ADP1046A Wide Input Range, Full Bridge Phase Shifted Topology

Wide Input Range, Full Bridge Phase
Shifted topology using ADP1046A
48V/600W
PRD1404
FEATURES
600W Phase Shifted Full Bridge Topology
Wide Input Range to minimize hold up capacitor
Wide ZVS range down to 10% rated load
Short circuit and Fast Over Voltage protection
Remote voltage sensing
Line voltage feedforward
I2C serial interface to PC
Software GUI
Programmable digital filters for DCM and CCM
7 PWM outputs including Auxiliary PWM
Digital Trimming
Current, voltage, and temperature sense through GUI
Calibration and trimming
CAUTION
This evaluation board uses high voltages and currents. Extreme caution must be taken especially on the primary
side, to ensure safety for the user. It is strongly advised to power down the evaluation board when not in use. A
current limited power supply is recommended as input as no fuse is present on the board.
ADP1046A EVALUATION BOARD OVERVIEW
This evaluation board features the ADP1046A in a switching power supply application. With the evaluation board and
software, the ADP1046A can be interfaced to any PC running Windows 2000/XP/Vista/NT/7 via the computer's USB port. The
software allows control and monitoring of the ADP1046A internal registers. The board is set up for the ADP1046A to act as an
isolated switching power supply with a rated load of 48V/12.5A from an input voltage ranging from a 340VDC to 400VDC.
Figure 1 – Prototype
Rev. 1.0
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statutory including, but not limited to, any implied warranty of merchantability or fitness for a
particular purpose. No license is granted by implication or otherwise under any patents or other
intellectual property by application or use of reference designs. Information furnished by Analog
Devices is believed to be accurate and reliable. However, no responsibility is assumed by Analog
Devices for its use, nor for any infringements of patents or other rights of third parties that may
result from its use. Analog Devices reserves the right to change devices or specifications at any
time without notice. Trademarks and registered trademarks are the property of their respective
owners. Reference designs are not authorized to be used in life support devices or systems.
One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106, U.S.A.
Tel: 781.329.4700
Fax: 781.461.3113
©2009 Analog Devices, Inc. All rights reserved.
Phase Shifted Full
Bridge 48V/600W
PRD1404
TABLE OF CONTENTS
Features ....................................................................................................................................................................................... 1
CAUTION ..................................................................................................................................................................................... 1
TOPOLOGY AND circuit description ............................................................................................................................................ 3
CONNECTORS ............................................................................................................................................................................ 4
SETTING FILES AND EEPROM .................................................................................................................................................. 7
BOARD EVALUATION ................................................................................................................................................................. 8
EQUIPMENT ............................................................................................................................................................................ 8
SETUP...................................................................................................................................................................................... 8
BOARD SETTINGS ................................................................................................................................................................ 10
Theory of operation during startup ............................................................................................................................................. 10
FLAGS SETTINGS CONFIGURATIONS ................................................................................................................................ 11
PWM SETTINGS ....................................................................................................................................................................... 12
BOARD EVALUATION AND TEST DATA ................................................................................................................................... 13
STARTUP ............................................................................................................................................................................... 13
OVERCURRENT AND SHORT CIRCUI PROTECTION......................................................................................................... 14
PRIMARY GATE DRIVER DEADTIME ................................................................................................................................... 15
CS1 PIN VOLTAGE (PRIMARY CURRENT) .......................................................................................................................... 17
SYnchronous rectifier peak inverse voltage ............................................................................................................................ 17
OUTPUT VOLTAGE RIPPLE .................................................................................................................................................. 18
TRANSIENT Voltage at 385VDC (NOMINAL VOLTAGE) ....................................................................................................... 18
HOLD UP TIME AND VOLTAGE DROP OUT ......................................................................................................................... 20
LINE VOltage FEEDFORWARD ............................................................................................................................................. 20
ZVS WAVEFORMS FOR QA (PASSIVE TO ACTIVE TRANSITION)...................................................................................... 21
ZVS WAVEFORMS FOR QB (PASSIVE TO ACTIVE TRANSITION) ..................................................................................... 23
ZVS WAVEFORMS FOR QC (Active TO PaSSIVE TRANSITION) ........................................................................................ 24
ZVS WAVEFORMS FOR QD (Active TO PaSSIVE TRANSITION) ........................................................................................ 24
CLOSED LOOP FREQUENCY RESPONSE .......................................................................................................................... 25
EFFICIENCY .......................................................................................................................................................................... 26
TRANSFORMER SPECIFICATION ........................................................................................................................................... 27
Thermal TEST DATA .................................................................................................................................................................. 29
APPENDIX I – SCHEMATIC ...................................................................................................................................................... 32
APPENDIX IV – LAYOUT ........................................................................................................................................................... 36
NOTES ....................................................................................................................................................................................... 39
REVISION HISTORY
04/28/2013—Revision 1.0: SPM
05/02/2013—Revision 2.0: SPM
Phase Shifted Full
Bridge 48V/600W
PRD1404
BOARD SPECIFICATIONS
Specification
VIN
MIN
TYP
MAX
Units
340
385
400
V
VOUT
IOUT
48
0.0
12.5
Switching frequency
Output Voltage Ripple
V
15
A
With 400 LFM air
flow.
