SiP11206DB Vishay Siliconix 200 W 1/16th Brick IBC Demo Board using SiP11206 DESCRIPTION SiP11206 is a half-bridge controller for intermediate bus converters. While SiP11206 allows for overall better efficiency through out the input voltage range, since its duty cycle is fixed and is optimally set closer to its maximum 50 %. This also limits the input voltage range to a narrower 42 V to 55 V typical range because of the fixed duty cycle the output voltage will have a proportionally wider voltage swing. The SiP11206 is best for applications where efficiency is key and a wider output voltage can be tolerated. This demo board is a sixteenth-brick IBC power converter, which plugs into a baseboard. The IBC board has the following specifications and options: • Narrow input voltage range (42 V to 55 V) with SiP11206 controller IC • Nominal 12 V output, nominal load current 17 A • PowerPAK® 1212-8 for primary and secondary power MOSFETs The baseboard contains input fuse, input/output terminals, remote enable connectors, enable switch, input bulk capacitors and output voltage measurement BNC connector. The cutout in the baseboard allows for probing of both sides of the IBC board. Photos are shown in figure 1. Size comparison of Vishay 1/8th and 1/16th Brick Modules Figure 1. Photos of Demo Board with PowerPAK MOSFET Options This document details the following of the demo board: 1. Set up 2. Operation 3. Waveforms and performance curves 4. Schematic and BOM 5. Board layout Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 SET UP The connection diagram for the demo board is depicted in figure 2. Power and sense connections are provided at the input and output for the main current path and for voltage sensing for efficiency monitoring. Wire rated at 5 A should be used for the input connections and 2 x 10 A rated wire should be used for the output lines. The board can be enabled/disabled manually by using the on-board switch or by connecting a 0 V/5 V logic signal in the disable connector. 5 V represents ‘disable’. www.vishay.com 1 SiP11206DB Vishay Siliconix Wiring lengths should be kept as short as possible, especially at the output in order to avoid excessive voltage drop across the cable length. The demo board has two 47 µF capacitors at the input to help minimize the issues with long cables lengths used at the input. It should be noted that with long cable lengths, the input voltage might be quite oscillatory on power up, potentially leading to under-voltage or the converter cycling in and out of operation until the voltage becomes steady. A small fan should be placed so that air is blown over both sides of demo board in the direction shown. If the temperature of the board exceeds ~ 105 ºC, the board will be disabled by the over temperature shutdown mechanism. Figure 2. Connection Diagram (a) 48 V with 0 A, 1 DL, 2 VLOUT OPERATION AND TEST RESULTS The power circuit is a half-bridge converter controlled by the SiP11206 IC. In the SiP11206, the converter duty cycle is fixed and is set by R2. This version of the chip was used on the demo board which