DEMO MANUAL DC1335B-B LTC4269-1 PoE+ (802.3at) Powered Device Controller and Synchronous Flyback DESCRIPTION Demonstration circuit 1335B-B is a high-power supply featuring the LTC®4269-1. This board acts as an IEEE 802.3at compliant, high power Power-over-Ethernet (PoE), Powered Device (PD) and connects at the RJ45 to a compatible high power Power Sourcing Equipment (PSE) device, such as the DC1366. The LTC4269-1 provides IEEE 802.3at standard (PoE+) PD interfacing and power supply control. When the PD is fully powered, the PD interface switches power over from the PSE to the switcher through an internal, low resistance, high power MOSFET. The highly integrated LTC4269-1 PERFORMANCE SUMMARY controls a high-power, small-sized power supply that utilizes a highly efficient isolated flyback topology with synchronous rectification. The DC1335B-B supplies a 5V output at up to 4.5A. DC1335B-B also demonstrates the use of an auxiliary 48V wall adapter. When present, the auxiliary supply becomes the dominant supply over PoE to provide power. Design files for this circuit board are available at http://www.linear.com/demo L, LT, LTC, LTM, μModule, Linear Technology and the Linear logo are registered trademarks of Linear Technology Corporation. All other trademarks are the property of their respective owners. (TA = 25°C) PARAMETER CONDITIONS VALUE Port Voltage (VPORT) At Ethernet Port 37V to 57V Auxiliary Voltage (VAUX) From AUX– to AUX+ Terminals 44V to 57V Output Voltage (VOUT) Initial Set-point VPORT = 37V to 57V, IOUT = 0A to 5A 5V ±1% Maximum Output Current VPORT = 42V 4.5A Typical Output Voltage Ripple VIN = 50V, IOUT = 4.6A 40mVP–P (Typ) Output Regulation Over Entire Input Voltage and Output Current Range ±0.4% (Typ) Load Transient Response Peak to Peak Deviation with Load Step of 2.5A to 5A ±240mV (<±5%) (Typ) Settling Time (within 1% of VOUT) <100μs (Typ) Switching Frequency Efficiency 250kHz (Typ) VPORT = 50V, IOUT = 4A, Not Including Diode Bridge 91% (Typ) OPERATING PRINCIPLES A compatible high power PSE board, such as the DC1366, is connected to the DC1335B-B at the RJ45 connector J1 (see the schematic in Figure 11). As required by IEEE 802.3at, a diode bridge is used across the data pairs and signal pairs. Schottky diodes (D2-9) are used at the input to improve efficiency over standard diode bridges. The LTC4269-1 provides an IEEE 802.3at standard PoE 25k signature resistance and is set for a power class 4. When the PD is powered and voltage is above the PoE on voltage, the LTC4269-1 switches the port voltage over to the power supply controller through its internal MOSFET which lies between the VPORTN and VNEG pins. This voltage charges C18/19 through a trickle charge resistor, R9 to power the bias pin, VCC, of the power supply controller. Once the bias power gets to its VCC(ON) threshold, the IC begins a controlled soft-start of the output. As the output dc1335bbf 1 DEMO MANUAL DC1335B-B OPERATING PRINCIPLES voltage rises, bias power is taken over by the bias supply made up of T1’s bias winding and D11. When the soft-start period is over, the output voltage is regulated by