15
A
OCP set to
shutdown PSU
after~10ms
96.35%
%
Typical reading at
385Vin, 12.5A load
111.6
KHz
550
mV
Overload current (OCP limit)
Efficiency
Notes
At 12.5A load
TOPOLOGY AND CIRCUIT DESCRIPTION
This application note consists of the ADP1046A in a typical isolated DC/DC switching power supply in a full bridge phase
shifted topology with synchronous rectification. The circuit is designed to provide a rated output load of 48V/12.5A from a
nominal input voltage of 385VDC operated in CCM at all times. The ADP1046A is can provide functions such as the output
voltage regulation, output over voltage protection, input and output current protection, primary cycle by cycle protection, and
over temperature protection.
provides a top level schematic that describes the power flow and auxiliary power supply
that starts up at 50VDC and provides power to the ADP1046A through a 3.3V LDO, the iCoupler isolation plus gate drivers,
the on board fan, and the synchronous rectifier drivers. The transformer is designed to provide a wide input voltage range
(340-410VDC) and the circuit has wide ZVS (Zero Voltage Switching) range down to 10% of the rated load.
The auxiliary power supply using transformer (T3) and IC (U10) generates a 12V rail on the primary side and a 13V rail on the
secondary side to power the iCoupler isolation devices (MOSFET drivers), synchronous rectifier driver and the ADP1046A
using the 3.3V LDO. This auxiliary supply starts up at approximately 50VDC.
The primary side consists of the input terminals (JP8, JP9), switches (Q1-Q4), the current sense transformer (T5) and the
main transformer (T1). There is also an resonant inductor that aids in zero voltage switching at lighter load conditions. The
ADP1046A is situated on the secondary side and is powered via the auxiliary power supply or the USB connector via the LDO.
The gate signal for the primary switches is generated by the ADP1046A through the iCouplers and fed into the MOSFET
drivers (U17, U18). Bypass capacitors (C71, C72, C114-116) are placed closed to the primary switches. Diodes (D36-37)
clamp the resonance between the resonant inductor and the output capacitance (COSS) of the output rectifiers.
The secondary (isolated) side of the transformer consists of a center tapped winding. The synchronous rectifier driver (U7)
provides the drive signals for the switches (Q9, Q23). The output inductor (L8) and output capacitor (C11, C41) act as a low
pass filter for the output voltage. The output voltage is fed back to the ADP1046A using a voltage divider and has a nominal
voltage of 1V which is differentially sensed. Output current measured using a sense resistor (R2) which is also differentially
sensed. To protect the synchronous rectifiers from exceeding the peak reverse voltage an RCD clamp is implemented (D58,
D59, R112-115, C94)
The primary current is sensed through the CS1 pin with a small RC time constant (R44, C22) that act as a low pass filter to
remove the high frequency noise on the signal. An additional RC can be placed, but the internal Σ-Δ ADC naturally averages
the signal. The position of the current transformer is placed in series with the resonant inductor to avoid saturation.
Line voltage feedforward is implemented using an RCD circuit (D13, R59, R64, C38, C43) that detects the peak voltage at the
synchronous FET. There are two time constants that can be implemented in series with each other. The time constants must
be matched such that it retains the peak value during the switching frequency period but also is not too long in case there is a
step down change in the input voltage. This peak voltage is further ratioed and fed in the ACSNS pin of the controller
(ADP1046A). A thermistor (RT1) is placed on the secondary side close to synchronous FET and acts thermal protection for the
power supply. A 16.5k resistor is placed in parallel with the thermistor that allows the software GUI to read the temperature
directly in degrees Celsius.
