Freescale Semiconductor Application Note AN3279 Rev. 3.0, 2/2009 MC34670 Usage and Configuration By: Jan Krellner 1 Purpose This document shows how to configure the IC to comply to the IEEE 802.3af standard and how to set-up the DC/DC converter part of the IC. 2 Scope The MC34670 combines a Power Interface Port for IEEE 802.3af Powered Devices (PD) and a high performance current mode switching regulator. It allows Freescale to build PDs with a minimum of external components by means of integrating the required IEEE 802.3af functions, and all functions necessary to build a high efficiency DC/DC converter. 3 Power-over-Ethernet and MC34670 Overview Figure 1 shows a simple 1-port PoE system, comprising a PSE Hub or Switch (PSE — Power Sourcing Equipment) and an Ethernet appliance or © Freescale Semiconductor, Inc., 2006. All rights reserved. Contents 1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 Power-over-Ethernet and MC34670 Overview . . . . . . . . . . . . . . . . . . . . . 1 3.1 Block Diagram of the MC34670. . . . . . . . . . 3 3.2 Typical Application Schematics . . . . . . . . . 4 4 Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.1 Signature Detection and UVLO Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7 4.2 Classification . . . . . . . . . . . . . . . . . . . . . . . . 8 4.3 Inrush Current . . . . . . . . . . . . . . . . . . . . . . 10 4.4 Flyback Configuration . . . . . . . . . . . . . . . . 10 4.5 Transient Voltage Suppression . . . . . . . . 33 5 References. . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Power-over-Ethernet and MC34670 Overview PD (PD — Powered Device). The PoE technology allows transmitting of power along with data over existing Cat5/Cat5e/Cat6 cables in a safe and reliable manner. It can be used to power e.g. IP Phones, WLAN Access Points, network cameras, and various other network terminals that are in the allowed power range of 13 W, as measured at the PD side. Power-over-Ethernet is also known as Power over LAN. It is based on the IEEE 802.3af Standard. RJ-45 PSE Hub or Switch Ethernet Appliance (PD) TX RX PHY PHY RX Host Processor TX Switch 48-V Power Supply Host Controller PSE Power Controller Cat 5 cable -48V PD Power Controller GND -48V Switch DC/DC Figure 1. Simple Power-over-Ethernet System There are many key benefits of PoE. Only one set of wires is necessary to bring power and data to the appliance, and this simplifies installation and saves space. There is no need to pay for an expensive electrician, or delay the installation to meet the electrician's schedule — thus it saves time and money. Furthermore, the appliance can be easily moved to wherever you can lay a LAN cable. Since there are no mains voltages present anywhere, it is safe. Using an uninterruptable power supply (UPS) can guarantee power to the appliance even during main power failure. The user can use SNMP (Simple Network Management Protocol) network management infrastructure to monitor and control the appliance, as well as the data transfer to and from the appliance. So, the appliances can be managed, shut down or reset remotely in a centralized matter. The PD interface of the MC34670 has been designed to comply with the requirements of the IEEE standard 802.3af. MC34670 Usage and Configuration, Rev. 3.0 2 Freescale Semiconductor Power-over-Ethernet and MC34670 Overview 3.1 Block Diagram of the MC34670 Figure 2 shows the block diagram of the MC34670. It can be divided into two sections: on the left hand side one can find all circuitry that belongs to the PD part of the IC, whereas on the right hand side all PWM controller functions are located. FREQ High Voltage Regulator VPWR VDD 2.5V 8V Internal Supply 0.8R 5.7V R POR RCLA S R OSC R GATE Q EN 3.5V Under Voltage Lock Out OV OR UVLO Over voltage Detection OV OR UVLO 5 A SS 0.3V Control Logic 5kΩ S R 4.5V PWM COMPARATOR Q 0.6 – 2.6V Blank CS 0.4V 1.4V 0.6V Current limitation ILIM 3 Gate Drive COMP Slope comp UVLO FB 250mV Rsense Temp. Sensor 1.2V Reg Detect VOUT VIN RESET Figure 2. MC34670 Block Diagram On the PD side, the MC34670 fully supports the IEEE802.3af standard and provides complete signature detection and power classification functions. It controls inrush current limiting and incorporates an adjustable undervoltage lockout. The MC34670 includes thermal protection circuitry to protect the device in case of high power dissipation. The MC34670 also offers an input overvoltage detection to protect the external switching MOSFET by disabling the gate driver in case of input line overvoltage. The MC34670 switching regulator provides excellent line and load regulation. It drives an external power MOSFET with a sense resistor. The switching frequency is adjustable between 100 kHz and 400 kHz. The output voltage feedback information can be accomplished by an optocoupler, if isolation is required. An internal logic control block manages the sequencing of signature detection, classification and proper turn-on and turn-off of the DC/DC converter. