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TI Designs 8-Ch Parallel 1-A High-Side Digital Output Module for PLC TI Designs Design Features TI Designs provide the foundation that you need including methodology, testing and design files to quickly evaluate and customize the system. TI Designs help you accelerate your time to market. TIDA-00183 TIDA-00233 BeagleBone-Black Design Folder • • • • • • Design Folder Community Featured Applications TPS1H100-Q1 ISO7141CC ISO7141FCC ISO7421 LM5009 LM5069-2 LM5050-1 MSP430F2132 SN74LV164A Little Logic NexFET Product Folder Product Folder Product Folder Product Folder Product Folder Product Folder Product Folder Product Folder Product Folder Product Selector Product Selector Design Resources • High-Density 8-Channel, 24-V High-Side Output 1 A per Channel Unregulated (20%), 3-A Peak 4-Wire SPI MCU Interface Fast Switching of Inductive Loads LEDs to Indicate Output State BeagleBone-Black Cape Form Factor for Easy Evaluation (Four Boards Stackable) Digital Outputs for – Programmable Logic Controller (PLC) – Distributed Control Systems (DCS) – Process Automation Controller (PAC) – Motor Control I/O Modules – Sensor Concentrators ASK Our E2E Experts WEBENCH® Calculator Tools 100-V Buck LM5009 Push-Pull SN6501 5V Protect TIDA-00233 24 V LED LED Beaglebone 3.3 V RST/IRQ OM1 EN1 LED TPS1H100 A0 .. A2 SPI Y0 LED Address logic SPI Iso SPI MSP430 ISO 7141 7421 OM2 EN2 TPS1H100 Y1 LED SPI OM8 EN8 TPS1H100 Y7 LED TLCS928 ISO 7141CC 7141FCC 8x LED red (fault) 8x LED orange (o-level) RSENSE Ground Isolation 500 V Debug An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other important disclaimers and information. All trademarks are the property of their respective owners. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 1 Key System Specifications 1 www.ti.com Key System Specifications Table 1. Key System Specifications SYMBOL SPECIFICATION CONDITIONS MIN TYP MAX UNIT VIN(max, off) Input voltage Overvoltage protection stops local power supply, VIN rising — 32 — V VIN(max, on) Input voltage Overvoltage protection stops local power supply, VIN falling — 30 — V VIN(min, on) Input voltage Undervoltage protection starts local power supply at rising VIN — 12 — V VIN(min, off) Input voltage Undervoltage protection stops local power supply at falling VIN — 11 — V IIN Input current Normal operation 0.01 (1) — 11 (2) A VLOAD Load supply voltage Normal operation ILOAD tOVER Load current Overcurrent time VIN Per channel TA = 85°C Per channel TA = 25°C All outputs on, RL = 18 Ω, VIN = 27 V, TA = 25°C All outputs on, RL = 18 Ω, VIN = 27 V, TA = 25°C 1.2 3.5 (3) A 1.25 4 (4) 3.5 (3) A — 25 — ms 12.4 A — mW 240 (5) mW 2 kHz Overcurrent limit PLOSS(25) Power loss per channel RL = 18 Ω, VLOAD = 21.6 V, TA = 25°C PLOSS(85) Power loss per channel RL = 18 Ω, VLOAD = 21.6 V, TA = 85°C fSW Switching frequency (PWM) Absolute maximum rating per TPS1H100 datasheet tON(min) Minimum on time Guaranteed by design per TPS1H100 datasheet 50 µs tOFF(min) Minimum off time Guaranteed by design per TPS1H100 datasheet 50 µs tRISE Load voltage rise time, 10% to 90% RL = 18 Ω, VLOAD = 24 V, TA = 25°C, one load 27 45 135 µs tFALL Load voltage fall time, 90% to 10% RL = 18 Ω, VLOAD = 24 V, TA = 25°C, one load 27 45 135 µs PIND Inductive power per output (2) (3) (4) (5) (6) 9.6 — 11 (2) IOVER (1) 2 PARAMETER 150 (5) — 70 (6) mJ/s Depends on the number of LEDs on and communication activity Limited by overcurrent protection Limited by current limit resistor designed into TIDA-00183 at TPS1H100 Protection limits total current to 10 A, load can be distributed for example 3 × 3 A + 5 × 0.2 A Based on calculations derived from TPS1H100 datasheet Based on inductive power capabilities of TPS1H100. If the clamping value of TVS diode D89 is set to a voltage level smaller than the clamping level of TPS1H100, then D89 takes all inductive energy. In this case, the total inductive power for all outputs together can be 1 J/s irrespective how the energy is distributed among the outputs. More copper area can increase the inductive power. Up to 3 J/s is possible 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback System Description www.ti.com 2 System Description The TIDA-00183 is a digital output (DO) module, which is a standard function in PLC or DCS systems. The DO module can energize or de-energize resistive, capacitive, or inductive loads or control them with pulse width modulation (PWM). A digital output can be a high-side, low-side, or push-pull switch. This design uses the high-side principle, which means that the load is installed between the output of the module and ground. The switch connects the load with the 24-V field supply to energize the load. An advantage of this principle is the intrinsic safe operation. If the isolation of the wire between output and load fails then the load can falsely connect to ground. The other side of the load is also connected to ground. Therefore, in this error case the load has no energy and is off. A high-side configuration is also less sensitive to corrosion because both sides of the load are permanently connected to ground when the load is off. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 3 Block Diagram 3 www.ti.com Block Diagram 100-V Buck LM5009 Push-Pull SN6501 5V Protect TIDA-00233 24 V LED LED Beaglebone 3.3 V RST/IRQ OM1 EN1 LED TPS1H100 A0 .. A2 SPI Y0 LED Address logic SPI Iso SPI MSP430 ISO 7141 7421 OM2 EN2 TPS1H100 Y1 LED SPI OM8 EN8 TPS1H100 Y7 LED TLCS928 ISO 7141CC 7141FCC 8x LED red (fault) 8x LED orange (o-level) RSENSE Ground Isolation 500 V Debug Figure 1. Block Diagram 3.1 Highlighted Products Find more details about these devices in Section 4. 3.1.1 TPS1H100 The TPS1H100-Q1 is a fully protected high-side power switch, with integrated NMOS power FET and a charge pump, targeted for the intelligent control of the variable kinds of resistive, inductive, and capacitive loads. It has an accurate current sense, a programmable current limit, and over temperature protection. 3.1.2 MSP430F2132 The MSP430F2132 is an ultra-low-power MCU with two built-in 16-bit timers, a fast 10-bit A/D converter with integrated reference, and a data transfer controller (DTC), a comparator, built-in communication capability using the universal serial communication interface, and up to 24 I/O pins. 3.1.3 ISO7141CC and ISO7141FCC The ISO7141CC and ISO7141FCC devices provide galvanic isolation up to 2500 VRMS for 1 minute per UL and 4242 VPK per VDE. The ISO7141 has three forward and one reverse-direction channels. These devices are capable of a 50-Mbps maximum data rate with 5-V supplies and a 40-Mbps maximum data rate with 3.3-V or 2.7-V supplies, with integrated filters on the inputs for noise-prone applications. The devices have TTL input thresholds. CC indicates that the output is high when the input side is not powered. FCC indicates that the output is low when the input side is not powered. 