Capacitor (C69) is a YCAP that reduces common mode noise from the transformer.
Phase Shifted Full
Bridge 48V/600W
PRD1404
Also present on the secondary is a 4 pin connector for I2C communication. This allows the PC software to communicate with
the IC through the USB port of the PC. The user can easily change register settings on the ADP1046A, and monitor the status
registers. It is recommended that the USB dongle be connected directly to the PC, not via external hub.
Switch (SW2) acts as a hardware PS_OFF switch. The polarity is configured using the GUI to be active high.
CONNECTORS
The following table lists the connectors on the board:
Connector
Evaluation Board Function
J8
DC Input positive terminal
J9
DC Input negative terminal
J11
Output voltage positive terminal
J12
Output voltage negative terminal
J16
Socket for auxiliary power supply
J18
I2C connector
The pin outs of the USB dongle are given below:
Pin (left to
right)
Figure 2 – I2C connector (pin1 on left)
Function
1
5V
2
SCL
3
SDA
4
Ground
Phase Shifted Full
Bridge 48V/600W
PRD1404
Figure 3 – PCB Side View
Phase Shifted Full
Bridge 48V/600W
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
SETTING FILES AND EEPROM
The ADP1046A communicates with the GUI software using the I2C bus.
The register settings (having extension .46r) and the board settings (having extension .46b) are two files that are associated
with the ADP1046A software. The register settings file is contains information such as the over voltage and over current limits,
softstart timing, PWM settings etc. that govern the functionality of the part. The ADP1046A stores all its settings in the
EEPROM.
The EEPROM on the ADP1046A does not contain any information about the board, such as current sense resistor, output
inductor and capacitor values. This information is stored in board setup file (extension .46b) and is necessary for the GUI to
display the correct information in the ‘Monitor’ tab as well as ‘Filter Settings’ window. The entire status of the power supply
such as the ORFET and synchronous rectifiers enable/disable, primary current, output voltage and current can be thus digitally
monitored and controlled using software only. Always make sure that the correct board file has been loaded for the board
currently in use.
Each ADP1046A chip has trim registers for the temperature, input current and the output voltage and current, and ACSNS.
These can be configured during production and are not overwritten whenever a new register settings file is loaded. This is
done in order to retain the trimming of all the ADCs for that corresponding environmental and circuit condition (component
tolerances, thermal drift, etc.). A guided wizard called the ‘Auto Trim’ is started which trims the above mentioned quantities so
that the measurement value matches the valued displayed in the GUI to allow ease of control through software.
Phase Shifted Full
Bridge 48V/600W
PRD1404
BOARD EVALUATION
EQUIPMENT
• DC Power Supply (300-400V, 600W)
• Electronic Load (60V/600W)
• Oscilloscope with differential probes
• PC with ADP1046A GUI installed
• Precision Digital Voltmeters (HP34401or equivalent - 6 digits) for measuring DC current and voltage
SETUP
NOTE: DO NOT CONNECT THE USB CABLE TO THE EVALUATION BOARD UNTIL THE SOFTWARE HAS
FINISHED INSTALLING
1)
Install the ADP1046A software by inserting the installation CD. The software setup will start automatically and a guided
process will install the software as well as the USB drivers for communication of the GUI with the IC using the USB
dongle.
2)
Insert the daughter card in connector J5 as shown in Figure 6
3)
Ensure that the PS_ON switch (SW1 on schematic) is turned to the OFF position. It is located on the bottom left half of the
board.
4)
Connect one end of USB dongle to the board and the other end to the board to the USB port on the PC using the “USB to
I2C interface” dongle.
5)
The software should report that the ADP1046A has been located on the board. Click “Finish” to proceed to the Main
Software Interface Window. The serial number reported on the side of the checkbox indicates the USB dongle serial
number. The windows also displays the device I2C address.
5. If the software does not detect the part it enters into simulation mode. Ensure that the connecter is connected to the
daughter card. Click on ‘Scan for ADP1046A now’ icon (magnifying glass) located on the top right hand corner of the screen.
Phase Shifted Full
Bridge 48V/600W
PRD1404
5. Click on the “Load Board Settings” icon (fourth button from the left) and select the ADP1046A_FBPS_600W_xxxx.46b file.
