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TPS2490: Design for power limiting of LM76005 with high bulk output capacitance [URGENT]

Part Number: TPS2490
Other Parts Discussed in Thread: LM5069, LM76005, TPS1663, TPS1653

Hello,

As referenced in this related post, we need precise inrush / continuous power limiting of an LM76005-based buck converter with a large amount of bulk output capacitance. At startup, we need to limit power to ~13W, and afterward this power limit will be increased in defined steps up to ~70W max using an MCU-controlled resistor ladder. For this purpose, the FAE in the other thread recommended the LM5069, and it appears that the TPS2490 is equally suitable for this purpose. We're on a tight timeline, and since the LM76005 does not appear to be effectively able to limit current using its soft-start function, we'd appreciate urgent design assistance from TI.

The biggest challenge in this design is that we require 6mF of output capacitance on the LM76005. It sounds like the topology that the other FAE was proposing was placing a hot-swap controller in front of the buck converter, with some amount of bulk input capacitance (we calculate ~14uF minimum). It would be helpful if you could provide a PSPICE simulation validating this approach. We were also planning to use a TPS259470x eFuse downstream of the buck to control inrush to a downstream module supplied by the buck.

Here are the overall parameters:

V_in 42-59V
V_out 21V
V_out(p-p) 100mV
I_out(max) 3.4A
P_lim(inrush) 13W
P_lim(max) 70W
C_out 6mF
C_in (upstream of HS controller) 160uF
  • Hi Kenneth,

    Thanks for reaching out to us.

    I'd like to request you also to look into TPS1663 and TPS1653. These are integrated eFuse solutions. Your design will be much simpler.

    Please refer to the below app note. This will help in charging 6 mF capacitor. 

    Reliable Startup with Large and Unknown Capacitive Loads (Rev. A)

  • I have looked at the TPS1633 and the TPS1653.

    • The TPS1653 is not suitable for our application due to the input voltage range (obviously, given the parameters we provided).
    • It appears that output power limiting is available on the TPS16632 only, which has a fixed overvoltage clamp of 39V maximum. So even if we could get our startup power dissipation below the maximums for T_a, we'd be dropping 3-20V using the MOSFET for clamping. Not workable.

    The parameters that eliminate these components as options were listed in the table above. Unless you've got a better suggestion, I presume that the LM5069 is the best choice for us, as an external FET will allow us to select something with an SOA reasonable for our P_d on startup. Is that correct? Am I missing something?

  • Hi Kenneth,

    I will check about TPS1663 and TPS1653 and let you know by today. 

    Meanwhile, please fill out the design calculators to start with the hot swap design.

    LM5069: https://www.ti.com/tool/download/LM5069QUICK-CALC 

    TPS2490: https://www.ti.com/tool/TPS2480-81-90-91-92-93_CALC 

    Robust Hot Swap Design (Rev. A) (ti.com)

  • Neither the LM5069 nor the TPS2490 appear to do any power limiting other than for the purpose of keeping their MOSFETs in their SOA. These clearly will not achieve our objectives as stated in the original post.

    As the FAE, I generally expect YOU AND YOUR TEAM to read and understand our requests, and help us select components that meet our objectives – which none of your recommendations have, thus far. I shouldn't have to tell you how to do your job. I'm sure you guys are under pressure, and I respect that, but you're wasting my time rather than escalating this issue, and that's not cool.

    Analog Devices FAEs have been very helpful in this regard, and we have a workable solution with them. You guys have 24 hours to come up with a solution that achieves the objective using your products, or we'll move our business over there.

    Finally: please reassign this ticket to someone in the Pacific (UTC-08:00) timezone. I need same-day responses on this issue, and it's 11PM my time.

  • Hi Kenneth,

    Sorry for the inconvenience to you. The applications engineer responsible for LM5069 or TPS2490 is located in India, not the US. I am not an FAE.

    TI doesn't have any released parts to meet your requirements. However, we have one part on the road map. If you are interested in learning more, please reach out to your TI representative to schedule a meeting with us. Otherwise, please share your email address. We will schedule a meeting with you. 

  • We're moving our efforts over to Analog Devices.