3.1.4 ISO7421 The ISO7421 has the same isolation capabilities as the ISO7141 above. It has two channels, one forward and one back channel and operates at maximum 1 Mbps with 3.3-V and 5-V supplies. The device has TTL input threshold. 4 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Block Diagram www.ti.com 3.1.5 TLC5928 The TLC5928 is a 16-channel, constant-current sink LED driver. Each channel can be turned on or off by writing serial data to an internal register. The constant-current value of all 16 channels is set by a single external resistor. The TLC5928 has two error detection circuits: one for LED open detection (LOD) and one for a pre-thermal warning (PTW). LOD detects a broken or disconnected LED and LEDs shorted to GND while the constant-current output is on. PTW indicates a high temperature condition. 3.1.6 SN74LV164A The SN74LV164A devices are 8-bit parallel-out serial shift registers designed for 2-V to 5.5-V VCC operation. 3.1.7 Little Logic These devices from TI's Little Logic™ family are in the design for address decoding, SPI chip select, and reset generation: SN74LVC1G07, SN74LVC2G86, SN74LVC1G332, SN74LVC1G19, SN74LVC1G58, and SN74LVC1G125. Little Logic gates have all the features of their bigger cousins but in single, double, and triple gate functions. They cover the full range of voltages from 0.8 to 5.5 V. They come in tiny packages making them excellent for handheld and any other equipment where space is a concern. 3.1.8 SN6501 The SN6501 is a monolithic oscillator/power-driver, specifically designed for small form factor, isolated power supplies in isolated interface applications. The device drives a low-profile, center-tapped transformer primary from a 3.3-V or 5-V DC power supply. The secondary can be wound to provide any isolated voltage based on transformer turns ratio. 3.1.9 LM5009 The LM5009 features all of the functions needed to implement a low-cost, efficient, Buck regulator. This device is capable of driving a 150-mA load current from a 9.5-V to 95-V input source. The output voltage can be 2.5 to 85 V. The regulator has an N-Channel buck switch and internal startup regulator. With its much smaller power loss, it is a perfect replacement for high-voltage LDOs. The control scheme requires no loop compensation, resulting in an ultra-fast transient response. An intelligent current limit is implemented with forced OFF time, which is inversely proportional to VOUT. This scheme ensures short circuit protection while providing minimum foldback. Other features include thermal shutdown, VCC undervoltage lockout, gate drive undervoltage lockout, and maximum duty cycle limiter. 3.1.10 LM5050-1 The LM5050-1 operates in conjunction with an external MOSFET as an ideal diode rectifier when connected in series with a power source. This ORing controller allows MOSFETs to replace diode rectifiers in power distribution networks, thus reducing both power loss and voltage drops. 3.1.11 LM5069 The LM5069 positive hot swap controller provides intelligent control of the power supply connections during insertion and removal of circuit cards from a live system backplane or other "hot" power sources. The LM5069 provides in-rush current control to limit system voltage droop and transients. The current limit and power dissipation in the external series pass N-Channel MOSFET are programmable, ensuring operation within the safe operating area (SOA). The POWER GOOD output indicates when the output voltage is within 1.25 V of the input voltage. The input undervoltage and overvoltage lockout levels and hysteresis are programmable, as well as the initial insertion delay time and fault detection time. The LM5069-1 latches off after a fault detection, while the LM5069-2 automatically restarts at a fixed duty cycle. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 5 System Design Theory 4 www.ti.com System Design Theory The TIDA-00183 has a BeagleBone-Black-Cape form factor. The BeagleBone-Black is an open source, low-cost microcomputer with Linux operating system. This makes the evaluation of our featured components very easy. With this methodology, it is possible to test all components in the target environment, which is an industrial switching cabinet for factory automation. The TIDA-00183 has all necessary components for safe operation in noisy industrial environment. This design uses digital isolators and an isolated power supply to separate the 24-V field side and the BeagleBone-Black. Therefore, the microprocessor (MPU) in BeagleBone-Black continues operation even when a lightning strike happens in the field. A ground shift of 500 V between BeagleBone-Black and field side has no impact on the correct operation. The MPU on the BeagleBone-Black talks to the TIDA-00183 through a 4-wire SPI. Therefore, only one isolation component with four channels is necessary for SPI. A second isolation component isolates a reset signal and an interrupt signal. A microcontroller unit (MCU) works as the isolated SPI slave within the TIDA-00183. The MCU also connects to eight high-side switches, one switch per load. Through the isolated SPI, the MCU receives and decodes the data from the BeagleBone-Black. This data tells the MCU which load to energize or deenergize. The MCU can also measure all load currents and calculate the power loss in all high-side switches. If the total power loss is more than permitted by the thermal budget of the TIDA-00183, then the MCU can de-energize outputs. The MCU can also use the measured output currents to implement electronic fuses. If the current of a certain output is more than a programmed threshold (optionally for more than a programmed time), then the MCU can de-energize the load on this output. A programmable current limit and the thermal limit function of the high-side switch do the protection (first line of defense) until the MCU responds. A smart diode protects the TIDA-00183 from reverse polarized field supply voltage and from reverse currents. The reverse currents can come from a short circuit of the field supply. In this case, the stored