UC1548 UC2548 UC3548 Primary Side PWM Controller FEATURES • Primary Side Voltage Feedforward Control of Isolated Power Supplies • Accurate DC Control of Secondary Side Short Circuit Current using Primary Side Average Current Mode Control • Accurate Programmable Maximum Duty Cycle Clamp • Maximum Volt-Second Product Clamp to Prevent Core Saturation • Practical Operation Up to 1MHz • High Current (2A Pk) Totem Pole Output Driver • Wide Bandwidth (8MHz) Current Error Amplifier • Undervoltage Lockout Monitors VCC, VIN and VREF • Output Active Low During UVLO • Low Startup Current (500µA) BLOCK DIAGRAM UDG-95037 DESCRIPTION Pin numbers refer to 16-pin DIL and SOIC packages only. The UC3548 family of PWM control ICs uses voltage feedforward control to regulate the output voltage of isolated power supplies. The UC3548 resides on the primary side and has the necessary features to accurately control secondary side short circuit current with average current mode control techniques. The UC3548 can be used to control a wide variety of converter topologies. In addition to the basic functions required for pulse width modulation, the UC3548 implements a patented technique of sensing secondary current from the primary side in an isolated buck derived converter. A current waveform synthesizer monitors switch current and simulates the inductor current downslope so that the complete current waveform can be constructed on the primary side without actual secondary side measurement. This information on the primary side is used by an average current mode control circuit to accurately limit maximum output current. The UC3548 circuitry includes a precision reference, a wide bandwidth error amplifier for average current control, an oscillator to generate the system clock, latching PWM comparator and logic circuits, and a high current output 4/97 driver. The current error amplifier easily interfaces with an optoisolator from a secondary side voltage sensing circuit. A full featured undervoltage lockout (UVLO) circuit is contained in the UC3548. UVLO monitors the supply voltage to the controller (VCC), the reference voltage (VREF), and the input line voltage (VIN). All three must be good before soft start commences. If either VCC or VIN is low, the supply current required by the chip is only 500µA and the output is actively held low. Two on board protection features set controlled limits to prevent transformer core saturation. Input voltage is monitored and pulse width is constrained to limit the maximum volt-second product applied to the transformer. A unique patented technique limits maximum duty cycle within 3% of a user programmed value. These two features allow for more optimal use of transformers and switches, resulting in reduced system size and cost. Both patents embodied in the UC3548 belong to Lambda Electronics Incorporated and are licensed for use in applications employing these devices. UC1548 UC2548 UC3548 ABSOLUTE MAXIMUM RATINGS Supply Voltage (Pin 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22V Output Current, Source or Sink (Pin 14) DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5A Pulse (0.5µs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2A Power Ground to Ground (Pin 1 to Pin 13) . . . . . . . . . . . ±0.2V Analog Input Voltages (Pins 3, 4, 7, 8, 12, 16) . . . . . . . . . . . . . . . . . . . . . -0.3 to 7V Analog Input Currents, Source or Sink (Pins 3, 4, 7, 8, 11, 12, 16) . . . . . . . . . . . . . . . . . . . . . . 1mA Analog Output Currents, Source or Sink (Pins 5 & 10) . . . 5mA Power Dissipation at TA = 60°C . . . . . . . . . . . . . . . . . . . . . . . . 1W Storage Temperature Range. . . . . . . . . . . . . . . −65°C to +150°C Lead Temperature (Soldering 10 seconds) . . . . . . . . . . +300°C Notes: All voltages are with respect to ground (DIL and SOIC pin 1). Currents are positive into the specified terminal. Pin numbers refer to the 16 pin DIL and SOIC packages. Consult Packaging Section of Databook for thermal limitations and considerations of packages. CONNECTION DIAGRAMS DIL-16, SOIC-16 (Top View) J, N, or DW Packages PLCC-20 & LCC-20 (Top View) Q & L Packages ELECTRICAL CHARACTERISTICS Unless otherwise stated, all specifications are over the junction temperature range of −55°C to +125°C for the UC1548, −40°C to +85°C for the UC2548, and 0°C to +70°C for the UC3548. Test conditions