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 3 Power-over-Ethernet and MC34670 Overview 3.2 Typical Application Schematics The MC34670 supports various configurations and settings. On the PD side, it complies with the IEEE 802.3af standard in terms of signature detection, classification, UVLO and inrush current requirements, but also supports legacy standards with different UVLO and inrush current needs. On the PWM controller side it supports isolated or non-isolated Flyback or Forward topologies, where the switching frequency is adjustable by the IC. In non-isolated applications, the RESET open-drain output can assert a reset signal whenever the output voltage VOUT is out of regulation. Figure 3 shows an application schematic of an isolated Flyback converter using an auxiliary winding to provide the supply voltage for the gate driver of the external switching MOSFET M1. T1 NAUX +VPORT VOUT = 5V@2A 3 NP 34670 RX NS VPWR 6 RESET 1 RCLA VDD TX 2 R1 CIN RCLASS UVLO R2 4 5 GATE CDD 0.1 F CPORT RV CS ILIM VIN M1 RCS SS FREQ COMP FB VOUT -VPORT CSS 7 8 Figure 3. Isolated Flyback Converter w/ Bias Winding In cases where the external MOSFET gate drive pulls more than 5 mA of current, an auxiliary winding is needed to reduce the power dissipation in the internal high voltage LDO. It is recommended to add a 0.1 μF ceramic capacitor in parallel with the existing load capacitor. This reduces noise at the VDD pin caused by the auxiliary winding. The schematic in Figure 3 shows how to configure the default inrush current and UVLO settings. Pins ILIM and UVLO are connected to VIN and ensure correct settings for IEEE 802.3af compliance. For applications which require a lower inrush current limit, a resistor RILIM is added between pins ILIM and VIN. To use a switching frequency other than the 250 kHz default frequency the FREQ pin has to be connected via a resistor RFREQ to VIN, as shown in Figure 4. To use the default switching frequency, the FREQ pin can be left open or directly connected to VIN as shown in Figure 3. MC34670 Usage and Configuration, Rev. 3.0 4 Freescale Semiconductor Power-over-Ethernet and MC34670 Overview +VPORT VOUT = 5V@2A T1 3 RX + NP 34670 RX D1 VPWR 6 RX RESET + 1 TX RCLA VPORT TX NS VDD 2 TX R1 CIN UVLO R2 4 M1 GATE RCLASS VIN RV CPORT CS ILIM 5 CDD RCS SS FREQ COMP FB VOUT SPARE+ -VPORT 7 CSS SPARE- 8 Figure 4. Isolated Flyback Converter w/o Bias Winding The MC34670 also supports Forward converter topology as depicted in Figure 5. The advantage of the Forward converter is better efficiency. However it adds a second diode and an inductor on the secondary side of the converter. If an auxiliary winding is required to supply the gate driver, the Forward transformer needs a total of 4 windings. This increases the overall cost of the PD slightly. Furthermore, a Forward converter is usually more difficult to configure and design, compared to a Flyback converter. The configuration in Figure 5 also shows the appropriate setup to adjust the UVLO trip point by adding resistors R1 and R2 between VPWR, UVLO, and VIN. T1 +VPORT NR 3 NP 34670 RX NS VPWR 6 RESET 1 RCLA VDD TX 2 R1 CIN RCLASS UVLO R2 4 GATE M1 CDD CPORT RV CS ILIM RCS Rv1 5 VIN SS FREQ COMP FB VOUT Rv2 -VPORT CSS 7 8 Figure 5. Isolated Forward Converter w/o Bias Winding MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 5 Power-over-Ethernet and MC34670 Overview Figure 6 shows an isolated Flyback Converter that utilizes primary control. Primary control offers a cheap power supply solution, since it doesn’t use an optocoupler nor a shunt regulator on the secondary side. However, the line and load regulation of a primary controlled Flyback regulator is less favorable to an optocoupler/shunt regulated one. T1 CAUX NAUX +VPORT VOUT = 5V@2A 3 NP 34670 RX NS VPWR 6 RESET 1 RCLA VDD TX 2 R1 CIN RCLASS UVLO R2 4 GATE 5 CDD CPORT CS ILIM VIN M1 RCS SS FREQ COMP -VPORT CSS FB VOUT C2 R2 7 C1 8 Figure 6. Isolated Flyback Converter with Primary Control Figure 7 shows a non-isolated Flyback converter. It uses the default configuration for UVLO and inrush current limit. In non-isolated applications, the RESET pin can be used to directly drive a microcontroller RESET pin. +VPORT T1 3 NP 34670 RX VOUT = 5V@2A NS D1 CO VPWR 6 RSIG RESET 1 RCLA Rpullup VDD TX 2 RCLASS CIN UVLO 5 VIN CDD CPORT to C RESET pin CS ILIM 4 RCS SS FREQ COMP -VPORT CSS FB VOUT C2 R1 R2 7 8 M1 GATE Rb C1 Figure 7. Non-Isolated Flyback Converter MC34670 Usage and Configuration, Rev. 3.0 6 Freescale Semiconductor Configuration 4 Configuration This chapter gives detailed explanations how to setup the MC34670. Chapters 4.1 to 4.3 cover the PD part of the IC, like the inrush current limit and UVLO setup. Chapter 4.4 describes the configuration of the DC/DC converter. This application note covers only the Flyback topology. 4.1 Signature Detection and UVLO Adjustment The MC34670 has default UVLO settings that are in line with the IEEE 802.3af Standard. The standard defines a maximum PD supply turn-on voltage of 42 V and a minimum power supply turn-off voltage of 30 V, respectively. The maximum turn-on voltage of the device is 40 V and the minimum turn-off voltage is 30 V, respectively. Nevertheless, the user can adjust the UVLO voltage by an external resistor divider as sketched in Figure 8. Since the UVLO resistor divider replaces the signature resistor, the total resistance of R1 and R2 must equal 25 kΩ. +VPORT VPWR RCLA R1 UVLO R2 ILIM VIN -VPORT Figure 8. UVLO Adjustment by External Resistor Divider To calculate the values for R1 and R2 the following equations should be used: R sig = R 1 + R 2 = 25kΩ V UVLO ( REF ) R 2 = ---------------------------- – R SIG V UVLO ( ON ) where VUVLO(ON) is the desired turn-on voltage threshold and VUVLO(REF) the UVLO reference voltage. R 1 = R SIG – R 2 MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 7 Configuration The typical turn-off voltage VUVLO(OFF) is 85% of the turn-on voltage VUVLO(ON): V UVLO ( OFF ) = V UVLO ( ON ) ⋅ 0.85 As previously mentioned, the default UVLO settings can be achieved by connecting the UVLO pin to VIN (Figure 9). +VPORT VPWR RCLA RSIG 25kΩ UVLO ILIM VIN -VPORT Figure 9. Default UVLO Settings 4.2 Classification The IEEE 802.3af Standard provides the