LM5025A
UVLO
COMP
OUT_A
OUT_B
VCC
SS
Rt SYNC
REF
TIME
RAMP
CS1
VIN
CS2
VIN
35 ± 78 V
PGND AGND
UP/DOWN
SYNC
VOUT
3.3 V
ERROR
AMP &
ISOLATION
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An IMPORTANT NOTICE at the end of this data sheet addresses availability, warranty, changes, use in safety-critical applications,
intellectual property matters and other important disclaimers. PRODUCTION DATA.
LM5025A
SNVS293F DECEMBER 2004REVISED AUGUST 2016
LM5025A Active Clamp Voltage Mode PWM Controller
1
1 Features
1 Internal Start-Up Bias Regulator
3-A Compound Main Gate Driver
Programmable Line Undervoltage Lockout (UVLO)
With Adjustable Hysteresis
Voltage Mode Control With Feedforward
Adjustable Dual Mode Overcurrent Protection
Programmable Overlap or Dead Time Between
the Main and Active Clamp Outputs
Volt × Second Clamp
Programmable Soft Start
Leading Edge Blanking
Single Resistor Programmable Oscillator
Oscillator UP and DOWN Sync Capability
Precision 5-V Reference
Thermal Shutdown
Packages:
16-Pin TSSOP
Thermally Enhanced 16-Pin WSON
(5 mm × 5 mm)
2 Applications
Server Power Supplies
48-V Telecom Power Supplies
42-V Automotive Applications
High-Efficiency DC-to-DC Power Supplies
3 Description
The LM5025A is a functional variant of the LM5025
active clamp PWM controller. The functional
differences of the LM5025A are that the CS1 and
CS2 current limit thresholds have been increased to
0.5 V, the internal CS2 filter discharge device has
been disabled and no longer operates each clock
cycle, and the internal VCC and VREF regulators
continue to operate when the line UVLO pin is below
threshold.
The LM5025A PWM controller contains all of the
features necessary to implement power converters
using the Active Clamp / Reset technique. With the
active clamp technique, higher efficiencies and
greater power densities can be realized compared to
conventional catch winding or RDC clamp / reset
techniques. Two control outputs are provided: the
main power switch control (OUT_A) and the active
clamp switch control (OUT_B). The two internal
compound gate drivers parallel both MOS and bipolar
devices, providing superior gate drive characteristics.
This controller is designed for high-speed operation
including an oscillator frequency range up to 1 MHz
and total PWM and current sense propagation delays
less than 100 ns. The LM5025A includes a high-
voltage start-up regulator that operates over a wide
input range of 13 V to 90 V. Additional features
include: line undervoltage lockout (UVLO), soft start,
oscillator UP and DOWN sync capability, precision
reference, and thermal shutdown.
Device Information(1)
PART NUMBER PACKAGE BODY SIZE (NOM)
LM5025A TSSOP (16) 5.00 mm × 4.40 mm
WSON (16) 5.00 mm × 5.00 mm
(1) For all available packages, see the orderable addendum at
the end of the data sheet.
Simplified Active Clamp Forward Power Converter
2
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Table of Contents
1 Features.................................................................. 1
2 Applications ........................................................... 1
3 Description............................................................. 1
4 Revision History..................................................... 2
5 Pin Configuration and Functions......................... 3
6 Specifications......................................................... 5
6.1 Absolute Maximum Ratings ...................................... 5
6.2 ESD Ratings.............................................................. 5
6.3 Recommended Operating Conditions....................... 5
6.4 Thermal Information.................................................. 5
6.5 Electrical Characteristics........................................... 6
6.6 Typical Characteristics.............................................. 9
7 Detailed Description............................................ 11
7.1 Overview................................................................. 11
7.2 Functional Block Diagram....................................... 12
7.3 Feature Description................................................. 13
7.4 Device Functional Modes........................................ 17
8 Application and Implementation ........................ 18
8.1 Application Information............................................ 18
8.2 Typical Application ................................................. 18
8.3 System Example..................................................... 23
9 Power Supply Recommendations...................... 23
10 Layout................................................................... 23
10.1 Layout Guidelines ................................................. 23
10.2 Layout Example .................................................... 24
10.3 Thermal Protection................................................ 24
11 Device and Documentation Support................. 25
11.1 Documentation Support ........................................ 25
11.2 Receiving Notification of Documentation Updates 25
11.3 Community Resources.......................................... 25
11.4 Trademarks........................................................... 25
11.5 Electrostatic Discharge Caution............................ 25
11.6 Glossary................................................................ 25
12 Mechanical, Packaging, and Orderable
Information........................................................... 25
4 Revision History
NOTE: Page numbers for previous revisions may differ from page numbers in the current version.
Changes from Revision E (March 2013) to Revision F Page
Added ESD Ratings table, Feature Description section, Device Functional Modes,Application and Implementation
section, Power Supply Recommendations section, Layout section, Device and Documentation Support section, and
Mechanical, Packaging, and Orderable Information section ................................................................................................. 1
Changed Thermal Information table ...................................................................................................................................... 5
Deleted the THERMAL RESISTANCE row from Electrical Characteristics .......................................................................... 8
Changes from Revision D (March 2013) to Revision E Page
Changed layout of National Semiconductor Data Sheet to TI format .................................................................................. 18
1VIN 16 UVLO
2RAMP 15 SYNC
3CS1 14 RT
4CS2 13 COMP
5TIME 12 SS
6REF 11 AGND
7VCC 10 PGND
8OUT_A 9 OUT_B
Not to scale
3
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5 Pin Configuration and Functions
PW or NHQ Packages
16-Pin TSSOP or WSON
Top View
Pin Functions
PIN I/O DESCRIPTION APPLICATION INFORMATION
NO. NAME
1 VIN I Source input voltage Input to start-up regulator. Input range 13 V to 90 V,
with transient capability to 105 V.
2 RAMP I Modulator ramp signal An external RC circuit from Vin sets the ramp slope.
This pin is discharged at the conclusion of every
cycle by an internal FET, initiated by either the
internal clock or the V × Sec Clamp comparator.
3 CS1 I Current sense input for cycle-by-
cycle limiting
If CS1 exceeds 0.5 V the outputs goes into Cycle-
by-Cycle current limit. CS1 is held low for 50 ns
after OUT_A switches high providing leading edge
blanking.
