Using the TPS2492/3EVM Hot Swap Controller
User's Guide
Literature Number: SLUU425A
May 2010 – Revised March 2011
User's Guide
SLUU425A – May 2010 – Revised March 2011
Using the TPS2492/3 Hot Swap Controller
This User’s Guide describes the setup and operation of the TPS2492/3 System Test Board.
1
Introduction
This User’s Guide describes the features of the TPS2492/3EVM. The TPS2492/3 schematic, layout and
List of Materials are provided.
2
Description
The EVM is a 9-V to 80-V module using the TPS2492/3 hot swap controller with external MOSFET. At
power on, the output is power limited to control inrush current and protect the MOSFET. On an
over-current condition, the controller interrupts power to the load at high speed and signals load status.
Operating current, MOSFET power dissipation, and fault timer settings are hardware programmable.
2.1
Applications
•
•
•
2.2
Features
•
•
•
•
•
•
•
•
•
•
•
2
Server
– Plug-In Circuit Boards
– RAID / Disk Drive
Telecom
– ATCA
– Micro-ATCA
General Hot Plug
9-V to 80-V Operation
Controlled Inrush Current
Fast Circuit Breaker Control
Hardware Programmable
– MOSFET Power Limit
– Fault Current
– Fault Timer to Avoid Nuisance Tripping
– TPS2492 Latch Off or TPS2493 Retry
LED Status Display
– FAULT
– POWER GOOD
Slide Switch Controling the ENABLE Signal.
25-A Nominal Operation with Thermal Characteristics for Proper MOSFET Operation
On-Board transorb for Over-Voltage Input Protection
Common Output Diode Prevents Negative Spiking if the Load is Removed While Powered On.
IMON Output Signal Voltage Representing Load Current.
Test Points for Circuit Operation Monitoring
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Description
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2.3
Equipment supplied
•
•
2.4
Equipment Required
•
•
•
2.5
EVM-491
The datasheet and this users guide is available on the TPS2492/3 product page at www.ti.com.
Power Supply is able to output twice the steady state current for pulse duration. For the 12-V factory
set EVM, steady state power is 25-A nominal.
Oscilloscope
Current Probe
EVM Documentation
The manufacturing and engineering documentation for the EVM is shown in sections 3 to 6. The EVM is
orderable in 12-V or 48-V configurations, latched off or retry on fault.
2.6
EVM Configuration
Components may be changed for operation at voltage or current not configured as supplied. The List of
Materials, , shows the parts to change to configure the EVM to 48 V at 5-A operation. Configure the circuit
board for other operating current to 50 A maximum. Changing the sense resistor, the power limit
programming components, and possibly the number of MOSFETs as required.
Use the List of Material as a guide when changing module configurations. The TPS2492/93 datasheet has
design example describing how to select parts based on specifications. A calculator tool is also available
from the product page at www.ti.com.
2.7
Other EVM Options
There are EVM options not described in the other TPS2492/3 documentation. These are described in this
section. They involve the not populated components of the EVM.
2.7.1
Trip Point Trim Resistors
R15 and R16 are added to fine tune the sense current when the required current cannot be achieved with
standard sense resistors. These resistors form a divider across the sense main sense resistor to increase
the trip point from the main sense setting. These are low power rated components. They should be kept
below 100 Ω to minimize the set point error.
For example, to select 30 A nominal,
• Bracket the setpoint. A 0.001-Ω sense resistor selects 50 A and a 0.002 Ω selects 25 A.
• Use the larger value sense resistor. In this case 0.002 Ω.
• At 30 A, the voltage across the 0.002-Ω sense resistor is 60 mV.
• R15 and R16 make a standard voltage divider. Use the formula (60 mV x R16) / (R15 + R16) = 50 mV.
• Let R16 = 33 Ω, solve for R15. In this case, R15 = 6.6 Ω, use standard value R = 6.55 Ω.
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3
EVM Block Diagram TPS2492EVM-491
2.7.2
www.ti.com
dv/dt Control
When the VPROG calculates below the 0.4 V minimum, one option is to use dv/dt control to start the
uncharged output capacitor. In this way, the power limiting is not used on power up. R11 and C4, (see
schematic Figure 2 for component reference), are normally not populated and control the power turn on
with a dv/dt soft start. Recommendation for R11 is at 1 kΩ. C4 can be calculated by knowing the output
capacitor, selecting the charge current and calculating the start time. Calculation is done by the capacitor
V I relationship equation, I = C dv/dt.