This file contains all the board information including values of shunt and voltage dividers. Note: All board setting files have an
extension of .46b
6. The IC on the board comes preprogrammed and this step is optional. The original register configuration is stored in the
ADP1046A_FBPS_600W_xxxx.46r register file (Note: All register files have an extension of .46r). The file can be loaded using
the second icon from the left in Figure 8.
7. Connect a DC power source (385VDC nominal, current limit to ~2A) and an electronic load at the output set to 1 Ampere.
8. Connect a voltmeter on test points TP26(+) and TP46(-). Ensure that the differential probes are used and the ground of the
probes are isolated if oscilloscope measurements are made on the primary side of the transformer.
9. Click on the Dashboard settings (3rd icon in Figure 7 and turn on the software PS_ON)
10. The board should now up and running, and ready for evaluation. The output should now read 12 VDC.
11. Click on the ‘MONITOR’ tab and then on the Flags and readings icon. This window provides a snapshot of the entire state
of the PSU in a single user friendly window.
Phase Shifted Full
Bridge 48V/600W
PRD1404
BOARD SETTINGS
The following screenshot displays the board settings.
THEORY OF OPERATION DURING STARTUP
The following steps briefly describe the startup procedure of the ADP1046A and the power supply and the operation of the
state machine for the preprogrammed set of registers that are included in the design kit.
1.
The on board auxiliary power starts up at approximately 50VDC. This provides a drive voltage on the isolated side to
an LDO (3.3V) that powers up the ADP1046A. After VDD (3.3V) is applied to the ADP1046A it takes approximately
20-50µs for VCORE to reach 2.5V. The digital core is now activated and the contents of the registers are downloaded
in the EEPROM. The ADP1046A is now ready for operation.
2.
PS_ON is applied. The power supply begins the programmed softstart ramp of 50ms (programmable).
3.
Since the ‘softstart from pre-charge’ setting is active the output voltage is sensed before the softstart ramp begins.
Depending upon the output voltage level of the effective softstart ramp is reduced by the proportional amount.
4.
The PSU now is running in steady state. PGOOD1 turns on after the programmed debounce.
5.
If a fault is activated during the softstart or steady state, the corresponding flag will be set and the programmed action
will be taken such as disable PSU and re-enable after 1 sec or ‘Disable SR and OrFET, Disable OUTAUX’ etc.
Phase Shifted Full
Bridge 48V/600W
PRD1404
FLAGS SETTINGS CONFIGURATIONS
Basically when a flag is triggered, the ADP1046A state machine waits for a programmable debounce time before taking any
action. The response to each flag can be programmed individually. The flags can be programmed in a single window by
selecting the FLAG SETTINGS icon in the MONITOR tab in the GUI. This monitor window shows all the fault flags (if any) and
the readings in one page. The ‘Get First Flag’ button determines the first flag that was set in case of a fault event.
Phase Shifted Full
Bridge 48V/600W
PRD1404
PWM SETTINGS
The ADP1046A has a fully programmable PWM setup that controls 7 PWMs. Due to this flexibility the
IC can function in several different topologies such as any isolated buck derived topology, push pull,
flyback and also has the control law for resonant converters.
Each PWM edge can be moved in 5ns steps to achieve the appropriate deadtime needed and the
maximum modulation limit sets the maximum duty cycle.