4 CS2 I Current sense input for soft restart
If CS2 exceeds 0.5 V, the outputs will be disabled
and a soft start commenced. The soft-start
capacitor will be fully discharged and then released
with a pullup current of 1 µA. After the first output
pulse (when SS =1 V), the SS charge current will
revert back to 20 µA.
5 TIME I Output overlap and dead-time
control
An external resistor (RSET) sets either the overlap
time or dead time for the active clamp output. An
RSET resistor connected between TIME and GND
produces in-phase OUT_A and OUT_B pulses with
overlap. An RSET resistor connected between TIME
and REF produces out-of-phase OUT_A and
OUT_B pulses with dead time.
6 REF O Precision 5-V reference output Maximum output current: 10-mA locally decouple
with a 0.1-µF capacitor. Reference stays low until
the VCC UV comparator is satisfied.
7 VCC POutput from the internal high
voltage start-up regulator. The VCC
voltage is regulated to 7.6 V.
If an auxiliary winding raises the voltage on this pin
above the regulation setpoint, the internal start-up
regulator shuts down, reducing the IC power
dissipation.
8 OUT_A O Main output driver Output of the main switch PWM output gate driver.
Output capability of 3-A peak sink current.
4
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Pin Functions (continued)
PIN I/O DESCRIPTION APPLICATION INFORMATION
NO. NAME
9 OUT_B O Active Clamp output driver Output of the Active Clamp switch gate driver.
Capable of 1.25-A peak sink current..
10 PGND G Power ground Connect directly to analog ground.
11 AGND G Analog ground Connect directly to power ground. For the WSON
package option, the exposed pad is electrically
connected to AGND.
12 SS I Soft-start control An external capacitor and an internal 20-µA current
source set the soft-start ramp. The SS current
source is reduced to 1 µA initially following a CS2
overcurrent event or an overtemperature event.
13 COMP I Input to the Pulse Width Modulator An internal 5-kΩresistor pullup is provided on this
pin. The external opto-coupler sinks current from
COMP to control the PWM duty cycle.
14 RT I Oscillator timing resistor pin An external resistor connected from RT to ground
sets the internal oscillator frequency.
15 SYNC I Oscillator UP and DOWN
synchronization input
The internal oscillator can be synchronized to an
external clock with a frequency 20% lower than the
internal oscillator’s free running frequency. There is
no constraint on the maximum sync frequency.
16 UVLO I Line undervoltage shutdown
An external voltage divider from the power source
sets the shutdown comparator levels. The
comparator threshold is 2.5 V. Hysteresis is set by
an internal current source (20 µA) that is switched
ON or OFF as the UVLO pin potential crosses the
2.5-V threshold.
EP G Exposed pad, underside of the
WSON package option Internally bonded to the die substrate. Connect to
GND potential for low thermal impedance.
5
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(1) Stresses beyond those listed under Absolute Maximum Ratings may cause permanent damage to the device. These are stress ratings
only, which do not imply functional operation of the device at these or any other conditions beyond those indicated under Recommended
Operating Conditions. Exposure to absolute-maximum-rated conditions for extended periods may affect device reliability.
(2) If Military/Aerospace specified devices are required, please contact the TI Sales Office/ Distributors for availability and specifications.
6 Specifications
6.1 Absolute Maximum Ratings
over operating free-air temperature range (unless otherwise noted)(1)(2)
MIN MAX UNIT
VIN to GND –0.3 105 V
VCC to GND –0.3 16 V
CS1, CS2 to GND –0.3 1 V
All other inputs to GND –0.3 7 V
Junction temperature, TJ150 °C
Storage temperature, Tstg –55 150 °C
(1) JEDEC document JEP155 states that 500-V HBM allows safe manufacturing with a standard ESD control process.
6.2 ESD Ratings VALUE UNIT
V(ESD) Electrostatic discharge Human-body model (HBM)(1) ±2000 V
6.3 Recommended Operating Conditions
over operating free-air temperature range (unless otherwise noted) MIN MAX UNIT
VIN voltage 13 90 V
External voltage applied to VCC 8 15 V
Operating junction temperature –40 125 °C
(1) For more information about traditional and new thermal metrics, see the Semiconductor and IC Package Thermal Metrics application
report.
6.4 Thermal Information
THERMAL METRIC(1) LM5025A
UNITPW (TSSOP) NHQ (WSON)
16 PINS 16 PINS
RθJA Junction-to-ambient thermal resistance 98.7 30 °C/W
RθJC(top) Junction-to-case (top) thermal resistance 27.8 25.9 °C/W
RθJB Junction-to-board thermal resistance 44.3 9.3 °C/W
ψJT Junction-to-top characterization parameter 1.2 0.2 °C/W
ψJB Junction-to-board characterization parameter 43.6 9.5 °C/W
RθJC(bot) Junction-to-case (bottom) thermal resistance 2.3 °C/W
6
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(1) All electrical characteristics having room temperature limits are tested during production with TA= TJ= 25°C. All hot and cold limits are
specified by correlating the electrical characteristics to process and temperature variations and applying statistical process control.
(2) Device thermal limitations may limit usable range.