local energy or stored output energy (capacitive loads or brushed DC motors) wants to flow back into the field supply. This can destroy the high-side switches. The reverse current protection effectively prevents this potential destruction. A smart diode has less of a voltage drop than a Schottky diode. This is important because of the power loss. At a 10-A total load current, a Schottky diode has a loss of typical 5 W. The smart diode only has a typical 0.5-W power loss. An in-rush current limiter and electronic fuse protect the TIDA-00183 from these effects: • Surges • Fast transients • Overvoltage • Undervoltage • Overcurrent • Short circuit Surges can come from lightning strikes nearby, and fast transient can come from inductive loads. The electronic fuse protects TIDA-00183 also from too high load currents. If the sum of all load currents is higher than 10 A, the electronic fuse stops the local power supply within a typical 45 µs (overcurrent protection). If the sum of all load currents is higher than 30 A, the local power supply stops instantly within a typical 450 ns and maximum 1.2 µs (circuit breaker). Through the isolated power from the BeagleBoneBlack, the MCU has still auxiliary power in this error case. It then can report the error to the BeagleBoneBlack. A power good signal from the electronic fuse tells the MCU that the field supply is present and within specification. The MCU also measures the local 24-V power supply. With this information, the MCU can detect miss-wiring. If 24 V is available on the local supply but the power good signal is not there, then this is an index for the field supply connected to an output (instead of the 24-V field supply connector). In this case, the protection from electronic fuse is not effective and the MCU must not energize any loads. Up to four TIDA-00183 boards can work together with one BeagleBone-Black. All share the same SPI bus. Discrete logic chips with single gate functions do the necessary address decoding. With this address decoding the BeagleBone-Black can talk to individual TIDA-00183 boards on the same SPI bus. 6 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback System Design Theory www.ti.com An isolated debug port is necessary to debug the MCU on the field side when the field side is in operation. Otherwise, a ground shift on the field side can cause unwanted current flow into the debugger PC. This current flow can be dangerous for the operator, stop the correct operation of the PC or destroy the PC. With the debug port isolation, there is no current flow into the PC and the debug operation is safe. 4.1 High-Side Switch The main task of the TIDA-00183 is to switch on and off electric loads, which are connected to ground on the machine side. For this task, it uses the high-side switch principle. The TPS1H100 is a device for this purpose. The TPS1H100 can switch resistive, inductive, and capacitive loads. Examples for load types are in Table 2. Table 2. Examples for Loads TYPE OF LOAD LOAD PROPERTIES LOAD EXAMPLE Resistive load Current nearly constant over time Resistors, heaters Inductive load Current starts at zero and increases over time, wants to continue flow when output switches off, causes high voltage spike Inductors, relays, magnetic valves, electric magnets Capacitive load Current starts high (in-rush) and decreases over time Capacitors, lamps, brushed DC motors, electric equipment which is energized from this output DRAIN(VS) Charge Pump Internal LDO VDS Clamp Internal Reference IN Gate Driver DIAG_EN ST Diagnostics and Protection Open Load Detection Current Limit CL SOURCE(OUT) Thermal Monitor Current Sense CS GND Figure 2. TPS1H100 Block Diagram TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 7 System Design Theory www.ti.com The TPS1H100 has protection against voltage spikes from inductive loads. It can limit the output current and slowly charge capacitive load. If the die temperature is more than 150°C, then the load is deenergized until the die has cooled down to 125°C. A current mirror and scaler drives a current through the CL pin to ground. This current is proportional to the output current. A sense resistor can convert this current to a voltage. In this design, the MCU measures this voltage and gets information about the load current. The TPS1H100 comes in a PWP package at a 5×7-mm board space and can drive 1.2 A simultaneously at each output with only PCB cooling. An area of about 30 cm2 copper for all TPS1H100 together is sufficient for operation at ambient temperatures of 85°C. The design provides around the 32-cm2 copper area. The TPS1H100s have internal clamping for inductive loads. The clamping voltage is more than 50 V below the 24-V power supply voltage and enables fast inductive discharge. The design considerations are in more detail in Section 4.6. 4.2 Digital Isolators The TIDA-00183 uses the ISO7141 devices for SPI bus isolation and for the debug port. The ISO7141 isolates three signals in one direction and one signal in opposite direction. For the SPI bus, the three signals from BeagleBone-Black towards the MCU are: • SCLK • CS • MOSI The one signal back from MCU towards BeagleBone-Black is MISO. For the reset signal from the BeagleBone-Black to the TIDA-00183 MCU, use an ISO7421 two-channel isolator. It has one channel in each direction. The back channel carries an interrupt signal from the TIDA00183 MCU to the BeagleBone-Black. When the debugger is not connected to the debug port then the power on that side of the digital isolator is missing. This is the normal operation mode. When the debug tool is not connected, these signals need to default to high: • TDI/TCLK • nRST • RXD When the debug tool is not connected, these signals need to default to low: • TCK • TMS • TEST For the debug port, use the digital isolators in two different configurations: • ISO7141CC outputs default to high when the input side is not powered • ISO7141FCC outputs default to low when the input side is not powered The ISO7141 isolators support up to 50 Mbps. This is well above the communication speed used in the design. The ISO7421 supports 1 Mbps, which is fast enough for reset and interrupt signals in this design. 8 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback System Design Theory www.ti.com 4.3 MCU The MCU in the TIDA-00183 comes from the MSP430 family of ultra-low power MCUs. The MSP430F2132 works at temperatures up to 105°C and has 8KB of Flash memory for program storage. 