60V-2A DC-DC Module Converter (template)

Highlighted Feature

High efficiency monolithic synchronous step-down DC/DC converter utilizing a constant frequency, average current mode control architecture. Capable of delivering up to 1.5A continuous load with excellent line and load regulation. The device operates from an input voltage range of 7.5V to 60 V and provides an adjustable output voltage from 1.0V to 40V.

Features:

Wide 7.5V to 60 V Operating input Range with
maximum 100V transiens
Peak Output Current: 2A
350μA Quiescent Current
Adjustable Output Voltages
Output Voltage Accuracy ：±2%
Frequency ：350kHz
Burst Mode Operation at Light Load
Cycle-by-Cycle Over Current Protection
Output Short Circuit Protection with Hiccup
Internal Soft Start

Block Diagram

PCB Overview

Pin Out Table

Pin 1	Vin	5-60V
Pin 2	GND	0V
Pin 3	GND	0V
Pin 4	Vout	1-40V

Test Results

To test the efficiency, four multimeters are used; two are set up as voltmeters to measure the input and
output voltages, and two are set up as ampmeters to measure the input and output currents.

The measurements are done at a room temperature of 22.5ºC

Efficiency curve ( draw by excel)

Efficency table at 18V input

V_in (V)	I_in (A)	V_out (V)	I_out (A)	η (efficency)
17,77	0,725	11,99	0,997	0,92787379
17,8	0,646	12	0,899	0,938184854
17,82	0,574	12,02	0,7995	0,93951419
17,85	0,502	12,03	0,699	0,938427801
17,87	0,428	12,03	0,6	0,943731728
17,89	0,363	12,03	0,5	0,926229622
17,91	0,298	12,03	0,4	0,901599721
17,93	0,223	12,1	0,301	0,910891634
17,97	0,145	12,16	0,201	0,938023142

Efficency table at 24V input

V_in (V)	I_in (A)	V_out (V)	I_out (A)	η (efficency)
23,77	0,539	12	0,997	0,933809865
23,8	0,489	12,02	0,899	0,928492379
23,82	0,439	12,02	0,7995	0,919002427
23,85	0,379	12,01	0,699	0,928736662
23,87	0,329	12,01	0,6	0,91758423
23,89	0,268	12,01	0,5	0,937911947
23,91	0,224	12,05	0,4	0,899952202
23,93	0,169	12,1	0,301	0,900580342
23,97	0,113	12,13	0,201	0,900140663

Efficency table at 48V input

V_in (V)	I_in (A)	V_out (V)	I_out (A)	η (efficency)
47.77	0.352	12.01	0.997	0.933728
47.8	0.331	12.01	0.899	0.935516
47.82	0.291	12.01	0.7995	0.943191
47.85	0.266	12.01	0.699	0.947382
47.87	0.237	12.01	0.6	0.950832
47.89	0.21	12.02	0.5	0.954707
47.91	0.186	12.08	0.4	0.958073
47.93	0.153	12.11	0.301	0.958937
47.95	0.13	12.22	0.201	0.954739

Thermal

The thermal pictures in below was taken at a room temperature of 26°C, with a 48-V input, 12V at 1A, 0.8A and 0.6A output without airflow.

0.6A Output

0.8A Output

1A Output

The thermal pictures was taken at a room temperature of 26°C, with a 48-V input after 30 minutes used for 0.6A, 0.8A, 1A output load.

Output Voltage Ripple
How to measure ripple current with oscilloscope probe properly? read this document

Ripple voltage with no-load output

Ripple voltage with 10mA output

Ripple voltage with 1A output

Transient Response

The transient response is below ±200 mV for load steps between 10 mA and 1 A, which were the design
requirements (±5%).

Measurements were done at 22.5°C room temperature with 48-V input voltage. The upper curve (1) is the
output voltage with oscilloscope in AC-coupling mode with 100 mV/div. The lower curve (2) is the output
current with the current probe 100 mV/A with 200 mV/div. The load step is applied with a 250-mA/μs slew
rate.

Start-up and Shutdown

For the start-up and the shutdown behavior, 48 V is applied at the input with a 1-A load at the output.
The EN setting resistors (R2 and R5) are not populated, and the Enable pin is controlled with a 5-V signal.
Measurements were done at 22.5ºC room temperature. The upper curve (1) is the output voltage with
oscilloscope in DC-coupling mode with 2 V/div. The lower curve (2) is the Enable signal with 5 V/div.

Overcurrent and Short-Circuit Test

The overcurrent protection was tested by having a transient load from 1- to 3-A output current while the
board is supplied with 12 V. The short-circuit protection was tested by shorting the output pin to ground.

Standby and No-Load Currents

The no-load current was measured with an ammeter at 22.5°C room temperature with a 12-V input
voltage, with the enable setting resistors populated and no load attached at the output. The
no-load current was measured at 76 μA

Reference document: 5V 1A Low EMI 94% Efficiency DC/DC Module in Dual Layer TO-220 Design Guide (Rev. A)