Mar 2007 - Isolated Forward Controllers Offer Buck Simplicity and Performance

L DESIGN FEATURES
Isolated Forward Controllers Offer
Buck Simplicity and Performance
by Charles Hawkes and Arthur Kelley
Buck converter designers have long
benefited from the simplicity, high
efficiency and fast transient response
made possible by the latest buck
controller ICs, which feature synchronous rectification and PolyPhase®
operation. Unfortunately, these
same features have been difficult or
impossible to implement in the buck
converter’s close relative, the forward
converter. That is, until now. The
LTC3706/26 secondary-side synchronous controller and its companion
smart gate driver, the LTC3705/25,
make it possible to create an isolated
forward converter with the simplicity
and performance of the familiar buck
converter.
rectifier timing and optoisolator feedback to control the output (secondary).
This architecture is commonly known
as primary-side control. By contrast,
secondary-side control places the
controller IC on the secondary side,
and uses a gate-drive transformer
to directly control the primary-side
MOSFETs. This approach eliminates
the need for an optoisolator and
puts the controller where it is really
needed: with the load. This results in
a significantly faster response, taming
large-signal overshoot and reducing
output capacitance requirements.
In addition, secondary-side control
simplifies the design of the loop compensation to that of a simple buck
converter.
With the apparent advantages of
secondary-side control, why is it not
used in more isolated applications?
This is primarily because of the need
for a separate bias supply to power
The Benefits of SecondarySide Control Made Accessible
Many isolated supplies place the
controller IC on the input (primary)
side and rely on indirect synchronous
VIN+
1µF
100V
×2
1µF
100V
VGATE
Si7450DP
92
36V
48V
72V
90
88
86
84
10
5
20
15
LOAD CURRENT (A)
365k
VCC, PRI
2•
4
• 10
3•
5
•7
2.2nF
200V
L2
0.85µH
11
100µF
6.3V
×2
1.2Ω
1/4W
9
HAT2165H
×2
0.0012Ω
2W
1nF
Q2
FCX491A
UVLO
VSLMT PGND
33nF
8
FS/IN–
3,4
T2
•
LTC3725
SSFLT
1µF
1
FB/IN+
VCC
220µF
6.3V
VOUT–
VCC, SEC
2.2µF
2.74k
1µF
0.1µF
IS
+
10µF
5.1k
NDRV GATE
30
VOUT+
3.3V
30A
D1
CMPSH1-4
HAT2165H
×2
25
Figure 2. Efficiency of the converter
shown in Figure 1
0.03Ω
1W
100k
Q1
FDC2512
15k
94
T1
23.4mm × 20.1mm × 9.4mm
PLANAR
L1
1µH
36V
TO
72V
VIN–
up the controller on the secondary
side, since there is initially no voltage
present there. With the introduction
of the LTC3706/26 and LTC3705/25,
however, this barrier has now been
completely eliminated. All of the complex issues associated with start-up
and fault monitoring in a secondaryside control forward converter have
EFFICIENCY (%)
Introduction
•
FG SW IS–
IS+
SG
NDRV MODE VCC
PT+
FB
LTC3706
5,6
PT–
FS
GND PGND REGSD PHASE RUN/SS
GND
VIN
SLP
ITH
162k
L1: VISHAY IHLP2525CZER0M01 T1: PULSE PA0815 (6:6:2:1)
L2: PULSE PA1294.910
T2: PULSE PA0297 (2:1:1)
100k
33nF
470pF
3.3k
604Ω
47nF
Figure 1. Complete 100W single-switch high efficiency, low cost, minimum part count, isolated
telecom converter. Other output voltages and power levels require only simple component changes.
10
Linear Technology Magazine • March 2007
DESIGN FEATURES L
been seamlessly integrated into these
powerful new products. Moreover, a
proprietary scheme is used to multiplex gate drive signals and DC bias
power across the isolation barrier
through a single, tiny pulse transformer. This eliminates the primary-side
bias winding that is otherwise needed.
