EVBUM2356/D NCP1034 Buck Converter Evaluation Board User's Manual www.onsemi.com EVAL BOARD USER’S MANUAL Table 1. GENERAL PARAMETERS Device Input Voltage Output Voltage Output Current Voltage Ripple Topology I/O Isolation NCP1034 48 V ±20% 5V 5A < 30 mV Buck None Key Features Description This evaluation board user’s manual describes high voltage, high power and high efficiency DC/DC buck converter featuring the NCP1034. The NCP1034 is voltage mode PWM controller for a high voltage synchronous buck. The controller drives two external N-MOSFETs with programmable frequency up to 500 kHz for wide applications range. The IC is able to be synchronized by external signal or is able to synchronize other ICs that simplify design of system level filter. The output voltage can be set as low as 1.25 V. Besides system and drivers UVLO there is an external UVLO that can be set to user value. Over current protection uses low side MOSFET RDSON as sensing resistor, which has no impact on efficiency. Current limit protection uses a hiccup mode. These protections provide application additional security level. • • • • • • • • • High Input Voltage High Operation Frequency High Efficiency Low Output Voltage Ripple Ceramic Capacitors Only Over-current Protection Under-voltage Protection Start to Pre-biased Output Small Size Connection Diagram − + Shut Down Power Supply: 48 V ±20% + + Load: 5 V <5A − − − + Ext. Sync Signal Figure 1. Connection Diagram © Semiconductor Components Industries, LLC, 2016 January, 2016 − Rev. 2 1 Publication Order Number: EVBUM2356/D Figure 2. Schematic of the NCP1034 Demo Board C3 100 nF R12A 0W R12B NU 14 1 16 4 15 5 12 R13 0W GND R7, 10 kW GND GND GND GND C10 100 nF MMSZ4699 GND GND GND JP1−1 2 1 GND SS/SD JP1−2 4 3 R5, 3.9 kW D2 R10, 10 kW SYNC GND GND R4 110 kW R11E, 12 kW R11D, 12 kW GND C5, 220 nF COMP FB PGND LDRV OCIN VS HDRV D1 1N4148 IO1 NCP1034SMD GND OCSET UVLO SS/SD RT SYNC VCC C2 100 nF C11 NU 8 DRVVCC R11C, 12 kW R6, 20 kW 9 VB 3 2 6 7 13 11 10 C6 12 nF C7 330 pF R3 4.7 kW R8 10 kW C12 NU C4 100 nF R14A NU R14B 0W Q3 NTD24N06 L1 13 mH Q2 NTD3055 2.2 mF 2.2 mF NU C1C C9B, 4.7 mF GND C9D, NU R15 0W NU C1D + C1B C9C, 4.7 mF C1A NU C1E + R11B, 12 kW NU C1F GND C9E, NU Q1 NU C9A, 4.7 mF GND 48 V ±20% R9 1.2 kW R11A, 12 kW R1, 16.9 kW R2 5.6 kW www.onsemi.com C8 1.8 nF 2 X2−2 X1−2 X1−1 X2−1 5 V @ 5 A, 200 kHz GND EVBUM2356/D Schematic EVBUM2356/D surface mounted types and almost all of them are on the top layer. On the bottom side there are power MOSFETs because it can be easy put on cooler (if demo board is used on prescribed operations conditions and at room temperature it is not needed). Some components must be placed very carefully. Blocking capacitors C2, C3 and bootstrap capacitor C4 have to be placed close to the IC. Low side MOSFET’s source have to be connected to the IC’s power ground with minimum resistance and inductance of connection so two layers connection between them is needed. Feedback and compensation network should be near the IC to minimize noise on them. Using signal and power ground connected in one point near the output connector improves load regulation. Inductor and output capacitors are placed close to the MOSFETs and output connector. The demo board was designed as board with many options. There is linear regulator for powering the IC only with Zener diode or with high voltage transistor (R12A and R12B selected one of these regulators), compensation circuit of second or third type (R14A and R14B), ceramic or electrolytic output capacitors (C9A–C9E) and various input capacity (C1A–C1F). For additional filtering there are R13 and C11 which is not currently used. There are two headers pins for easy connection to external synchronization pulse source or to direct connection to the other NCP1034 demo board and the SS/SD pin that can be used to shut down the controller by connecting it to the ground. Circuit Layout Circuit is designed on two layer FR4 board with 72 mm copper cladding. Except connectors all components are Figure 3. Top Layer Figure 4. Bottom Layer www.onsemi.com 3 EVBUM2356/D Figure 5. Top Side Components 70 mm Figure 6. Bottom Side Components 44 mm Figure 7. Demo Board Photos www.onsemi.com 4 EVBUM2356/D Measurement Table 2. OUTPUT PARAMETERS Characteristic Output Voltage Maximum Output Current Oscillator Frequency Typ Unit 5.02 V 5 A 200 Output Voltage Ripple IOUT = 0.1 A IOUT = 5 A 16.5 20.5 Load Regulation IOUT = 0−5 A, VIN = 48 A −0.34 kHz mVpk−pk mV/A Line Regulation VIN = 38−58 A IOUT = 0.1 A IOUT = 5 A % 0.004 0.011 Start Up Sequence Output Voltage SS Voltage Figure 8. Start to Nominal Load www.onsemi.com 5 Output Current EVBUM2356/D Output Voltage SS Voltage Output Current Figure 9. Start to Light Load Output Voltage SS Voltage Bridge Voltage Figure 10. Start to Pre-Biased Output www.onsemi.com 6 Output Current EVBUM2356/D Over-Current Protection Output Voltage SS Voltage Bridge Voltage Inductor Current Figure 11. Shorted Output and Release Output Voltage SS Voltage Bridge Voltage Figure 12. Overload from Nominal Load and Released www.onsemi.com 7 Inductor Current EVBUM2356/D Output Voltage SS Voltage Bridge Voltage Inductor Current Figure 13. Hicup Pulse Detail Shutdown Output Voltage SS Voltage Input Voltage Figure 14. Switch Off Input Voltage to Light Load www.onsemi.com 8 Output Current EVBUM2356/D Output Voltage SS Voltage Input Voltage Output Current Figure 15. Switch Off Input Voltage to Nominal Load Output Voltage SS Voltage Input Voltage Figure 16. Shut Down through SS/SD Pin www.onsemi.com 9 Output Current EVBUM2356/D Step Response and Output Voltage Ripple Output Voltage Bridge Voltage Output Current Figure 17. Load Step Response Output Voltage Bridge Voltage Inductor Current Figure 18. Output Voltage Ripple IOUT = 5 A www.onsemi.com 10 EVBUM2356/D Output Voltage Bridge Voltage Inductor Current Figure 19. Output Voltage Ripple IOUT = 0.1 A www.onsemi.com 11 EVBUM2356/D Synchronization Two independent boards connected (or not) via Sync pin and ground. First Demoboard Sync Pin Voltage First Demoboard Bridge Voltage Second Demoboard Sync Pin Voltage Second Demoboard Bridge Voltage Figure 20. No Synchronization First Demoboard Sync Pin Voltage First Demoboard Bridge Voltage Second Demoboard Sync Pin Voltage Second Demoboard Bridge Voltage Figure 21. Synchronized − Sync Pins Connected www.onsemi.com 12 EVBUM2356/D Line and Load Regulation 5.035 IOUT = 5 A IOUT = 0.1 A 5.030 VOUT (V) 5.025 5.020 5.015 5.010 38 40 42 44 46 48 50 52 54 56 58 3.5 4.0 4.5 5.0 VIN (V) Figure 22. Line Regulation 5.035 5.030 VOUT (V) 5.025 5.020 5.015 5.010 0.0 0.5 1.0 1.5 2.0 2.5 3.0 IOUT (A) Figure 23. Load Regulation VIN = 48 V www.onsemi.com 13 EVBUM2356/D Efficiency 90 85 Efficiency (%) 80 75 70 65 VIN = 38 V 60 VIN = 48 V 55 VIN = 58 A 50 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 IOUT (A) Figure 24. Efficiency Unit Pind, winding Pcore Pstatic, IC Phigh_gate Plow_gate Pdynam, IC