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rev. page date rev. page date description: point of load converter 1of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 w fax 503.612.2383 part number: vpol5a-5-smt 1. introduction 2. vpol5a-5-smtconverter features 3. general description 3.1 electrical description 3.2 thermal packaging and physical design. 4. technical specifications 5. main features and functions 5.1 operating temperature range 5.2 over-temperature protection (otp) 5.3 output voltage adjustment 5.4 safe operating area (soa) 5.5 over current protection 5.6 remote on/off 5.7 uvlo (under-voltage lockout) 6. safety 6.1 input fusing and safety considerations. 7. applications 7.1 layout design challenges. 7.2 convection requirements for cooling 7.3 thermal considerations 7.4 power de-rating curves 7.5 efficiency vs load curves 7.6 input capacitance at the power module 7.7 test set-up 7.8 vpol5a-5-smt series output voltage adustment. 7.9 output ripple and noise measurement 7.10 output capacitance 7.11 smt reflow profile 8. mechanical outline diagrams 8.1 sip/smt05 mechanical outline diagrams 8.2 smt tape and reel dimensions features * high efficiency topology, typically 94% at 3.3 vdc * industry standard footprint * wide ambient temperature range, -40c to +85c * cost efficient open frame design * programmable output voltage via external resistor from 0.75 to 3.63 vdc * no minimum load requirement (stable at all loads) * remote on/off * remote sense compensation * fixed switching frequency * continuous short-circuit protection and over current protection * over-temperature protection (otp) * monotonic startup with pre-bias at the output. * ul/iec/en60950-1 (e222736) certified. www.cui.com
rev. page date description: point of load converter 2of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 1. introduction this application note describes the features and functions of vpol5a-5-smt series of non isolated dc-dc converters. these are highly efficient, reliable and compact, high power density, single output dc-dc converters. these point of load modules serve the needs specifically of the fixed and mobile telecommunications and computing market, employing economical distributed power architectures. the vpol5a-5-smt series provide precisely regulated output voltage range from 0.75v to 3.63 vdc over a wide range of input voltage (vi=3.0 C 5.5 vdc) and can operate over an ambient temperature range of C40 to +85 . ultra-high efficiency operation is achieved through the use of synchronous rectification and drive control techniques. the modules are fully protected against short circuit and over- temperature condit ions. world class automated manufacturing methods, together with an extensive testing and qualification program, ensure that all vpol5a-5-smt series converters are extremely reliable. 2. vpol5a-5-smtconverter features high efficiency topology, typically 94% at 3.3 vdc industry standard footprint wide ambient temperature range, -40 c to +85 c cost efficient open frame design programmable output voltage via external resistor from 0.75 to 3.63 vdc no minimum load requirement (stable at all loads) remote on/off remote sense compensation fixed switching frequency continuous short-circuit protection and over current protection over-temperature protection (otp) monotonic startup with pre-bias at the output. ul/iec/en60950 cert ified. 3. general description 3.1 electrical description a block diagram of the vpol5a-5-smt series converter is shown in figure 1. extremely high efficiency power conversion is achieved through the use of synchronous rectification and drive techniques. essentially, the powerful vpol5a-5-smt series topology is based on a non-isolated synchronous buck converter. the control loop is optimized for unconditional stability, fast transient response and a very tight line and load regulation. in a typical pre-bias application the vpol5a-5- smt series converters do not draw any reverse current at start-up. the output voltage can be adjusted from 0.75 to 3.63vdc, using the trim pin with a external resistor. the converter can be shut down via a remote on/off input tha t is referenced to ground. this input is compatible with popular logic devices; a 'positive' logic input is supplied as standard. positive logic implies that the converter is enabled if the remote on/off input is high (or float ing), and disabled if it is low. the converter is also protected