PWM
Switching element being controlled
OUTA-OUTD
Primary switch PWM configured for Phase shifted
topology
SR1-SR2
Synchronous rectifier PWMs
OUTAUX
N/A
Phase Shifted Full
Bridge 48V/600W
PRD1404
BOARD EVALUATION AND TEST DATA
STARTUP
Figure 12 - Startup at 340VDC, 600W load(software PSON)
Green trace: Output voltage, 10V/div, 10ms/div
Yellow trace: Load current, 2A/div, 10ms/div
Red trace: Input voltage, 50V/div, 10ms/div
Figure 13 - Startup at 385VDC, 600W load (software PSON)
Green trace: Output voltage, 10V/div, 10ms/div
Yellow trace: Load current, 2A/div, 10ms/div
Red trace: Input voltage, 50V/div, 10ms/div
Phase Shifted Full
Bridge 48V/600W
OVERCURRENT AND SHORT CIRCUI PROTECTION
Figure 16 - OCP at 385VDC, 15A load(Action to shutdown after ~10ms)
Green trace: Output voltage, 10V/div, 5ms/div
Yellow trace: Load current, 5A/div, 5ms/div
Red trace: Input voltage, 50V/div, 5ms/div
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRIMARY GATE DRIVER DEADTIME
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
Phase Shifted Full
Bridge 48V/600W
CS1 PIN VOLTAGE (PRIMARY CURRENT)
SYNCHRONOUS RECTIFIER PEAK INVERSE VOLTAGE
PRD1404
Phase Shifted Full
Bridge 48V/600W
OUTPUT VOLTAGE RIPPLE
TRANSIENT VOLTAGE AT 385VDC (NOMINAL VOLTAGE)
LOAD STEP OF 15-50%
PRD1404
Phase Shifted Full
Bridge 48V/600W
LOAD STEP OF 50-100%
LOAD STEP OF 0-50%
PRD1404
Phase Shifted Full
Bridge 48V/600W
HOLD UP TIME AND VOLTAGE DROP OUT
LINE VOLTAGE FEEDFORWARD
PRD1404
Phase Shifted Full
Bridge 48V/600W
Figure 42 – Line voltage Feed forward DISABLED, 600W load
Red trace: Input voltage step 350-385VDC, 50V/div
Green trace: Output voltage (AC Coupled), 200mV/div
PRD1404
Figure 43 – Line voltage Feed forward ENABLED, 600W load
Red trace: Input voltage step 350-385VDC, 50V/div
Green trace: Output voltage (AC Coupled), 200mV/div
ZVS WAVEFORMS FOR QA (PASSIVE TO ACTIVE TRANSITION)
Phase Shifted Full
Bridge 48V/600W
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
ZVS WAVEFORMS FOR QB (PASSIVE TO ACTIVE TRANSITION)
Figure 50 –Resonant transition at 300W load, 100us/div
Red trace: VDS of QB, 100V/div
Yellow trace: VGS of QB, 5V/div
Figure 51 –Resonant transition at 600W load, 100us/div
Red trace: VDS of QB, 100V/div
Yellow trace: VGS of QB, 5V/div
Phase Shifted Full
Bridge 48V/600W
PRD1404
ZVS WAVEFORMS FOR QC (ACTIVE TO PASSIVE TRANSITION)
ZVS WAVEFORMS FOR QD (ACTIVE TO PASSIVE TRANSITION)
Phase Shifted Full
Bridge 48V/600W
PRD1404
CLOSED LOOP FREQUENCY RESPONSE
A network analyzer (AP200) was used to test the bode plots of the system. A continuous noise signal of 300mV
was injected across the entire frequency range across a 10Ω resistor in series (R35) with the output voltage divider
using an isolation transformer. The operating condition was 385VDC input and a load condition of 600W with a
soaking time of 45 minutes.
Phase Shifted Full
Bridge 48V/600W
EFFICIENCY
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
TRANSFORMER SPECIFICATION
PARAMETER
MIN
TYP
MAX
UNITS
NOTES
Core and Bobbin
PQ3535, Magnetics Inc
R Material or equivalent
Primary inductance
3.316
mH
Pins 1 to pin 6
Leakage inductance
4
µH
Pins 1 to pin 6 with all
other windings shorted
KHz
Pins 1 to pin 6 with all
other windings open
Resonant frequency
850
Table 5 - Transformer specifications
11,12
5T, Copper foil,
10 mil
1
14T,
75 strands, 40AWG,
Litz wire
3
14T,
75 strands, 40AWG,
Litz wire
6
9,10
5T, Copper foil,
10 mil
7,8
Phase Shifted Full
Bridge 48V/600W
6
3
7,8
11,12
7,8
9,10
3
1
PRD1404
Phase Shifted Full
Bridge 48V/600W
THERMAL TEST DATA
A thermal snapshot of the unit was taken after running at 600W with a 45 minute soaking time.