512 bytes are available as RAM working memory. If the control routines for the MCU need less memory, these controllers are available with less memory: • MSP430F2122 with 4KB Flash and 512-Byte RAM • MSP430F2112 with 2KB Flash and 256-Byte RAM In • • • • • • the TIDA-00183, use these features of this MCU family: 10-bit A/D converter Timer SPI UART GPIO Temperature sensor The A/D converter measures the output currents in the high-side switches and the local 24-V power supply voltage. The GPIOs energize the load through the high-side switches. The timer functions control the measurement intervals for the output currents and optional the fuse function. The UART can send live status information about the health of the TIDA-00183 when the user evaluates the function. The temperature sensor can measure the ambient temperature before the evaluation and the board temperature profile during the evaluation. The MCU core has enough performance to protect the SPI data stream with error detection and correction codes. It can also start an emergency program if the data connection to the BeagleBone-Black is lost. The MCU can then energize and de-energize the loads to a pre-defined safe state. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 9 System Design Theory 4.4 www.ti.com Power Supply The MCU on the TIDA-00183 and the high-side switches need a stable power supply for correct operation. The 24-V field supply voltage can have destructive conditions for the high-side switches and for the MCU. Therefore, a filter is necessary to remove these destructive conditions. The filter has two stages. In the first stage, it reduces surge voltages from 500 V down to 85 V. It also uses smart diode technology to protect the TIDA-00183 against wrong polarized power supplies. The smart diode function comes from an LM5050 OR-ing controller and a NexFET. The second stage uses an LM5069 and a NexFET and protects against these conditions: • Overcurrent • Undervoltage • Overvoltage • Short circuit The second stage also breaks the current-flow when the input voltage is more than 45 V during a surge pulse. The output voltage of the power filter is never higher than 45 V. The MCU has a dual power supply. It can receive power from the BeagleBone-Black through an isolating power supply. This is the auxiliary power and it is based on an SN6501 push-pull driver with integrated oscillator. A forward converter transformer does the isolation and voltage conversion from 5 V to 3.3 V. It powers the MCU to start a diagnostic process before the start of normal operation. This diagnostics includes these tests: • Miss-wiring test • 24-V field supply test for spec compliance • Host communication test With miss-wiring or if the field supply voltage is out of specification, it can happen that no 24-V local power supply is available. In this case the auxiliary power can help the MCU to do diagnostics and give the BeagleBone-Black detailed information about the source of the problem. The auxiliary power has a second purpose. The field supply can have an intermittent failure or the surge protection can briefly interrupt the power supply. With the auxiliary power, the MCU can preserve the actual working state. The MCU can resume correct operation once the 24-V supply is stable again. When a correct 24-V local power is available, then the 3.3 V for the MCU come from a buck regulator. Then the MCU has power for initialization and diagnostics even if the BeagleBone-Black is not working. In this case, the MCU can bring the TIDA-00183 with all connected loads into a safe state. This buck regulator uses an LM5009. The LM5009 is a high-voltage buck regulator IC and can operate at up to 100-V input voltage. When a surge happens, then the LM5009 based regulator can still supply stable 3.3 V to the MCU. 10 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback System Design Theory www.ti.com 4.5 Thermal Management The thermal management budget has been calculated based on the following design considerations: • The junction temperature must not be above 150°C. • The thermal resistance of the package is 2.7 K/W junction to bottom plate. • Board space provides thermal resistance to air of around 900 K/W per cm2 (see formula 23 in Thermal Considerations for Surface Mount Layouts [2]). The RDS(ON) of the TPS1H100 is always smaller than 0.166 Ω. With an output current of 1.2 A the total power dissipation is 0.24 W per device. The accumulated power is then 1.92 W. 4.6 Switch Off an Inductive Load The TIDA-00183 can switch inductive loads. Such loads are stepper motors, valves, or relays. An inductive load has the property that it stores energy. When the switch wants to de-energize the inductive load, this energy is released. The inductor tries to keep the current flowing, which could result in a high voltage spike at the output of the switch. A free-wheeling diode is a typical method to block the spike. This diode limits the voltage at the inductor to 0.7 V. The resulting voltage at the output of the switch is 0.7 V negative. The method is simple and used for non-timing-critical switching processes. A free-wheeling voltage of more than 0.7 V releases the energy faster. The release time is reverse proportional to the freewheeling voltage. High-speed actuators (for example, injection valves in process control systems) need a high free-wheeling voltage. The TPS1H100 clamps at 50 V below the 24-V power supply. This reduces the energy release time by a factor of 30 compared to a 0.7-V free-wheeling voltage. 4.7 Switching Light Bulbs and Brushed DC Motors The TIDA-00183 can switch conventional light bulbs. Such a load has typically a 10 times higher cold current than continuous current. A 24 V, a 5-W light bulb can have an in-rush current of 2 A, which is within the operating range of the TPS1H100. Larger light bulbs trigger the current limit of the TPS1H100. This does not harm the TPS1H100 but it takes longer for the light bulb to light up. Brushed DC motors can have a similar start-up behavior. Here the ratio between the start-up current and the continuous current can be even higher. A factor of more than 30 is possible. Motors with a high efficiency have a high current ratio. Here the current limit of the TPS1H100 helps with a controlled start of the motor. There is a high-voltage drop in the TPS1H100 when it does current limit. This can heat up the TPS1H100 until it thermally shuts down its operation. A PWM control for motor start is more power effective. It reduces the risk of thermal shutdown of TPS1H100. The MCU can use PWM for outputs, which are configured to drive a motor. 