against over-temperature conditions. if the converter is overloaded or the ambient temperature gets too high, the converter will shut down to protect the unit. c1 c2 q2 q1 d1 l1 +vin com com +vo pwm ic r1 r2 r trim err amp on/off trim figure 1. electrical block diagram 3.2 thermal packaging and physical design. the vpol5a-5-smt series uses a multi-layer fr4 pcb construction. all surface mount power components are placed on one side of the pcb, and all low-power control components are placed on the other side. thus, the heat dissipation of the power components is optimized, ensuring that control components are not thermally stressed. the converter is an open-frame product and has no case or case pin. the open-frame design has several advantages over encapsulated closed devices. among these advantages are: efficient thermal management: the heat is removed from the heat generating components without heating more sensitive, small signal control components. environmental: lead free open-frame converters are more easily re-cycled. cost efficient: no encapsulation . cost efficient open-frame construction. reliable: efficient cooling provided by open frame construction offers high reliability and easy diagnostics. cui incs cui incs
rev. page date description: point of load con v erter 3 of 11 09/2010 20050 sw 112 th a ve. t ualatin , oregon 97062 ph one 503.612.2300 www.cui.com f a x 503.612.2383 part number: vpol5 a -5- smt 4. t echnical specifications (all spe cifications a r e typical at nominal input, full load at 25 unl ess otherwise noted.) p aramete r notes and co nditions device min. t y pical max . units abs olute maximum ra tings input v oltage continuous c d v 8 . 5 0 l l a operating t emp erature see therm al co nsiderations section 5 8 + 0 4 - l l a 5 2 1 + 5 5 - l l a e r u t a r e p m e t e g a r o t s input char acteristic s operating input v oltage v o,set v in-0.5 vdc all 5 5.5 vdc input under-v olt age lockout l l a d l o h s e r h t e g a t l o v n o - n r u t 2.0 l l a d l o h s e r h t e g a t l o v f f o - n r u t 1.9 vdc l l a e g a t l o v s i s e r e t s y h t u o k c o l 0.1 vdc . x a m , o i = o i , c d v 5 . 5 o t 0 = n i v t n e r r u c t u p n i m u m i x a m all 5 a no-load i nput current v o=0.75v v o=1.2v v o=1.5v v o=1.8v v o=2.0v v o=2.5v v o=3.3v all 25 30 30 35 35 35 35 ma l l a t n e r r u c e l d i t u p n i n w o d t u h s t n e r r u c t u p n i r e t r e v n o c f f o 10 ma inrush current (i 2 t) all 0.1 a 2 s input reflected-ripple current p-p thru 1u h inductor , 5hz to 20 mhz all 150 ma output characteristic output v oltage s et point v in=nominal v in , io=io.max, t c=25 all -1.5% v o,set +1.5% v dc l l a r o t s i s e r l a n r e t x e n a y b d e t c e l e s e g n a r t n e m t s u j d a m i r t e g a t l o v t u p t u o 0.75 3.63 vdc n o i t a l u g e r e g a t l o v t u p t u o l l a x a m . o i o t n i m . o i = o i n o i t a l u g e r d a o l -0.5 +0.5 % % 4 . 0 + 4 . 0 - l l a e n i l h g i h o t e n i l w o l = n i v n o i t a l u g e r e n i l t em pera t ure co ef ficient t a=-40 to 85 all -0.03 +0.03 % / output v oltage r i pple and noise 5hz to 20mhz band w i dth l l a m u l a t n a t f u 0 1 d n a c i m a r e c f u 1 , d a o l l l u f k a e p - o t - k a e p 50 mv l l a m u l a t n a t f u 0 1 d n a c i m a r e c f u 1 , d a o l l l u f s m r 20 mv f u 0 0 0 3 l l a r s e w o l d a o l e v i t i c a p a c l a n r e t x e a 5 0 l l a e g n a r t n e r r u c t u p t u o g n i t a r e p o output dc cu rre nt-limit inception output v oltage = 90% nominal ou tput v oltage all 6 9.5 15 a e d o m p u c c i h h t i w s u o u n i t n o c n o i t c e t o r p t i u c r i c t u o h s 3.0 vdc
rev. page date description: point of load converter 4of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt parameter notes and conditions device min. typical max. units dynamic characteristics e s n o p s e r t n e i s n a r t e g a t l o v t u p t u o v m 0 0 2 l l a s u / a 1 . 0 = t d / i d , e g n a h c d a o l p e t s % 0 5 d n a r b r o r r e setting time (within 1% vout nominal) 50% step load change, di/dt=0.1a/us all 200 us efficiency 100% load vo=0.75v vo=1.2v vo=1.5v vo=1.8v vo=2.0v vo=2.5v vo=3.3v all 79 85 87 89 90 92 94 % isolation characteristics c d v 0 l l a n o i t a l o s i - n o n t u p t u o o t t u p n i feature characteristics z h k 0 0 3 l l a y c n e u q e r f g n i h c t i w s on/off control, positive logic remote on/off logic low (module off) logic high (module on) or open circuit standard model 0 vin 0.4 vdc vdc on/off control, negative logic remote on/off logic low (module on) logic high (module off) or open circuit suffix n model 0 2.8 0.4 vin vdc vdc a m 1 l l a v 0 . 