observing the pulses across the bias winding during the flyback time. The Primary Gate drive (PG) and Synchronous Gate (SG) drive is then Pulse Width Modulated (PWM) in order to keep the output voltage constant. The synchronous gate drive signal is transmitted to the secondary via the small signal transformer, T2. The output of T2 then drives a discrete gate drive buffer, R22 and Q6/7 in order to achieve fast gate transition times, hence a higher efficiency. The two-stage input filter, C5, L2, and C6 and output filter, C1/3, L1, and C10 are the reasons that this PoE flyback supply has exceptionally low differential mode conducted emissions. QUICK START PROCEDURE Demonstration circuit 1335B-B is easy to set up to evaluate the performance of the LTC4269-1 in a PoE+ PD application. Refer to Figure 1 for proper equipment setup and follow the procedure below: NOTE: When measuring the input or output voltage ripple, care must be taken to avoid a long ground lead on the oscilloscope probe. Measure the output (or input) voltage ripple by touching the probe tip and probe ground directly across the +VOUT and –VOUT (or VPORT_P and VPORT_N) terminals. See Figure 2 for proper scope probe technique. 1. Place test equipment (voltmeter, ammeter, and electronic load) across output. 2. Input supplies: a. Connect a PoE+ capable PSE with a CAT-5 cable to the RJ45 connector, J1. See Figure 1. b. Or, connect a 37V to 57V capable power supply (Power Supply in Figure 1) across VPORT_P and VPORT_N. c. If evaluating the auxiliary power supply (Auxiliary Supply in Figure 1) capability, connect a 44V to 57V capable power supply across AUX+ to AUX–. 3. Check for the proper output voltage of 5V. 4. Once the proper output voltage is confirmed, adjust the load within the operating range and observe the output voltage regulation, ripple voltage, efficiency and other parameters. dc1335bbf 2 Figure 1. Demo Board Setup DEMO MANUAL DC1335B-B QUICK START PROCEDURE Figure 1. Proper Measurement Equipment Setup GND VIN Figure 2. Measuring Input or Output Ripple dc1335bbf 3 DEMO MANUAL DC1335B-B MEASURED DATA Figures 3 through 10 are measured data for a typical DC1335B-B. 92 90 EFFICIENCY (%) 88 86 84 82 80 78 76 42V 50V 57V 74 72 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT CURRENT (A) dc1335b F03 Figure 3. Efficiency (Not Including Diode Bridge) 5.25 5.20 OUTPUT VOLTAGE (V) 5.15 5.10 5.05 5.00 4.95 4.90 4.85 42V 50V 57V 4.70 4.75 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 OUTPUT CURRENT (A) dc1335b F04 Figure 4. Regulation dc1335bbf 4 DEMO MANUAL DC1335B-B MEASURED DATA Figure 5. Input and Output Ripple (48VPORT, 5A) Figure 6. Load Transient Response (48VPORT, 2.5A to 5A to 2.5A) dc1335bbf 5 DEMO MANUAL DC1335B-B MEASURED DATA Figure 7. Temp Data (37VPORT, 5A, Top) Figure 8. Temp Data (37VPORT, 5A, Bottom) dc1335bbf 6 DEMO MANUAL DC1335B-B MEASURED DATA Figure 9. Stresses (57VPORT, 5A) dc1335bbf 7 DEMO MANUAL DC1335B-B MEASURED DATA Figure 10. Stresses (37VPORT, 5A) dc1335bbf 8 DEMO MANUAL DC1335B-B PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Required Circuit Components 1 2 C1, C3 