Application Note 119A April 2008 Powering Complex FPGA-Based Systems Using Highly Integrated DC/DC µModule Regulator Systems Part 1 of 2 Circuit and Electrical Performance Alan Chern and Afshin Odabaee In a recent discussion with a system designer, the requirement for his power supply was to regulate 1.5V and deliver up to 40A of current to a load that consisted of four FPGAs. This is up to 60W of power that must be delivered in a small area with the lowest height profile possible to allow a steady flow of air for cooling. The power supply had to be surface mountable and operate at high enough efficiency to minimize heat dissipation. He also demanded the simplest possible solution so his time could be dedicated to the more complex tasks. Aside from precise electrical performance, this solution had to remove the heat generated during DC to DC conversion quickly so that the circuit and the ICs in the vicinity do not overheat. Such a solution requires an innovative design to meet these criteria: contribute to lower system cost, consuming less power to remove heat). Figure 1 shows a test board for such a circuit. The design regulates 1.5V output while delivering 40A (up to 48A) of load current. Each “black square” is a complete DC/DC circuit and is housed in a 15mm × 15mm × 2.8mm surface mount package. With a few input and output capacitors and resistors, the design using these DC/DC µModule® regulator systems is as simple as it’s shown in the photo. 1. Very low profile to allow efficient air flow and to prevent thermal shadow on surrounding ICs 2.High efficiency to minimize heat dissipation 3.Current sharing capability to spread the heat evenly to eliminate hot spots and minimize or eliminate the need for heat sinks 4.Complete DC/DC circuit in a surface mount package that includes the DC/DC controller, MOSFETs, inductor, capacitors and compensation circuitry for a quick and easy solution Innovation in DC/DC Design The innovation is a modular but surface mount approach that uses efficient DC/DC conversion, precise current sharing and low thermal impedance packaging to deliver the output power while requiring minimal cooling. Because of the low profile and power sharing among four devices, a system using this solution depends on fewer fans or a slower fan speed as well as few or no heat sinks. (These Figure 1. Four DC/DC µModule Regulator Systems Current Share to Regulate 1.5V at 48A with Only 2.8mm Profile and 15mm × 15mm of Board Area. Each µModule Regulator Weighs Only 1.7g and Has an IC Form-Factor That Can Easily Be Used with Any Pick-and-Place Machine During Board Assembly DC/DC µModule Regulators: Complete Systems in an LGA Package The LTM4601 µModule DC/DC regulator is a high performance power module shrunk down to an IC form factor. It is a completely integrated solution—including the PWM controller, inductor, input and output capacitors, ultralow RDS(ON) FETs, Schottky diodes and compensation circuitry. Only external bulk input and output capacitors and one resistor are needed to set the output from 0.6V to 5V. The 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. an119afc AN119A-1 Application Note 119A VOUT CLOCK SYNC 0° PHASE VIN 4.5V TO 20V 51.1k 51.1k PGOOD 59k LTC6902 V+ SET DIV MOD PH GND OUT1 OUT4 OUT2 OUT3 0.1µF + MPGM RUN COMP INTVCC DRVCC CIN* 100µF 25V 10µF 25V ×2 392k PLLIN TRACK/SS VOUT VIN PGOOD LTM4601 SGND PGND 5% MARGIN 4-PHASE OSCILLATOR VFB MARG0 MARG1 TRACK/SS CONTROL VOUT 1.5V 48A MAX 220pF 22µF 6.3V 470µF 6.3V VOUT_LCL DIFFVOUT VOSNS+ VOSNS– fSET 60.4k + R SET N RSET N = NUMBER OF PHASES VOUT = 0.6V RSET 10k + 120pF MARGIN CONTROL CLOCK SYNC 90° PHASE 4.5V TO 20V TRACK/SS CONTROL VIN PGOOD PGOOD MPGM RUN COMP INTVCC DRVCC 10µF 25V ×2 PLLIN TRACK/SS VOUT LTM4601-1 392k SGND PGND VFB MARG0 MARG1 22µF 6.3V + VOUT_LCL NC3 NC2 NC1 470µF 6.3V fSET CLOCK SYNC 180° PHASE 4.5V TO 20V TRACK/SS CONTROL VIN PGOOD PGOOD MPGM RUN COMP INTVCC DRVCC 10µF 25V ×2 PLLIN TRACK/SS VOUT LTM4601-1 392k SGND PGND VFB MARG0 MARG1 22µF 6.3V + VOUT_LCL NC3 NC2 NC1 470µF 6.3V fSET CLOCK SYNC 270° PHASE 4.5V TO 20V TRACK/SS CONTROL VIN PGOOD PGOOD MPGM RUN COMP INTVCC DRVCC 10µF 25V ×2 0.1µF PLLIN TRACK/SS VOUT LTM4601-1 392k SGND PGND VFB MARG0 MARG1 VOUT_LCL NC3 NC2 NC1 22µF 6.3V + 470µF 6.3V fSET an119a F02 *CIN OPTIONAL TO REDUCE ANY LC RINGING. NOT NEEDED FOR LOW INDUCTANCE PLANE CONNECTION Figure 2. Simply Parallel Multiple DC/DC µModule Regulator Systems to Achieve Higher Output Current. Board Layout Is as Easy as Copying and Pasting Each µModule Regulator’s Layout With Very Few External Components Required an119afc AN119A-2 Application Note 119A supply can produce 12A (more, if paralleled) from a wide input range of 4.5V to 20V, making it extremely versatile. The pin-compatible LTM4601HV extends the input range to 28V. Another significant advantage of the LTM4601 over powermodule- or IC-based systems is its ability to easily scale up as loads increase. If load requirements are greater than one µModule regulator can produce, simply add more modules in parallel. The design of a parallel system involves little more than copying and pasting the layout of each 15mm × 15mm µModule regulator. Electrical layout issues are taken care of within the µModule package—there are