0 = f f o / n o v t a f f o / n o i ) c i g o l f f o / n o e t o m e r h t o b r o f ( t n e r r u c f f o / n o a m 1 l l a v 4 1 = f f o / n o v , h g i h c i g o l ) c i g o l f f o / n o e t o m e r h t o b r o f ( t n e r r u c e g a k a e l e m i t e s i r d n a y a l e d n o - n r u t s m 2 l l a t e s , o v % 0 1 o t f f o / n o v l o r t n o c f f o / n o m o r f , e m i t y a l e d n o - n r u t s m 2 l l a t e s , o v % 0 1 o t . n i m , n i v t u p n i m o r f , e m i t y a l e d n o - n r u t s m 5 . 4 l l a t e s , o v % 0 9 o t t e s , o v % 0 1 e m i t e s i r e g a t l o v t u p t u o 0 2 1 l l a n o i t c e t o r p e r u t a r e p m e t r e v o general specifications mtbf io=100%of io.max;ta=25 per mil-hdbk- 217f all 1.5 m hours s m a r g 3 . 2 l l a t h g i e w dimensions ) m m 6 . 5 x 6 1 . 0 1 x 9 . 2 2 ( s e h c n i 2 2 . 0 x 4 . 0 x 9 . 0 s e g a k c a p p i s ) m m 9 0 . 6 x 3 4 . 1 1 x 3 . 0 2 ( s e h c n i 4 2 . 0 x 5 4 . 0 x 8 . 0 s e g a k c a p t m s
rev. page date description: point of load converter 5of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 5. main features and functions 5.1 operating temperature range cui incs vpol5a-5-smt series converters highly efficient converter design has resulted in its ability to operate over a wide ambient temperature environment ( -40 to 85 ). due consideration must be given to the de-rating curves when ascertaining maximum power that can be drawn from the converter. the maximum power drawn is influenced by a number of factors, such as: input voltage range. output load current. air velocity (forced or natural convection). mounting orientation of converter pcb with respect to the airflow. motherboard pcb design, especially ground and power planes. these can be effective heat sinks for the converter. 5.2 over-temperature protection (otp) the vpol5a-5-smt series converters are equipped with non-latching over-temperature protection. a te mperature sensor monitors the temperature of the hot spot (typically, top switch). if the temperature exceeds a threshold of 120 c (typical) the converter will shut down, disabling the ou tput. when the temperature has decreased the converter will automatically restart. the over-temperature condition can be induced by a variety of reasons such as external overload condition or a system fan failure. 5.3 output voltage adjustment section 7.8 describes in detail as to how to trim the output voltage with respect to its set point. the output voltage on all models is trimmable in the range 0.75 C 3.63 vdc. 5.4 safe operating area (soa) figure 2 provides a graphical representation of the safe operating area (soa) of the converter. this representation assumes ambient operating conditions such as airflow are met as per thermal guidelines provided in sections 7.2 and 7.3. vo io io,cl io,max vo,nom safe operating area current (a) voltage (v) figure 2. maximum output current safe operating area 5.5 over current protection all different voltage models have a full continuous short-circuit protection. the unit will auto recover once the short circuit is removed. to provide protection in a fault condition, the unit is equipped with internal over- current protection. the unit operates normally once the fault condition is removed. the power module will supply up to 150% of rated current. in the event of an over current converter will go into a hiccup mode protection. 5.6 remote on/off the remote on/off input feature of the converter allows external circuitry to turn the converter on or off. active-high remote on/off is available as standard. the vpol5a-5-smt series converters are turned on if the remote on/off pin is high, or left open or floating. setting the pin low will turn the converter off. the signal level of the remote on/off input is defined with respect to ground. if not using the remote on/off pin, leave the pin open (module will be on). the part number suffix n is negative remote on/off version. the unit is guaranteed off over the full temperature range if this voltage level exceeds 2.8 vdc. the converters are turned on if the on/off pin input is low or left open. the recommended smtremote on/off drive circuit as shown as figure 3, 4.
