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8-Ch Parallel 1-A High-Side Digital Output Module for PLC
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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
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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
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8-Ch Parallel 1-A High-Side Digital Output Module for PLC
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1
Key System Specifications
1
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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
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System Description
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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
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Block Diagram
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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
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Block Diagram
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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.
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System Design Theory
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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
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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
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System Design Theory
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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
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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.
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4.4
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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
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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.
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Getting Started Hardware
5
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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
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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.
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Test Setup
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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
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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.
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Test Data
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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
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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
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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
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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
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Test Data
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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
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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
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Figure 10. Digital Isolators and Field Power Supply
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Figure 11. MCU and Isolated Debug
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Figure 12. Digital Output Stage
24
8-Ch Parallel 1-A High-Side Digital Output Module for PLC
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Figure 13. Output Connectors and Surge Protection
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Design Files
8.2
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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
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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
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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
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Design Files
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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
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Design Files
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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
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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
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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
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Design Files
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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
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8-Ch Parallel 1-A High-Side Digital Output Module for PLC
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31
Design Files
8.3.1
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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
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Design Files
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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
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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
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Revision History
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Revision History
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