6.5 Electrical Characteristics
Typical limits are for TJ= 25°C, and minimum and maximum limits apply over the operating junction temperature range
(–40°C to 125°C). VIN = 48 V, VCC = 10 V, RT = 31.3 kΩ, RSET = 27.4 kΩ) unless otherwise stated (1)
PARAMETER TEST CONDITIONS MIN TYP MAX UNIT
START-UP REGULATOR
VCC
Reg VCC regulation No load TJ= 25°C 7.6 V
TJ= Tlow to Thigh 7.3 7.9
VCC current limit See (2) TJ= 25°C 25 mA
TJ= Tlow to Thigh 20
I-VIN Start-up regulator leakage
(external Vcc Supply) VIN = 100 V TJ= 25°C 165 µA
TJ= Tlow to Thigh 500
VCC SUPPLY
VCC undervoltage lockout
voltage (positive going Vcc)
TJ= 25°C VCC Reg -
120 mV V
TJ= Tlow to Thigh VCC Reg -
220 mV
VCC undervoltage
hysteresis TJ= 25°C 1.5 V
TJ= Tlow to Thigh 1 2
VCC supply current (ICC) Cgate = 0 TJ= Tlow to Thigh 4.2 mA
REFERENCE SUPPLY
VREF
Ref voltage IREF = 0 mA TJ= 25°C 5 V
TJ= Tlow to Thigh 4.85 5.15
Ref voltage regulation IREF = 0 to 10mA TJ= 25°C 25 mV
TJ= Tlow to Thigh 50
Ref current limit TJ= 25°C 20 mA
TJ= Tlow to Thigh 10
CURRENT LIMIT
CS1
Prop CS1 delay to output CS1 Step from 0 to 0.6 V,
Time to onset of OUT Transition (90%),
Cgate = 0 40 ns
CS2
Prop CS2 delay to output CS2 Step from 0 to 0.6 V,
Time to onset of OUT Transition (90%),
Cgate = 0 50 ns
Cycle by cycle threshold
voltage (CS1) TJ= 25°C 0.5 V
over full operating junction temperature 0.45 0.55
Cycle skip threshold voltage
(CS2) Resets SS capacitor;
auto restart TJ= 25°C 0.5 V
TJ= Tlow to Thigh 0.45 0.55
Leading edge blanking time
(CS1) 50 ns
CS1 sink impedance
(clocked) CS1 = 0.4 V TJ= 25°C 30 Ω
TJ= Tlow to Thigh 50
CS1 sink impedance (post
fault discharge) CS1 = 0.6 V TJ= 25°C 15 Ω
TJ= Tlow to Thigh 30
CS2 sink impedance (post
fault discharge) CS2 = 0.6 V TJ= 25°C 55 Ω
TJ= Tlow to Thigh 95
CS1 and CS2 leakage
current CS = CS Threshold
100 mV TJ= Tlow to Thigh 1 µA
7
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Electrical Characteristics (continued)
Typical limits are for TJ= 25°C, and minimum and maximum limits apply over the operating junction temperature range
(–40°C to 125°C). VIN = 48 V, VCC = 10 V, RT = 31.3 kΩ, RSET = 27.4 kΩ) unless otherwise stated (1)
PARAMETER TEST CONDITIONS MIN TYP MAX UNIT
SOFT-START
Soft-start current source
normal TJ= 25°C 22 µA
over full operating junction temperature 17 27
Soft-start current source
following a CS2 event TJ= 25°C 1 µA
over full operating junction temperature 0.5 1.5
OSCILLATOR
Frequency1 TA= 25°C, 180 200 220 kHz
TJ= Tlow to Thigh 175 225
Frequency2 RT = 10.4 kΩTA= 25°C, 580 kHz
TJ= Tlow to Thigh 510 650
Sync threshold 2 V
Min sync pulse width TJ= Tlow to Thigh 100 ns
Sync frequency range TJ= Tlow to Thigh 160 kHz
PWM COMPARATOR
Delay to output COMP step 5 V to 0 V,
Time to onset of OUT_A transition low 40 ns
Duty cycle range TJ= Tlow to Thigh 0% 80%
COMP to PWM offset TA= 25°C, 1 V
TJ= Tlow to Thigh 0.7 1.3
COMP open-circuit voltage TJ= Tlow to Thigh 4.3 5.9 V
COMP short-circuit current COMP = 0 V TA= 25°C, 1 mA
TJ= Tlow to Thigh 0.6 1.4
VOLT × SECOND CLAMP
Ramp clamp level
Delta RAMP
measured from onset
of OUT_A to Ramp
peak,
COMP = 5 V
TA= 25°C, 2.5
V
TJ= Tlow to Thigh 2.4 2.6
UVLO SHUTDOWN
Undervoltage shutdown
threshold TA= 25°C, 2.5 V
TJ= Tlow to Thigh 2.44 2.56
Undervoltage shutdown
hysteresis TA= 25°C, 20 µA
TJ= Tlow to Thigh 16 24
OUTPUT SECTION
OUT_A high saturation MOS device at
Iout = –10 mA TA= 25°C, 5 Ω
TJ= Tlow to Thigh 10
OUTPUT_A peak current
sink Bipolar Device at Vcc/2 3 A
OUT_A low saturation MOS device at
Iout = 10 mA TA= 25°C, 6 Ω
TJ= Tlow to Thigh 9
OUTPUT_A rise time Cgate = 2.2 nF 20 ns
OUTPUT_A fall time Cgate = 2.2 nF 15 ns
OUT_B high saturation MOS device at
Iout = –10 mA TA= 25°C, 10 Ω
TJ= Tlow to Thigh 20
OUTPUT_B peak current
sink Bipolar device at Vcc/2 1 A
8
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Electrical Characteristics (continued)
Typical limits are for TJ= 25°C, and minimum and maximum limits apply over the operating junction temperature range
(–40°C to 125°C). VIN = 48 V, VCC = 10 V, RT = 31.3 kΩ, RSET = 27.4 kΩ) unless otherwise stated (1)
PARAMETER TEST CONDITIONS MIN TYP MAX UNIT
OUT_B low saturation MOS device at
Iout = 10 mA TA= 25°C, 12 Ω
TJ= Tlow to Thigh 18
OUTPUT_B rise time Cgate = 1 nF 20 ns
OUTPUT_B fall time Cgate = 1 nF 15 ns
OUTPUT TIMING CONTROL
Overlap time RSET = 38 kΩ
connected to GND,
50% to 50%
transitions
TA= 25°C, 105 ns
TJ= Tlow to Thigh 75 135
Dead time RSET = 29.5 kΩ
connected to REF,
50% to 50%
transitions
TA= 25°C, 105 ns
TJ= Tlow to Thigh 75 135
THERMAL SHUTDOWN
TSD Thermal shutdown
threshold 165 °C
Thermal shutdown
hysteresis 25 °C
-40 25 _75 _125
TEMPERATURE (oC)
80
90
100
110
120
130
140
OVERLAP TIME (ns)
020 40 60 80 100 120
RSET (k:)
0
50
100
150
200
250
300
350
400
OVERLAP TIME (ns)
0 2 4 6 8 10 12 14 16
VIN (V)
0
2
4
6
8
10
12
14
16
VCC (V)
VIN
VCC
0 5 10 15 20 25
0
2
4
6
8
10
VCC (V)
ICC (mA)
9
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6.6 Typical Characteristics
Figure 1. VCC Regulator Start-Up Characteristics, VCC vs VIN Figure 2. VCC vs ICC
Figure 3. VREF vs IREF Figure 4. Oscillator Frequency vs RT
Figure 5. Overlap Time vs RSET
RSET = 38 K
Figure 6. Overlap Time vs Temperature
-40 25 75 125
TEMPERATURE (oC)
14
16
18
20
22
24
26
SS CURRENT (PA)
-40 25 75 125
TEMPERATURE (oC)
80
90
100
110
120
130
140
DEADTIME (ns)
020 40 60 80 100 120
RSET (k:)
0
50
100
150
200
250
300
350
400
DEADTIME (ns)
10
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Typical Characteristics (continued)
Figure 7. Dead Time vs RSET
RSET = 29.5 K
Figure 8. Dead Time vs Temperature
Figure 9. SS Pin Current vs Temperature
11
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7 Detailed Description
7.1 Overview
The LM5025A PWM controller contains all of the features necessary to implement active clamp / reset technique
voltage-mode controlled power converters. Synchronous rectification allows higher conversion efficiency and
greater power density than conventional PN or Schottky rectifier techniques. The high voltage start-up regulator
of the LM5025A can be configured to operate with input voltages ranging from 13 V to 90 V. Additional features
include line undervoltage lockout, cycle-by-cycle current limit, voltage feed-forward compensation, hiccup mode
fault protection with adjustable delays, soft-start, a 1-MHz capable oscillator with synchronization capability,
precision reference, and thermal shutdown. These features simplify the design of active voltage-mode active
clamp / reset DC-DC power converters.