CAP., X5R, 22μF, 6.3V, 1206 MURATA, GRM31CR60J226KE19 2 1 C4 CAP., X7R, 1500pF, 50V, 0805 AVX, 08055C152JAT 3 1 C7 CAP., NPO, 22pF, 200V, 1206 muRata, GRM31A7U2J220JW31D 4 1 C10 CAP., TANT, 100μF, 6.3V, 3528 NEO CAPACITOR, PSLB20J107M(45) 5 1 C18 CAP., TANT, 10μF, 16V, B2 NEO CAPACITOR, ESVB21C106M 6 1 C26 CAP., X7R, 3300pF, 50V, 0603 AVX, 06035C332JAT 7 1 C33 CAP., X7R, 1000pF, 50V, 0603 AVX, 06035C102JAT 8 1 C30 CAP., NPO, 33pF, 50V, 0603 AVX, 06035A330KAT2A 9 1 C28 CAP., X7R, 2200pF, 50V, 0603 AVX, 06035C222JAT 10 1 C11 CAP., X7R, 2200pF, 2KV, 1808 AVX, 1808GC222MAT1A 11 1 C8 CAP., X7R, 0.1μF, 100V, 0805 AVX, 08051C104JAT 12 1 C32 CAP., X7R, 0.1μF, 50V, 0603 AVX, 06035C104KAT2A 13 3 C19, C24, C27 CAP., X7R, 1μF, 16V, 0805 MURATA, GRM21BR71C105KA01 14 1 C6 CAP., X7R, 2.2μF, 100V, 1210 MURATA, GRM32ER72A225KA01 15 1 C5 CAP., ELEC., 10μF, 100V NIC COMP., NACEW100M100V6.3X8TR13F 16 1 D1 DIODE, 58V, 400W, TVS, SMA-DIODE DIODES INC., SMAJ58A-13-F 17 2 D11, D16 DIODE, FAST SWITCHING, SOT23 DIODES INC., BAS21-7-F 18 1 D14 DIODE, SCHOTTKY, SOT23 DIODES INC., BAT54-7-F 19 1 L1 INDUCTOR, 180μH, DO1813H-181MLB COILCRAFT, DO1813H-181MLB 20 1 L2 INDUCTOR, 10μH, DO1608C-103MLB COILCRAFT, DO1608C-103MLB 21 1 Q1 MOSFET, N-CH, 150V, 4.1A, SO8 FAIRCHILD, FDS2582 22 1 Q2 MOSFET, N-CH, 30-V, SO8 FAIRCHILD, FDS8880 23 1 Q6 TRANSISTOR, PNP, SILICON POWER, SOT23 ON SEMI., MMBT3906 24 1 Q7 TRANSISTOR, NPN, SILICON POWER, SOT23 ON SEMI., MMBT3904 25 1 R9 RES., CHIP, 39k, 1/4W, 5%, 1206 VISHAY, CRCW120639K0JNEA 26 1 R13 RES., CHIP, 27.4k, 1/10W, 1%, 0603 VISHAY, CRCW060327K4FKEA 27 1 R16 RES., CHIP, 0.033Ω, 1/8W, 1%, 1206 IRC, LRC-LRF1206LF-01-R033-F 28 1 R22 RES., CHIP, 15Ω, 1/16W, 5%, 0603 VISHAY, CRCW060315R0JNEA 29 1 R25 RES., CHIP, 1.21k, 1/16W, 1%, 0603 VISHAY, CRCW06031K21FKEA 30 1 R27 RES., CHIP, 10k, 1/16W, 1%, 0603 VISHAY, CRCW060310K0FKEA 31 1 R10 RES., CHIP, 20Ω, 1/10W, 5%, 0805 VISHAY, CRCW080520R0JNEA 32 1 R34 RES., CHIP, 5.1Ω, 1/4W, 5%, 1206 VISHAY, CRCW12065R10JNEA 33 1 R36 RES., CHIP, 30.9Ω, 1/16W, 1%, 0603 VISHAY, CRCW060330R9FKEA 34 1 R17 RES., CHIP, 100Ω, 1/16W, 1%, 0603 VISHAY, CRCW0603100RFKEA 35 1 R2 RES., CHIP, 150Ω, 1/4W, 5%, 1206 VISHAY, CRCW1206150RJNEA 36 1 R20 RES., CHIP, 3.01k, 1/16W, 1%, 0603 VISHAY, CRCW06033K01FKEA 37 1 R28 RES., CHIP, 10k, 1/16W, 5%, 0603 VISHAY, CRCW060310K0JKEA 38 1 R23 RES., CHIP, 12k, 1/16W, 5%, 0603 VISHAY, CRCW060312K0JKEA 39 1 R19 RES., CHIP, 14.0k, 1/16W, 1%, 0603 VISHAY, CRCW060314K0FKEA 40 1 R26 RES., CHIP, 38.3k, 1/16W, 1%, 0603 VISHAY, CRCW060338K3FKEA 41 1 R1 RES., CHIP, 51k, 1/16W, 1%, 0603 VISHAY, CRCW060351K0FKEA dc1335bbf 9 DEMO MANUAL DC1335B-B 42 1 R24 RES., CHIP, 100k, 1/16W, 1%, 0603 VISHAY, CRCW0603100KFKEA 43 1 R12 RES., CHIP, 383k, 1/16W, 1%, 0603 VISHAY, CRCW0603383KFKEA 44 1 T1 XFMR, FLYBACK, PA2369NL PULSE, PA2369NL 45 0 T1 (ALTERNATE) XFMR, FLYBACK, EPC3409G-LF PCA ELEC., EPC3409G-LF 46 1 T2 XFMR, GATE DRIVE PULSE, PE-68386NL 47 1 U1 IC, LTC4269IDKD-1, DFN32 LINEAR TECH., LTC4269IDKD-1 48 1 U2 IC, OPTOCOUPLERS PS2801-1-L NEC, PS2801-1-F3--L-A Additional Demo Board Circuit Components2 1 0 C9 OPT., 1206 2 1 C17 CAP., X7R, 