possibility that a PD may optionally be classified by the PSE (Power Sourcing Equipment). The intent of classification is to provide a method for more efficient power allocation through the PSE. Knowing the power consumption of all connected PD’s gives the PSE the ability to budget it’s power resources to always stay within the limits of the power supply. The PD classification allows the PSE to identify four different power classes depending on the required power that the PD will draw during normal operation. The classes and the corresponding maximum power that will be drawn by the PD is shown in Table 1. Table 1. PD Classes Class Usage Maximum Power [W] 0 Default 0.44 - 12.95 1 Optional 0.44 - 3.84 2 Optional 3.84 - 6.49 3 Optional 6.49 - 12.95 4 Reserved MC34670 Usage and Configuration, Rev. 3.0 8 Freescale Semiconductor Configuration During classification, the PSE applies a voltage in the range of 15.5 V to 20.5 V to the PD. When the voltage is applied, the PSE measures the current and determines the class. Table 2 shows the relationship between class and current. Table 2. PD Class vs. Classification Current Classification Current [mA] Class 0 1 2 3 4 Min Max 0 9 17 26 36 4 12 20 30 44 To generate a constant current during classification, the MC34670 provides the appropriate circuitry. An internal LDO generates a constant voltage at pin RCLA and the external resistor Rclass sets the current depending on the PD class (see Figure 10) following the simple relation: V RCLA I CLASS = -----------------R CLASS +VPort MC34670 VREF VPWR + - EN RSIG RCLA ICLASS VIN RCLASS -VPort Figure 10. Classification Circuitry Table 3 shows the value for RCLASS that correspond to a PD class. Table 3. PD Class vs. Classification Resistor Rclass Classification Current [mA] Rclass [Ω] 0 2.0 4.42k 1 2 3 4 10.5 18.5 28.0 40.0 475 261 169 113 Class MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 9 Configuration 4.3 Inrush Current The MC34670 has been also designed to interface with legacy PoE-PSEs, which do not meet the inrush current requirements of the IEEE 802.3af Standard. By setting the initial inrush current limit to a low level, a PD using the MC34670 minimizes the current drawn from the PSE during start-up. The maximum inrush current level can be set by connecting a resistor from pin ILIM to VIN as illustrated in Figure 11. +VPORT VPWR RCLASS RCLA RSIG 25kΩ UVLO RILIM ILIM VIN -VPORT Figure 11. Inrush Current Limitation by External Resistor RILIM Table 4 shows the selectable current limits and the corresponding value for the resistor that has to be connected between pins ILIM and VIN. Table 4. Inrush Current Limit vs. RILIM Inrush Current Limit [mA] RILIM Value [kΩ] 180 12.1 110 42.2 65 191 After powering up, the MC34670 switches to the high level current limit, thereby allowing the PD to consume up to 12.95 watts if a 802.3af PSE is present. 4.4 4.4.1 Flyback Configuration Flyback Basics Flyback converters are widely used for output powers from about 150 W down to under 5 W. They do not require a secondary output inductor (as a Forward converter does), which leads to power supply cost savings and reduced board space. Usually Flyback converters are easy to MC34670 Usage and Configuration, Rev. 3.0 10 Freescale Semiconductor Configuration design and very robust. They are attractive for multi-output supplies, since line and load regulation is far better than for the Forward topology. Flyback topologies store energy during the on time of the power transistor in the power transformer and deliver energy to the load when the power transistor turns off. This is a fundamentally different way compared to pure transformer based converters, like the Forward converter. 4.4.1.1 Topology A typical Flyback converter is sketched in Figure 12. ip T1 is D1 V 1:n C vp Np Ns R rC Vg R1 R2 Q1 DC voltage controlled variable-width pulse generator VREF Figure 12. General Flyback Topology The circuitry in Figure 12 has only one output, but multi-output supplies are very common. A negative feedback loop that includes the resistor divider R1 and R2, the voltage reference comparator and a PWM controller regulates the output voltage against line and load changes. A fraction of the output voltage is compared to a reference VREF and the error voltage controls the on and off time of Q1. It is important to connect the transformer T1 as indicated in Figure 12 with the dot end (or no-dot end) of the primary side to the positive terminal of Vg and the dot end (or no-dot end) of the secondary side to the common secondary ground. 4.4.1.2 Discontinuous Conduction Mode (DCM) In discontinuous conduction mode the Flyback converter works as follows. During Q1 on time, the current in the primary winding ramps up linearly at a rate: MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 11 Configuration di p V = -----gdt L At the end of the on time of Q1 the primary current has ramped up to: Vg I p = ------ ⋅ T on L When Q1 turns off, the primary current transfers to the secondary side of T1: I I s = ---pn where n is the winding ratio between the secondary and primary side: The current ramps down linearly at a rate: N n = ------s Np di s V = ----Ls dt In discontinuous conduction mode the current ramps down to zero before the start of a new cycle, and all the energy stored in the primary has been delivered to the secondary and thus to the load. The current Ip at the end of Ton represents the stored Energy in Joules: 2 L ⋅ ( Ip ) E = -----------------2 Consequently, the power drawn from the supply Vg in a time T is: 2 L ⋅ ( Ip ) P = -----------------2T 2 But, V g ⋅ T on ( V g ⋅ T on ) I p = ------------------, so P in = -------------------------- [W] . If we let P in = P out 2TL L and assuming 100 % efficiency, we get the following relation between output voltage and input voltage: 2 2 ( V g ⋅ T on ) V --------------------------- = -----2TL R V R D After some algebra we find for the conversion ratio: M ( D, K ) = ----- = T on ----------- = -------- , whereas Vg 2L K = -------RT 2TL K and T on = DT . To ensure that the core doesn’t saturate and the circuit remains in the discontinuous mode, the volt-second products A1 and A2 (see Figure 13) must be equal. MC34670 Usage and Configuration, Rev. 3.0 12 Freescale Semiconductor Configuration Ip Ton Is Tr Tdt A2 Vdc A1 Figure 13. Waveforms in DCM It is therefore advisable to add a dead time Tdt to give extra time and margin before starting a new cycle. On-time plus reset time should not exceed 80% of one full cycle, or: T on + T r = 0.8T. 4.4.1.3 Continuous Conduction Mode (CCM) By changing the transformer’s magnetizing inductance and output load, the Flyback converter changes operating mode. For a given magnetizing inductance the converter works in discontinuous conduction mode for a certain load, but changes to continuous conduction mode with increasing load. Generally, a Flyback converter should be designed to work optimally in either continuous or discontinuous mode. The difference in the waveforms can be immediately seen in Figure 14. Compared to Figure 13 the primary and secondary currents ip and is have a step at its front end. As for the discontinuous mode Flyback, the volt-second product across the primary when Q1 is on must be equal that across it when Q1 is off: V⋅T off V ⋅T = ------------------g on n N whereas n = -------s . Rearranged, the term for V leads to: N p T V = V on ⋅ 1--- ⋅ ---------g n T off Thus, the conversion ratio is given by: whereas D D V M ( D ) = ------- = n ⋅ ------------- = n -----1–D D′ V g T T on off D = ---------- , D′ = 1 – D = ----------- . T T MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 13 Configuration Ip ip Ton Is is Toff A1 Vg A2 V + nVg vp Figure 14. Waveforms in CCM 4.4.1.4 Conversion Ratio CCM vs. DCM As previous calculations showed, the conversion ratios for CCM and DCM are very different. For CCM the conversion ratio depends on the transformer secondary to primary ratio and the duty cycle. For DCM the conversion ratio depends on K, the duty cycle, and T = 1/f. Figure 15 shows the curves for CCM and DCM conversion ratio. (a) (b) Figure 15. Conversion Ratio (a) CCM, (b) DCM MC34670 Usage and Configuration, Rev. 3.0 14 Freescale Semiconductor Configuration 4.4.1.5 4.4.1.5.1 Flyback Converter Transfer Function and Bode Plot Continuous Conduction Mode DCM and CCM have significantly different dynamic behaviors. Figure 16 shows the transfer function of a Flyback converter in CCM. The transfer function has a right-half-plane zero (RHP) that is difficult to stabilize and may lead to oscillations of the converter under certain circumstances. RHP zeros are a characteristic of several converters, including Flybacks in CCM, caused by mutually responding in the wrong direction when a load change occurs. Figure 16 shows typical open loop gain and phase characteristics of a Flyback converter in CCM. Figure 16. Open Loop Flyback in CCM The open loop control-to-output transfer function of a Flyback converter in CCM under current mode control is defined as: s ⎞ s⎞ ⎛ ⎛ 1 + ------ ⋅ 1 – ------------⎝ ω zrhp⎠ ω z⎠ ⎝ f ( s ) = K ⋅ ------------------------------------------------------s 1 + -----ωp with a dominant pole at: 1+D ω p = -------------RC and the RHP zero at: 2 2 R(1 – D) ω zrhp = ------------------------- , L = L p ⋅ n DL MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 15 Configuration The ESR zero is located at: 1 ω z = --------rC C K can be calculated as: R ⋅ (1 – D) K = ---------------------------------------------------n ⋅ R CS ⋅ A v ⋅ ( 1 + D ) where RCS is the current sense resistor and AV the gain factor of the CS voltage amplifier. AV is 3 for the MC34670. 4.4.1.5.2 Discontinuous Conduction Mode Figure 17 shows phase and gain plots of a Flyback converter working in DCM under current mode control. Figure 17. Open Loop Flyback in DCM For DCM operation, the control-to-output transfer function of the Flyback converter using current mode control is given by: • S 1 + -------- ωz f ( s ) = K • ------------------S 1 + -------- ωp MC34670 Usage and Configuration, Rev. 3.0 16 Freescale Semiconductor Configuration As for the Flyback in CCM the ESR zero is located at: 1 ω z = --------rc C A dominant pole exists at: 2 ω p = --------RC Contrary to the flyback converter in CCM, there is no RHP zero. The DC gain does not change as the input voltage varies. 4.4.2 MC34670 Flyback Configuration The configuration of the device is explained by means of a specific example, but alternatives are shown where applicable. For most applications, the device is configured as isolated Flyback converter with the following specification: • Input voltage VI: 36-57 V • Output voltage VO: 5 V • Output current IO: 0.4 - 2 A • Maximum output ripple Vr: 50 mV • Converter operates in CCM Other than the above mentioned specification items, a few design assumptions can be made prior to the design process. Since the output voltage is set to 5 V@2 A, an appropriate transformer can be selected off-the-shelf from different suppliers, e.g. the DA 2362-AL from Coilcraft. This specific transformer is designed for CCM at 250 kHz switching frequency and has a bias winding supplying 12 V@20 mA output. The input capacitor CIN (see Figure 3) is given by the IEEE 802.3af standard and must not exceed 0.12 μF, we choose 0.1 μF/100 V. The decoupling capacitor CPORT should be in a range of 22 μF to 47 μF (100 V rated) with low ESR. Place them near the transformer T1. 