rev. page date description: point of load converter 6of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt figure 3. positive remote on/off input drive circuit q1 on/off control +vin remote on/off common common +vo vpol5a-5-smt figure 4. negative remote on/off input drive circuit 5.7 uvlo (under-voltage lockout) the voltage on the vcc pin determines the start of the operation of the converter. when the input vcc rises and exceeds about 2.0v the converter initiates a soft start. the uvlo function in the converter has a hysteresis (about 100mv) built in to provide noise immunity at start-up. 6. safety 6.1 input fusing and safety considerations. agency approvals: the power supply shall be submitted to and receive formal approval from the following test agencies. 1.the power supply shall be approved by a nationally recognized testing laboratory to ul/csa 60950 3 rd edition (north america) and en60950 (international) 2. cb certificate from an internationally recognized test house in accordance with en 60950. the vpol5a-5-smt series converters do not have an internal fuse. however, to achieve maximum safety and system protection, always use an input line fuse. the safety agencies require a time-delay fuse with a maximum rating of 10a. 7. applications 7.1 layout design challenges. in optimizing thermal design the pcb is utilized as a heat sink. also some heat is transferred from the smt module to the main board through connecting pins. the system designer or the end user must ensure that other components and metal in the vicinity of the vpol5a-5-smt series meet the spacing requirements to which the system is approved. low resistance and low inductance pcb layout traces are the norm and should be used where possible. due consideration must also be given to proper low impedance tracks between power module, input and output grounds. the recommended smt footprint as shown as figure 5. pa d size min : 0.120" x 0.095 " max : 0.135" x 0.110 " dimensions are in inches ( millimetes ) recommended pad layout 0.340 0.180 0.160 0.160 0.190 0.350 0.690 0.05 vout trim gnd vin on/off (4.57) (4.06) (4.06) (4.83) 0.06 (1.5) (1.3) (17.53) (8.89) 0.010 (0.25) (8.64) figure 5. recommended smt footprint (top view) q1 vpol5a-5-smt on/off control +vin +vo remote on/off common common
rev. page date description: point of load converter 7of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 0 10 203040 50607080 90100 ambient temperature( c) output current(a) 100lfm 0lfm 200lfm 0.0 1.0 2.0 3.0 4.0 5.0 6.0 o figure 3. typical power de-rating for 5v in 3.3vout typical power derating for 5vin 3.3vout note: 1. specific input & output derating curves available, please contact cui inc for details
rev. page date description: point of load converter 8of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 7.5 efficiency vs load curves vo=3.3v (eff vs io) 70% 75% 80% 85% 90% 95% 100% 00.511.522.533.544.55 current load (a) efficincy (%) 4.5v 5.0v 5.5v vo=2.5v (eff vs io) 70% 75% 80% 85% 90% 95% 100% 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 current load (a) efficincy (%) 3.0v 5.0v 5.5v vo=1.8v (eff vs io) 70% 75% 80% 85% 90% 95% 100% 00.511.522.533.544.55 current load (a) efficincy (%) 3.0v 5.0v 5.5v vo=1.5v (eff vs io) 70% 75% 80% 85% 90% 95% 100% 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 current load (a) efficincy (%) 3.0v 5.0v 5.5v vo=1.2v (eff vs io) 70% 75% 80% 85% 90% 95% 100% 00.511.522.533.544.55 current load (a) efficincy (%) 3.0v 5.0v 5.5v vo=0.75v (eff vs io) 60% 65% 70% 75% 80% 85% 90% 95% 100% 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 current load (a) efficincy (%) 3.0v 5.0v 5.5v vpol5a-5-smt vpol5a-5-smt t m s - 5 - a 5 l o p v t m s - 5 - a 5 l o p v t m s - 5 - a 5 l o p v t m s - 5 - a 5 l o p v
rev. page date description: point of load converter 9of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 7.6 input capacitance at the power module the smtconvert ers must be connected to a low ac source impedance. to a void problems with loop stability source inductance should be low. also, the input capacitors should be placed close to the converter input pins to de-couple distribution inductance. however, the external input capacitors are chosen for suitable ripple handling capability. low esr polymers are a good choice. they have high capacitance, high ripple rating and low esr (typical <100mohm). electrolytic capacitors should be avoided. circuit as shown in figure 10 represents typical measurement methods for ripple current. input reflected-ripple current is measured with a simulated source inductance of 1uh. current is measured at the input of the module. +vin common vpol5a-5-smt 220uf esr<0.1ohm 2*100uf tantalum l1 1uh + power supply to oscilloscope figure 10. input reflected-ripple test setup 7.7 test set-up the basic test set-up to measure parameters such as efficiency and load