• Assume a 12-V system with a 1000-µF output capacitor. Select the charge at 0.5 A. Use the formula to
solve for time. T = CV/I, T = 24 ms.
• Since the output FET is a gate follower, the time calculated applies to the gate rise time. Use the same
formula to solve for Ct but this time the current is the gate sourcing current in the datasheet
specifications section, 22 µA nominal.
• The voltage, again from the datasheet is the output VGS, 14 V.
• Ct = IT / V = 22 µA x 24 ms / 14 = 37.7 nF, use standard value 39 nF.
2.7.3
Disable Power Limit
It’s not usually done, but sometimes because of high voltage with high current the power limit may be
disabled on over load. TPS2492 can be configured to run in current limit only. To disable power limit
remove R3 and install 47 kΩ in R2, (see schematic Figure 2 for component reference). With power limit
disabled, dv/dt start outlined in the previous section would be used for power on.
3
EVM Block Diagram TPS2492EVM-491
VIN
VOUT
MOSFET
STATUS
PROG
TPS 2492
ENABLE
IMON
GND
GND
Figure 1. EVM Block Diagram
4
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Schematic
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4
Schematic
Figure 2. HPA270A Schematic, TPS2420EVM
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5
Test Points
5
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Test Points
Table 1. TPS249xEVM Test Points
TEST POINT
6
NAME
DESCRIPTION
TP1
VIN
Input voltage power supply
TP2
GND
Ground
TP3
EN-UV
TP4
None
TP5
PROG
TP6
CT
Fault timer capacitor
TP7
OV
Over-voltage detection
TP8
IMON
Output current monitor
TP9
GATE
Gate output
TP10
PG
Power good signal, low true
TP11
FLT
Fault signal, low true
TP12
VOUT
Output voltage
TP13
GND
Scope ground test point
TP14
GND
Scope ground test point
TP15
GND
Scope ground test point
TP16
GND
Scope ground test point
TP17
GND
Scope ground test point
TP18
SENSE
Low-side sense resistor
Enable signal, high true (and under-voltage detection)
Program input
Connectors
Table 2. Connectors
7
CONNECTOR
DESCRIPTION
J1
Main power input, VIN
J3
Main power ground, GND
J2
Load
J4
Load ground, GND
Jumpers
None.
8
Switches
8.1
Enable Switch, S1
The Enable slide switch turns on the hot plug controller to ramp the output voltage .When the switch is off,
the output is off.
9
Indicators
•
•
6
Green LED indicator for Power Good (PG)
Red LED indicator for FAULT (FLT)
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Board Outline
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10
Board Outline
Figure 3. Board Outline (top view)
Figure 4. Board Outline (bottom view)
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List of Materials
11
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List of Materials
11.1 12-V TPS2492EVM-001/TPS2493EVM-002
This is the List of Material for the 12-V TPS2492EVM-001/TPS2493EVM-002.
Table 3. 12-V TPS2492EVM-001/TPS2493EVM-002 (1) (2) (3) (4)
(1)
(2)
