor Combinations
VOUT 2.5V 3.3V 5V 12V 2.5V 3.3V 5V 12V 2.5V 3.3V 5V 12V C5 22F Ceramic 22F Ceramic 22F Ceramic 22F Ceramic 47F SP-Cap 47F SP-Cap 47F SP-Cap 47F SP-Cap 560F/6.3V, AL 30m ESR 560F/6.3V, AL 30m ESR 470F/10V, AL 30m ESR 220F/25V, AL 30m ESR R3 3.9k 5.1k 7.5k 18k 8.2k 10k 16k 36k 100k 120k 150k 180k C3 None None None None None None None None 150pF 120pF 82pF 33pF C4 4.7nF 3.9nF 2.7nF 1.2nF 2.2nF 2.2nF 1.5nF 1nF 1nF 1nF 1nF 1nF
Where VREF is the feedback threshold voltage, 1.230V, AVEA is the transconductance error amplifier voltage gain, 400 V/V, and GCS is the current sense gain (roughly the output current divided by the voltage at COMP), 3.5 A/V. The system has 2 poles of importance; one is due to the compensation capacitor (C4) and the other is due to the output capacitor (C5). These are:
fP1 G MEA = (2 x A VEA x C4)
Where fP1 is the first pole, and GMEA is the error amplifier transconductance (770S) and
fP2 = 1 (2 x R LOAD x C5)
The system has one zero of importance due to the compensation capacitor (C4) and the compensation resistor (R3) which is
f Z1 1 = (2 x R3 x C4)
If large value capacitors with relatively high equivalent-series-resistance (ESR) are used, the zero due to the capacitance and ESR of the output capacitor can be compensated by a third pole set by R3 and C3
f P3 = 1 (2 x R3 x C3)
Note: "AL" = Electrolytic
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER To optimize the compensation components that are not listed in Table 4, use the following procedure. Choose the compensation resistor to set the desired crossover frequency. Determine the value by the following equation:
R3 = 2 x C5 x VOUT x f C G EA x G CS x VREF
Example: VOUT = 5V, C5 = 22F Ceramic (ESR = 10m) R3 6.88x107 (22x10-6) (5) = 7568 Use the nearest standard value of 7.5k. C4 > 1.93x10-5 / 7.5K = 2.57nF Use standard value of 2.7nF. 8 x C5 x RESR x fC = 0.22, which is less than 1. Therefore, no second compensation capacitor (C3) is required. External Bootstrap Diode It is recommended that an external bootstrap diode be added when the system has a 5V fixed input or the power supply generates a 5V output. This helps improve the efficiency of the regulator. The bootstrap diode can be a low cost one such as IN4148 or BAT54.
5V
Putting in the know constants and setting the crossover frequency to the desired 33KHz:
R3 6.88 x 10 7 x C5 x VOUT
Choose the compensation capacitor to set the zero below one fourth of the crossover frequency. Determine the value by the following equation:
C4 > 2 1.93 x 10 -5 R3 x R3 x f C
Determine if the second compensation capacitor, C3, is required. It is required if the ESR zero of the output capacitor occurs at less than four times the crossover frequency, or
8 x C5 x R ESR x f C 1
BS
1
MP1591
SW 3
10nF
If this is the case, then add the second compensation resistor. Determine the value by the equation:
C3 = C5 x R ESR(MAX ) R3
Figure 2--External Bootstrap Diode This diode is also recommended for high duty cycle operation (when
VOUT >65%) and high VIN
output voltage (VOUT>12V) applications.
Where RESR(MAX) is the maximum ESR of the output capacitor.
