Application Note 1901 Author: Philip McKenzie ZL8800-2PH-DEMO1Z Demonstration Board Target Specifications The ZL8800 is a digital power conversion and management IC that combines an efficient step-down DC/DC converter with key power and thermal management functions in a single package. The ZL8800 incorporates compensation-free ChargeMode control to achieve single-cycle transient response. • VIN = 12V • VOUT = 1.2V/60A max • fSW = 400kHz The ZL8800-2PH-DEMO1Z demonstration board is a 6-layer board demonstrating a 2 phase 60A synchronous buck converter. Sequencing, margining, plus other features can be evaluated using this demonstration board. • Efficiency: 91% at 40A • Output Ripple: ±1% • Dynamic response: ±1% (50% to 100% to 50% load step, di/dt = 10A/µs) A USB to PMBus™ adapter board is used to connect the demonstration board to a PC. The PMBus command set is accessed by using the Zilker Labs PowerNavigator™ evaluation software from a PC running Microsoft Windows. • Board temperature: +25°C Functional Description The ZL8800-2PH-DEMO1Z provides all circuitry required to demonstrate the features of the ZL8800. The ZL8800-2PH-DEMO1Z has a functionally-optimized ZL8800 circuit layout that allows efficient operation up to the maximum output current. Key Features • 2 phase 60A synchronous buck converter with compensation-free ChargeMode control • Designed to be easy to use and modify. Optimized for small circuit footprint and dynamic response A majority of the features of the ZL8800, such as compensation-free ChargeMode control, soft-start delay and ramp times, supply sequencing, voltage tracking, and voltage margining are available on this demonstration board. For voltage tracking and sequencing demonstration, the board can be connected to any other Zilker Labs demonstration board that supports the Digital-DC™ (DDC) bus. Figure 1 shows a simplified schematic diagram of the ZL8800-2PH-DEMO1Z board. • Configurable through PMBus • VIN range of 4.5V to 14V, VOUT adjustable from 0.54 to 5.5V • Enable switches and power-good indicators Ordering Information PART NUMBER DESCRIPTION ZL8800-2PH-DEMO1Z ZL8800 Demonstration Kit (EVB, USB Adapter, Cable) VDD Control & Status VIN EN0 EN1 PG0 PG1 Vin VDD VDRV ZL8800 PWMH0 PWM PWML0 EN BST DrMOS VIN 4.5V - 14V Vsw GND VOUT 0.6V - 5V ISENA0 ISENB0 DDC VIN Vin VDRV VDD Inter-Device Communication PMBus PWM PWML1 EN SDA SCL SALRT DrMOS PWMH1 BST Vsw GND ISENA1 ISENB1 VSENP VSENN GND FIGURE 1. ZL8800-2PH-DEMO1Z SIMPLIFIED SCHEMATIC October 31, 2013 AN1901.0 1 CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. 1-888-INTERSIL or 1-888-468-3774 | Copyright Intersil Americas LLC 2013. All Rights Reserved Intersil (and design), PowerNavigator and Digital-DC are trademarks owned by Intersil Corporation or one of its subsidiaries. All other trademarks mentioned are the property of their respective owners. Application Note 1901 The hardware enable function is controlled by a toggle switch on the ZL8800-2PH-DEMO1Z board. The power-good (PG) LEDs indicate the correct