LOGIC
VIN
REF
SS 20 A
RT
LOGIC
PGND
AGND
5V
REFERENCE
OSCILLATOR
CLK
CS1
TIME
0.5V
0.5V
PWM
5 k
5V
1V
R
S
Q
Q
SS
FF RAMP
CS2
RAMP
SLOPE .TO VIN
CLK + LEB
7.6V SERIES
REGULATOR
OUT_B
DRIVER
VCC
COMP
SS
SS Amp
(Sink Only)
MAX V*S
CLAMP
SYNC
UVLO
HYSTERESIS
(20 A)
2.5V
+
-
UVLO +
-
OUT_A
DRIVER
VCC
VCC
VCC
UVLO
2.5V
19 A
DEADTIME
OR
OVERLAP
CONTROL
+
-
+
-
+
-
ENABLE
OUTPUTS
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7.2 Functional Block Diagram
13
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7.3 Feature Description
7.3.1 High-Voltage Start-Up Regulator
The LM5025A contains an internal high-voltage start-up regulator that allows the input pin (VIN) to be connected
directly to the line voltage. The regulator output is internally current-limited to 20 mA. When power is applied, the
regulator is enabled and sources current into an external capacitor connected to the VCC pin. The recommended
capacitance range for the VCC regulator is 0.1 µF to 100 µF. When the voltage on the VCC pin reaches the
regulation point of 7.6 V and the internal voltage reference (REF) reaches its regulation point of 5 V, the
controller outputs are enabled. The outputs remain enabled until VCC falls below 6.2 V or the line undervoltage
lockout detector indicates that VIN is out of range. In typical applications, an auxiliary transformer winding is
connected through a diode to the VCC pin. This winding must raise the VCC voltage above 8 V to shut off the
internal start-up regulator. Powering VCC from an auxiliary winding improves efficiency while reducing the
controller power dissipation.
When the converter auxiliary winding is inactive, external current draw on the VCC line must be limited so the
power dissipated in the start-up regulator does not exceed the maximum power dissipation of the controller.
An external start-up regulator or other bias rail can be used instead of the internal start-up regulator by
connecting the VCC and the VIN pins together and feeding the external bias voltage into the two pins.
7.3.2 Line Undervoltage Detector
The LM5025A contains a line undervoltage lockout (UVLO) circuit. An external setpoint voltage divider from VIN
to GND, sets the operational range of the converter. The divider must be designed such that the voltage at the
UVLO pin is greater than 2.5 V when VIN is in the desired operating range. If the undervoltage threshold is not
met, both outputs are disabled, all other functions of the controller remain active. UVLO hysteresis is
accomplished with an internal 20-µA current source that is switched ON or OFF into the impedance of the
setpoint divider. When the UVLO threshold is exceeded, the current source is activated to instantly raise the
voltage at the UVLO pin. When the UVLO pin voltage falls below the 2.5-V threshold, the current source is turned
off, causing the voltage at the UVLO pin to fall. The UVLO pin can also be used to implement a remote enable
and disable function. Pulling the UVLO pin below the 2.5-V threshold disables the PWM outputs.
7.3.3 PWM Outputs
The relative phase of the main (OUT_A) and active clamp outputs (OUT_B) can be configured for the specific
application. For active clamp configurations using a ground-referenced P-channel clamp switch, the two outputs
must be in-phase with the active clamp output overlapping the main output. For active clamp configurations using
a high-side N-channel switch, the active clamp output must be out-of-phase with main output, and there must be
a dead time between the two gate drive pulses. A distinguishing feature of the LM5025A is the ability to
accurately configure either dead time (both OFF) or overlap time (both ON) of the gate driver outputs. The
overlap and dead-time magnitude is controlled by the resistor value connected to the TIME pin of the controller.
The opposite end of the resistor can be connected to either REF for dead-time control or GND for overlap
control. The internal configuration detector senses the connection and configures the phase relationship of the
main and active clamp outputs. The magnitude of the overlap and dead time can be calculated in Equation 1 and
Equation 2.
Overlap Time (ns) = 2.8 × RSET 1.2 (1)
Dead Time (ns) = 2.9 × RSET +20
where
RSET in kΩ
Time in ns (2)
VCC
PGND
CNTRL
OUT
OUT_A
OUT_B
OUT_A
OUT_B
K1 * RSET
N-Channel Active Clamp
(RSET to REF)
P-Channel Active Clamp
(RSET to GND)
K2 * RSET
K1 * RSET
K2 * RSET
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Feature Description (continued)
Figure 10. PWM Outputs
7.3.4 Compound Gate Drivers
The LM5025A contains two unique compound gate drivers, which parallel both MOS and Bipolar devices to
provide high-drive current throughout the entire switching event. The bipolar device provides most of the drive
current capability and provides a relatively constant sink current which is ideal for driving large power MOSFETs.
As the switching event nears conclusion and the bipolar device saturates, the internal MOS device continues to
provide a low impedance to compete the switching event.