4.4.2.1 Calculating RCS To calculate the current sense resistor it is necessary to know the maximum primary peak current Ipeak of the transformer drawn at minimum input voltage. This value can usually be found from the datasheet of the transformer. If not, use the following equations: 1 V I dc = n ⋅ ----- ⋅ ------o D' R o V PORT ⋅ D ⋅ T s Δi m = ----------------------------------2L I peak = I dc + Δi m The equations calculate the magnetizing DC current Idc and the current ripple Δim. Both the datasheet and the calculations gives the same maximum peak current: Ipeak = 1 A. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 17 Configuration The MC34670 device offers two voltage trip levels, a high limit at 600 mV without blanking and a low limit at 400 mV with 50 ns (typical) blanking time. In case of an overcurrent condition, where the high limit trip point is reached, the GATE output is immediately pulled low and the current cycle is terminated. The current sense resistor can then be calculated as follows: V cs 400mV R cs = ----------= ------------------- = 400mΩ 1A I peak We choose the next smaller standard value, which is 330 mΩ. This gives a maximum peak current of 1.2 A which is acceptable and tolerable by the transformer. A higher value of the current sense resistor would lead to a higher voltage drop across the resistor and thus reaching the low voltage trip level of the current comparator, which leads to premature termination of the switch cycle at high load and low line condition. 4.4.2.2 Calculating Co The output capacitor(s) see high stresses in Flyback converters. It is important to select capacitors which can sustain high current ripple and have low ESR. We’re actually looking for the minimum output capacitor Co and maximum ESR to be below the maximum specified ripple voltage Vr. Assuming Vr = VC/2 + VrC/2: 0.37 D C o = I o ⋅ ---------------- = 2A ⋅ ----------------------------------------- = 120μF 250kHz ⋅ 25mV VC f s ⋅ ------2 The maximum duty cycle D can be found easily: The maximum ESR value is: 1 1 D = ---------------------------------- = ---------------------------------------- = 0.37 36V ⋅ 0.25 V PORT ⋅ n ------------------------------ + 1 -----------------------+1 5V + 0.36V Vo + Vd 1 – 0.37 1–D ESR = V rC ⋅ ------------- = 25mV ⋅ --------------------- = 8mΩ 2A Io 4.4.2.3 Snubber Design Despite the many advantages of the Flyback converter, it has the disadvantage of (large) transient voltage spikes at the drain of the power switch and also at the secondary rectifier diode. These spikes are caused by mainly the leakage inductance of the transformer and must be suppressed to avoid destruction of semiconductors and to reduce noise. The leakage inductance rings with stray capacitances (PCB layout) and produces the characteristic waveforms. Snubbers are designed to control and to minimize the effects of the leakage inductance. Figure 18 shows the waveforms at the drain of the switching MOSFET M1 (a) and at the anode of the secondary rectifier (b). MC34670 Usage and Configuration, Rev. 3.0 18 Freescale Semiconductor Configuration snubbed waveform un-snubbed waveform un-snubbed waveform (a) snubbed waveform (b) Figure 18. Primary and Secondary Snubbed and Un-Snubbed Waveforms Figure 19 shows the RC snubber for the primary and secondary side. The resistor Rsn damps the LC resonance and the series capacitor Csn prevents the voltages from being applied across the resistor. RESET Csn T1 VDD GATE Rsn VO Csn M1 Rsn NP NS CS RCS COMP FB VOUT Figure 19. Snubber Circuits for Primary and Secondary Side There is a simple step-by-step approach to determine the correct values for the snubber elements. This includes as a first step the measurement of the ringing frequency on both the primary and the secondary sides. See Figure 20, for where to measure the waveforms. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 19 Configuration RESET T1 VDD GATE NP M1 VO NS CS RCS COMP FB VOUT Figure 20. Measurement of Waveforms Once the ringing frequency is know, the remaining steps can be performed as follows: Z = 2πf r L l R = Z 1 C = --------------2πf r R where Ll is the leakage inductance of the transformer. The leakage inductance for the transformer can be obtained from the datasheet of the transformer. Assuming the ringing frequencies have been measured as fr(primary) = 17 MHz and fr(secondary) = 37 MHz we can complete the calculations. Primary side: Z = R sn ( primary ) = 2π ⋅ 17MHz ⋅ 1.9μH = 203Ω 1 C sn ( primary ) = --------------------------------------------------- = 46pF 2π ⋅ 17MHz ⋅ 203Ω Secondary side: Z = R sn ( sec ondary ) = 2π ⋅ 37MHz ⋅ 43nH = 10Ω 1 C sn ( sec ondary ) = ----------------------------------------------- = 430pF 2π ⋅ 37MHz ⋅ 10Ω 4.4.2.4 Converter Transfer Function and Bode Plot With the information given in chapter 4.4.1 Flyback Basics we can easily estimate the transfer function of our Flyback example and draw a Bode plot. In a later step we calculate the compensation loop elements. MC34670 Usage and Configuration, Rev. 3.0 20 Freescale Semiconductor Configuration NOTE It is essential for every power supply design to measure the open loop gain of the converter and re-measure the system after closing the loop. Never trust only the theoretical calculations and simulations. Real world systems behave differently, due to parasitics and nonlinearities of the circuitry or simply due to simplifications we made during the