There are three common ways of implementing reverse polarity protection:
- Series Diode
- Shunt Diode + Fuse or other over-current trip
- Series MOSFET
Lets discuss (1) a series diode:
What is "voltage - Forward (Vf) (Max) @ if" when selecting a reverse polarity. Something that i am lost with.
It all depends on whether your load can tolerate the Vf forward voltage drop at the expected load current. If it can't, and you've already found the lowest Vf highest If diode that you can afford or that will fit, then you have to choose a different method. The datasheet will give some worst case 'spot' values of Vf for various If, and better manufacturers datasheets also include a typical Vf vs If graph. However that isn't a worst case graph so you may have to plot whatever worst case figures you have on the graph, then scale it to get an intermediate value for you actual peak load current then allow a generous safety factor because you are extrapolating from the original limiting data. Obviously the diode also dissipates power so you need to work out whether the package can dissipate Vf*If at your expected If and maximum ambient temperature.
For (2) the shunt diode, everything is *FAR* more scary!
The diode is no longer in series with the load so its Vf drop no longer subtracts from the supply voltage. However the diode must now survive an extremely high pule If, big enough to blow the fuse, which is probably well outside the specs given in the datasheet. If you are making a few million units, contact the diode manufacturer for a recommendation for a diode that can survive a non-repetitive surge of hundreds of Amps to blow a fuse of a specified characteristic but is still in a small enough package, but the rest of us have to do our own destructive testing to establish suitability. If you pick a diode thats too small, it will probably fail shorted when it blows the fuse, and continue to blow the fuse even when the reverse polarity is corrected.
If you pick one that's far too small it will short, then blow open before the fuse blows and your product will DIE!, probably with lots of smoke and maybe even flames
A further complication of (2) is that your device 'sees' the Vf of the diode at the peak surge current as reverse voltage. You need enough die area to keep this voltage low enough to avoid damage.