The result is an isolated supply that
has been architected from the ground
up to achieve unprecedented simplicity
and performance. Figure 1 illustrates
how this remarkable new architecture
is used to make a complete 100W forward converter with minimal design
effort and complexity.
Family of Products Supports
Single or Dual Switch
Topologies
Table 1 summarizes how the
LTC3706/26 and LTC3705/25 products can be combined to cover a broad
range of applications. The LTC3706
is a full-featured product available
in a 24-lead SSOP package. For high
precision applications, the LTC3706
includes a 1% accuracy output voltage,
a remote-sense differential amplifier
and a power good output voltage monitor. The high voltage linear regulator
controller simplifies the design of the
bias supply, and PLL frequency synchronization with selectable phase
angle enables PolyPhase operation
with up to twelve phases. In addition,
the flexible current-sense inputs allow
the LTC3705 greatly facilitates the use
of the simple and robust dual switch
forward converter topology. Figure 3
shows a typical dual-switch converter
application using the LTC3705 and
the LTC3706.
Table 2 highlights some of the relative merits of using either single or dual
switch forward converter topologies.
In general, for applications that have
a limited input voltage variation, or
where a robust and simple design is
a priority, the dual-switch forward
converter may be preferred. For a wide
input voltage application (greater than
2:1), or whenever a lower cost or size
justifies the complication of the transformer reset design, a single-switch
forward should be used.
Table 1. LTC3705/06/25/26 combinations
LTC3705
LTC3725
LTC3706
LTC3726
Dual-Switch,
PolyPhase
Dual-Switch,
Single Phase
Single-Switch, Single-Switch,
PolyPhase
Single Phase
for the use of either resistive or current transformer sensing techniques.
Protection features include an output
overvoltage crowbar as well as currentlimiting and over-current protection.
The 16-lead LTC3726 does not include
the remote voltage sensing or linear
regulator features, so it is more suitable for a single phase application.
Both the LTC3706 and the LTC3726
have a selectable maximum duty cycle
limit of either 75% or 50% to support a
single or dual-switch forward converter
application, respectively.
The LTC3725 primary driver is
intended for use in single-switch
forward converter. The LTC3725 includes a start-up linear regulator and
an integrated bridge rectifier for bias
generation. Protection features include
volt-second limit, over-current protection and a fault monitoring system that
detects a loss of encoded gate-drive
signal from the signal transformer.
The LTC3705 is a dual-switch forward
driver, and includes an 80V (100V
transient) high side gate driver. The
integration of this high side driver into
VIN+
Bringing the Power of
PolyPhase to Isolated Supplies
The LTC3706/26 defies typical forward
converter limits by allowing simple
implementation of a PolyPhase current
share design. PolyPhase operation
allows two or more phase-interleaved
power stages to accurately share the
load. The advantages of PolyPhase
current sharing are numerous, including much improved efficiency, faster
transient response and reduced input
and output ripple.
The LTC3706/26 supports standard output voltages such as 5V, 12V,
28V and 52V as well as low voltages
down to 0.6V. Figure 4 shows how
T1
•
Si7852DP
1µF
100V
x3
•
1.2Ω
MURS120
Si7852DP
Si7336ADP
×2
Si7336ADP
VOUT+
L1
1.2µH
330µF
6.3V
×3
CMPSH1-4
MURS120
2mΩ
2W
30mΩ
1W
VIN–
10µF
25V
VOUT–
CZT3019
100k
FQT7N10
365k
1%
L1: COILCRAFT SER2010-122
T1: PULSE PA0807
T2: PULSE PA0297
BAS21 0.22µF
NDRV
BOOST TG
TS BG IS
UVLO
15k
1%
2.2µF
25V
33nF
VCC
SS/FLT
LTC3705
GND PGND VSLMT
FB/IN+
1µF
T2
•
•
FS/IN–
162k
33nF
2.2µF
16V
IS–
IS+
PT+
FG
SW SG
VIN
NDRV
102k
1%
VCC
FS/SYNC
LTC3706
FB
ITH
PT–
RUN/SS GND PGND PHASE SLP MODE REGSD
680pF
20k
22.6k
1%
Figure 3. Isolated forward converter for 36V–72V input to 3.3V/20A out
Linear Technology Magazine • March 2007
11
L DESIGN FEATURES
easy it is to parallel two 1.2V supplies
to achieve a 100A supply. Figure 5
shows excellent output inductor current tracking during a 0A to 100A load
current step and the smooth handoff
during start-up to secondary-side control at approximately VOUT = 0.25V.