Phigh_switch, cond Plow_switch, cond Phigh_switch, sw Plow_switch, sw Plow_switch, body Plow_dead_time P_switch_capacit Ppreregulator Ploss, total Pout Pin Effectivity 0.32 1.20 0.03 0.02 0.06 0.07 0.32 0.72 0.21 0.00 0.92 0.11 0.07 0.31 4.37 25.00 29.37 85 W W W W W W W W W W W W W W W W W % ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← Inductor Winding Loss Core Loss in Inductor. Available in Inductor Data Sheet Static Power Loss of the IC Power Loss of High Power Switch Gate Charge Power Loss of Low Power Switch Gate Charge Dynamic Power Loss of the IC Conduction Loss of High Power Switcher Conduction Loss of Low Power Switcher Switching Loss of High Power Switcher Switching Loss of Low Power Switcher Body Diode Recovery Charge Loss Body Diode Conduction Loss Switchers Capacitance Loss Power Loss of Linear Preregulator VIN → VCC Total Loss Output Power Input Power = Output Power + Total Loss Efficiency of Converter (Est: ±5%) Figure 25. Power Loss Review from Spreadsheet www.onsemi.com 14 EVBUM2356/D Bode Plot 60 200 Phase 40 150 Gain 100 20 0 0 −50 −20 −100 −40 −150 −200 −60 0.01 0.1 1 10 f (MHz) Figure 26. Bode Plot VIN = 48 V, IOUT = 5 A www.onsemi.com 15 100 1000 Phase (5) Gain (dB) 50 EVBUM2356/D Table 3. BILL OF MATERIALS FOR THE NCP1034 DEMOBOARD (Note 1) Parts Qty Description Value Tolerance Footprint Manufacturer Manufacturer Part Number Substitution Allowed R9 1 Resistor SMD 1.2 kW 1% 1206 Vishay CRCW12061K20FKEA Yes R5 1 Resistor SMD 3.9 kW 1% 1206 Vishay CRCW12063K90FKEA Yes R3 1 Resistor SMD 4.7 kW 1% 1206 Vishay CRCW12064K70FKEA Yes R2 1 Resistor SMD 5.6 kW 1% 1206 Vishay CRCW12065K60FKEA Yes R1 1 Resistor SMD 16.9 kW 1% 1206 Vishay CRCW120616K9FKEA Yes R6 1 Resistor SMD 20 kW 1% 1206 Vishay CRCW120620K0FKEA Yes R11A, R11B, R11C, R11D, R11E 5 Resistor SMD 12 kW 1% 1206 Vishay CRCW120612K0FKEA Yes R4 1 Resistor SMD 110 kW 1% 1206 Vishay CRCW1206110KFKEA Yes R7, R8, R10 3 Resistor SMD 10 kW 1% 1206 Vishay CRCW120610K0FKEA Yes R12A, R13, R14B, R15 4 Resistor SMD 0W 1% 1206 Vishay CRCW120600R0FKEA Yes R12B, R14A 2 Resistor SMD NU − 1206 − − − C8 1 Ceramic Capacitor SMD 1.8 nF 10% 1206 Kemet C1206C182K5RAC-TU Yes C6 1 Ceramic Capacitor SMD 12 nF 10% 1206 Kemet C1206C123K5RACTU Yes C5 1 Ceramic Capacitor SMD 220 nF 10% 1206 Kemet C1206C224K5RACTU Yes C7 1 Ceramic Capacitor SMD 330 pF 10% 1206 Yageo CC1206KRX7R9BB331 Yes C11, C12 2 Ceramic Capacitor SMD NU − 1206 − − Yes C2, C3, C4, C10 4 Ceramic Capacitor SMD 100 nF 10% 1206 Kemet C1206F104K1RACTU Yes C9A, C9B, C9C 3 Ceramic Capacitor SMD 47 mF/6.3 V 20% 1206 Kemet C1210C476M9PAC7800 Yes C1A, C1B 2 Ceramic Capacitor SMD 2.2 mF/100 V 10% 1206 Murata GRM32ER72A225KA35L Yes C1C, C1D, C1E, C1F 4 Ceramic Capacitor SMD NU − 1206 − − Yes C9D, C9E 2 Electrolytic Capacitor NU − 8x15 − − Yes L1 1 Inductor SMD 13 mH 20% 13.2x12.8 Wurth 7443551131 Yes D1 1 Switching Diode MMSD4148 − SOD−123 ON Semiconductor MMSD4148T1G Yes D2 1 Zener Diode 500 mW 12 V MMSZ4699 − SOD1−23 ON Semiconductor MMSZ4699T1G Yes Q1 1 NPN Transistor NU − DPAK − − Yes Q2 1 Power N-MOSFET NTD3055 − DPAK ON Semiconductor NTD3055-150G Yes Q3 1 Power N-MOSFET NTD24N06 − DPAK ON Semiconductor NTD24N06T4G Yes IO1 1 High Voltage Synchronous PWM Buck Controller NCP1034 − SOIC−16 ON Semiconductor NCP1034DR2G No X1 1 Inlet Terminal Block PCB 2 WAY − Pitch: 5 mm Lumberg KRM 02 Yes X2 1 Outlet Terminal Block PCB 2 WAY − Pitch: 5 mm Lumberg KRM 02 Yes 1. 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