calculations. The open loop control-to-output transfer function for the Flyback example is: s s⎞ ⎛ ⎛ 1 + ----- ⋅ 1 – -------------⎞ ⎝ ω zrhp⎠ ω z⎠ ⎝ f p ( s ) = K ⋅ ------------------------------------------------------s 1 + -----ωp For high load and low input line we get the dominant pole at: 1+D 1 + 0.37 f p = ---------------- = ----------------------------------------------- = 727Hz 2πRC 2π ⋅ 2.5Ω ⋅ 120μF and the RHP zero at: 2 2 R(1 – D) 2.5Ω ( 1 – 0.37 ) f zrhp = ------------------------- = -------------------------------------------- = 54kHz 2πDL 2π ⋅ 0.37 ⋅ 7.9μH The ESR zero is located at: 1 1 f z = ---------------- = ----------------------------------------------- = 166kHz 2πr c C 2π ⋅ 8mΩ ⋅ 120μF K can be calculated as follows and represents the DC gain: R ⋅ (1 – D) 2.5Ω ⋅ ( 1 – 0.37 ) K = ---------------------------------------------------- = ----------------------------------------------------------------------- = 4.6 = 13dB n ⋅ R CS ⋅ A v ⋅ ( 1 + D ) 0.25 ⋅ 0.33Ω ⋅ 3 ⋅ ( 1 + 0.37 ) Figure 21 shows the transfer function of our example Flyback converter. One can see the poles and zeros and the DC gain as calculated. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 21 Configuration 20 10 DC gain fp Gain (dB) 0 fzrhp fz -10 -20 -30 -40 -50 10 100 1000 10000 Frequency (Hz) 100000 1000000 100000 1000000 0 -50 Phase (deg) -100 -150 -200 -250 -300 10 100 1000 10000 Frequency (Hz) Figure 21. Transfer Function of Flyback Example 4.4.2.5 Flyback Converter Current-Mode Compensation The compensation network of choice for current mode control is a Type-II amplifier which gives two poles and one zero, see 4.4.2.6 Type II Amplifier for details. A simple drawing of the working principle of the Type-II amplifier and the compensation of the Flyback power stage is shown in Figure 22. There are different approaches where to set the poles and zeros: a) The first pole is placed at origin for DC regulation. The second pole should be placed just after the RHP or ESR zero, or at half the switching frequency, whichever is lower in frequency. The first zero should be placed at about 1/5 of the desired crossover, see Figure 22. b) Poles and zeros are placed using the K-Factor approach, explained in 4.4.2.8 Feedback Design Using the K-Factor Approach. MC34670 Usage and Configuration, Rev. 3.0 22 Freescale Semiconductor Configuration fp Flyback Power Stage fs/2 frhp fesr Type II Amplifier Loop Gain 0 dB Figure 22. Flyback Compensation with Type-II Amplifier 4.4.2.5.1 Loop Gain Crossover Frequency In general, the selection on the loop gain crossover frequency depends on: • Power supply topology • Switching frequency fs • Voltage mode or current mode control • Output capacitor C • Power stage components (variations) Higher crossover frequency can reduce output overshoot but can also increase noise. 4.4.2.5.2 RHP Zero Crossover Limit As we have seen in the previous chapters, the RHP zero crossover is constrained by the Flyback power stage dynamics: 2 R ⋅ (1 – D) f c = ----------------------------2π ⋅ D ⋅ L s The crossover frequency should not exceed 1/3 the RHP zero. 2 R ⋅ (1 – D) f c ≤ ----------------------------6π ⋅ D ⋅ L s 4.4.2.5.3 Switching Frequency Crossover Limit Switching power supplies are sampled data systems. The Nyquist frequency fs/2 is the absolute limit for fc. However, a more reasonable limit is: MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 23 Configuration fs f c ≤ --5 Noise becomes an issue if you come closer to the theoretical limit. 4.4.2.5.4 Capacitor ESR Crossover Limit If the main performance objective of the switch mode power supply is driven by step load requirements, there is no benefit in raising the crossover frequency above the output capacitor ESR frequency: 1 f c ≤ -----------------------2π ⋅ C ⋅ r c 4.4.2.5.5 Choosing the Right Crossover Frequency With the formulas given in chapters 4.4.2.5.2 to 4.4.2.5.4 we are able to choose the right crossover frequency by picking the one with the lowest frequency: 2 2.5Ω ⋅ ( 1 – 0.37 ) f c ( rhp ) ≤ ---------------------------------------------- = 18kHz 6π ⋅ 0.37 ⋅ 7.9μH 250kHz f c ( fs ) ≤ --------------------- = 50kHz 5 1 f c ( esr ) ≤ ----------------------------------------------- = 166kHz 2π ⋅ 120μF ⋅ 8mΩ which results in a crossover frequency of 18 kHz, constrained by the RHP zero. 4.4.2.6 Type II Amplifier The Type-II amplifier schematic and Bode plot is shown in Figure 23. Rb doesn’t play any role in the transfer function and has no effect on amplifier gain, but is needed to adjust the output steady-state voltage. UGF (unity gain frequency) denotes the pole at the origin. The Type-II amplifier gives a maximum 90 degree phase boost. In practice, fz and fp are placed symmetrically around the desired loop crossover frequency and gives the maximum phase boost at crossover. The gain at crossover is roughly the ratio of R2 to R1. It is recommended to connect R2 rather than C1 to the summing node of the error amplifier. MC34670 Usage and Configuration, Rev. 3.0 24 Freescale Semiconductor Configuration C2 R2 C1 R1 Rb Gain dB Vref Phase deg -1 fz fp -1 UGF -180 Boost -270 Figure 23. Type-II Amplifier Schematic and Bode Plot Below is the transfer function of the Type-II amplifier: 1 + sR 2 C 1 T ( s ) = --------------------------------------------------------------------------------C1 C2 ⎞ sR 1 ( C 1 + C 2 ) ⎛ 1 + sR 2 ------------------⎝ C 1 + C 2⎠ 1 UGF = ------------------------------------------2π ⋅ R 1 ( C 1 + C 2 ) 1 f z = --------------------2πR 2 C 1 1 f p = --------------------------------------C1C2 2π ⋅ R 2 ------------------C1 + C2 MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 25 Configuration 4.4.2.7 Optocoupler and Shunt Regulator as Feedback For isolated applications it is necessary to use an optocoupler to close the feedback loop and to cross the isolation barrier between primary and secondary side. The optocoupler is used in conjunction with a TL431. 