During turnoff at the Miller plateau region, typically around 2 V to 3 V, is where gate driver current capability is
needed most. The resistive characteristics of all MOS gate drivers are adequate for turnon because the supply to
output voltage differential is fairly large at the Miller region. During turnoff however, the voltage differential is
small and the current source characteristic of the bipolar gate driver is beneficial to provide fast drive capability.
Figure 11. Compound Gate Drivers
7.3.5 PWM Comparator
The PWM comparator compares the ramp signal (RAMP) to the loop error signal (COMP). This comparator is
optimized for speed to achieve minimum controllable duty cycles. The internal 5-kΩpullup resistor, connected
between the internal 5-V reference and COMP, can be used as the pullup for an optocoupler. The comparator
polarity is such that 0 V on the COMP pin produces a zero duty cycle on both gate driver outputs.
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Feature Description (continued)
7.3.6 Volt Second Clamp
The Volt × Second Clamp comparator compares the ramp signal (RAMP) to a fixed 2.5-V reference. By proper
selection of RFF and CFF, the maximum ON-time of the main switch can be set to the desired duration. The ON-
time set by Volt × Second Clamp varies inversely with the line voltage because the RAMP capacitor is charged
by a resistor connected to VIN while the threshold of the clamp is a fixed voltage (2.5 V). An example illustrates
the use of the Volt × Second Clamp comparator to achieve a 50% duty cycle limit, at 200 KHz, at a 48-V line
input: A 50% duty cycle at a 200 KHz requires a 2.5 µs of ON-time. At 48-V input the Volt × Second product is
120 V × µs (48 V × 2.5 µs). To achieve this clamp level, use Equation 3 and Equation 4:
RFF × CFF = VIN × TON / 2.5 V (3)
48 × 2.5 µ / 2.5 = 48 µ (4)
Select CFF = 470 pF
RFF = 102 kΩ
The recommended capacitor value range for CFF is 100 pF to 1000 pF.
The CFF ramp capacitor is discharged at the conclusion of every cycle by an internal discharge switch controlled
by either the internal clock or by the V × S Clamp comparator, whichever event occurs first.
7.3.7 Current Limit
The LM5025A contains two modes of overcurrent protection. If the sense voltage at the CS1 input exceeds 0.5 V
the present power cycle is terminated (cycle-by-cycle current limit). If the sense voltage at the CS2 input exceeds
0.5 V, the controller terminates the present cycle, discharge the soft-start capacitor and reduce the soft-start
current source to 1 µA. The soft-start (SS) capacitor is released after being fully discharged and slowly charges
with a 1-µA current source. When the voltage at the SS pin reaches approximately 1 V, the PWM comparator
produces the first output pulse at OUT_A. After the first pulse occurs, the soft-start current source reverts to the
normal 20-µA level. Fully discharging and then slowly charging the SS capacitor protects a continuously
overloaded converter with a low duty cycle hiccup mode.
These two modes of overcurrent protection allow the user great flexibility to configure the system behavior in
over-load conditions. If it is desired for the system to act as a current source during an overload, then the CS1
cycle-by-cycle current limiting must be used. In this case the current sense signal must be applied to the CS1
input and the CS2 input must be grounded. If during an overload condition it is desired for the system to briefly
shutdown, followed by soft-start retry, then the CS2 hiccup current limiting mode must be used. In this case the
current sense signal must be applied to the CS2 input and the CS1 input must be grounded. This shutdown and
soft-start retry repeats indefinitely while the overload condition remains. The hiccup mode greatly reduces the
thermal stresses to the system during heavy overloads. The cycle-by-cycle mode has higher system thermal
dissipations during heavy overloads, but provides the advantage of continuous operation for short duration
overload conditions.
It is possible to use both overcurrent modes concurrently, whereby slight overload conditions activate the CS1
cycle-by-cycle mode while more severe overloading activates the CS2 hiccup mode. Generally the CS1 input is
always configured to monitor the main switch FET current each cycle. The CS2 input can be configured in
several different ways depending upon the system requirements.
The CS2 input can also be set to monitor the main switch FET current except scaled to a higher threshold
than CS1
An external overcurrent timer can be configured which trips after a predetermined overcurrent time, driving
the CS2 input high, initiating a hiccup event.
In a closed-loop voltage regulaton system, the COMP input rises to saturation when the cycle-by-cycle
current limit is active. An external filter and delay timer and voltage divider can be configured between the
COMP pin and the CS2 pin to scale and delay the COMP voltage. If the CS2 pin voltage reaches 0.5 V a
hiccup event will initiate.
TI recommends a small RC filter placed near the controller for each of the CS pins. The CS1 input has an
internal FET which discharges the current sense filter capacitor at the conclusion of every cycle, to improve
dynamic performance. This same FET remains on an additional 50 ns at the start of each main switch cycle to
attenuate the leading edge spike in the current sense signal. The CS2 discharge FET only operates following a
CS2 event, UVLO, and thermal shutdown.
CS2
SS 20 PA
1 PA
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Feature Description (continued)
The LM5025A CS comparators are very fast and may respond to short duration noise pulses. Layout
considerations are critical for the current sense filter and sense resistor. The capacitor associated with the CS
filter must be placed very close to the device and connected directly to the pins of the IC (CS and GND). If a
current sense transformer is used, both leads of the transformer secondary must be routed to the filter network,
which must be placed close to the IC. If a sense resistor in the source of the main switch MOSFET is used for
current sensing, a low inductance type of resistor is required. When designing with a current sense resistor, all of
the noise-sensitive, low-power ground connections must be connected together near the IC GND and a single
connection must be made to the power ground (sense resistor ground point).
Figure 12. Current Limit
7.3.8 Oscillator and Sync Capability
The LM5025A oscillator is set by a single external resistor connected between the RT pin and GND. To set a
desired oscillator frequency (F), the necessary RT resistor can be calculated in Equation 5:
RT = (5725/F)1.026
where
F is in kHz and RT in kΩ(5)
The RT resistor must be placed very close to the device and connected directly to the pins of the IC (RT and
GND).