regulation is shown in figure 11. things to not e are that this converter is non-isolated, as such the input and output share a common ground. these grounds should be connected together via low impedance ground plane in the application circuit. when testing a converter on a bench set-up, ensure that -v in and -v o are connected together via a low impedance short to ensure proper efficiency and load regulation measurements are being made. when testing the cui incs vpol5a-5-smt series under any transient conditions please ensure that the transient response of the source is sufficient to power the equipment under test. we can calculate the efficiency load regulation and line regulation. the value of efficiency is defined as: % 100 iin vin io vo where: vo is output voltage, io is output current, vin is input voltage, iin is input current. the value of load regulation is defined as: % 100 . nl nl fl v v v reg load v nl is the output voltage at no load the value of line regulation is defined as: % 100 . = ll ll hl v v v reg line where: v hl is the output voltage of maximum input voltage at full load. v ll is the output voltage of minimum input voltage at full load. +vin common vpol5a-5-smt 100uf + power supply a v current meter voltage meter +vo common +sense load v a figure 11. vpol5a-5-smt test setup ? = x x x = _ = _ x
rev. page date description: point of load converter 10 of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 7.8 vpol5a-5-smt series output voltage adustment. the output voltage of the vpol5a-5-smts33a can be adjusted in the range 0.75v to 3.63v by connecting a single resistor on the motherboard (shown as rtrim) in figure 12. when trim resistor is not connected the output voltage defaults to 0.75v +vin common common +vo vpol5a-5-smt r trim-up r-load trim figure 12. trim-up voltage setup the value of rtrim-up defined as: where: rtrim-up is the external resistor in ohm, vo is the desired output voltage to give an exa mple of the above calculation, to set a voltage of 3.3 vdc, rtrim is given by: rtrim = 3153 ohm for various output values various resistors are calculated and provided in table 3 for co nvenience. vo,set (v) rtrim (kohm) 0.75 open 1.20 41.71 1.50 22.98 1.80 14.96 2.00 11.75 2.50 6.93 3.30 3.15 3.63 2.20 table 3 C trim resistor values 7.9 output ripple and noise measurement the test set-up for noise and ripple measurements is shown in figure 13. a coaxial cable with a 50ohm termination was used to prevent impedance mismatch reflections disturbing the noise readings at higher frequencies figure 13. output voltage ripple and noise measurement set-up 7.10 output capacitance cui incs vpol5a-5-smt series converters provide unconditional stability with or without external capacitors. for good transient response low esr output capacitors should be located close to the point of load. for high current applications point has already been made in layout considerations for low resistance and low inductance tracks. output capacitors with its associated esr values have an impact on loop stability and bandwidth. s converters are designed to work with load capacitance up-to 3,000uf. it is reco mmended that any additional capacitance, maximum 3,000uf and low esr, be connected close to the point of load and outside the remote compensation point. 7.11 smt reflow profile an example of the smt reflow profile is given in figure 14. equipment used: smd hot air reflow hd-350sar alloy : amq-m293ta or n c-smq92 ind-82088 sn63 refl ow profil e 0 40 80 120 160 200 240 0 30 60 90 120 150 180 210 240 time (seconds) temperature (c ) figure 14 smt reflow profile ) 5110 75 . 0 21070 ( vo rtrim ) 5110 75 . 0 21070 ( vo rtrim +vin common common +vo vpol5a-5-smt r-load 10uf tant. 1uf ceramic test jack = _ _ = _ _ cui inc
rev. page date description: point of load converter 11 of 11 09/2010 20050 sw 112 th ave. tualatin, oregon 97062 phone 503.612.2300 www.cui.com fax 503.612.2383 part number: vpol5a-5-smt 8. mechanical outline diagrams 8.1 vpol5a-5-smt mechanical outline diagrams dimensions are in millimeters and inches tolerance: x.xx 0.02 in. (0.5mm) , x.xxx 0.010 in. (0.25 mm) unless otherwise noted dimensions are in inches (millimeters) toleranc es :x.xx 0.02in.( x.x 0.5mm) , unless otherwise noted bottom view of board 0.80 0.340 0.450 0.05 0.180 0.35 0.062 0.090 0.160 0.160 0.190 0.062 0.24 x.xxx 0.010in. ( x.xx 0.25mm) surface mount contact 5 places 3 2 1 gnd trim vout on/off 5 4 vin (4.83) (4.06) (4.06) (4.06) (20.3) (2.29) (1.57) (8.9) (8.64) (11.43) (1.5) (1.3) 0.06 (1.57) (6.09) figure 15 vpol5a-5-smt mechanical outline diagram 8.2 smt tape and reel dimensions the ta pe reel dimensions for the smt module is shown in figure 16. e po t p2 d d1 on/off vin trim common +vo 5 4 2 3 function pin 1 p f ko ao bo w figure 16 C smt tape a nd reel dimensions

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