Table 2. Single and dual switch forward converter relative merits
+
LTC3705/LTC3706 VOUT
36V-72VIN TO 1.2VOUT
50A SUPPLY
VIN–
VOUT–
SSP VBIAS SYNC ITH
VIN+
Requires Design
Transformer Reset Circuit
to Prevent Saturation
+
75% Max Duty
(>2:1)
VIN+
VIN–
Simple Design
Wide Input Supply Range
The circuit of Figure 1 shows a
complete 100W, one-switch forward
converter. In this example, the
LTC3706 controller is used on the
secondary and the LTC3725 driver
with self-starting capability is used
on the primary. This design features
off-the-shelf magnetics and high efficiency (see Figure 2). The start-up
behavior of this supply is illustrated
in Figure 6. When input voltage is
first applied, the LTC3725 uses Q1
to generate a bias voltage VCC,PRI, and
begins a controlled soft-start of the
output voltage. As the output voltage
begins to rise, the LTC3706 secondary controller is quickly powered up
by using T1, D1 and Q2 to generate
VCC,SEC. As shown in Figure 6, the
VCC,SEC voltage rises very quickly as
compared with the output voltage
VOUT of the converter. The LTC3706
VIN+
Single-Switch
–
Anatomy of a Start-Up:
A Simple Isolated 3.3V,
30A Forward Converter
SSP VBIAS SYNC ITH
Requirement
SSS
+
High Efficiency
–
+
Two FETs
+
One FET and Better
Transformer Utilization
then assumes control of the output
voltage by sending encoded PWM gate
pulses to the LTC3725 primary driver
via signal transformer T2. As soon as
the LTC3725 begins decoding these
PWM gate pulses, it shuts down the
linear regulator by tying NDRV to VCC
and begins extracting bias power for
VCC,PRI from the signal transformer T2.
This complete transition from primary
to secondary control occurs seamlessly
at a fraction of the output voltage. From
PRIMARYSIDE MODE
+
Limited to VIN
–
One FET
Small Size
–
50% Max Duty
Good
Can be 2 × VIN or Greater
Low Cost
+
Reset Circuit not
Required—Can’t Saturate
+
Good
Low Switch Voltage Stress
Dual-Switch
–
Two FETs and 50%
Transformer Utilization
that point on, operation and design
simplifies to that of a simple buck
converter. Even the design and optimization of the feedback loop makes use
of the familiar and proven OPTI-LOOP®
compensation techniques.
A 10V–30V Input, 15V Output
at 5A Forward Converter
Figure 7 highlights the flexibility of
the LTC3706 and LTC3725 by illustrating a 12V/24V input application.