maintains the highest overall efficiency since the duty cycle is constant. It is typically set to a value close to 50 % for maximum efficiency. The output voltage is then determined by the input voltage and the transformer turns ratio. In this demo board, the transformer turns ratio is 4:1. The controller IC is powered at startup by its own internal 9.5 V pre-regulator, which is driven from the line voltage. Once converter switching commences, a separate 10.3 V VCC supply is supplied from an auxiliary transformer winding, and linear regulator R18, Q7, D8. The secondary side synchronous rectifiers are self-driven, but with a controlled gate voltage that does not vary with input voltage. The result is improved efficiency and safer drive voltages because the secondary gate drive is generated locally and clamped to ~ 10 V through D9, R19, C12 and D10. MOSFETs Q8 and Q3 are triggered by the opposite transformer node, and the 10 V is coupled to the synchronous rectifier gate less a threshold voltage drop. A Schottky diode can be connected across the output filter which improves efficiency for longer dead times. During dead time, the synchronous rectifiers are off as there is no transformer voltage available to turn them on. Hence, without the Schottky diode present, the inductor current will flow through the body diodes of the synchronous rectifiers. The Schottky diode has a smaller voltage drop than the body diodes, and so may enhance efficiency dependent on deadtime, sync-fets, layout etc…. Some typical converter waveforms are shown in figures 3 to 7. (b) 48 V with 10 A, 1 DL, 2 VLOUT Figure 3. Secondary Switching Waveforms www.vishay.com 2 Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 SiP11206DB Vishay Siliconix Startup 0 A Load 1 VREF, 2 DL, 3 SS, 4 VOUT Startup 10 A Load 1 VREF, 2 DL, 3 SS, 4 VOUT Startup 0 A Load 1 VDET, 2 DL, 3 SS, 4 VOUT Startup 10 A Load 1 VDET, 2 DL, 3 SS, 4 VOUT Figure 4. Startup Waveforms Shutdown 0 A Load 1 VREF, 2 DL, 3 SS, 4 VOUT Shutdown 10 A Load 1 VREF, 2 DL, 3 SS, 4 VOUT Shutdown 0 A Load 1 VDET, 2 DL, 3 SS, 4 VOUT Shutdown 10 A Load 1 VDET, 2 DL, 3 SS, 4 VOUT Figure 5. Shutdown Waveforms Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 www.vishay.com 3 SiP11206DB Vishay Siliconix 25 A Load 1 VREF, 2 DL, 3 SS, 4 VOUT 25 A Load 1 VDET, 2 DL, 3 SS, 4 VOUT Figure 6. Over Current Protection/Hiccup Waveforms No Load 33 mVpk-pk 10 A Load 47 mVpk-pk Figure 7. Ripple Waveforms 97 % 16 VIN = 42 V 96 % 95 % 14 VIN = 48 V 94 % 12 93 % VIN = 55 V 10 92 % 91 % VOUT Efficiency Line Reg = 55 V Line Reg = 48 V 90 % 89 % 8 Line Reg = 42 V 6 88 % 4 87 % 86 % 2 85 % 84 % 0 0 2 4 6 8 10 12 14 16 Output Current (A) www.vishay.com 4 18 20 0 2 4 6 8 10 12 14 16 18 20 Load SiP11206 1/16th Brick Efficiency 1/16th Brick Line-Load Regulation Figure 8. Efficiency Figure 9. Line-Load Regulation Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 SiP11206DB Vishay Siliconix PCB LAYOUT The demo board is an 10 layer board in the sixteenth-brick form factor, manufactured with 2 oz copper on the outer layers and 3 oz copper on the inner