state of PG for each phase when external power is applied to the ZL8800-2PH-DEMO1Z board and the corresponding phase is functioning properly. The right angle headers at opposite ends of the board are for connecting a USB to PMBus adapter board or for daisy chaining multiple demonstration boards together to build multi-output configurations. Figures 2 and 3 show the detailed demonstration circuit. Figure 2 shows the ZL8800 IC with its minimal component count to realize a 60A output. Figure 3 has interface circuitry unique to the demonstration board that is not typically contained in a user’s application circuit. Figures 4 through 10 show typical performance data, and Figures 15 through 22 demonstrate the PCB board layout. The default configuration file is shown on page 6, and the Bill of Materials (BOM) is included for reference beginning on page 5. Quick Start Guide Stand Alone Operation 1. Set ENABLE switch to “DISABLE” 2. Apply load to VOUT0 and/or VOUT1 3. Connect the USB to PMBus adapter board to J8 (labeled “DONGLE”) of ZL8800-2PH-DEMO1Z 4. Connect supplied USB cable from computer to USB to PMBus adapter board 5. Connect power supply to VIN (supply turned off) 6. Turn power supply on 7. Set ENABLE switch to “ENABLE” 8. Monitor ZL8800-2PH-DEMO1Z board operation using an oscilloscope USB (PMBus) Operation 1. Set ENABLE switch to “DISABLE” Operation 2. Apply load to VOUT and/or VOUT1 PMBus Operation 3. Connect power supply to VIN (supply turned off) The ZL8800 utilizes the PMBus protocol. The PMBus functionality can be controlled via USB from a PC running the PowerNavigator evaluation software in a Windows XP or Windows 7 operating systems. 4. Turn power supply on Install the evaluation software from the following Intersil website: http://www.intersil.com/en/products/powermanagement/zilker-labs-digital-power/powernavigator.html For board operation, connect the included USB-to-PMBus adapter board to J8 of the ZL8800-2PH-DEMO1Z board labeled “DONGLE”. Connect the desired load and an appropriate power supply to the input and connect the included USB cable to the PC running the PowerNavigator evaluation software. Place the ENABLE switches in “DISABLE” and turn on the power. 5. Connect USB to PMBus adapter board to J8 of ZL8800-2PH-DEMO1Z 6. Connect supplied USB cable from computer to USB to PMBus adapter board. Install the PowerNavigator evaluation software from the following Intersil website: http://www.intersil.com/en/products/powermanagement/zilker-labs-digital-power/powernavigator.html. 7. Set ENABLE switch to “ENABLE”. 8. Monitor and configure the ZL8800-2PH-DEMO1Z board using PMBus commands in the evaluation software. 