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
Figure 64 – Thermals, Output inductor
Figure 65 – Thermals, output current sense resistor
Figure 66 – Thermals, Transformer
Figure 67 – Thermals, Resonant inductor
Phase Shifted Full
Bridge 48V/600W
Figure 68 – Thermals, Primary MOSFET
PRD1404
Figure 69 – Thermals, Transformer
Phase Shifted Full
Bridge 48V/600W
PRD1404
APPENDIX I –SCHEMATICS (MAIN, DAUGHTER CARD, AND
TOPLEVEL)
FULL BRIDGE
PHASE SHIFTED
SYNC
RECT
48VDC/600W, 720W overload power
MOSFET
Drivers
ADP1046 Daughter CARD Socket
MOSFET
Drivers
3.3V LDO
OR
3.3V
VDD_PRI= 12V
340-410VDC
ADuM4223
icoupler +
driver
Auxillary PSU
Primary= +12V
Secondary= +13V
OUTA-D
VDD_SEC= 13V
Figure 70 – Schematic – Top Level Schematic
I2C Interface
5V from USB
VIN-
J9
VIN+
1
TP4
Vin+
TP12
Vin-
400V
C106
100uF
450V
PRI_GND
GATE_QB+
R132
4.99
R120
0
GATE_QB-
R25
10k
TP15
G-QB 1
650V 20.7A
QB
SPP20N60CFD
R34
10k
1
C115
1uF
630V
650V 20.7A
QA
SPP20N60CFD
TP13
G-QA
GATE_QA+ R133
4.99
GATE_QA-
PRI_GND
250VAC 3A
#0875003
450V
C71
C72
0.33uF 0.33uF
2
3
2
3
L9
2
PRI_GND
LSM-28285-0330,33uH
1
C116 C114
1uF
1uF
VDD_PRI
VDD_PRI
D37
ES1J
C21
0.1uF
C17
0.1uF
2
650V
20.7A
QD
1:100
1
1
25V
25V
GATE_QD+
GATE_QDC29
1uF
GATE_QC+
GATE_QC-
600V 1A
D11
RS1J
1
GATE_QB+
GATE_QBC18
1uF
T5
R65
10k
25V
C30
0.1uF
R129
4.99
25V
16
0 15
14
13
12
11
0 10
9
16
0 15
14
13
12
11
0 10
9
VSS
VDDA
VOA
GNDA
NC4
NC3
VDDB
VOB
GNDB
VIA
VIB
VDD1
GND1
DISABLE
NC1
NC2
VDD2
U18
ADuM4223
VIA
VIB
VDD1
GND1
DISABLE
NC1
NC2
VDD2
U17
ADuM4223
VDDA
VOA
GNDA
NC4
NC3
VDDB
VOB
GNDB
PRI_GND
500VAC
C69
2200pF
250V
1A
D58
ES1D
7
12
9
10
A
1
2
3
4
5
6
7
8
C
B
1
2
3
4
5
6
7
8
250V
1A
AGND
25V
AGND
C16
1uF
+3.3V
25V
C15
1uF
+3.3V
200V
C94
33nF
R114
R113
R112
VSS
0
2
R109 1
Q22
IPB107N20N3 G
1
D62
1N5819
100V
C120
0.1uF
OUTC
VIB_U18
OUTA
VIB_U17
90k
90k
90k
1
SR1_out
R111
1
200V
88A
3
200V
88A
R122
10k
100V
C111
2.2uF
25A
L8
4.7uH
VSS
Q23
FQT3P20TF
1
50V
C48
1uF
2
50V
CS2-
CS2+
R118
0
R2
0.002
R119
0
1
TP41
VS3-
TP39
VS3+
CSNL1206FT2L00
2
R51
10
C41
680uF VS3+
63V
VS1
R123
0
63V
C70
10uF
R117
10
VS3-
PRI_GND
TP47TP48
GNDGND
PGND
TP49TP50
GNDGND
VSS
TP52
VSS
OUTPUT CURRENT & VOLTAGE SENSING
80V
C11 C53
330uF 1uF
Not needed in Resonant mode due to softsw itching:
R112, R113, R114, D58, D59, C94, L8
Q9, Q22 can be replaced by 200V diodes
VS1
Q9
IPB107N20N3 G
R116
SR2_out
D59
ES1D
OUTAUX
SECONDARY
GATE DRIVERS FOR PRIMARY FETS
R45
R49
25V
C31
1uF
R43
R42
25V
C20
1uF
1
2
4
5
6
T12
PQ3230
1.25KVDC
C75
0.022UF
GATE_QC-
GATE_QC+
R131 GATE_QD+
4.99
R121
0
R68
10k
C19
0.1uF
R128
4.99
2
R130
4.99
CSTP16
G-QB
GATE_QD-
1
CS+
PE-67100
1
TP14
G-QC
PRIMARY
GATE_QA+
GATE_QA-
600V 1A
D10
RS1J
PRI_GND
2
QC
650V
20.7A
PRI_GND
D36
Vin_Aux
ES1J
1
2
1
2
3
2
SPP20N60CFD
3
2
SPP20N60CFD
3
4
F2
5A
3
11
8
Vin_400V
2
1
2
1
1
3
2
1
2
1
2
3
J8
63V
C68
10uF
PGND
TP26
VOUT+
1
TP46
VOUT-
C1
1
1
2
PGND
VOUT+
VOUT-
J12
VOUT
J1
J11
Phase Shifted Full