layers. The circuit schematics for the demo board are illustrated in figures 10 and 11. The transformer is a planar magnetic component with an EI core. The primary winding has 4 turns, located on layers 2, 4, 5 and 7, with 1 turns per layer. Each secondary winding has 2 turns, located on layers 1, 3, 6, and 8 with 2 turn per layer. The auxiliary winding has 2 turns, consisting of 2 turns on the bottom layer figure 12. Figure 13 shows the top bottom of the base board. Figure 10. Layers 1 to 4 of PCB (l-r) Figure 11. Layers 5 to 8 of PCB (l-r) Figure 12. Top and Bottom Layout Figure 13. Top and Bottom PCB layout of Base Board Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 www.vishay.com 5 SiP11206DB Vishay Siliconix The schematics are shown in figures 14 and 15, and parts list are shown in table 1 and 2. TABLE 1 - IBC PARTS LIST - PART VALUES ARE FOR NARROW INPUT VERSION Designator Description C1 Capacitor Comment Footprint Quantity Value 603 1 100 nF/25 V C3 Capacitor 603 1 1 µF/16 V C4 Capacitor 402 1 100 pF/25 V C5 Capacitor 402 1 22 nF/25 V C6 Capacitor 402 1 220 pF/25 V C8 Capacitor 1812 1 4.7 µF/50 V C10 Capacitor 1812 1 4.7 µF/50 V C12 Capacitor 603 1 0.1 µF/25 V C13 Capacitor 603 1 1 µF/16 V C14 Capacitor 1812 1 22 µF/16 V C15 Capacitor 1812 1 22 µF/16 V C17 Capacitor 603 1 0.1 µF/25 V C18 Capacitor 603 1 1 µF/16 V D1 Default Diode BAV19WS SOD323/X.85 1 D5 Schottky Diode SSC54 Diode SMC 1 D7 Schottky Diode BAS170WS SOD323/X.85 1 D8 Schottky Diode BZX384B11-11V2 % SOD323/X.85 1 D9 Schottky Diode BAS170WS SOD323/X.85 1 D10 Schottky Diode BZX384B11-11V2 % SOD323/X.85 1 L1 Inductor IHLP2525CZ-01 IHLP2525CZ-01 1 0.47 µH P1 VIN Pin-through-hole 1 3102-3-00-xx-00-00-08-0 P2 On/Off Pin-through-hole 1 3102-3-00-xx-00-00-08-0 P3 GND Pin-through-hole 1 3102-3-00-xx-00-00-08-0 P4 12 VO Pin-through-hole 1 3144-3-00-xx-00-00-08-0 P5 0V Pin-through-hole 1 3144-3-00-xx-00-00-08-0 Q1 Synch MOSFET Si7174DN PowerPAK-1212-8-single 1 Q2 Synch MOSFET Si7174DN PowerPAK-1212-8-single 1 Q3 MOSFET Si2308DS SOT23 1 Q4 Synch MOSFET Si7156DN PowerPAK-1212-8-single 1 Q5 Synch MOSFET Si7156DN PowerPAK-1212-8-single 1 Q7 SOT23 NPN Silicon ZXTN2031F SOT23 1 Q8 MOSFET Si2308DS SOT23 1 R1 Resistor 402 1 R2 Resistor 402 1 80.6K R3 Resistor 402 1 220R/1 % R5 Resistor 402 1 33K/1 % R6 Resistor 402 1 3.6K/1 % R7 Resistor 402 1 10 R R9 Resistor 402 1 100K R10 Resistor 402 1 100K R12 Resistor 402 1 82K R15 Resistor 402 1 10K www.vishay.com 6 82K Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 SiP11206DB Vishay Siliconix TABLE 1 - IBC PARTS LIST - PART VALUES ARE FOR NARROW INPUT VERSION Designator Description Footprint Quantity Value R16 Resistor Comment 402 1 10K R17 Resistor 1206 1 0.01 R R18 Resistor 402 1 1.5K/1 % R19 Resistor 1.5K T1 402 1 EI-18 Planar E18-Planar-TFM 1 U1 PWM CTLR SiP11206 MLP44-16-Pitch 0.65 mm 1 U2 Temperature Sensor LM26-Thermal-Sensor SO-G5/P.95 1 Z1 Micropower Voltage Reference LM4120-VREF SO-G5/P.95 1 TABLE 2 - BASE BOARD PARTS LIST Designator Description Comment Footprint Quantity COAX-F Coax-F Connector 1 H3183-05 1 Value COAX-F Coax-F