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
TYPICAL APPLICATION CIRCUITS
INPUT 6.5V to 32V C2 10nF
2
1 IN BS 3 SW
OFF ON OPEN NOT USED
7
EN
8
MP1591
REF GND 4 FB COMP 6 5
D1
OUTPUT 2.5V 2A
C3 OPEN
C4 4.7nF
Figure 3--MP1591 with Murata 22F / 10V Ceramic Output Capacitor
INPUT 6.5V to 32V C2 10nF
2
1 IN BS 3 SW
OFF ON OPEN NOT USED
7
EN
8
MP1591
REF GND 4 FB COMP 6 5
D1
OUTPUT 2.5V 2A
C3 OPEN
C4 2.2nF
Figure 4--MP1591 with Panasonic 47F / 6.3V Special Polymer Output Capacitor
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
PACKAGE INFORMATION
SOIC8
0.189(4.80) 0.197(5.00) 8 5 0.063(1.60) 0.024(0.61) 0.050(1.27)
PIN 1 ID
0.150(3.80) 0.157(4.00)
0.228(5.80) 0.244(6.20)
0.213(5.40)
1
4
TOP VIEW
RECOMMENDED LAND PATTERN
0.013(0.33) 0.020(0.51)
0.053(1.35) 0.069(1.75) SEATING PLANE 0.004(0.10) 0.010(0.25) 0.050(1.27) BSC
0.0075(0.19) 0.0098(0.25) SEE DETAIL "A"
FRONT VIEW
SIDE VIEW
0.010(0.25) x 45o 0.020(0.50) GAUGE PLANE 0.010(0.25) BSC
NOTE:
1) CONTROL DIMENSION IS IN INCHES. DIMENSION IN BRACKET IS IN MILLIMETERS. 2) PACKAGE LENGTH DOES NOT INCLUDE MOLD FLASH, PROTRUSIONS OR GATE BURRS. 3) PACKAGE WIDTH DOES NOT INCLUDE INTERLEAD FLASH OR PROTRUSIONS. 4) LEAD COPLANARITY (BOTTOM OF LEADS AFTER FORMING) SHALL BE 0.004" INCHES MAX. 5) DRAWING CONFORMS TO JEDEC MS-012, VARIATION AA. 6) DRAWING IS NOT TO SCALE.
0o-8o
0.016(0.41) 0.050(1.27)
DETAIL "A"
MP1591 Rev. 2.3 9/27/2006
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MP1591 - 2A, 32V, 330KHz STEP-DOWN CONVERTER
SOIC8E (WITH EXPOSED PAD)
0.189(4.80) 0.197(5.00) 8 5 0.124(3.15) 0.136(3.45)
PIN 1 ID
0.150(3.80) 0.157(4.00)
0.228(5.80) 0.244(6.20)
0.089(2.26) 0.101(2.56)
1
4
TOP VIEW
BOTTOM VIEW
SEE DETAIL "A" 0.051(1.30) 0.067(1.70) SEATING PLANE 0.000(0.00) 0.006(0.15) 0.050(1.27) BSC
0.0075(0.19) 0.0098(0.25)
0.013(0.33) 0.020(0.51)
SIDE VIEW
FRONT VIEW
GAUGE PLANE 0.010(0.25) BSC
0.010(0.25) x 45o 0.020(0.50)
0.024(0.61)
0.050(1.27) 0o-8o 0.016(0.41) 0.050(1.27)
0.063(1.60)
DETAIL "A"
0.103(2.62)
0.213(5.40)
NOTE:
1) CONTROL DIMENSION IS IN INCHES. DIMENSION IN BRACKET IS IN MILLIMETERS. 2) PACKAGE LENGTH DOES NOT INCLUDE MOLD FLASH, PROTRUSIONS OR GATE BURRS. 3) PACKAGE WIDTH DOES NOT INCLUDE INTERLEAD FLASH OR PROTRUSIONS. 4) LEAD COPLANARITY (BOTTOM OF LEADS AFTER FORMING) SHALL BE 0.004" INCHES MAX. 5) DRAWING CONFORMS TO JEDEC MS-012, VARIATION BA. 6) DRAWING IS NOT TO SCALE.
0.138(3.51)
RECOMMENDED LAND PATTERN
NOTICE: The information in this document is subject to change without notice. Users should warrant and guarantee that third party Intellectual Property rights are not infringed upon when integrating MPS products into any application. MPS will not assume any legal responsibility for any said applications.
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