1000pF, 2KV, 1808 AVX, 1808GC102MAT 3 4 C13, C14, C15, C16 CAP., X7R, 0.01μF, 100V, 0805 MURATA, GRM21BR72A103KA01 4 0 C25, C31 OPT. 0603 5 8 D2-D9 DIODE, SCHOTTKY, 1A, SMA-DIODE 6 0 D10 OPT. 7 1 D12 DIODE, 1A, PASSIVATED RECTIFIER 8 1 D13 DIODE, SMT ZENER, 36V, 400mW NXP, PDZ36B 9 1 D15 LED, SMT GREEN PANANSONIC, LN1351C-(TR) 10 14 E1-E14 TP, TURRET, 0.094" MILL-MAX, 2501-2-00-80-00-00-07-0 11 1 J1 CONN., RJ-45 RIGHT ANGLE, RJ45 STEWART CONN. SYS.,SS-6488-NF-K1 12 0 J2 OPT., JUMPER, 2X3, .079CC, HD2X3-079 13 1 Q5 TRANSISTOR, PNP, SILICON POWER, SOT23 ON SEMI., BSS63LT1 14 1 R11 RES., CHIP, 0Ω, JUMPER, 0603 PANASONIC, ERJ3GEY0R00V 15 4 R4, R5, R6, R7 RES., CHIP, 75Ω, 1/16W, 5%, 0603 VISHAY, CRCW060375R0JNEA 16 0 R15 OPT. 0805 17 1 R18 RES., CHIP, 10.0k, 1/16W, 1%, 0603 VISHAY, CRCW060310K0FKEA 18 1 R8 RES., CHIP, 20k, 1/16W, 5%, 0603 VISHAY, CRCW060320K0JKEA 19 1 R21 RES., CHIP, 24k, 1/16W, 5%, 0603 VISHAY, CRCW060324K0JKEA 20 1 R14 RES., CHIP, 107k, 1/16W, 1%, 0603 VISHAY, CRCW0603107KFKEA 21 1 R33 RES., CHIP, 620Ω, 1/16W, 1%, 0603 VISHAY, CRCW0603620RFKEA 22 1 R35 RES., CHIP, 0Ω, JUMPER, 0603 PANASONIC, ERJ3GEY0R00V 23 1 T3 XFMR, POE PLUS, ETH1-230LD COILCRAFT, ETH1-230LB 24 4 for 4 Corners STAND-OFF, NYLON (SNAP ON), 0.625” TALL KEYSTONE, 8834 DIODES INC., B1100-13-F DIODES INC., S1B-13-F dc1335bbf 10 Information furnished by Linear Technology Corporation is believed to be accurate and reliable. However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights. A B C D E4 E7 E8 E9 TXCT RXCT SPARE1 SPARE2 E11 VPORT_N 7A 5A 2A 3.3V 5V 12V DC1335B-B DC1335B-C 5 IOUT +VOUT ASSY VPORTN D6 D7 D2 D3 DC1335B-A * E12 AUX- PD IN = 37V - 57V E10 AUX- SPARE2 SPARE1 RXCT TXCT Auxiliary Supply 48V, 30W E2 AUX+ 8 7 5 4 4.7uF 4.7uF 22uF 22uF 22uF C3 22uF C1 D16 BAS21 D9 D8 D5 D4 R18 10.0K 1% 1 470pF 1.5nF 2.2nF 47pF 22pF 22pF C7 R7 75 C16 0.01uF 100V D13 36V PDZ36B R21 24K C9 Opt. Opt. Opt. 1 2 R12 383K 1% 4.7nF 4 3.3nF 10uF 22uF 6.8nF C26 C25 Opt. 10uF 100V +C5 47uF 22uF C18 R19 14.0K 1% 14 1nF 1nF 18 1 4 16 UVLO SHDN NC FB VPORTP D10 Opt. Opt. B0540W R36 30.9 1% R20 3.01K 1% 2.2nF C33 C6 2.2uF 100V 1210 U1 LTC4269IDKD-1 32 R13 * L2 10uH DO1608C-103 100uF 100uF C10 D12 S1B D1 SMAJ58A R6 75 C15 0.01uF 100V 12 RXCT 13 11 10 9 TXCT Q5 BSS63LT1 C8 0.1uF 100V C17 1000pF 2KV R14 107K 1% C4 C13 0.01uF 100V R4 75 VPORTP C14 0.01uF 100V R5 75 SPARE2 SPARE1 B1100 x 8 places RX+ 6 3 VPORTP VPORT_P IN FROM HIGH POWER PSE TX- 1 2 TX+ R9 20K 39K 20K E5 R13 29.4K 27.4K 28.7K R15 R23 12K Opt. Opt. 47 RD- RCT RD+ TD- TCT TD+ 3 6 5 4 3 2 1 PHY TO OUT D11 BAS21 R10 20 J2 Opt. exposed pad, solder side E6 PWRGD PWRGD 1 2 3 4 5 6 29 2 1 2 2 3 30 1 3 1 3 1 RCLASS 3 NC VPORTN VPORTN 7 6 5 PWRGD NC VNEG VNEG 28 27 26 10K 10K 5.1K R27 2K 620 270 R33 E13 R26 38.3K 15 5.1 5.1 R34 GND C30 33pF C31 Opt. 0 0 Opt. R35 * C18 VCMP SENSE- 330nH 180nH 180nH L1 C32 0.1uF 17 19 20 T1 R27 * C26 * R16 0.033 1/2W C7 * 1206 R2 150 1206 EPC3408G-LF or PA2466NL PA2369NL or EPC3409G-LF PA2467NL or EPC3410G-LF R11 0 C19 1uF 16V 0805 SENSE+ 3528 CUSTOMER NOTICE R25 * + R9 * 1206 VPORTP 3 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. 