Connector 2 H3183-05 1 COAX-F Coax-F Connector 3 H3183-05 1 Cap2 Capacitor C1 RB5-10.5 1 47 µF/160 V Cap2 Capacitor C2 RB5-10.5 1 100 pF Cap Semi Capacitor (Semiconductor SIM Model) C3 CR3216-1206 1 100 pF BAS16 Silicon Switching Diode for High-Speed Switching D1 SO-G3/C2.5 1 BAS16 Silicon Switching Diode for High-Speed Switching D2 SO-G3/C2.5 1 Fuse 2 Fuse F1 CR3216-1206 1 COAX-F Coaxial-Connection J4 Test Point Test Point J8 0364-0-15-01-13-27-10-0 1 1 Test Point Test Point J9 0364-0-15-01-13-27-10-0 1 Header 6 Header, 6-Pin JP1 1727056 1 Header 4 Header, 4-Pin JP2 1727036 1 MHDR1X2 Header, 2-Pin JP3 1727010 1 MMUN2213LT1G NPN Bipolar Transistor Q1 SO-G3/X.9 1 Res1 Resistor R2 CR3216-1206 1 16K 1.5K Res1 Resistor R3 CR3216-1206 1 SW-SPDT SPDT Toggle Switch S1 ET01MD1 1 Test Point Test Point TP4 20-313137 1 Test Point Test Point TP1 20-313137 1 Test Point Test Point TP2 20-313137 1 Test Point Test Point TP3 20-313137 1 Document Number: 69086 S09-0324-Rev. B, 02-Mar-09 www.vishay.com 7 SiP11206DB Vishay Siliconix + VP + VP + VP R9 0402 100K C8 1812 4.7 µF 50 V T1 R10 0402 100K EI-18 Planar 10 1 C10 Q4 SD2 1812 4.7 µF 50 V 9 Q1 D1 BAV19WS 2 Aux 2 P5 SSC54 1 Si2308DS R19 SGND 0402 1.5K SGND C12 0603 SGND SGND 0V D10 BZX384B11-11V2 % 0.1 µF 25 V Aux-DC 2 2 1 Pzen 5 R18 0402 1.5K1 % SGND C17 0603 0.1 µF 25 V D8 C18 PGND PGND 2 4 3 P4 1 C15 1812 12 VO Q3 1 Q7 ZXTN2031F PGND R16 0402 10K D5 IHLP2525CZ-01 C14 1812 D9 0.47 µH 2 PGND 1 22 µF 16 V 1 R7 0402 10R 1 R2 0402 80.6K 1% 5 1 2 3 1 1 VIN 2 VO PGND Q5 Si7156DN D7 BAS170WS Aux-R 3 REF GND ENA PGND R3 C4 C3 0402 R1 220R1 % R12 0603 0402 0402 100 pF 1 µF 0402 82K 25 V 16 V 82K 1% R17 1206 0.01R Rss+ 5 4 VREG Z1 1 2 3 PGND SD V+ 4 2 HYST GND VTEMP 25 V C5 0402 RDB 22 nF Cosc Rosc 1 2 3 VREF SS PGND U2 LM26-Thermal-Sensor 8 7 6 5 C6 PGND 0402 220 P 25 V PGND RDB COSC ROSC VREF PGND Q2 12 D 11 4 L 10 9 1 VCC LX COMP U1 DL CS PGND SiP11206 AGND SS 8 Isen 1 GND 1 2 3 4 7 6 5 P3 Vcc Si7174DN 22 µF 16 V BAS170WS SG2 3 DH BST VDET VIN R6 0402 3.6K1 % 75 6 7 68 SV+ L1 SCT 8 2 3 13 14 15 16 1 ON/OFF PGND SVREG 2 C1 Vdet SG1 4 R5 0402 33K1 % P2 0603 100 nF LX 25 V 3 2 1 VIN Boot 1 Si2308DS 1 2 3 2 1 R15 Q8 0402 10K 3 1 7 6 5 4 + VP 8 7 6 5 P1 Si7174DN DH 4 Si7156DN SD8 0603 1 µF 16 V C13 0603 1 µF 16 V LM4120-VREF PGND BZX384B11-11V2 % PGND Figure 14. Schematic TP3 TP1 JP2 4 3 2 1 + F1 1 Header 4 JP1 J4 COAX-F COAX-F J9 COAX-F 1 COAX-F SMB C1 Cap2 47 µF 160 V C3 Cap Semi 100 pF C2 Fuse 2 Cap2 100 pF 2 1 2 3 4 5 6 Header 6 TB4 COAX-F R2 Res1 16K 2 J8 COAX-F 2 D1 COAX-F 3 S1 R3 Res1 1.5K 1 SW-SPDT BAS16 Q1 TP2 COAX-F 3 MMUN2213LT1G COAX-F D2 JP3 2 1 BAS16 MHDR1X2 Figure 15. Schematic - Base Board Vishay Siliconix maintains worldwide manufacturing capability. Products may be manufactured at one of several qualified locations. Reliability data for Silicon Technology and Package Reliability represent a composite of all qualified locations. For related documents such as package/tape drawings, part marking, and reliability data, see www.vishay.com/ppg?69086. www.vishay.com 8 Document Number: 69086 S09-0324-Rev. B, 02-Mar-09