Bridge 48V/600W
PRD1404
VDD_SEC
C74
1nF
C44
VSS
0.1uF 4.7uF
NC2
VDD
OUTB
OUTA
INB
PND
NC1
VSS
3
1
4
2
SR1 SR2
R77 DNI
R75 0
R79 DNI
R78 0
INA
U7
ADP3654
PSON
18
17
13
11
9
CS2-
12V
AGND
3.3V
5V
VS3-
VS3+
GATE
VS2
VS1
PGND
CS2+
SR2
SR1
ACSNS
CS1
OUTA
OUTB
OUTC
OUTD
OUTAUX
PSON
30
29
28
27
26
25
24
23
22
21
20
19
16
15
14
12
10
AGND
PGND
ACSNS
2
OUTA
OUTC
OUTAUX
R93 2k2
VDD_SEC
+3.3V
+5V
VS3-
VS3+
GATE
VS2
VS1
CS2+
D49
RED
D51
YELLOW
AGND
1
1
PGND
C43
DNI
R66
PGND
D20
DNI
TP23
CS1
CS1
LED INDICATORS
R40 2k22
FLAGIN
CS2-
PGOOD1
PGOOD2
ADP1046 DAUGHTER CARD CONNECTIONS
GATE DRIVERS FOR SR
8
6
5
7
VIB_U18
VIB_U17
AGND
C82
SR2_out
SR1_out
+3.3V
SW2
PSON
1
2
2.5V
D19
C38
DNI
R64 0
DNI
1
2
D13
1N4148
1
2
1
2
B
AGND
D63
BAV99
3
D64
BAV99
3
Q10
DNI
RTD
D13= DNI for Resonant mode
R66= 0ohm for Resonant mode
change ACSNS resistor div ider
accordingly to giv e >0.45V on
DC
LINE FEED-FORWARD
R59
200
C
CS1 SENSING
MMSZ5222BT1G
C22 R76
1000pF 51
R44
0
1
R74
0
R70
16.5k
R71
0
TEMP SENSING
RTD
100k
2
3
SCL
1
2
CS-
CS+
AGND
PGND
R73 0
R52
22K
OUTAUX
R87
100 2
VDD_SEC
J28
1
1 2
2
3
Q21
BSS138
C61 100
33pF
R96
C63 100
33pF
R95
AGND
C62
33pF
AGND
C60
33pF
+5V
120X120X25MM 48VDC
FAN CONTROL
Part #: 3106KL-04W-B50-B01
D47
1N4148
I2C INTERFACE AND FILTERING
SDA
SCL
PGND
1
1
2
SDA
2
1
SHAREI
AGND
+5V
J18
VIN_AUX1
VIN_AUX2
PRI_GND1
PRI_GND2
PRI_GND3
PRI_GND4
VDD_PRI1
VDD_PRI2
NC1
NC2
NC3
NC4
PGND1
PGND2
VDD_SEC1
VDD_SEC2
PGND
13
14
PRI_GND
3
4
5
6
1
2
3
4
5
6
7
8
9
10
1
2
3
4
Miro MaTch
SCL
GND A
SDA
VBUS
SPI MISO
NC
SPI SCLK
SPI MOSI
SPI CS A
GND B
J17
COM2
5V
SCL
SDA
GND
J16
COM1
AUXILLARU PSU
PRIMARY +12V
SECONDARY +12V
15
16
7
8
9
10
11
12
1
2
AGND
400V
D50
BAW56
D48
BAV70
VDD_SEC
VDD_PRI
Vin_Aux
1
2
SHAREO
3
3
J15
ADP1046_DC
1
SHAREO
2
SHAREI
3
SDA
4
SCL
5
RTD
6
FLAGIN
7
PGOOD2
8
PGOOD1
Phase Shifted Full
Bridge 48V/600W
PRD1404
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
None-Inverting Remote Voltage Sense Input
OrFET Gate Drive Output
OrFET Drain Sense Input
Local Voltage Sense Input
Power GND
None Inverting Differential Current Sense Input
Inverting Differential Current Sense Input
Synchronous Rectifier Output
Synchronous Rectifier Output
AC Sense Input
Primary Side Differential Current Sense Input
PWM Output for Primary Side Switch
PWM Output for Primary Side Switch
PWM Output for Primary Side Switch
PWM Output for Primary Side Switch
Auxiliary PWM Output
Power Supply On Input
Power Good Output (Open Drain)
Power Good Output (Open Drain)
Flag Input
2
1
Analog Share Bus Feedback Pin
Share Bus Output Voltage
NOTES:
3
I2C Serial Clock Input
I2C Serial Data Input and Output
C26 = 330pF 50V X7R
VCORE
DNI
DNI
Low Side 4.99k 4.99k DNI
High Side 110k 110k DNI
DNI
33pF 33pF
DNI
C10 C13 C16 C17
R14, R15 = 2.2k 1%
PGOOD1/2
R4
R33, R32 = 2.2k 1%
SHARE O/I
R3
R19 = 10k 1%
ADD
1: R3, R4, R5, R6, R7, R8, R10, R11,R20 ARE 0.1% 25ppm
UNLESS OTHERWISE SPECIFIED.