(3)
(4)
8
REF DES
PART
NUMBER
-001
-002
DESCRIPTION
MFR
3
3
C1, C3, C7 Capacitor, ceramic, 100 V, X7R, 10%, 0.1 µF, 0805
Std
Std
1
1
C5
Capacitor, ceramic, 25 V, X7R, 10%, 3.3 nF, 0805
Std
Std
C2, C9
Capacitor, aluminum, 100 VDC, ±20%, 47 µF, 0.670 inch x
0.750 inch
EEVFK2A4 Panasonic
70Q
2
2
1
1
C6
Capacitor, ceramic, 25 V, X7R, 10%, 1000 pF, 0603
Std
Std
1
1
C8
Capacitor, ceramic, 25 V, X7R, 10%, 1.5 nF , 0603
Std
Std
D1
Diode, SMT TVS 400W, 1 A, 15 V, SMA
SMAJ15A13F
Diodes
D2
Diode, Schottky 3 A, 100 V, SMC
MBRS3100 On Semi
T3G
D3
Diode, LED, red, 20 mA, 0.9 mcd, 0.068 inch x 0.049 inch
LN1271R
Panasonic
D4
Diode, LED, green, 20 mA, 0.9 mcd, 0.068 inch x 0.049 inch
LN1371G(TR)
Panasonic
J1, J2, J3,
J4
Lug, copper, 35 A, 0.380 inch x 1.020 inch
CX35-36CY
Panduit
Q1, Q3
MOSFET, N-channel, 25 V, 37 A, 1.3 mΩ, QFN 5X6 mm
CSD16401
Q5A-R
Ciclon
1
1
1
1
1
1
1
1
4
4
2
2
2
2
R1, R12
Resistor, chip, 1/16 W, 1%, 10 Ω, 0603
Std
Std
1
1
R15
Resistor, chip, 1/16 W, 1%, 0 Ω, 0603
Std
Std
1
1
R17
Resistor, chip, 1/16 W, 1%, 1 kΩ, 0603
Std
Std
1
1
R2
Resistor, chip, 1/16 W, 1%, 100 kΩ, 0603
Std
Std
2
2
R3, R6
Resistor, chip, 1/16 W, 1%, 15 kΩ, 0603
Std
Std
1
1
R4
Resistor, chip, 1/16 W, 1%, 143 kΩ, 0603
Std
Std
1
1
R5
Resistor, chip, 1/16 W, 1%, 7.32 kΩ, 0603
Std
Std
R8
Resistor, power metal strip, 3 W, ±x1%, 0.002 Ω, 4527
1
1
WSR32L000FE
A
Vishay
Dale
2
2
R9, R10
Resistor, chip, 1/16 W, 1%, 5.1 kΩ, 0603
Std
Std
These assemblies are ESD sensitive, ESD precautions shall be observed.
These assemblies must be clean and free from flux and all contaminants. Use of no clean flux is not acceptable.
These assemblies must comply with workmanship standards IPC-A-610 Class 2.
Ref designators marked with an asterisk ('**') cannot be substituted. All other components can be substituted with equivalent
MFG's components.
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List of Materials
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Table 3. 12-V TPS2492EVM-001/TPS2493EVM-002 (1) (2) (3) (4) (continued)
-001
-002
1
1
17
REF DES
S1
PART
NUMBER
DESCRIPTION
MFR
Switch, SPDT, slide, PC mount, 500 mA, 0.400 inch x 0.100 inch 09.03201.0 EAO
2
TP1, TP2, Test point, white, thru hole, 5012, 0.125 inch x 0.125 inch
TP3, TP4,
TP5, TP6,
TP7, TP8,
TP9, TP10,
TP11,
TP12,
TP13,
TP14,
TP15,
TP16,
TP17
5012
Keystone
U1
Positive High-Voltage Power-Limiting Hotswap Controller,
TSSOP-14
TPS2492P
W
TI
U1
Positive High-Voltage Power-Limiting Hotswap Controller,
TSSOP-14
TPS2493P
W
TI
0.500 inch
1
0
0
1
4
4
Screw, panhead
#10-32
4
4
Washer, flat
#10
4
4
Washer, split
M5
4
4
Nut, hex
#10-32
1
1
--
PCB, 5.4 inch x 3.3 inch x 0.06 inch
HPA491
Any
4
4
--
Bumpons, cylindrical, black
SJ5514-0
3M
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48-V TPS2492EVM-003/TPS2493EVM-004
12
www.ti.com
48-V TPS2492EVM-003/TPS2493EVM-004
This is the List of Material for the 48-V TPS2492EVM-003/TPS2493EVM-004.