3 5 Q2 FDS8880 2 SCALE = NONE RYAN H. KT APPROVALS FDS3572 3 T2 PE-68386 1 C27 1uF 16V 0805 R17 100 FDS8670 C33 * T1 * C28 2.2nF D14 BAT54 2 C3 * 1206 L1 * R28 10K R22 15 1% 3 C24 1uF 16V 0805 R15 * D10 * -VOUT * E3 D15 LED GREEN E1 LTC4269IDKD-1 1 DEMO CIRCUIT 1335B Wednesday, March 10, 2010 IC NO. SHEET 1 OF 1 2 REV. 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only * 3528 R33 * +VOUT * RYAN H. C9 * 1206 T2P +VOUT +C10 R35 * R8 20K E14 DATE 03-10-10 APPROVED HIGH POWER, HIGH EFFICIENCY POE PD INTERFACE WITH INTEGRATED SWITCHING REGULATOR DATE: SIZE DESCRIPTION TECHNOLOGY 2 1 REVISION HISTORY PRODUCTION REBUILD W CHANGES Q7 MMBT3904 Q2 * C1 * 1206 2 REV Q6 MMBT3906 3 C4 * 0805 R34 * 1206 1 ECO TITLE: SCHEMATIC C11 2.2nF 2KV 4 6 6 7 10 9 3 2 1 4 2 U2 PS2801-1-L 2 1 Q1 FDS2582 R1 51K 1% LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES. VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. 2.2K 1.21K 1K R25 R24 100K TON 11 SYNC 13 RCMP 22 ENDLY 12 PGDLY 23 /PWRGD 2 T2P 25 NC 31 NC 8 NC T3 ETH1-230LD VCC 24 PG 10 OSC 15 SFST 14 CCMP 21 9 SG GND 33 4 1 2 1 5 3 1 1 J1 SS-6488-NF-K1 A B C D DEMO MANUAL DC1335B-B SCHEMATIC DIAGRAM dc1335bbf 11 DEMO MANUAL DC1335B-B DEMONSTRATION BOARD IMPORTANT NOTICE Linear Technology Corporation (LTC) provides the enclosed product(s) under the following AS IS conditions: This demonstration board (DEMO BOARD) kit being sold or provided by Linear Technology is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not provided by LTC for commercial use. As such, the DEMO BOARD herein may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety measures typically found in finished commercial goods. As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations. If this evaluation kit does not meet the specifications recited in the DEMO BOARD manual the kit may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY THE SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. EXCEPT TO THE EXTENT OF THIS INDEMNITY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user releases LTC from all claims arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all appropriate precautions with regard to electrostatic discharge. Also be aware that the products herein may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). No License is granted under any patent right or other intellectual property whatsoever. LTC assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind. LTC currently services a variety of customers for products around the world, and therefore this transaction is not exclusive. Please read the DEMO BOARD manual prior to handling the product. Persons handling this product must have electronics training and observe good laboratory practice standards. Common sense is encouraged. This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact a LTC application engineer. Mailing Address: Linear Technology 1630 McCarthy Blvd. Milpitas, CA 95035 Copyright © 2004, Linear Technology Corporation dc1335bbf 12 Linear Technology Corporation LT 0711 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com © LINEAR TECHNOLOGY CORPORATION 2011