9. Test the ZL8800-2PH-DEMO1Z operation using an oscilloscope and the evaluation software. The evaluation software allows modification of all ZL8800 PMBus parameters. The ZL8800 device on the board has been pre-configured as described in this document, but the user may modify the operating parameters through the evaluation software or by loading a predefined set-up from a configuration file. The ENABLE switch can then be moved to “ENABLE” and the ZL8800-2PH-DEMO1Z board can be tested. Alternately, the PMBus ON_OFF_CONFIG and OPERATION commands may be used from the PowerNavigator GUI. 2 AN1901.0 October 31, 2013 ZL8800-2PH-DEMO1Z Board Schematics 3 Application Note 1901 AN1901.0 October 31, 2013 FIGURE 2. APPLICATION CIRCUIT ZL8800-2PH-DEMO1Z Board Schematics (Continued) 4 Application Note 1901 AN1901.0 October 31, 2013 FIGURE 3. ZL8800-2PH-DEMO1Z AUXILIARY CIRCUITRY Application Note 1901 ZL8800-2PH-DEMO1Z Bill of Materials QTY REFERENCE VALUE TOL RATING TYPE 1 U2 ZL8800 - 14V - 8 C1, C2, C3, C5, C6, C7, C8, C9 100µF 20% 6.3V X5R 4 C4, C10, C11, C12 470µF 20% 2V AL 5 C13, C46, C34, C48, C29 10µF 10% 10V 10 C15, C18, C30, C31, C32, C33, C42, C43, C44, C45 22µF 20% 1 C17 330u 4 C47, C26, C28, C35 1µF 2 C27, C36 4 C38, C39, C41, C37 1 PCB FOOTPRINT MLF44_7X7_XX MFR Intersil-Zilker Labs PART NUMBER ZL8800ALAFTK SM1210 Taiyo Yuden JMK325BJ107MY-T SM7343P Panasonic EEF-SX0D471E4 X5R SM0805 Taiyo Yuden LMK212B7106KG-TD 16V X5R SM1206 Murata GRM31CR61C226ME15L 20% 16V AL POLY SM_CAP_10.5X10.5 UNITED CHEMI APXA160ARA331MJC0G 20% 16V X7R SM0603 TDK 100p 5% 50V NPO SM0402_WSS MURATA GRM1555C1H101JZ01D 10µ 0.2 16V X5R SM0603 Taiyo Yuden EMK107BBJ106MA-T C40 2.2µ 10% 25V X5R SM0805 MURATA GRM21BR71E225KA73L 2 L1, L2 0.231µH 5% 35A FERRITE IND_SLC1175 Coil Craft SLC1175-231ME_ 2 Q6, Q3 FDMF5821DC - 60A/20V DR MOS 2 Q2, Q4 2N3904 - 40V NPN 2 R1, R33 100k 1% 63mW 1 R2 6.65k 1% 1 R3 100 1 R7 5mΩ 2 R16, R11 2 C1608X7R1C105K PQFN40_5X5_P5S Fairchild FDMF5821DC SOT-23 ON SEMI MMBT3904LT1G THK FILM SM0603 Panasonic ERJ-3EKF1003V 63mW THK FILM SM0603 Panasonic ERJ-3EKF6651V 1% 100mW THK FILM SM0805 Panasonic ERJ-6ENF1000V 1% 3W THK FILM WSL3637 Vishay Dale WSL36375L000FEA 1 5% 63mW THK FILM SM0603 Panasonic ERJ-2RKF1R00X R10, R12 953 1% 63mW THK FILM SM0603 Panasonic ERJ-3EKF9530V 1 R18 28.7k 1% 50mW THK FILM SM0402 Panasonic ERJ-3EKF2872V 1 R25 31.6k 1% 63mW THK FILM SM0603 Panasonic ERJ-3EKF3162V 0 R26 90.9k 1% 63mW THK FILM SM0603 Panasonic ERJ-3EKF9092V 2 R17, R13 30k 5% 63mW THK FILM SM0603 Panasonic ERJ-3GEYJ303V 2 R14, R15 3.3Ω 5% 63mW THK FILM SM0603 Panasonic ERJ-3GEYJ3R3V DEMONSTRATION BOARD SPECIFIC AUXILIARY PARTS BILL OF MATERIALS 2 R30, R31 392 1% 0 R24 NOT USED - 1 R8 4.75k 1% 63mW THK FILM SM0603 Panasonic ERJ-2RKF4751X 4 R4, R5, R6, R32 10.0k 1% 63mW THK FILM SM0603 Panasonic ERJ-2RKF1002X 2 P2 JACK_BANANA - 15A - JACK_F_NI_2P.750SP EMERSON 108-0740-001 2 D3, D4 GREEN - 2V, 20mA LED SM0805 CHICAGO MINI CMD17-21VGC/TR8 1 EN1 SW_SPDT - - PCB VERT 3 J1, J2, J105 2 POS - - VERT 2 J8, J9 HDR_3X2_RA - - RA HDRMDUALRA100X100 SAMTEC TSW-103-08-T-D-RA 2 J10, J11 SKT_3X2_RA - - RA HDRFDUALRA100X100 SAMTEC SSQ-103-02-T-D-RA 4 J101, J102, J103, J104 VOUT+, PGND - - - 1 C14 10µF 10% 10V X5R 0 VDD TP - Red 0 GND TP - Black 5 63mW THK FILM SM0603 Panasonic ERJ-3EKF3920V - SM0603 - - SW_TOG_SPDT NKK G12AP SIP2/100 SAMTEC TSW-102-07-L-S JACK_F_.175PLUG Burndy KPA8CTP SM1206 Murata