4.8 EMI Each output connector pin has a 10-nF capacitor connected to earth nearby. This reduces ESD sensitivity and EMI. There are also two steering diodes connected to each output. One diode guides positive surges into the local 24-V power supply where they are clamped to 45 V. The other diode guides negative surges into a transient protection diode with a clamping voltage of 45 V below ground. This diode becomes effective if the clamping capability of the TPS1H100 switch is not sufficient for the strength of the negative surge pulse. 4.9 Output Signage and Output Connector All TPS1H100 outputs are connected to blue LEDs. The LED current is set to 2.2 mA at 24 V. The LEDs show the output state. They have light guides so that they are visible even if multiple capes are stacked. The board connector is a low profile type so that it is possible to stack capes and still have access to each of the boards. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 11 Getting Started Hardware 5 www.ti.com Getting Started Hardware The TIDA-00183 can be used either as cape with the BeagleBone-Black evaluation platform or as a standalone card. For the connection to the BeagleBone-Black, connectors J20 and J21 will handle the communication. If standalone operation is planned, there exist two options: • SPI communication through the BeagleBone-Black connector • UART communication through the MSP430 isolated debug port 5.1 Pin Assignment Table 3. Pin Assignments 5.2 TIDA-00183 FUNCTION TIDA-00183 HEADER BBB HEADER SOFTWARE DIRECTION Address A0 J2, PIN 11 P9_11 UART4 RXD OUT Address A1 J2, PIN 13 P9_13 UART4 TXD OUT Address A2 J1, PIN 22 P8_22 MMC1_DAT5 OUT SPI0 CS J2, PIN 17 P9_17 SPI0_CS OUT SPI0 D0 J2, PIN 21 P9_21 SPI0_D0 OUT SPI0 D1 J2, PIN 18 P9_18 SPI0_D1 IN SPI0 SCLK J2, PIN 22 P9_22 SPI0_SCLK OUT OUT XRST_n J2, PIN 15 P9_15 GPIO1_16 /XSDRDY J2, PIN 23 P9_23 GPIO1_17 IN I2C2_SCL J2, PIN 19 P9_19 I2C2_SCL OUT I2C2_SDA J2, PIN 20 P9_20 I2C2_SDA IN/OUT Initialization and Control In this test version, the control of the board is limited to a simple ASCII terminal control. With this, it is possible to switch on and off outputs in any combination. The control scheme is sufficient to test and evaluate the TPS1H100 high-side driver and the power section of the TIDA-00183. A separate future software reference design will cover the BeagleBone-Black software and the MSP430 SPI communication software. 5.3 Power Supply The board is connected to a 24-V field supply. The 3.3 V for the isolators are coming from this supply as well as the voltage VS for the TPS1H100 parts. A combination of 33-V TVS diodes and an electronic fuse is used as protection against surge pulses of 500 V 1.2/50 µs (250 A, 8/20µs). This protection scheme is available as separate reference design, the TIDA-00233. The electronic fuse also limits the maximum current into all outputs together to 10 A. It resets when the short circuit or over current condition disappears. 12 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Test Setup www.ti.com 6 Test Setup 6.1 Undervoltage and Overvoltage Lockout Table 4. Equipment DEVICE TYPE DESCRIPTION Power supply GW instek GPS4303 Voltmeter Fluke 45 Prerequisite: • Connect the 24-V input connector to power supply Test 1 — Undervoltage lockout • Start power supply at 0 V • Increase VIN until LED D95 is on • Measure and protocol VIN • Decrease VIN until LED D95 is off • Measure and protocol VIN Test 2 — Overvoltage lockout • Start VIN at 0 V • Increase VIN until LED D95 is on • Further increase VIN until LED D95 is off • Measure and protocol VIN • Decrease supply voltage until LED D95 is on • Measure and protocol VIN 6.2 Overcurrent Timing Table 5. Equipment DEVICE TYPE DESCRIPTION Power supply GW instek GPS4303 and 2229 Statron Oscilloscope Tektronix TDS 3034 Load Wirewound resistor Dale RH-50 50 W Prerequisite: • Connect the 24-V input connector to power supply. • Connect the second power supply in parallel to first power supply. Test 1 — Overload test: • Connect all outputs Y0 to Y7 to 18-Ω, 50-W resistors. • Connect the oscilloscope to Y0. • Set the oscilloscope to trigger on the rising edge of the signal with trigger level set to 2.4 V. • Use normal trigger mode, one shot. • Set VIN to 27 V on both power supplies. • Set the oscilloscope to "ready". • Set all outputs simultaneously to "on". • Measure the time from the trigger point to the falling edge of the signal at Y0. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 13 Test Setup 6.3 www.ti.com Output Current Capability Table 6. Equipment DEVICE TYPE DESCRIPTION Power supply GW instek GPS4303 and 2229 Statron Ampere meter Built into power supply (2% gain accuracy, zero offset) Load Wirewound resistor Dale RH-50 50 W Prerequisite: • Connect the 24-V input connector to power supply. • Connect the second power supply in parallel to first power supply. Test 1 — Standard load test at 1.2 A per output, all outputs loaded: • Connect all outputs Y0 to Y7 to 18-Ω, 50-W resistors, Y0 with Ampere measurement. • Set the supply voltage to a value that the load current is 1.2 A per output (21 to 22 V). • Take a thermal image and take the maximum temperature rise. 6.4 Rise and Fall Times +24 V 18 Y7 18 Ch 1 Y6 18 Y5 18 DC 0 ± 33 V ~ Oscilloscope Y4 GND Earth +24 V Y3 Y2 Y1 18 18 18 18 Y0 GND Earth Figure 3. Measurement Setup for Rise and Fall Times 14 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Test Setup www.ti.com Table 7. Equipment DEVICE TYPE DESCRIPTION Power supply GW instek GPS4303 Oscilloscope Tektronix TDS 3034 Ampere meter Built into power supply (2% gain accuracy, zero offset) Load Wirewound resistor Dale RH-50 50 W Prerequisite: • Connect loads and power supply according to Figure 3. Test 1 — Rise time single output switching, one output loaded: • Connect any single output (example Y7) to 18-Ω, 50-W resistor. • Connect the oscilloscope to this output (example Y7). • Set the oscilloscope to trigger on the rising edge with trigger level set to 2.4 V. • Use normal trigger mode, single shot o Set VIN to 24 V. • Set the oscilloscope to ‘ready’ o Set output (example Y7) to "on". • Measure the time from 10% output voltage to 90% output voltage. Test 2 — Fall time single output switching, one output loaded: • Connect any single output (example Y7) to 18-Ω, 50-W resistor. • Connect the oscilloscope to this output (example Y7). • Set the oscilloscope to trigger on the falling edge with