SECONDARY-SIDE MODE
VOUT+
1.2V/100A
VOUT–
SSS
VIN
+
LTC3705/LTC3706 VOUT
36V-72VIN TO 1.2VOUT
–
50A SUPPLY
VIN
VOUT–
VCCPRI SUPPLIED BY Q1
VCCPRI SUPPLIED BY
TRANSFORMER T2
VCCPRI
VGATE CONTROLLED BY LTC3706
Figure 4. Paralleling supplies for higher power operation
VGATE
VGATE CONTROLLED BY LTC3725
ILOUT1
ILOUT2
10A/DIV
10µs/DIV
VOUT
VCC,SEC
VOUT
0.5V/DIV
2ms/DIV
VPT+,VPT –
Figure 5. 1.2V, 100A load current step
(top trace) and start-up (bottom trace)
12
Figure 6. Anatomy of a start-up
Linear Technology Magazine • March 2007
DESIGN FEATURES L
L1
13µH
VOUT+
VIN+
10Ω
C3
0.5W
2.2nF
220pF
100V
200V
T1
C1
220µF
50V
×2
VIN
C2
10µF
35V
×5
Si7852DP
2.2nF
250VAC
Q4
100Ω
68pF
C3
10µF
25V
×2
R3
33k
0.5W
Q6
150Ω
IRF6648
×2
5mΩ
2W
Q5
Q7
1:3
–
D1
ES1C
174Ω
C4
180µF
16V
C6
10µF
200V
6mΩ
1W
VOUT–
470pF
383k
Q2
301Ω
100Ω
Q3
R1
10k
1nF
5.1kΩ
Q1
NDRV GATE
VCC
0.1µF
•
2:1
68pF
162k
75k
•
470pF
FS/IN–
SS/FLT GND PGND VSLMT
68pF
68nF
L1: PULSE PA1961.133
T1: PULSE PA0810
T2: PULSE PA0297
SW
SG
VIN NDRV
25.5k
1%
D2 BAT54
LTC3706
ITH
C5
0.1µF
GND PGND PHASE SLP MODE REGSD
33pF
1.07k
1%
330pF
33nF
C1: NIPPON CHIMICON EMZA500ADA221MUA0G
C2: TAIYO YUDEN GMK325BJ106MN
C3: TAIYO YUDEN TMK325BJ106MM
C4: SANYO OSCON 16SVP180MX
VCC
R2
8.66k
FB
1µF
PT–
RUN/SS
10µF
16V
FS/SYNC
PT+
T2
100Ω
LTC3725
1µF
25V
FG
IS–
IS+
IS
FB/IN+
UVLO
FCX1051A
100Ω
1nF
Q1: FMMT38C
Q2: MMBFJ201
Q3: ZVN3320F
Q4: FDMS2572 ×2
100k
43.2k
Q5: FMMT 618
Q6: FMMT 718
Q7: MMBT 2907A
Figure 7. Isolated forward converter for 10V–30V input to 15V/5A out
Linear Technology Magazine • March 2007
gate of Q2) during normal operation
when VCC = VNDRV = 12V and VIN is
less than 12V.
On the secondary side, the output
voltage is used directly as a source
of bias voltage for the LTC3706. This
is possible for output voltages of 9V
or greater. Q3 is used to limit the
peak voltage seen by the SW pin on
the LTC3706, while still allowing the
detection circuits in the LTC3706 to
function normally. Capacitor C3 is
used to establish the resonant reset
of the main transformer T1 during the
off-time of the primary-side switches.
In order to reduce the inrush current
during start-up, D2, R2 and C5 are
continued on page 39
95
VIN = 12V
90
VOUT
200mV/DIV
EFFICIENCY (%)
In this circuit, the main transformer
T1 is used to step up the voltage so
that the output can be either higher
or lower than the input. This circuit
is an excellent alternative to a flyback
converter where higher efficiency or
lower noise is a priority.
The UVLO on the LTC3725 has been
set to turn on at VIN = 9.5V and off at
VIN = 7.5V, and a linear regulator (Q1)
is used to establish bias for start-up.