are: VCC = 12V, CT = 400pF, CI = 100pF, IOFF = 100µA, CDC = 100nF, Cvs = 100pF, and Ivs = 400µA, TA = TJ. PARAMETER TEST CONDITIONS MIN TYP MAX UNITS 0.95 1 1.05 V 20 25 Real Time Current Waveform Synthesizer Ion Amplifier Offset Voltage Slew Rate (Note 1) lib V/µs -2 -20 µA IOFF Current Mirror Input Voltage 0.95 1 1.05 V Current Gain 0.9 1 1.1 A/A 60 100 Current Error Amplifier AVOL Vio 12V ≤ VCC ≤ 20V, 0V ≤ VCM ≤ 5V 10 mV -0.5 -3 µA 3.3 3.5 V 0.3 0.6 V 1.4 1.6 2.0 5 8 MHz 8 10 V/µs 240 250 lib Voh IO = −200µA Vol IO = 200µA Source Current VO = 1V GBW Product f = 200kHz 3.1 Slew Rate (Note 1) dB mA Oscillator Frequency TA = 25°C 235 2 260 kHz 265 kHz UC1548 UC2548 UC3548 ELECTRICAL CHARACTERISTICS (cont.): Unless otherwise stated, all specifications are over the junction temperature range of −55°C to +125°C for the UC1548, −40°C to +85°C for the UC2548, and 0°C to +70°C for the UC3548. Test conditions are: VCC = 12V, CT = 400pF, CI = 100pF, IOFF = 100µA, CDC = 100nF, Cvs = 100pF, and Ivs = 400µA, TA = TJ. PARAMETER TEST CONDITIONS MIN TYP MAX UNITS 73.5 76.5 79.5 % 13 14 V Duty Cycle Clamp Max Duty Cycle V(DMAX) = 0.75 • VREF VCC Comparator Turn-on Threshold Turn-off Threshold 9 10 2.5 3 3.5 V 4.1 4.35 4.6 V Vuv = 4.2V 77 90 103 kΩ TA = 25°C 4.95 5 0 < IO < 10mA, 12 < VCC < 20 4.93 Hysteresis V UV Comparator Turn-on Threshold RHYSTERESIS Reference VREF 5.05 V 5.07 V Line Regulation 12V < VCC < 20V 4 15 mV Load Regulation 0 < IO < 10mA 3 15 mV Short Circuit Current VREF = 0V 50 70 mA 20 45 ns 30 Output Stage Rise & Fall Time (Note 1) Cl = 1nF IO = 20mA 0.25 0.4 V IO = 200mA 1.2 2.2 V Output High Saturation IO = -200mA 2.0 3.0 V UVLO Output Low Saturation IO = 20mA 0.8 1.2 V ISTART VCC = 12V 0.2 0.4 mA ICC (pre-start) VCC = 15V, V(UV) = 0 0.5 1 mA 22 26 mA Output Low Saturation ICC ICC (run) Note 1: Guaranteed by design. Not 100% tested in production. PIN DESCRIPTIONS CAO: Output of the current error amplifier. Also the resistor load for the collector of an optocoupler. ION: Input pin to inductor current waveform synthesizer. Apply a voltage proportional to switch current to this pin. CDC: Connect a charge balance integration capacitor from CDC to GND to achieve an accurate duty cycle clamp. This capacitor also sets the soft start time. NI: Noninverting input of the current error amplifier. OUT: Output driver for the gate of a power FET. PGND: Power ground pin for the output driver. This ground circuit should be connected to GND at a single point. CI: Output of the inductor current waveform synthesizer. Requires a capacitor to ground. CT: A capacitor from CT to GND sets the oscillator frequency. UV: Line voltage sense pin to insure the chip only operates with sufficient line voltage. Program with a resistive divider from the converter input voltage to UV to GND. DMAX: Programs maximum duty cycle with a resistive divider from VREF to DMAX to GND. GND: Signal ground. VCC: Chip supply voltage. Bypass with a 1µF ceramic capacitor to PGND. INV: Inverting input of the current error amplifier. VREF: Precision voltage reference. Bypass with a 1µF ceramic capacitor to GND. IOFF: Programs the discharge slope of the capacitor on CI to emulate the down slope of the inductor current waveform. VS: Volt second clamp programming pin and feedforward ramp waveform for the pulse width modulator. Connect a resistor to the input line voltage and a capacitor to GND. 3 UC1548 UC2548 UC3548 UNDERVOLTAGE LOCKOUT The undervoltage lockout block diagram is shown in Figure 1. The VCC comparator monitors chip supply voltage. Hysteretic thresholds are set at 13V and 10V to facilitate off-line applications. If the VCC comparator is low, ICC is low (<500µA) and the output is low. When the UV comparator is low, ICC is low (<500µA) and the output is low. When both the UV and VCC comparators are high, the internal bias circuitry for the remainder of the chip is activated. The CDC pin (see discussion on Maximum Duty Cycle Control and Soft Start) and the Output are held low until VREF exceeds the 4.5V threshold of the VREF comparator. When VREF is good, control of the output driver is transferred to the PWM circuitry and CDC is allowed to charge. The UV comparator monitors input line voltage (VIN). A pair of resistors divides the input line to UV. Hysteretic input line thresholds are programmed by Rv1 and Rv2. The thresholds are VIN(on) = 