trigger level set to 21.6 V. • Use normal trigger mode, one shot o Set VIN to 24 V. • Set the output to "on". • Set the oscilloscope to "ready". • Set the output to "off". • Measure the time from 90% output voltage to 10% output voltage. TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 15 Test Data 7 www.ti.com Test Data Table 8. Test Results SYMBOL SPECIFICATION CONDITIONS MIN TYP MAX MEAS UNIT VIN(max, off) Input voltage Overvoltage protection stops local power supply, VIN rising — 32 — 32.07 V VIN(max, on) Input voltage Overvoltage protection stops local power supply, VIN falling — 30 — 30.05 V VIN(min, on) Input voltage Undervoltage protection starts local power supply at rising VIN — 12 — 12.01 V VIN(min, off) Input voltage Undervoltage protection stops local power supply at falling VIN — 11 — 11.05 V IIN Input current Normal operation 0.01 (1) — 11 (2) 10 (2) A VLOAD Load supply voltage Normal operation ILOAD Load current VIN Per channel TA = 85°C Per channel TA = 25°C 1.2 3.5 (3) 3.15 A 1.25 4 (4) 3.5 (3) 3.15 A tOVER Overcurrent time All outputs on, RL = 18 Ω, VIN = 27 V, TA = 25°C — 25 — 25.4 ms IOVER Overcurrent limit All outputs on, RL = 18 Ω, VIN = 27 V, TA = 25°C 9.6 11 (2) 12.4 10 A PLOSS(25) Power loss per channel RL = 18 Ω, VLOAD = 21.6 V, TA = 25°C — 150 (5) — mW PLOSS(85) Power loss per channel RL = 18 Ω, VLOAD = 21.6 V, TA = 85°C — 240 (5) mW fSW Switching frequency (PWM) Absolute maximum rating per TPS1H100 datasheet tON(min) Minimum on time Guaranteed by design per TPS1H100 datasheet tOFF(min) Minimum off time tRISE — kHz 50 — µs Guaranteed by design per TPS1H100 datasheet 50 — µs Load voltage rise time, 10% to 90% RL = 18 Ω, VLOAD = 24 V, TA = 25°C, one load 27 45 135 42.8 µs tFALL Load voltage fall time, 90% to 10% RL = 18 Ω, VLOAD = 24 V, TA = 25°C, one load 27 45 135 38 µs PIND Inductive power per output (1) (2) (3) (4) (5) (6) 16 PARAMETER 2 70 (6) mJ/s Depends on number of LEDs on and communication activity Limited by overcurrent protection Limited by current limit resistor designed into TIDA-00183 at TPS1H100 Protection limits total current to 10 A, load can be distributed for example 3 × 3 A + 5 × 0.2 A Based on calculations derived from TPS1H100 datasheet Based on inductive power capabilities of TPS1H100. If the clamping value of TVS diode D89 is set to a voltage level smaller than the clamping level of TPS1H100 then D89 takes all inductive energy. In this case the total inductive power for all outputs together can be 1J/s irrespective how the energy is distributed among the outputs. More copper area can increase the inductive power. Up to 3 J/s is possible. 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Test Data www.ti.com Figure 4 shows the measurement results for the timing of the overcurrent protection. Overcurrent is the condition when the total input current into the connector 24 V is above 10 A and below 20 A. When an overcurrent event occurs, then for a period of 200 ns the current can flow according to Ohm’s law. After the period of 200 ns, the total current gets limited to 10 A. If the overcurrent condition is longer than 25 ms, the local power supply is set to zero. This sets also all outputs to zero. Figure 4. Overcurrent Time TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 17 Test Data www.ti.com Figure 5 shows the measurement results for the fall time. The TPS1H100 controls the slew such that the fall time is in the range of 40 μs. This is necessary to prevent EMI. Figure 5. Fall Time 18 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Test Data www.ti.com Figure 6 shows the measurement results for the rise time. The TPS1H100 controls the slew such that also the rise time is in the range of 40 μs. This is necessary to prevent EMI. Figure 6. Rise Time TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 19 Test Data www.ti.com The thermoscan shows the board operating at full load with an 8×1.2-A output current. The result of the heat management verification is visible in Figure 7 for the top of the PCB and in Figure 8 for the bottom of PCB. The bottom side reaches 78°C on the top surface of the TPS1H100s and the top side peaks at 76°C on the top surface of the TPS1H100s. This corresponds to a temperature rise of 50K in the silicon above the ambient temperature. Based on the heat distribution on thermal images with all eight TPS1H100 active, the temperature rise is small enough for operation at ambient temperatures of 85°C. Assuming a maximum silicon temperature of 150°C, an ambient temperature of 100°C is the absolute maximum. 85°C leaves sufficient guard band for safe operation. Figure 7. Thermal Scan of PCB Top Under Full Load Figure 8. Thermal Scan of PCB Bottom Under Full Load One area of potential improvement on the top layer is the trace marked with 75.2 in Figure 7. When it is made wider, the temperature will go down. This has also a positive effect on the ambient temperature for the protection circuit with the two NexFETs on the bottom side and on the two hottest TPS1H100. Another area of improvement is the cooling of the shunt resistors R98 and R99 between the two NexFETs Q1 and Q2. When the two NexFETs are set apart by 1 cm more, then the temperature of the shunt resistors will go down by 20 K. The hot trace on the top layer will also benefit from this change. 20 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Design Files www.ti.com 8 Design Files 8.1 Schematics To download the schematics, see the design files at TIDA-00183. Figure 9. BeagleBone-Black Connector, ID Prom, and Signage TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 21 Design Files www.ti.com Figure 10. Digital Isolators and Field Power Supply 22 8-Ch Parallel 1-A High-Side Digital Output Module for PLC TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Copyright © 2015, Texas Instruments Incorporated Design Files www.ti.com Figure 11. MCU and Isolated Debug TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 23 Design Files www.ti.com Figure 12. Digital Output Stage 24 8-Ch Parallel 1-A High-Side Digital Output Module for PLC TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Copyright © 2015, Texas Instruments Incorporated Design Files www.ti.com Figure 13. Output Connectors and Surge Protection TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 25 Design Files 8.2 www.ti.com Bill of Materials To download the bill of materials (BOM), see the design files at TIDA-00183. Table 9. BOM ITEM # 26 DESIGNATOR QTY VALUE PARTNUMBER MANUFACTURER