GRM31CR61A106KA01L PC Test Point TP_036H_SSREF Keystone Electronics 5000 PC Test Point TP_036H_SSREF Keystone Electronics 5001 AN1901.0 October 31, 2013 Application Note 1901 Configuration File The following text is loaded into the ZL8800 device on the ZL8800-2PH-DEMO1Z as default settings. Each PMBus command is loaded via the PowerNavigator software. The # symbol is used for a comment line. # Initialize device to factory settings RESTORE_FACTORY STORE_DEFAULT_ALL STORE_USER_ALL ### Begin Default Store RESTORE_DEFAULT_ALL # Global commands FREQUENCY_SWITCH 0xfb20 # 400 kHz VIN_OV_FAULT_LIMIT 0xd380 # 14 V VIN_OV_FAULT_RESPONSE 0xff VIN_OV_WARN_LIMIT 0xd360 # 13.5 V VIN_UV_WARN_LIMIT 0xca40 # 4.5 V VIN_UV_FAULT_LIMIT 0xca00 #4V VIN_UV_FAULT_RESPONSE 0xff IIN_CAL_GAIN 0xca80 # 5 mV/A DDC_ENG 0xa5a USER_GLOBAL_CONFIG 0x100 VMON_OV_FAULT_RESPONSE 0x80 VMON_UV_FAULT_RESPONSE 0x80 PRIVATE_PASSWORD PUBLIC_PASSWORD UNPROTECT 0x00FFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFF FFFFFFFFFFFFFF # PAGE 0 commands PAGE 0x0 ON_OFF_CONFIG 0x17 VOUT_COMMAND 0x2666 # 1.2 V VOUT_TRIM 0x0 #0V VOUT_CAL_OFFSET 0x0 #0V VOUT_MAX 0x4000 #2V VOUT_MARGIN_HIGH 0x2852 # 1.26 V VOUT_MARGIN_LOW 0x247b # 1.14 V VOUT_TRANSITION_RATE 0xba00 # 1 mV/us VOUT_DROOP 0x0 # 0 mV/A INTERLEAVE 0x0 IOUT_CAL_GAIN 0xb127 # 0.288 mV/A IOUT_CAL_OFFSET 0xbe00 # -1 A VOUT_OV_FAULT_LIMIT 0x2a6f # 1.326 V VOUT_OV_FAULT_RESPONSE 0x80 VOUT_UV_FAULT_LIMIT 0x225e # 1.074 V VOUT_UV_FAULT_RESPONSE 0x80 IOUT_OC_FAULT_LIMIT 0xe370 # 55 A IOUT_UC_FAULT_LIMIT 0xe490 # -55 A OT_FAULT_LIMIT 0xebe8 # 125 °C OT_FAULT_RESPONSE 0x80 OT_WARN_LIMIT 0xeb70 # 110 °C UT_WARN_LIMIT 0xdc40 # -30 °C UT_FAULT_LIMIT 0xe530 # -45 °C 6 UT_FAULT_RESPONSE 0x80 POWER_GOOD_ON 0x228f # 1.08 V TON_DELAY 0xca80 # 5 ms TON_RISE 0xca80 # 5 ms TOFF_DELAY 0xca80 # 5 ms TOFF_FALL 0xca80 # 5 ms DEADTIME_MAX 0x3838 ISENSE_CONFIG 0x4204 USER_CONFIG 0x786 DDC_CONFIG 0x101 POWER_GOOD_DELAY 0xba00 # 1 ms PID_TAPS 0x64 INDUCTOR 0xb114 # 0.27 uH VOUT_MARGIN_RATIO 0xca80 #5% OVUV_CONFIG 0x0 XTEMP_SCALE 0xba00 # 1 1/°C XTEMP_OFFSET 0x8000 # 0 °C TEMPCO_CONFIG 0xa7 DEADTIME 0x1010 DEADTIME_CONFIG 0x8080 ASCR_CONFIG 0x15a0100 SEQUENCE 0x0 TRACK_CONFIG 0x0 DDC_GROUP 0x0 MFR_IOUT_OC_FAULT_RESPONSE 0x80 MFR_IOUT_UC_FAULT_RESPONSE 0x80 IOUT_AVG_OC_FAULT_LIMIT 0xe230 # 35 A IOUT_AVG_UC_FAULT_LIMIT 0xe5d0 # -35 A SNAPSHOT_CONTROL 0x0 MFR_VMON_OV_FAULT_LIMIT 0xcb00 #6V MFR_VMON_UV_FAULT_LIMIT 0xca00 #4V # PAGE 1 commands PAGE 0x1 VOUT_COMMAND 0x2666 # 1.2 V VOUT_MAX 0x4000 #2V VOUT_MARGIN_HIGH 0x2852 # 1.26 V VOUT_MARGIN_LOW 0x247b # 1.14 V IOUT_CAL_GAIN 0xb127 # 0.288 mV/A IOUT_CAL_OFFSET 0xbe00 # -1 A VOUT_OV_FAULT_LIMIT 0x2a6f # 1.326 V VOUT_UV_FAULT_LIMIT 0x225e # 1.074 V IOUT_OC_FAULT_LIMIT 0xe370 # 55 A IOUT_UC_FAULT_LIMIT 0xe490 # -55 A POWER_GOOD_ON 0x228f # 1.08 V USER_CONFIG 0x786 DDC_CONFIG 0x2101 INDUCTOR 0xb114 # 0.27 uH TEMPCO_CONFIG 0xa7 IOUT_AVG_OC_FAULT_LIMIT 0xe230 # 35 A IOUT_AVG_UC_FAULT_LIMIT 0xe5d0 # -35 A MFR_VMON_OV_FAULT_LIMIT 0xcb00 #6V MFR_VMON_UV_FAULT_LIMIT 0xca00 #4V STORE_DEFAULT_ALL ### End Default Store AN1901.0 October 31, 2013 Application Note 1901 Measured Data The following data was acquired using a ZL8800-2PH-DEMO1Z Rev B demonstration board. MEASURED OUTPUT CURRENT (A) 35 30 MEASURED 25 IDEAL 20 15 10 5 0 0 5 10 15 20 25 30 35 ACTUAL OUTPUT CURRENT (A) FIGURE 4. OUTPUT CURRENT MEASUREMENT ACCURACY (Single Phase) 100 100 90 90 80 VOUT = 1.8V VOUT = 1.5V VOUT = 1.2V VOUT = 1V VOUT = 0.8V 70 60 EFFICIENCY (%) EFFICIENCY (%) 80 50 60 50 40 40 30 30 20 0 10 20 30 40 50 20 60 VOUT = 1.8V VOUT = 1.5V VOUT = 1.2V VOUT = 1V VOUT = 0.8V 70 0 10 FIGURE 5. EFFICIENCY, V IN = 12V, f SW = 300kHz 100 90 90 40 50 60 80 EFFICIENCY (%) 80 EFFICIENCY (%) 30 FIGURE 6. EFFICIENCY, V IN = 5V, f SW = 300kHz 100 VOUT = 1.8V 70 VOUT = 1.5V VOUT = 1.2V 60 VOUT = 1V 50 VOUT = 0.8V VOUT = 1.8V 70 VOUT = 1.5V 60 VOUT = 1.2V VOUT = 1V 50 40 40 30 30 20 20 LOAD CURRENT (A) LOAD CURRENT (A) 0 10 20 30 40 50 LOAD CURRENT (A) FIGURE 7. EFFICIENCY, V IN = 12V, f SW = 400kHz 7 60 20 VOUT = 0.8V 0 10 20 30 40 50 60 LOAD CURRENT (A) FIGURE 8. EFFICIENCY, V IN = 5V, f SW = 400kHz AN1901.0 October 31, 2013 Application Note 1901 Measured Data The following data was acquired using a ZL8800-2PH-DEMO1Z Rev B demonstration board. (Continued) 100 100 90 90 80 VOUT = 1.8V 70 VOUT = 1.5V 60 VOUT = 1.2V EFFICIENCY (%) EFFICIENCY (%) 80 VOUT = 1V 50 VOUT = 0.8V VOUT = 1.8V 70 VOUT = 1.5V 60 VOUT = 1.2V VOUT = 1V 50 40 40 30 30 20 0 10 20 30 40 50 60 LOAD CURRENT (A) 20 VOUT = 0.8V 0 10 20 30 40 50 FIGURE 9. EFFICIENCY, V IN = 12V, f SW = 516kHz FIGURE 10. EFFICIENCY, VIN = 5V, f SW = 516kHz FIGURE 11. RAMP UP FIGURE 12. RAMP DOWN FIGURE 13. STEP RESPONSE, 20A TO 40A @ 5A/µs, ASCR = 1200 TOTAL DEVIATION WINDOW 25mV = 2.5% FIGURE 14. STEP RESPONSE, 20A TO 40A @ 5A/µs, ASCR = 400 TOTAL DEVIATION WINDOW 50mV = 5% 8 60 LOAD CURRENT (A) AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout FIGURE 15. PCB - TOP ASSEMBLY 9 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 16. PCB - TOP LAYER 10 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 17. PCB - INNER LAYER 1 (TOP VIEW) 11 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 18. PCB - INNER LAYER 2 (TOP VIEW) 12 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 19. PCB - INNER LAYER 3 (TOP VIEW) 13 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 20. PCB - INNER LAYER 4 (TOP VIEW) 14 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 21. PCB - BOTTOM LAYER (TOP VIEW) 15 AN1901.0 October 31, 2013 Application Note 1901 ZL8800-2PH-DEMO1Z Board Layout (Continued) FIGURE 22. PCB - BOTTOM ASSEMBLY (TOP VIEW) Related Tools and Documentation DOCUMENT FN7558 DESCRIPTION ZL8800 Datasheet, “Dual Channel/Dual Phase PMBus™ ChargeMode Control DC/DC Digital Controller” Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is cautioned to verify that the Application Note or Technical Brief is current before proceeding. For information regarding Intersil Corporation and its products, see www.intersil.com 16 AN1901.0 October 31, 2013