2
3
SHARE0
SHAREi
SDA
SCL
RTD
FLAGIN
PGOOD2
PGOOD1
PSON
OUTAUX
OUTD
OUTC
OUTB
OUTA
CS1
ACSNS
SR1
SR2
CS2-
CS2+
VS1
VS2
GATE
VS3+
VS3-
+5V
+3.3V
Short trace from pin 25 DGND to pin 2 AGND
4
Thermistor Input
4
5
6
26
Inverting Remote Voltage Sense Input
27
+12V
C18
DNI
R2
1k
R1
65
C10
100pF
ACSNS
C5
1.0uF
50V
DNI
D1
+12V
2
C17
R4
DNI 4.99k
CS2+
5
6
8
7
2
GND
NR
OUT1
OUT2
U2
ADP3303
SD
ERR
IN1
IN2
R6
1k
R5
46.4k
VS1
R3
4.99k
D2
1N4148
+5V
C13
100pF
C16
DNI
CS2-
4
3
1
2
C8
0.1uF
C2
DNI
C1
DNI
C15
1000pF
C4
DNI
C3
DNI
R11
1k
C12
4.7uF
R21 5.1K
+3.3V
CS1
R8
1k
R7
46.4k
VS2
R10
46.4k
D6
LED
RED
8
7
6
5
4
3
2
1
C14
0.1uF
VS3+
PGND
CS1
ACSNS
CS2+
CS2-
VS1
AGND
VS2
C9
DNI
C7
DNI
VS3-
2
10k
29 R19
3
RTD
3
C11
+3.3V
U1
ADP1046A
ADD
28
PGND
R13
0 Ohm
4
AGND DGND
SCL
SDA
PSON
FLAGIN
PGOOD2
PGOOD1
SHAREO
SHAREI
0.1uF
25
DGND
29
2
1
33
PAD
31
32
VS3+
10
SR1
9
SR1
28
RTD
C6
330pF
26
VCORE
10k
11
VS3-
30 R20
RES
OUTA
OUTA
OUTB
12
OUTB
OUTC
13
OUTC
R29
2.2k
17
18
19
20
21
22
23
24
R33
2.2k
3
+3.3V
R24
2.2k
2.2k
R32
30
2
1
14
SR2
SR2
27
VDD
OUTD
OUTD
GATE
16
GATE
OUTAUX
15
OUTAUX
2.2k
R15
Analog GND
2
1
J1
SDA
SCL
+5V
R14
2.2k
+3.3V
4
3
2
1
SCL
SDA
PSON
J7
FLAGIN
PGOOD2
PGOOD1
SHARE0
SHAREi
Phase Shifted Full
Bridge 48V/600W
PRD1404
Phase Shifted Full
Bridge 48V/600W
PRD1404
APPENDIX IV – LAYOUT
Figure 75 – Bottom side placement of components
Phase Shifted Full
Bridge 48V/600W
PRD1404
Figure 77 – Layout Layer 2
Phase Shifted Full
Bridge 48V/600W
PRD1404
Phase Shifted Full
Bridge 48V/600W
NOTES
PRD1404
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property of their respective owners.
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