TIDA-00183 Any DESCRIPTION PACKAGE REFERENCE 1 !PCB1 1 2 C1, C2, C3, C4, C5, C6, C7, C21, C22, C23, C24, C31, C42, C43, C44, C45, C46, C63 18 0.1uF GRM188R71C104KA01D MuRata CAP, CERM, 0.1 µF, 16 V, +/10%, X7R, 0603 0603 3 C8 1 100pF GRM1885C1H101JA01D MuRata CAP, CERM, 100 pF, 50 V, +/5%, C0G/NP0, 0603 0603 4 C25, C29 2 0.1uF GCM188R71H104KA57D MuRata CAP, CERM, 0.1 µF, 50 V, +/10%, X7R, 0603 0603 5 C26 1 0.022uF C0603C223K5RACTU Kemet CAP, CERM, 0.022 µF, 50 V, +/10%, X7R, 0603 0603 6 C27, C41 2 1000pF 202R18W102KV4E Johanson Technology 7 C28, C61, C62, C64, C65, C67, C68, C70, C71, C95 10 1uF C2012X7S2A105K125AB TDK CAP, CERM, 1 µF, 100 V, +/10%, X7S, 0805 0805 8 C30 1 4.7uF GRM21BR71A475KA73L MuRata CAP, CERM, 4.7 µF, 10 V, +/10%, X7R, 0805 0805 9 C47, C69 2 1000pF GRM188R71E102KA01D MuRata CAP, CERM, 1000 pF, 25 V, +/10%, X7R, 0603 0603 10 C66, C81, C82, C83, C84, C85, C86, C87, C88 9 0.01uF C1608X7R2A103K TDK CAP, CERM, 0.01 µF, 100 V, +/10%, X7R, 0603 0603 11 C89, C90, C92, C93 4 4700pF 1812GC472KA1 AVX CAP, CERM, 4700 pF, 2000 V, +/- 10%, X7R, 1812 1812 12 C91 1 4700pF C2012X7R2A472K TDK CAP, CERM, 4700 pF, 100 V, +/10%, X7R, 0805 0805 13 C94 1 10uF C5750X7S2A106M TDK CAP, CERM, 10 µF, 100 V, +/20%, X7S, 2220 2220 14 C96, C97, C99 3 0.1uF GRM188R72A104KA35D MuRata CAP, CERM, 0.1 µF, 100 V, +/10%, X7R, 0603 0603 15 C98 1 0.47uF GRM188R71E474KA12D MuRata CAP, CERM, 0.47 µF, 25 V, +/10%, X7R, 0603 0603 16 C100 1 4.7uF C3225X7S2A475K200AB TDK CAP, CERM, 4.7uF, 100V, +/10%, X7S, 1210 1210 17 D1, D24, D44, D91, D95 5 Green LTST-C190KGKT Lite-On 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Printed Circuit Board CAP, CERM, 1000 pF, 2000 V, +/- 10%, X7R, 1206_190 LED, Green, SMD 1206_190 1.6x0.8x0.8mm TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Copyright © 2015, Texas Instruments Incorporated Design Files www.ti.com Table 9. BOM (continued) ITEM # DESIGNATOR QTY VALUE PARTNUMBER MANUFACTURER DESCRIPTION PACKAGE REFERENCE 18 D2, D3, D4, D5, D6, D7, D8, D9 8 Orange LTST-C190KFKT Lite-On LED, Orange, SMD 1.6x0.8x0.8mm 19 D10, D11, D12, D13, D14, D15, D16, D17, D43 9 Red LTST-C190CKT Lite-On LED, Red, SMD Red LED, 1.6x0.8x0.8mm 20 D21, D92, D93 3 100V CD0603-S01575 Bourns Diode, Switching, 100 V, 0.15 A, 0603 Diode 0603 Diode 21 D22 1 70V BAV70-V Vishay-Semiconductor Diode, Switching, 70 V, 0.25 A, SOT-23 SOT-23 22 D25 1 30V BAT54C-7-F Diodes Inc. Diode, Schottky, 30 V, 0.2 A, SOT-23 SOT-23 23 D41, D42 2 3V MMBZ5225BLT1G ON Semiconductor Diode, Zener, 3 V, 225 mW, SOT-23 SOT-23 24 D81, D82, D83, D84, D85, D86, D87, D88 8 Blue LB Q39G-L2N2-35-1 OSRAM LED, Blue, SMD 25 D89, D94 2 33V 5.0SMDJ33A Littelfuse Diode, TVS, Uni, 33 V, 5000 W, SMC SMC 26 D90 1 33V SMCJ33CA Bourns Diode, TVS, Bi, 33V, 1500W, SMC SMC 27 FID1, FID2, FID3, FID4, FID5 5 N/A N/A Fiducial mark. There is nothing to buy or mount. N/A 28 H1, H2 2 1841161 Phoenix Contact 29 J1, J2 2 SSHQ-123-D-08-F-LF Major League Electronics 30 J41 1 SBH11-PBPC-D07-RABK Sullins Connector Solutions Header (Shrouded), 2.54 mm, 7x2, Gold, R/A, TH Header (Shrouded), 2.54 mm, 7x2, R/A, TH 31 J81, J82 2 1844265 Phoenix Contact Header (Shrouded), 3.5 mm, 7x1, R/A, TH TH, 7-Leads, Body 9.2x25.9, Pitch 3.5mm 32 L21 1 600 ohm BLM18KG601SN1D MuRata Ferrite Bead, 600 ohm @ 100 MHz, 1.3 A, 0603 0603 33 L22 1 68uH SRN4026-680M Bourns Inductor, Wirewound, Ferrite, 68 µH, 0.35 A, 0.852 ohm, SMD SMD, 2-Leads, Body 4.2x4.2mm 34 LBL1 1 THT-14-423-10 Brady Thermal Transfer Printable Labels, 0.650" W x 0.200" H 10,000 per roll PCB Label 0.650"H x 0.200"W 35 Q81, Q82 2 60V CSD18532Q5B Texas Instruments MOSFET, N-CH, 60V, 172A, SON 5x6mm SON 5x6mm 36 R1, R2, R17, R35, R44 5 0 CRCW06030000Z0EA Vishay-Dale TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback BLUE 0603 LED Fiber optics - MC 1,5/10-LWL 1,5-3,5 for Phoenix connectors Female Connector, 2.54mm, 23x2, TH RES, 0, 5%, 0.1 W, 0603 Female Connector, 2.54mm, 23x2, TH 0603 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 27 Design Files www.ti.com Table 9. BOM (continued) ITEM # 28 DESIGNATOR QTY VALUE PARTNUMBER MANUFACTURER DESCRIPTION PACKAGE REFERENCE 37 R3, R5, R6, R7, R16, R18, R23, R24, R25, R26 10 10.0 CRCW060310R0FKEA Vishay-Dale RES, 10.0, 1%, 0.1 W, 0603 0603 38 R4, R32 2 453 CRCW0603453RFKEA Vishay-Dale RES, 453, 1%, 0.1 W, 0603 0603 39 R8, R9, R10, R11, R12, R13, R14, R21, R22 9 5.62k CRCW06035K62FKEA Vishay-Dale RES, 5.62 k, 1%, 0.1 W, 0603 0603 40 R15 1 21.0k CRCW060321K0FKEA Vishay-Dale RES, 21.0 k, 1%, 0.1 W, 0603 0603 41 R27 1 649 CRCW0603649RFKEA Vishay-Dale RES, 649, 1%, 0.1 W, 0603 0603 42 R28, R29 2 66.5k CRCW060366K5FKEA Vishay-Dale RES, 66.5 k, 1%, 0.1 W, 0603 0603 43 R30 1 1.00 CRCW06031R00FKEA Vishay-Dale RES, 1.00, 1%, 0.1 W, 0603 0603 44 R31 1 86.6k CRCW060386K6FKEA Vishay-Dale RES, 86.6 k, 1%, 0.1 W, 0603 0603 45 R33 1 2.00k CRCW06032K00FKEA Vishay-Dale RES, 2.00 k, 1%, 0.1 W, 0603 0603 46 R34 1 1.00Meg CRCW06031M00FKEA Vishay-Dale RES, 1.00 M, 1%, 0.1 W, 0603 0603 47 R41, R42, R45, R48 4 499 CRCW0603499RFKEA Vishay-Dale RES, 499, 1%, 0.1 W, 0603 0603 48 R43, R65 2 33.2 CRCW060333R2FKEA Vishay-Dale RES, 33.2, 1%, 0.1 W, 0603 0603 49 R46, R47 2 47.5k CRCW060347K5FKEA Vishay-Dale RES, 47.5 k, 1%, 0.1 W, 0603 0603 50 R61, R62, R66, R67, R70, R71, R76, R77 8 806 CRCW0603806RFKEA Vishay-Dale RES, 806, 1%, 0.1 W, 0603 0603 51 R63, R64, R68, R69, R73, R74, R78, R79, R81 9 1.00k CRCW06031K00FKEA Vishay-Dale RES, 1.00 k, 1%, 0.1 W, 0603 0603 52 R72 1 316k CRCW0603316KFKEA Vishay-Dale RES, 316 k, 1%, 0.1 W, 0603 0603 53 R75 1 16.5k CRCW060316K5FKEA Vishay-Dale RES, 16.5 k, 1%, 0.1 W, 0603 0603 54 R80, R82 2 249 CRCW0603249RFKEA Vishay-Dale RES, 249, 1%, 0.1 W, 0603 0603 55 R83, R84, R85, R86, R87, R88, R89, R90, R91, R100 10 10.0k CRCW060310K0FKEA Vishay-Dale RES, 10.0k ohm, 1%, 0.1W, 0603 0603 56 R92 1 95.3k CRCW060395K3FKEA Vishay-Dale RES, 95.3k ohm, 1%, 0.1W, 0603 0603 57 R93 1 8.06k CRCW06038K06FKEA Vishay-Dale RES, 8.06k ohm, 1%, 0.1W, 0603 0603 58 R94 1 47.5k CRCW060347K5FKEA Vishay-Dale RES, 47.5k ohm, 1%, 0.1W, 0603 0603 59 R95 1 14.0k CRCW060314K0FKEA Vishay-Dale RES, 14.0k ohm, 1%, 0.1W, 0603 0603 60 R96 1 57.6k CRCW060357K6FKEA Vishay-Dale RES, 57.6k ohm, 1%, 0.1W, 0603 0603 8-Ch Parallel 1-A High-Side Digital Output Module for PLC TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Copyright © 2015, Texas Instruments Incorporated Design Files www.ti.com Table 9. BOM (continued) ITEM # DESIGNATOR QTY VALUE PARTNUMBER MANUFACTURER DESCRIPTION 61 R97 1 100 CRCW0603100RFKEA