no external inductors, switches or other components to worry about. Output features include output voltage tracking and margining. The high switching frequency, typically 850kHz at full load, constant on-time, zero latency controller delivers fast transient response to line and load changes while maintaining stability. Should frequency harmonics be a concern, an external clock can control synchronization via an on-chip phase-locked loop. 48A from Four Parallel DC/DC µModule Regulators Figure 2 shows a regulator comprising four parallel LTM4601s, which can produce a 48A (4 × 12A) output. The regulators are synchronized but operate 90° out-ofphase with respect to each other, thereby reducing the amplitude of input and output ripple currents through cancellation (Figure 3). Synchronization and phase shifting is implemented via the LTC6902 oscillator, which provides four clock outputs, each 90° phase shifted (for 2- or 3-phase relationships, the LTC6902 can be adjusted via a resistor). By operating the µModule regulators out-of-phase, peak input and output current is reduced by approximately 20% depending on the duty cycle (see the LTM4601 data sheet). The attenuated ripple, in turn, decreases the external capacitor RMS current rating and size requirements, further reducing solution cost and board space. The clock signals serve as input to the PLLIN (phase-locked loop in) pins of the four LTM4601s. The phase-locked loop of the LTM4601 is comprised of a phase detector and a voltage controlled oscillator, which combine to lock onto the rising edge of an external clock with a frequency range of 850kHz. The phase-locked loop is turned on when a pulse of at least 400ns and 2V amplitude at the PLLIN pin is detected, though it is disabled during start-up. Figure 3 shows the switching waveforms of four LTM4601 µModule regulators in parallel. 1µs/DIV an119a F03 Figure 3. By Operating Each DC/DC µModule Regulator 90° Outof-Phase, the Input and Output Ripples Are Reduced, Which Also Reduces the Requirement for Input and Output Capacitors. Photo Shows Individual µModule Regulator Switching Waveforms for Figure 2 Only one resistor is required to set the output voltage. In a parallel set-up, the value of the resistor depends on the number of LTM4601s used. This is because the effective value of the top (internal) feedback resistor changes as you parallel LTM4601s. The LTM4601’s reference voltage is 0.6V and its internal top feedback resistor value is 60.4kΩ, so the relationship between VOUT, the output voltage setting resistor (RFB), and the number of modules (n) placed in parallel is: VOUT 60.4k +RFB n = 0.6V RFB an119afc 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. AN119A-3 Application Note 119A 100 90 12V EFFICIENCY (%) 80 VIN 5V/DIV 70 60 0V 50 VOUT 1V/DIV 40 3.3VOUT 2.5VOUT 1.8VOUT 1.5VOUT 1.2VOUT 30 20 10 0 0 10 ILOAD 20A/DIV 20 30 LOAD CURRENT (A) VIN = 12V VOUT = 1.5V LOAD = 40A 50 40 an119a F04 Figure 4. Efficiency of the Four DC/DC µModule Regulators in Parallel Remains High Over a Wide Range of Output Voltages (12V Input) Figure 4 illustrates the system’s high efficiency over the vast output current range up to 48A. The system performs impressively with no dipping in the efficiency curve for a broad range of output voltages. The soft-start feature of the LTM4601 prevents large inrush currents at start-up by slowly ramping the output voltage to its nominal value. The relation of start-up time to VOUT and the soft-start capacitor (CSS) is: ( ) an119a F05 Figure 5. Controlled Soft-Start Is Important in Proper Start-Up of the FPGA or the System as a Whole; Soft-Start Current and Voltage Ramp for Four DC/DC µModule Regulators in Parallel VIN 5V/DIV IOUT(IC1) 5A/DIV Start-Up, Soft-Start and Current Sharing tSOFTSTART =0.8 • 0.6V-VOUT(MARGIN) • 2ms/DIV CSS 1.5µA IOUT(IC2) 5A/DIV VIN = 12V VOUT = 1.5V LOAD = 20A 5ms/DIV an119a F06 Figure 6. Each DC/DC µModule Regulator Starts and Ends By Sharing the Load Current Evenly and Balanced, a Crucial Feature to Prevent One Regulator from Overheating; Two Parallel LTM4601s, as Each Rises to a Nominal 10A Each, 20A Total where VOUT(MARGIN) = Conclusion %VOUT • VOUT 100 For example, a 0.1µF soft-start capacitor yields a nominal 8ms ramp (see Figure 5) with no margining. Current sharing among parallel regulators is well balanced through start-up to full load. Figure 6 shows an evenly distributed output current curve for a 2-parallel LTM4601 system, as each rises to a nominal 10A each, 20A total. The DC/DC µModule regulators are self-contained and complete systems in an IC form factor. The low profile, high efficiency and current sharing capability allow practical high power solutions for the new generation of digital systems. Thermal performance is impressive at 48A of output current with balanced current sharing and smooth uniform start-up. The ease and simplicity of this design minimizes development time while saving board space. In part two of this discussion, the focus will be on thermal performance and layout of this circuit. an119afc Linear Technology Corporation McCarthy Blvd., Milpitas, CA 95035-7417 AN119A-4 1630 (408) 432-1900 FAX: (408) 434-0507 www.linear.com ● ● LT 0515 REV C • PRINTED IN USA LINEAR TECHNOLOGY CORPORATION 2008