A unique feature of LM5025A is the ability to synchronize the oscillator to an external clock with a frequency that
is either higher or lower than the frequency of the internal oscillator. The lower frequency sync frequency range is
80% of the free-running internal oscillator frequency. There is no constraint on the maximum SYNC frequency. A
minimum pulse width of 100 ns is required for the synchronization clock. If the synchronization feature is not
required, the SYNC pin must be connected to GND to prevent any abnormal interference. The internal oscillator
can be completely disabled by connecting the RT pin to REF. Once disabled, the sync signal acts directly as the
master clock for the controller. Both the frequency and the maximum duty cycle of the PWM controller can be
controlled by the SYNC signal (within the limitations of the Volt × Second Clamp). The maximum duty cycle (D)
will be (1-D) of the SYNC signal.
7.3.9 Feed-Forward Ramp
An external resistor (RFF) and capacitor (CFF) connected to VIN and GND are required to create the PWM ramp
signal. The slope of the signal at the RAMP pin varies in proportion to the input line voltage. This varying slope
provides line feedforward information necessary to improve line transient response with voltage mode control.
The RAMP signal is compared to the error signal at the COMP pin by the pulse width modulator comparator to
control the duty cycle of the main switch output. The Volt Second Clamp comparator also monitors the RAMP pin
and if the ramp amplitude exceeds 2.5 V the present cycle is terminated. The ramp signal is reset to GND at the
end of each cycle by either the internal clock or the Volt Second comparator, which ever occurs first.
UVLO
Soft Start
Thermal Shut Down
CBC
Hiccup
Normal Operation
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Feature Description (continued)
7.3.10 Soft Start
The soft-start feature allows the power converter to gradually reach the initial steady-state operating point, thus
reducing start-up stresses and surges. At power on, a 20-µA current is sourced out of the soft-start pin (SS) into
an external capacitor. The capacitor voltage ramps up slowly and limits the COMP pin voltage and therefore the
PWM duty cycle. In the event of a fault as determined by VCC undervoltage, line undervoltage (UVLO) or second
level current limit, the output gate drivers are disabled, and the soft-start capacitor is fully discharged. When the
fault condition is no longer present a soft-start sequence is initiated. Following a second level current limit
detection (CS2), the soft-start current source is reduced to 1 µA until the first output pulse is generated by the
PWM comparator. The current source returns to the nominal 20-µA level after the first output pulse
(approximately 1 V at the SS pin).
7.4 Device Functional Modes
The LM5025A active clamp voltage mode PWM controller has six functional modes:
UVLO Mode
Soft-Start Mode
Normal Operation Mode
Cycle-by-Cycle Current Limit Mode
Hiccup Mode
Thermal Shut Down Mode
Figure 13. Functional Mode Transition Diagram
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8 Application and Implementation
NOTE
Information in the following applications sections is not part of the TI component
specification, and TI does not warrant its accuracy or completeness. TI’s customers are
responsible for determining suitability of components for their purposes. Customers should
validate and test their design implementation to confirm system functionality.
8.1 Application Information
The LM5025A PWM controller contains all of the features necessary to implement power converters using the
active clamp and reset technique. This section provides design guidance for a typical active clamp forward
converter design. An actual application schematic of a 36-V to 78-V input, 3.3-V, 30-A output active clamp
forward converter is also provided in Figure 22.
8.2 Typical Application
Figure 14 shows a simplified schematic of an active clamp forward power converter.
Power converters based on the forward topology offer high-efficiency and good power-handling capability in
applications up to several hundred Watts. The operation of the transformer in a forward topology does not
inherently self-reset each power switching cycle, a mechanism to reset the transformer is required. The active
clamp reset mechanism is presently finding extensive use in medium-level power converters in the range of 50 W
to 200 W.
The forward converter is derived from the Buck topology family, employing a single modulating power switch.
The main difference between the topologies is the forward topology employs a transformer to provide input and
output ground isolation and a step-down or step-up function.
Each cycle, the main primary switch turns on and applies the input voltage across the primary winding. The
transformer turns the voltage to a lower-level on the secondary side. The clamp capacitor along with the reset
switch reverse biases the transformer primary each cycle when the main switch turns off. This reverse voltage
resets the transformer. The clamp capacitor voltage is VIN / (1–D).
The secondary rectification employs self-driven synchronous rectification to maintain high-efficiency and ease of
drive.
Feedback from the output is processed by an amplifier and reference, generating an error voltage, which is
coupled back to the primary side control through an opto-coupler. The LM5025A voltage mode controller pulse
width modulates the error signal with a ramp signal derived from the input voltage. Deriving the ramp signal slope
from the input voltage provides line feedforward, which improves line transient rejection. The LM5025A also
provides a controlled delay necessary for the reset switch.
LM5025A
UVLO
COMP
OUT_A
OUT_B
VCC
SS
Rt SYNC
REF
TIME
RAMP
CS1
VIN
CS2
VIN
35 ± 78 V
PGND AGND
UP/DOWN
SYNC
VOUT
3.3 V
ERROR
AMP &
ISOLATION
Copyright © 2016, Texas Instruments Incorporated
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Typical Application (continued)
Figure 14. Simplified Active Clamp Forward Power Converter
8.2.1 Design Requirements
This typical application provides an example of a fully-functional power converter based on the active clamp
forward topology in an industry standard half-brick footprint.
The design requirements are:
Input: 36 V to 78 V (100-V peak)
Output voltage: 3.3 V
Output current: 0 A to 30 A
Measured efficiency: 90.5% at 30 A, 92.5% at 15 A
Frequency of operation: 230 kHz
Board size: 2.3 × 2.4 × 0.5 inches
Load regulation: 1%
Line regulation: 0.1%
Line UVLO, hiccup current limit
8.2.2 Detailed Design Procedure
Before the controller design begins, the power stage design must be completed. This section describes the
calculations needed to configure the LM5025A controller to meet the power stage design requirements.