Vishay-Dale RES, 100 ohm, 1%, 0.1W, 0603 62 R98, R99 2 0.01 WSLP1206R0100FEA Vishay-Dale RES, 0.01 ohm, 1%, 1W, 1206 PACKAGE REFERENCE 0603 1206 63 S1 1 219-4LPST CTS Electrocomponents Switch, SPST 4 Pos, Top Actuated, SMT SMD, 8-Leads, Body 11.93x6.95mm, Pitch 2.54mm 64 S21 1 219-2LPST CTS Electrocomponents Switch, Slide, SPST 2 poles, SMT 2 poles SPST Switch 65 T21 1 475uH 760390014 Wurth Elektronik Transformer, 475uH, SMT 10.05x4.19x6.73 mm 66 TP41 1 Black 5001 Keystone Test Point, Miniature, Black, TH Black Miniature Testpoint DCT0008A 67 U1 1 SN74LVC2G86DCTR Texas Instruments Dual 2-Input Exclusive-OR Gate, DCT0008A 68 U2 1 SN74LVC1G332DCKR Texas Instruments Single 3-Input Positive-OR Gate, DCK0006A DCK0006A 69 U3 1 SN74LVC1G19DCKR Texas Instruments 1-OF-2 DECODER/DEMULTIPLEXER, DCK0006A DCK0006A 70 U4 1 SN74LVC1G58DCKR Texas Instruments Configurable Multiple-Function Gate, DCK0006A DCK0006A DBQ0024A 71 U5 1 TLC5928DBQ Texas Instruments 16-Channel Constant Current LED Driver with LED Open Detection, 3 to 5.5 V, -40 to 85 degC, 24-pin SOP (DBQ24), Green (RoHS & no Sb/Br) 72 U6 1 CAT24C256WI-G ON Semiconductor 256 kb I2C CMOS Serial EEPROM, SOIC-8 73 U7, U8 2 SN74LVC1G125DCKR Texas Instruments Single Bus Buffer Gate With 3State Output, DCK0005A 74 U21 1 ISO7421DR Texas Instruments 1 Mbps Dual Channels, 1 / 1, Digital Isolator, 3.3 V / 5 V, -40 to +105 degC, 8-pin SOIC (D), Green (RoHS & no Sb/Br) 75 U22, U41 2 ISO7141CCDBQR Texas Instruments 4242-VPK Small-Footprint and Low-Power Quad Channels Digital Isolators, DBQ0016A 76 U23 1 LM5009MM/NOPB Texas Instruments 150 mA, 100V Step-Down Switching Regulator, 8-pin MSOP, Pb-Free 77 U25 1 SN6501DBV Texas Instruments Transformer Driver for Isolated Power Supplies, DBV0005A TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback SOIC-8 DCK0005A D0008A DBQ0016A MUA08A DBV0005A 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 29 Design Files www.ti.com Table 9. BOM (continued) ITEM # QTY VALUE PARTNUMBER MANUFACTURER DESCRIPTION PACKAGE REFERENCE 78 U26, U42, U45 3 SN74LVC1G07DCK Texas Instruments SINGLE BUFFER/DRIVER WITH OPEN-DRAIN OUTPUT, DCK0005A DCK0005A 79 U43 1 ISO7141FCCDBQR Texas Instruments 4242-VPK Small-Footprint and Low-Power Quad Channels Digital Isolators, DBQ0016A DBQ0016A Texas Instruments 16 MHz Mixed Signal Microcontroller with 2 KB Flash, 256 B SRAM and 24 GPIOs, -40 to 105 degC, 32-pin QFN (RHB), Green (RoHS & no Sb/Br) RHB0032E PWP0014C 80 U44 81 U61, U62, U64, U65, U66, U67, U68, U69 8 TPS1H100BQPWPRQ1 Texas Instruments 40V/100mO Single Channel Smart High Side Switch, Automotive Qualified, PWP0014C 82 U63 1 SN74LV164APWR Texas Instruments 8-BIT PARALLEL-OUT SERIAL SHIFT REGISTERS, PW0014A PW0014A 83 U81, U82, U83, U84 4 SR70-02CTG Littelfuse ESD Suppressor Diode Arrays, 70V, SMD 3.04X1.22X1.4 84 U85 1 LM5050MK-1/NOPB Texas Instruments LM5050-1 High Side OR-ing FET Controller, DDC0006A DDC0006A National Semiconductor Positive High Voltage Hot Swap / Inrush Current Controller with Power Limiting, 10-pin MSOP, Pb-Free MUB10A 85 30 DESIGNATOR U86 1 MSP430F2112TRHBR 70V 1 LM5069MM-2/NOPB 8-Ch Parallel 1-A High-Side Digital Output Module for PLC TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Copyright © 2015, Texas Instruments Incorporated Design Files www.ti.com 8.3 PCB Layout Recommendations and Guidelines Sufficient cooling of the TPS1H100s is critical to the design and requires thermal vias under the devices and contiguous copper area. In this design, thermal vias are also used to transfer the heat between the layers if traces break the cooling area. Surges can cause high current flow transients in excess of 200 A. The impedance of the power supply traces must be low. Therefore, they must be optimized to wide and short. The protective devices must be located close to the connector. This stops the high current transients before the sensitive inner part of the design. Figure 14. Top View Figure 15. Bottom View TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 31 Design Files 8.3.1 www.ti.com Layer Plots To download the layer plots, see the design files at TIDA-00183. 32 Figure 16. Top Silkscreen Figure 17. Top Solder Mask Figure 18. Top Layer Figure 19. Signal Layer 1 Figure 20. Signal Layer 2 Figure 21. Bottom Layer Figure 22. Bottom Solder Mask Figure 23. Bottom Silkscreen 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Design Files www.ti.com Figure 24. Mechanical Dimensions 8.4 Figure 25. Fabrication Altium Project To download the Altium project files, see the design files at TIDA-00183. Figure 26. Altium Project Image 1 8.5 Gerber Files To download the Gerber files, see the design files at TIDA-00183. 8.6 Assembly Drawings To download the assembly drawings, see the design files at TIDA-00183. Figure 27. Top Assembly Drawing TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Figure 28. Bottom Assembly Drawing 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated 33 References 9 www.ti.com References 1. Texas Instruments, 24-V DC,10-A eFuse and Protection Circuit for Programmable Logic Controllers (PLC), TIDA-00233 Design Guide (TIDU415) 2. Texas Instruments, Thermal Considerations for Surface Mount Layouts, Seminar (Web) 3. Texas Instruments, 8-Ch Parallel 0.5-A Low-Side Digital Output Module for Programmable Logic Controllers (PLCs), TIDA-00320 Design Guide (TIDU705) 10 About the Author INGOLF FRANK is a systems engineer in the Texas Instruments Factory Automation and Control team, focusing on programmable logic controller I/O modules. Ingolf works across multiple product families and technologies to leverage the best solutions possible for system level application design. Ingolf earned his electrical engineering degree (Dipl. Ing. (FH)) in the field of information technology at the University of Applied Sciences Bielefeld, Germany in 1991. 34 8-Ch Parallel 1-A High-Side Digital Output Module for PLC Copyright © 2015, Texas Instruments Incorporated TIDUA37A – June 2015 – Revised June 2015 Submit Documentation Feedback Revision History www.ti.com Revision History Changes from Original (June 2015) to A Revision ......................................................................................................... Page • Changed from preview page ............................................................................................................. 1 NOTE: Page numbers for previous revisions may differ from page numbers in the current version. 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