4.35V • (1 + Rv1/Rv2′) and VIN(off) = 4.35V • (1 + Rv1/Rv2) where Rv2′ = Rv2||90k. The resulting hysteresis is VIN(hys) = 4.35V • Rv1 / 90k. If any of the three UVLO comparators go low, the UVLO latch is set, the output is held low, and CDC is discharged. This state will be maintained until all three comparators are high and the CDC pin is fully discharged. UDG-95038 Figure 1: Undervoltage Lockout Oscillator Frequency as a Function of CT Frequency Decrease as a Function of RT 2000 RT = Open 1000 500 100 20 50 UDG-95039 Figure 2: Oscillator Frequency 4 100 500 1000 C (pF) 5000 UC1548 UC2548 UC3548 OSCILLATOR A capacitor from the CT pin to GND programs oscillator frequency, as shown in Figure 2. Frequency is determined by: F = 1 / (10k • CT). The sawtooth wave shape is generated by a charging current of 200µA and a discharge current of 1800µA. The discharge time of the sawtooth is guaranteed dead time for the output driver. If the maximum duty cycle control is defeated by connecting DMAX to VREF, the maximum duty cycle is limited by the oscillator to 90%. If an adjustment is required, an additional trim resistor RT from CT to ground can be used to adjust the oscillator frequency. RT should not be less than 40kohms. This will allow up to a 22% decrease in frequency. UDG-95040 Figure 3: Error Amplifier Gain and Phase Response over Frequency INDUCTOR CURRENT WAVEFORM SYNTHESIZER the input to the follower. The discharge current is programmed at IOFF. Average current mode control is a very useful technique to control the value of any current within a switching converter. Input current, output inductor current, switch current, diode current or almost any other current can be controlled. In order to implement average current mode control, the value of the current must be explicitly known at all times. To control output inductor current (IL) in a buck derived isolated converter, switch current provides inductor current information, but only during the on time of the switch. During the off time, switch current drops abruptly to zero, but the inductor current actually diminishes with a slope dIL/dt = −Vo/L. This down slope must be synthesized in some manner on the primary side to provide the entire inductor current waveform for the control circuit. The follower has a one volt offset, so that zero current corresponds to one volt at CI. The best utilization of the UC3548 is to translate maximum average inductor current to a 4 volt signal level. Given N and Ns (the turns ratio of the power and current sense transformers respectively), proper scaling of IL to V(CI) requires a sense resistor Rs as calculated from: Rs = 4V • Ns • N / IL(max). Restated, the maximum average inductor current will be limited to: IL(max) = 4V • Ns • N/Rs. IOFF and CI need to be chosen so that the ratio of dV(CI)/dt to dIL/dt is the same during switch off time as on time. Recommended nominal off current is 100µA. This requires CI = (100µA • N • Ns • L) / (Rs • Vo(nom)) where L is the output inductor value and Vo(nom) is the converter regulated output voltage. The patented current waveform synthesizer (Figure 4) consists of a unidirectional voltage follower which forces the voltage on capacitor CI to follow the on time switch current waveform. A programmable discharge current synthesizes the off time portion of the waveform. ION is 5 UC1548 UC2548 UC3548 INDUCTOR CURRENT WAVEFORM SYNTHESIZER (cont.) even during short circuit conditions. Actual inductor downslope is closer to zero during a short circuit. The penalty is that the average current is understated by an amount approximately equal to the nominal inductor ripple current. Output short circuit is therefore higher than the designed maximum output current. There are several methods to program IOFF. If accurate maximum current control is required, IOFF must track output voltage. The method shown in Figure 4 derives a voltage proportional to VIN • D (where D = duty cycle). In a buck converter, output voltage is proportional to VIN • D. A resistively loaded diode connection to the bootstrap winding yields a square wave whose amplitude is proportional to VIN and is duty cycle modulated by the control circuit. Averaging this waveform with a filter generates a primary side replica of secondary regulated Vo. A single pole filter is shown, but in practice a two or three pole filter provides better