Table 4. 48-V TPS2492EVM-003/TPS2493EVM-004 (1) (2) (3) (4)
(1)
(2)
(3)
(4)
10
-004
3
3
C1, C3, C7 Capacitor, ceramic, 100 V, X7R, 10%, 0.1 µF, 0805
Std
Std
1
1
C5
Capacitor, ceramic, 25 V, X7R, 10%, 0.1 µF, 0805
Std
Std
2
2
C2, C9
Capacitor, aluminum, 100 VDC, ±20%, 47 µF, 0.670 inch x
0.750 inch
EEVFK2A4 Panasonic
70Q
1
1
C6
Capacitor, ceramic, 25 V, X7R, 10%, 1000 pF, 0603
Std
Std
1
1
C8
Capacitor, ceramic, 25 V, X7R, 10%, 1.5 nF, 0603
Std
Std
D1
Diode, SMT TVS 400 W, 1 A, 70 V, SMA
SMAJ70A13F
Diodes
D2
Diode, Schottky 3 A, 100 V, SMC
MBRS3100 On Semi
T3G
D3
Diode, LED, red, 20 mA, 0.9 mcd, 0.068 inch x 0.049 inch
LN1271R
Panasonic
D4
Diode, LED, green, 20 mA, 0.9 mcd, 0.068 inch x 0.049 inch
LN1371G(TR)
Panasonic
J1, J2, J3,
J4
Lug, copper, 35 A, 0.380 inch x 1.020 inch
CX35-36CY
Panduit
Q2
Transistor, NFET, 100 V, 33 A, 44 mΩ, D2PAK
IRF540NS- IR
PBF
1
1
1
1
1
1
REF DES
PART
NUMBER
-003
DESCRIPTION
MFR
1
1
4
4
1
1
1
1
R14
Resistor, chip, 1/16 W, 1%, 10 Ω, 0603
Std
Std
1
1
R15
Resistor, chip, 1/16 W, 1%, 0 Ω, 0603
Std
Std
1
1
R17
Resistor, chip, 1/16 W, 1%, 1 kΩ, 0603
Std
Std
1
1
R2
Resistor, chip, 1/16 W, 1%, 100 kΩ, 0603
Std
Std
2
2
R3, R6
Resistor, chip, 1/16 W, 1%, 15 kΩ, 0603
Std
Std
1
1
R4
Resistor, chip, 1/16 W, 1%, 604 kΩ, 0603
Std
Std
1
1
R5
Resistor, chip, 1/16 W, 1%, 4.42 kΩ, 0603
Std
Std
R7
Resistor, metal strip, 0.01 Ω, 2 W, 1%, 0.01, 2512
LRCIRC
LRF2512L
F-01-R010F
R9, R10
Resistor, chip, 1/16 W, 1%, 20 kΩ, 0603
Std
1
1
2
2
Std
These assemblies are ESD sensitive, ESD precautions shall be observed.
These assemblies must be clean and free from flux and all contaminants. Use of no clean flux is not acceptable.
These assemblies must comply with workmanship standards IPC-A-610 Class 2.
Ref designators marked with an asterisk ('**') cannot be substituted. All other components can be substituted with equivalent
MFG's components.
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48-V TPS2492EVM-003/TPS2493EVM-004
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Table 4. 48-V TPS2492EVM-003/TPS2493EVM-004 (1) (2) (3) (4) (continued)
-003
-004
1
1
REF DES
S1
PART
NUMBER
DESCRIPTION
MFR
Switch, SPDT, slide, PC mount, 500 mA, 0.400 inch x 0.100 inch 09.03201.0 EAO
2
TP1, TP2, Test point, white, thru hole, 5012, 0.125 inch x 0.125 inch
TP3, TP4,
TP5, TP6,
TP7, TP8,
TP9, TP10,
TP11,
TP12,
TP13,
TP14,
TP15,
TP16,
TP17
5012
Keystone
U1
Positive High-Voltage Power-Limiting Hotswap Controller,
TSSOP-14
TPS2492P
W
TI
U1
Positive High-Voltage Power-Limiting Hotswap Controller,
TSSOP-14
TPS2493P
W
TI
0.500 inch
1
0
0
1
4
4
Screw, panhead
#10-32
4
4
Washer, flat
#10
4
4
Washer, split
M5
4
4
Nut, hex
#10-32
1
1
--
PCB, 5.4 inch x 3.3 inch x 0.06 inch
HPA491
Any
4
4
--
Bumpons, cylindrical, black
SJ5514-0
3M
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EVM Warnings and Restrictions
It is important to operate this EVM within the input voltage range of 9 V to 80 V and the output voltage range of 9 V to 80 V .
Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are
questions concerning the input range, please contact a TI field representative prior to connecting the input power.
Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the
EVM. Please consult the EVM User's Guide prior to connecting any load to the EVM output. If there is uncertainty as to the load
specification, please contact a TI field representative.
During normal operation, some circuit components may have case temperatures greater than 50° C. The EVM is designed to
operate properly with certain components above 65° C as long as the input and output ranges are maintained. These components
include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of
devices can be identified using the EVM schematic located in the EVM User's Guide. When placing measurement probes near
these devices during operation, please be aware that these devices may be very warm to the touch.
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