8.2.2.1 Oscillator
The desired switching frequency F is set by a resistor connected between RT pin and ground. The resistance
value RTis calculated from Equation 6:
hiccup SS 1V
T (ms) C (nF) 1 A
u P
SS
SS SS V 1V
T (ms) C (nF) 20 A
u P
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Typical Application (continued)
RT= (5725/F)1.026
where
F is in kHz and RTin kΩ(6)
8.2.2.2 Soft-Start Ramp Time and Hiccup Interval
The soft-start ramp time and hiccup internal is programmed by a capacitor (CSS) on the SS pin to ground. The
soft-start ramp time is determined by comparing the SS pin voltage with COMP pin voltage. When the SS voltage
is less than COMP voltage, the COMP voltage is clamped by SS voltage. The PWM duty is limited by the
clamped COMP voltage, so that soft start can be achieved. The first PWM pulse is generated after COMP
voltage reaches 1 V. So the soft-start ramp time of the output voltage can be estimated by Equation 7:
where
VSS is the steady-state COMP pin voltage. This voltage is determined by the output voltage, voltage divider,
and the compensation network. (7)
In hiccup mode, the SS current source is reduced to 1 µA. When the first PWM pulse is generated, the current
source switches to 20 µA, and the power supply tries to start up again. The hiccup interval can be calculated by
Equation 8:
(8)
8.2.2.3 Feedforward Ramp and Maximum On-Time Clamp
An example illustrates the use of the Volt × Second Clamp comparator to achieve a 50% duty cycle limit, at
200 KHz, at a 48-V line input: A 50% duty cycle at a 200 KHz requires a 2.5 µs of ON-time. At 48-V input the
Volt × Second product is 120 V × µs (48 V × 2.5 µs). To achieve this clamp level, see Equation 9 and
Equation 10:
RFF × CFF = VIN × TON / 2.5 V (9)
48 × 2.5 µF / 2.5 = 48 µF (10)
Select CFF = 470 pF
RFF = 102 kΩ
The recommended capacitor value range for CFF is 100 pF to 1000 pF.
8.2.2.4 Dead Times
The magnitude of the overlap and dead time can be calculated as follows in Equation 11 and Equation 12:
Overlap Time (ns) = 2.8 × RSET 1.2 (11)
Dead Time (ns) = 2.9 × RSET + 20
where
RSET in kΩ, Time in ns (12)
P-Channel Active Clamp
(RSET to GND)
N-Channel Active Clamp
(RSET to REF)
OUT_A
OUT_B
K1 x RSET
K2 x RSET
OUT_A
OUT_B
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Typical Application (continued)
Figure 15. PWM Outputs
1
1
2
1
1
1
2
1
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Typical Application (continued)
8.2.3 Application Curves
Conditions: input voltage = 48 VDC, output current = 5 A
Trace 1: output voltage Volts/div = 0.5 V
Horizontal resolution = 1 ms/div
Figure 16. Output Voltage During Typical Start-Up
Conditions: input voltage = 48 VDC, output current = 5 A to 25 A
Trace 1: output voltage Volts/div = 0.5 V
Trace 2: output current, Amps/div = 10 A
Horizontal resolution = 1 μs/div
Figure 17. Transient Response
Conditions: input voltage = 48 VDC, output current = 30 A
Bandwidth limit = 25 MHz
Trace 1: output ripple voltage Volts/div = 50 mV
Horizontal resolution = 2 μs/div
Figure 18. Output Ripple
Conditions: input voltage = 38 VDC, output current = 25 A
Trace 1: Q1 drain voltage Volts/div = 20 V
Horizontal resolution = 1 µs/div
Figure 19. Drain Voltage
Conditions: input voltage = 78 VDC, output current = 25 A
Trace 1: Q1 drain voltage Volts/div = 20 V
Horizontal resolution = 1 μs/div
Figure 20. Drain Voltage
Conditions: input voltage = 48 VDC, output current = 5 A
Synchronous rectifier, Q3 gate Volts/div = 5 V
Trace 1: synchronous rectifier, Q3 gate Volts/div = 5 V
Trace 2: synchronous rectifier, Q5 gate Volts/div = 5 V
Horizontal resolution = 1 μs/div
Figure 21. Gate Voltages of the Synchronous Rectifiers
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8.3 System Example
Figure 22 shows an application circuit with 36-V to 78-V input and 3.3-V, 30-A output capability.
Figure 22. Application Circuit
9 Power Supply Recommendations
The VCC pin is the power supply for the device. There must be a 0.1-µF to approximately 100-µF capacitor
directly from VCC to ground. REF pin must be bypassed to ground as close as possible to the device using a 0.1-
µF capacitor.
10 Layout
10.1 Layout Guidelines
Connect two grounds PGND (power ground) and AGND (analog ground) directly as device ground ICGND.
The connection must be as close to the pins as possible.
If there are multiple PCB layers and there is a inner ground layer, use two vias or one big via on GND and
connect them to the inner ground layer (ICGND).
The power stage ground PSGND must be separated with the ICGND. PSGND and ICGND must be
connected at a single point close to the device.
The bypass capacitors to the VCC pin and REF pin must be as close as possible to the pins and ground
(ICGND).
The filtering capacitors connected to CS1 and CS2 pins must have connections as short as possible to
ICGND; if an inner ground layer is available, use vias to connect the capacitors to the ground layer (ICGND).
The resistors and capacitors connected to the timing configuration pins must be as close as possible to the
pins and ground (ICGND).
A
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10.2 Layout Example
Figure 23. LM5025A Layout Recommendation
10.3 Thermal Protection
Internal thermal shutdown circuitry is provided to protect the integrated circuit in the event the maximum junction
temperature is exceeded. When activated, typically at 165°C, the controller is forced into a low-power standby
state with the output drivers and the bias regulator disabled. The device restarts after the thermal hysteresis
(typically 25°C). During a restart after thermal shutdown, the soft-start capacitor is fully discharged and then
charged in the low current mode (1 µA) similar to a second level current limit event. The thermal protection
feature is provided to prevent catastrophic failures from accidental device overheating.
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11 Device and Documentation Support
11.1 Documentation Support
11.1.1 Related Documentation
For related documentation, see the following:
LM5025 Isolated Active Clamp Forward Converter Ref Design User Guide (SNVU096)
11.2 Receiving Notification of Documentation Updates
To receive notification of documentation updates, navigate to the device product folder on ti.com. In the upper
right corner, click on Alert me to register and receive a weekly digest of any product information that has
changed. For change details, review the revision history included in any revised document.
11.3 Community Resources
The following links connect to TI community resources. Linked contents are provided "AS IS" by the respective
contributors. They do not constitute TI specifications and do not necessarily reflect TI's views; see TI's Terms of
Use.
TI E2E™ Online Community TI's Engineer-to-Engineer (E2E) Community. Created to foster collaboration
among engineers. At e2e.ti.com, you can ask questions, share knowledge, explore ideas and help
solve problems with fellow engineers.
Design Support TI's Design Support Quickly find helpful E2E forums along with design support tools and
contact information for technical support.