Note that the LTC3725 requires that
the NDRV pin be at least 1V above
the VCC pin for proper linear regulator
operation. To meet this requirement,
while providing the lowest possibly
dropout voltage, a darlington transistor is used (Q1). JFET Q2 is used to
provide adequate bias current for the
NDRV pin at low input voltage, while
limiting the maximum current seen at
high input voltage. R11 is needed to
prevent back-feeding of current from
the NDRV pin into base of Q1 (and
VIN = 24V
85
80
IOUT
5A/DIV
20µs/DIV
VIN = 12V
VOUT = 15V
LOAD STEP = 0A TO 5A
Figure 8. Transient response
of the circuit in Figure 7
75
0
2
4
LOAD CURRENT (A)
6
Figure 9. Efficiency of
the circuit in Figure 7
13
DESIGN IDEAS L
Single-Ended Output
The LT6411 produces a differential
output, but if a single-ended logic
output is needed, there are multiple
options for data conversion. One such
way is shown in Figure 8, in which
the MC10H350 PECL-TTL translator
performs the conversion. To translate
OPTION
5V
+
OVDD
LT1715
–
5V
700mVPP
(DIFFERENTIAL)
MINIMUM
5V
(INPUT
CIRCUITRY
OMITTED)
Conclusion
OUT
OGND
R3
200Ω
R4
200Ω
R1
200Ω
5V
LT6411
TTL OUTPUT
R2
200Ω
1/4 MC10H350
PECL-TTL TRANSLATOR
PECL LEVELS
Figure 8. If a single-ended output is needed, there are many options available for translators.
One example is ON Semiconductor’s MC10H350 PECL-TTL translator. The 200Ω resistors shift
the output of the LT6411 up to PECL voltage levels. Alternatively, a level-translating comparator
such as the LT1715 could be used to give a variety of logic output levels.
LT3740, continued from page 36
The LT3740 uses a valley mode current control system that boasts a fast
response to load changes. As shown
in Figure 3, this design responds to
0A–10A step load change in 10µs,
yielding a voltage transient of less
than 50mV.
the voltage levels from the LT6411 to
PECL input voltage levels, two resistive dividers level-shift and attenuate
the output signal of the LT6411. Alternatively, a high speed comparator
such as Linear Technology’s LT1715
can also perform this task without the
level-shifting resistors.
The LT6411 is a dual high speed amplifier with flexible features and superb
AC characteristics, making it suitable
for use as a high data rate receiver.
The ability to select different gain
configurations with minimal external
components makes the LT6411 easy
to use. Its small footprint and low
power consumption allow it to fit into
almost any application without painful
compromises, especially for portable
or peripheral applications where space
and power are at a premium. L
Conclusion
The LT3740 is a synchronous buck
controller that boasts a rich feature set
which allows the designer to optimize
power and volumetric efficiency by exploiting the advantages of a low input
voltage. Through a combination of its
onboard boost regulator, user programmable current limit thresholds,
fast transient response and flexible
soft-start system, the designer can
produce a small, efficient, full featured
converter. L
Soft-Start
The LT3740 is also equipped with a
flexible soft-start design that allows for
either ramped current or tracking. If
the XREF pin is held above 1V, and an
RC timer is applied to the SHDN pin,
the converter soft-starts by ramping
the current available to the load. If the
SHDN pin is high, enabling the chip,
and a 0V to 0.8V tracking signal is
applied to the XREF pin, the internal
reference of the LT3740 follows the
tracking signal.
LTC3706/26, continued from page 13
used to provide a gradual increase
in peak current during the soft-start
interval. The circuit of Figure 7 also
includes an optional falling-edge delay
circuit on the gate of synchronous
switch Q4. This delay has been used
to optimize the dead time for this
specific application, thereby improving
Linear Technology Magazine • March 2007
VOUT
50mV/DIV
INDUCTOR
CURRENT
5A/DIV
20µs/DIV
Figure 3. Output voltage and inductor current response to a
0A–10A step load transient applied to the circuit in Figure 1
the efficiency by about 1%. Figure 8
shows the transient response that is
achieved using the circuit of Figure 7,
and Figure 9 shows the efficiency at
VIN = 12V and VIN = 24V.
Conclusion
The new LTC3706/26 controller and
LTC3705/25 driver bring an un-
precedented level of simplicity and
performance to the design of isolated
power supplies. Each controller-driver
pair works in concert to offer high
efficiency, low cost solutions using
off-the-shelf components. The devices
are versatile and easy to use, covering
a broad range of forward converter
applications. L
39