transient response. Filtered voltage is converted by ROFF to a current to the IOFF pin to control CI downslope. A third method of generating IOFF is to add a second winding to the output inductor core (Figure 6). When the power switch is off and inductor current flows in the free wheeling diode, the voltage across the inductor is equal to the output voltage plus the diode drop. This voltage is then transformed by the second winding to the primary side of the converter. The advantages to this approach are its inherent accuracy and bandwidth. Winding the second coil on the output inductor core while maintaining the required isolation makes this a more costly solution. In the example, ROFF = Vo / 100µA. The 4 • ROFF resistor is added to compensate the one volt input level of the IOFF pin. Without this compensation, a minor current foldback behavior will be observed. If accurate system maximum current is not a critical requirement, Figure 5 shows the simplest method of downslope generation: a single resistor (ROFF = 40k) from IOFF to VREF. The discharge current is then 100µA. The disadvantage to this approach is that the synthesizer continues to generate a down slope when the switch is off UDG-95041 Figure 4: Inductor Current Waveform Synthesizer UDG-95042 UDG-95043 Figure 6: Second Inductor Winding Generation of IOFF Figure 5: Fixed IOFF 6 UC1548 UC2548 UC3548 FEED FORWARD PULSE WIDTH MODULATION The soft start time constant is approximately: T(ss) = 20k • CDC. Pulse width modulation is achieved by comparing the output of the current error amplifier to the feed forward ramp generated at VS (Figure 7). The charge slope of the ramp is determined by a resistor (RVS) from VS to VIN and a capacitor (CVS) from VS to GND. In the event that CAO is at its maximum voltage, typically 3.3V, the UC3548 will limit the power stage to a volt-second product of: GROUND PLANES The output driver on the UC3548 is capable of 2A peak currents. Careful layout is essential for correct operation of the chip. A ground plane must be employed (Figure 8). A unique section of the ground plane must be designated for high di/dt currents associated with the output stage. This point is the power ground to which to PGND pin is connected. Power ground can be separated from the rest of the ground plane and connected at a single point, although this is not strictly necessary if the high di/dt paths are well understood and accounted for. VCC should be bypassed directly to power ground with a good high frequency capacitor. The source of the power MOSFET should connect to power ground as should the return connection for input power to the system and the bulk input capacitor. The output should be clamped with a high current Schottky diode to both VCC and PGND. Nothing else should be connected to power ground. VIN • TON(max) = 3.3V • Rvs • Cvs. An isolated voltage control loop can be implemented with a secondary side reference, error amplifier and an optoisolator. The optoisolator can be used to override the current amplifier output which is current limited by a 2.5k resistor. In overcurrent situations, the voltage loop turns the optoisolator off and the current error amplifier then assumes duty cycle control resulting in accurately limited maximum output current. MAXIMUM DUTY CYCLE AND SOFT START A patented technique is used to accurately program maximum duty cycle. Programming is accomplished by a divider from VREF to DMAX (Figure 7). The value programmed is: D(max) = Rd1 / (Rd1 + Rd2). For proper operation, the integrating capacitor, CDC, should be larger than T(osc) / 80k, where T(osc) is the oscillator period. CDC also sets the soft start time constant, so values of CDC larger than minimum may be desired. VREF should be bypassed directly to the signal portion of the ground plane with a good high frequency capacitor. Low ESR/ESL ceramic 1µF capacitors are recommended for both VCC and VREF. The capacitors from CT, CDC, CI and VS should likewise be connected to the signal ground plane. UDG-95044 Figure 7: Duty Cycle Control 7 UDG-95045-1 UC1548 UC2548 UC3548 UDG-95046 Figure 8: Ground Plane Considerations UDG-95047-1 Figure 9: Typical Application - Voltage Feedforward Control Isolated Forward Converter with Average Current Limiting UNITRODE CORPORATION 7 CONTINENTAL BLVD. • MERRIMACK, NH 03054 TEL. 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