11.4 Trademarks
E2E is a trademark of Texas Instruments.
All other trademarks are the property of their respective owners.
11.5 Electrostatic Discharge Caution
These devices have limited built-in ESD protection. The leads should be shorted together or the device placed in conductive foam
during storage or handling to prevent electrostatic damage to the MOS gates.
11.6 Glossary
SLYZ022 TI Glossary.
This glossary lists and explains terms, acronyms, and definitions.
12 Mechanical, Packaging, and Orderable Information
The following pages include mechanical, packaging, and orderable information. This information is the most
current data available for the designated devices. This data is subject to change without notice and revision of
this document. For browser-based versions of this data sheet, refer to the left-hand navigation.
PACKAGE OPTION ADDENDUM
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Addendum-Page 1
PACKAGING INFORMATION
Orderable Device Status
(1)
Package Type Package
Drawing Pins Package
Qty Eco Plan
(2)
Lead/Ball Finish
(6)
MSL Peak Temp
(3)
Op Temp (°C) Device Marking
(4/5)
Samples
LM5025AMTC/NOPB ACTIVE TSSOP PW 16 92 Green (RoHS
& no Sb/Br) CU NIPDAU | CU SN Level-1-260C-UNLIM -40 to 125 L5025A
MTC
LM5025AMTCX/NOPB ACTIVE TSSOP PW 16 2500 Green (RoHS
& no Sb/Br) CU NIPDAU | CU SN Level-1-260C-UNLIM -40 to 125 L5025A
MTC
LM5025ASD/NOPB ACTIVE WSON NHQ 16 1000 Green (RoHS
& no Sb/Br) CU SN Level-1-260C-UNLIM -40 to 125 5025ASD
LM5025ASDX/NOPB ACTIVE WSON NHQ 16 4500 Green (RoHS
& no Sb/Br) CU SN Level-1-260C-UNLIM -40 to 125 5025ASD
(1) The marketing status values are defined as follows:
ACTIVE: Product device recommended for new designs.
LIFEBUY: TI has announced that the device will be discontinued, and a lifetime-buy period is in effect.
NRND: Not recommended for new designs. Device is in production to support existing customers, but TI does not recommend using this part in a new design.
PREVIEW: Device has been announced but is not in production. Samples may or may not be available.
OBSOLETE: TI has discontinued the production of the device.
(2) Eco Plan - The planned eco-friendly classification: Pb-Free (RoHS), Pb-Free (RoHS Exempt), or Green (RoHS & no Sb/Br) - please check http://www.ti.com/productcontent for the latest availability
information and additional product content details.
TBD: The Pb-Free/Green conversion plan has not been defined.
Pb-Free (RoHS): TI's terms "Lead-Free" or "Pb-Free" mean semiconductor products that are compatible with the current RoHS requirements for all 6 substances, including the requirement that
lead not exceed 0.1% by weight in homogeneous materials. Where designed to be soldered at high temperatures, TI Pb-Free products are suitable for use in specified lead-free processes.
Pb-Free (RoHS Exempt): This component has a RoHS exemption for either 1) lead-based flip-chip solder bumps used between the die and package, or 2) lead-based die adhesive used between
the die and leadframe. The component is otherwise considered Pb-Free (RoHS compatible) as defined above.
Green (RoHS & no Sb/Br): TI defines "Green" to mean Pb-Free (RoHS compatible), and free of Bromine (Br) and Antimony (Sb) based flame retardants (Br or Sb do not exceed 0.1% by weight
in homogeneous material)
(3) MSL, Peak Temp. - The Moisture Sensitivity Level rating according to the JEDEC industry standard classifications, and peak solder temperature.
(4) There may be additional marking, which relates to the logo, the lot trace code information, or the environmental category on the device.
(5) Multiple Device Markings will be inside parentheses. Only one Device Marking contained in parentheses and separated by a "~" will appear on a device. If a line is indented then it is a continuation
of the previous line and the two combined represent the entire Device Marking for that device.
(6) Lead/Ball Finish - Orderable Devices may have multiple material finish options. Finish options are separated by a vertical ruled line. Lead/Ball Finish values may wrap to two lines if the finish
value exceeds the maximum column width.
PACKAGE OPTION ADDENDUM
www.ti.com 15-Feb-2016
Addendum-Page 2
Important Information and Disclaimer:The information provided on this page represents TI's knowledge and belief as of the date that it is provided. TI bases its knowledge and belief on information
provided by third parties, and makes no representation or warranty as to the accuracy of such information. Efforts are underway to better integrate information from third parties. TI has taken and
continues to take reasonable steps to provide representative and accurate information but may not have conducted destructive testing or chemical analysis on incoming materials and chemicals.
TI and TI suppliers consider certain information to be proprietary, and thus CAS numbers and other limited information may not be available for release.
In no event shall TI's liability arising out of such information exceed the total purchase price of the TI part(s) at issue in this document sold by TI to Customer on an annual basis.
TAPE AND REEL INFORMATION
*All dimensions are nominal
Device Package
Type Package
Drawing Pins SPQ Reel
Diameter
(mm)
Reel
Width
W1 (mm)
A0
(mm) B0
(mm) K0
(mm) P1
(mm) W
(mm) Pin1
Quadrant
LM5025AMTCX/NOPB TSSOP PW 16 2500 330.0 12.4 6.95 5.6 1.6 8.0 12.0 Q1
LM5025ASD/NOPB WSON NHQ 16 1000 178.0 12.4 5.3 5.3 1.3 8.0 12.0 Q1
LM5025ASDX/NOPB WSON NHQ 16 4500 330.0 12.4 5.3 5.3 1.3 8.0 12.0 Q1
PACKAGE MATERIALS INFORMATION
www.ti.com 7-Jun-2017
Pack Materials-Page 1
*All dimensions are nominal
Device Package Type Package Drawing Pins SPQ Length (mm) Width (mm) Height (mm)
LM5025AMTCX/NOPB TSSOP PW 16 2500 367.0 367.0 35.0
LM5025ASD/NOPB WSON NHQ 16 1000 210.0 185.0 35.0
LM5025ASDX/NOPB WSON NHQ 16 4500 367.0 367.0 35.0
PACKAGE MATERIALS INFORMATION
www.ti.com 7-Jun-2017
Pack Materials-Page 2
MECHANICAL DATA
NHQ0016A
www.ti.com
SDA16A (Rev A)
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