5V Vo R4 = 5k CTR ⋅ R 1 1 + sR 1 C 1 T ( s ) = -----------------------4- ⋅ --- ⋅ -------------------------R 5 R 1 C 1 s 1 + sR 4 C 3 R5 Ve CTR ⋅ R 4 UGF = -------------------------------2 π ⋅ R5R1C1 C3 CTR C1 TL431 R1 1 f z = --------------------2 π R1 C1 Rb 1 f p = --------------------2 π R4C3 Figure 24. Schematic of Optocoupler with Shunt Regulator Forming Type-II Amplifier The circuitry shown in Figure 24 is still a Type-II amplifier. The mid-band gain (between fz and fp in Figure 23) depends on the current transfer ratio of the optocoupler (CTR) and R4 and R5. R4 is already determined by the 5 kΩ pull-up resistor of the MC34670. The high frequency pole of the optocoupler feedback circuitry in mainly determined by the characteristic of the optocoupler and it’s bias point. The more current flowing in the device, the higher the bandwidth. The rolloff of the gain is usually around 8 kHz to 10 kHz. Figure 25 shows the gain and phase for the optocoupler feedback circuitry for the values given below: R1 = Rb = 5 kΩ R5 = 2 kΩ C1 = 100 nF C3 = 3.9 nF CTR = 100% MC34670 Usage and Configuration, Rev. 3.0 26 Freescale Semiconductor Configuration 60.00 dB(ve/vin) 45.00 fz = 318Hz 30.00 fp = 8.2kHz (dB) 15.00 0.000 UGF = 3.2 kHz -15.00 -30.00 -45.00 -60.00 10.00 100.0 1.000k Frequency (Hz) 10.00k 150.0 100.0k PHASE(ve/vin) 140.0 130.0 120.0 (Deg) 110.0 100.0 90.00 80.00 70.00 60.00 50.00 10.00 100.0 1.000k Frequency (Hz) 10.00k 100.0k Figure 25. Compensation Gain using TL431 4.4.2.8 Feedback Design Using the K-Factor Approach For designing the feedback loop, we are using the K-Factor approach to synthesize an amplifier to design a stable feedback loop. For that reason a few preliminary steps are required to proceed: • Calculate or measure the power stage • Choose the crossover frequency • Choose your desired phase margin e.g. 90°/60°/30° • Determine the required compensator gain at cross-over • Calculate the required phase boost: Boost = M – P – 90 — M: Modulator phase shift — P: Desired phase margin As outlined in chapter 4.4.2.4 Converter Transfer Function and Bode Plot it is good practice to measure the power stage open loop gain and phase. The calculated poles and zeros should be in line with the measurement results. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 27 Configuration We proceed with the proper choice of the crossover frequency as described in chapter 4.4.2.5.5 Choosing the Right Crossover Frequency. After that, we choose our desired phase margin. 60 degrees is a good compromise between high stability (90 degrees) and fast transient response (30 degrees). Systems with 30 degrees or less phase margin tend to ring and offer less tolerance against component variations. For our example: fc = 18kHz M = 60 P = -107 degrees We can now determine the required compensator gain at cross-over and calculate the required phase boost. Boost = M – P – 90 = 60 – (-107) – 90 = 77 degrees 4.4.2.8.1 Calculating Components for Type-II Amplifier Below are the calculations to get the components for the Type-II amplifier: • 77 Boost K = tan ⎛ ----------------⎞ + 45 = tan ⎛ ------⎞ + 45 = 8.8 ⎝ 2⎠ ⎝ 2 ⎠ • Set R2 to 10 kΩ • K 8.8 C 1 = -------------------------- = ------------------------------------------------- = 7.8nF 2 π ⋅ fc ⋅ R2 2 π ⋅ 18kHz ⋅ 10k Ω • C1 7.8nF C 2 = --------------= ------------------- = 102pF 2 2 K –1 8.8 – 1 • 1 1 R 1 = -------------------------------------------- = ------------------------------------------------------------------------ = 2k Ω 2 π ⋅ fc ⋅ G ⋅ K ⋅ C2 2 π ⋅ 18kHz ⋅ 5 ⋅ 8.8 ⋅ 102pF The poles and zeros of the compensator can be determined as follows: 1 1 UGF = ------------------------------------------------ = ------------------------------------------------------------------------ = 10kHz 2 π ⋅ R1 ⋅ ( C1 + C2 ) 2 π ⋅ 2k Ω ⋅ ( 7.8nF + 120pF ) 1 1 f z = ----------------------------- = ----------------------------------------------- = 2kHz 2 π ⋅ R2 ⋅ C1 2 π ⋅ 10k Ω ⋅ 7.8nF 1 1 f p = ------------------------------------------- = ----------------------------------------------------------------------- = 158kHz C1 ⋅ C2 7.8nF ⋅ 102pF 2 π ⋅ 10k Ω ⋅ ---------------------------------------2 π ⋅ R 2 ⋅ -------------------7.8nF + 102pF C1 + C2 MC34670 Usage and Configuration, Rev. 3.0 28 Freescale Semiconductor Configuration The resulting transfer function for the compensator is shown in Figure 26. 70 60 Gain (dB) 50 40 30 fz 20 10 fp UGF 0 Phase (deg) 10 100 1000 10000 Frequency (Hz) 0 -10 -20 -30 -40 -50 -60 -70 -80 -90 -100 100000 1000000 Boost 10 100 1000 10000 Frequency (Hz) 100000 1000000 Figure 26. Transfer Function of the Type-II Compensator The process of determining the components for the optocoupler feedback circuitry is similar to the previously shown process. However, as discussed in chapter 4.4.2.7 Optocoupler and Shunt Regulator as Feedback the second pole cannot be placed at a higher frequency than the rolloff frequency of the optocoupler. Typically, and depending on the bias current of the optocoupler, the rolloff frequency is around 8 kHz to 10 kHz. 4.4.2.8.2 Bode Plot — Power Stage, Compensator, and Loop After calculation of the components for the Type-II amplifier it is good practice to plot the closed loop transfer function in worst case conditions, e.g. at high input line and light load and at low input line and full load. To guarantee stability over the entire input voltage and output load range, the compensator should be designed at low input line and full load. Furthermore, the design has to be done in such a way, that mode transitions from CCM to DCM and vice versa don’t lead to unstable behavior. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 29 Configuration NOTE If the Flyback converter works in CCM and DCM, design the feedback loop for CCM. This guarantees stability in CCM and DCM. The Bode plot in Figure 27 shows the Flyback converter at high input line and light load. The dominant pole and RHP zero have moved compared to the locations with low input line and full load and the converter works now in DCM. But as mentioned previously, the converter is still stable in DCM Gain (dB) 100 80 Power stage 60 Compensator 40 Loop 20 0 -20 -40 -60 10 100 1000 10000 Frequency (Hz) 100000 1000000 100000 1000000 0 Phase (deg) -50 -100 -150 -200 -250 10 100 1000 10000 Frequency (Hz) Figure 27. Flyback Converter at High Input Line and Light Load As for the Flyback in CCM the ESR zero is located at the same location and doesn’t change therefore. The DC gain increased to 22 dB and the dominant pole moves to approximately 200 Hz. Figure 28 shows again the converter Bode plots at full load and low input line, as already shown in chapter 4.4.2.4. MC34670 Usage and Configuration, Rev. 3.0 30 Freescale Semiconductor Configuration 80 Power stage 60 Compensator Gain (dB) 40 Loop 20 0 -20 -40 -60 10 100 1000 10000 Frequency (Hz) 100000 1000000 0 -50 Phase (deg) -100 -150 -200 -250 -300 -350 -400 10 100 1000 10000 Frequency (Hz) 100000 1000000 Figure 28. Flyback Converter at Low Input Line and High Load 4.4.3 VDD High Voltage Supply The internal high voltage supply regulates from the input voltage across VPWR and VIN down to the VDD voltage. During start-up the high voltage regulator provides the necessary voltage for the internal gate driver to commence switching. If the external MOSFET gate drive pulls less than 3 mA to 4 mA (average) after start-up and during normal operating conditions, an auxiliary transformer winding that usually provides the bias voltage for the chip and the gate driver is not required. Use the following equation to calculate the average current: 1 I avg = --- ⋅ C eff ⋅ VDD Reg ⋅ f s 2 where VPWR + VDD Reg - ⋅ C rss C eff = C iss + ---------------------------------------------VDD Reg Ciss and Crss can be found in the datasheet of the external switching MOSFET and fs is the switching frequency. VPWR is the input voltage of the MC34670 and VDDReg the high voltage regulator output voltage. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 31 Configuration In cases where the external MOSFET gate drive pulls more than 5 mA, an auxiliary winding is needed to reduce the power dissipation in the internal high voltage LDO. Alternatively, the switching frequency can be reduced or a MOSFET with lower Ceff is used. A load capacitor on pin VDD is needed to ensure proper behavior and stability of the high voltage supply. The supply has been designed to allow capacitors with a wide spread of ESRs. Use a electrolytic capacitor with 10 μF to 20 μF for best performance at lowest cost. It is recommended to add a 0.1 μF ceramic capacitor in parallel with the existing load capacitor if the auxiliary winding is used. This reduces noise at the VDD pin caused by the auxiliary winding when switching on and off. 4.4.4 Efficiency Figure 29 shows efficiency plots for different PoE transformers with or without use of the bias winding. It can be seen, that the efficiency is slightly better with bias winding. MC34670 Efficiency Plot: Vo = 5V, w/o bias winding, Coilcraft DA2142-AL 90.00 85.00 80.00 % 75.00 70.00 65.00 60.00 57V 55.00 48V 36V 50.00 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 I O [A] MC34670 Efficiency Plot: Vo = 5V, w/ bias winding, Coilcraft DA2362-AL 90.00 85.00 80.00 % 75.00 70.00 65.00 60.00 57V 48V 55.00 36V 50.00 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00 IO [A] Figure 29. Efficiency Plots for 13 W Transformers MC34670 Usage and Configuration, Rev. 3.0 32 Freescale Semiconductor Configuration 4.5 Transient Voltage Suppression The application can see over 80 V transients at the RJ45 connector, due to possible long cables (up to 100 m) and Ethernet data transformers. Transients in excess of kV’s are not uncommon. To prevent these transients from exceeding the device’s maximum voltage rating of 80 V, one can place a transient voltage surge suppressor (TVS) between VPORT+ and VPORT- in parallel with CIN. +VPORT 3 RX 6 1 E.g. SMAJ58A TX 2 CIN 4 5 -VPORT 7 8 Figure 30. Transient Voltage Suppression The TVS should be selected so it doesn’t trigger below 57 V (maximum PD input voltage), but must trigger before reaching 80 V (absolute maximum rating of the MC34670). A good choice is the SMAJ58A or SMAJ60A. MC34670 Usage and Configuration, Rev. 3.0 Freescale Semiconductor 33 References 5 References Abraham I. Pressman, Switching Power Supply Design, Second Edition, McGraw-Hill, 1998. Ron Lenk, Practical Design of Power Supplies, IEEE Press, 2005. Robert W. Erickson, Dragan Maksimovic, Fundamentals of Power Electronics, Second Edition, Kluwer, 2001. Dr. Ray Ridley, Power Supply Design Workshop 2005, Ridley Engineering, Inc., 2005. MC34670 Usage and Configuration, Rev. 3.0 34 Freescale Semiconductor How to Reach Us: Home Page: www.freescale.com E-mail: [email protected] USA/Europe or Locations Not Listed: Freescale Semiconductor Technical Information Center, CH370 1300 N. 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