MIC9130 Power Over Ethernet IEEE 802.3af PD Evaluation Board (Isolated) General Description The MIC9130 Power Over Ethernet (POE) Powered Device (PD) Evaluation Board is designed to offer a complete IEEE802.3af compliant power solution. The evaluation board includes a low cost POE signature and classification circuit, an EMI filter, and an isolated flyback dc/dc converter using the MIC9130 control IC. The MIC9130 is a high speed current mode PWM dc/dc controller that features a high voltage start-up circuit than enables the device to operate directly from the 36V to 57V POE source voltage. When a powered Ethernet cable is plugged into the evaluation board, the front end handshaking circuit will apply the correct signature and classification impedances to accept power from the Power Sourcing Equipment (PSE). At the application of power from the PSE, with input voltages between 36V and 57V, the dc/dc flyback converter will engage and generate a 3.3V output with up to 2.5A of output current. Features • • • • • • • • • • 36V to 57V input voltage 3.3V output voltage RJ45 input and output connectors IEEE 802.3af signature circuit IEEE 802.3af classification circuit* EMI filter Low cost single winding transformer MIC9130 DC/DC flyback converter >1500VAC isolation 400KHz fixed frequency PWM control Related Documentation • MIC9130 Datasheet This evaluation board is for use with IEEE802.3af enabled Switch/Routers which provide power to the Ethernet cable as defined in IEEE802.3af PSE requirements. * Patent Pending Evaluation Board Evaluation Board Picture July 2004 Top View: Layout and Dimensions M9999-052402 MIC9130 Power Over Ethernet Evaluation Board Description When the RJ45 connector is plugged into a PSE, the At the application of power, the Flyback primary Front end handshaking circuit will apply the correct circuit is applied with between 36V and 57V. This signature and classification impedances to gain then converts power to the secondary circuit at 3.3V power from the PSE. up to 2.5A. __________________________________________________________________________________________ Schematic * NF: Optional components Not Fitted on the evaluation board Evaluation Board Setup with PSE The follow steps describe the procedure for setting up the evaluation board with available 802.3af compliant Power Sourcing Equipment. 2. After automatic hand-shaking sequence, 3.3V power will be applied to post PL1 3. Data from input is available at output connector RJ45_2 1. Plug in IEEE 802.3af compliant powered Ethernet cable into RJ45_1 input connector 2 M9999-052402 MIC9130 Power Over Ethernet Evaluation Board Discrete Setup 5. Turn on all apparatuses The follow steps describe the procedure for setting up the evaluation board discretely to emulate 802.3af power sourcing equipment. 6. Check Signature a. Set PSU to 9V b. Ammeter 1 should read between 280µA to 368µA 1. Plug in one end of CAT5 Ethernet cable into RJ45_1 input connector, with the wires of the other end exposed 7. Check Classification a. Set PSU to: 15V to 20V range b. Ammeter 1 should read between 26mA to 30mA (Class 3) 2. Connect banana plug termination to brown, blue, orange, and green pairs. 3. Prepare test gear: 8. DC/DC Power Supply Turn On & Startup a. Set PSU to: 36V to 57V range b. DMV2 at the PL1 post should read 3.3V a. 1 Power Supply Unit PSU capable of supplying 60V with a 1A current limit b. 2 Digital Volt Meters (DVMs) with 60V measuring capability c. 2 amps meters: 300µA to 400mA range (input side), and 2.5A rated for output side d. Electronic Load. 3.3V capable set to 2.5A load. 4. Apply test setup Test Setup 3 M9999-052402 MIC9130 Power Over Ethernet PD Controller Circuit Signature To comply with IEEE 802.3af, it mandatory to provide a 25K resistance (R11) and 100nF capacitance (C13) across the power line to receive power from the PSE (signature). MOSFET Q5 is used to hold off the input capacitance of the dc/dc converter during the signature detection phase. Classification The MIC9130 POE eval board is set to Class 3. Power classification is optional, and can be removed to reduce cost. The default classification is Class 0. To remove the Classification option, the following components can be removed from the MIC9130 POE eval board: R1, Q6, R12, D3, Q3, Q4, R13. To set a Classification Level, the MIC9130 POE eval board’s classification circuit can be configured as follows: Class Input Current VIN =14.5V to 20.5V PD Power Class Component Modification Class 0 0mA – 4mA 0.5W to 12.95W Class 1 Class 2 Class 3 Class 4 9mA – 12mA 7mA – 20mA 26mA – 30mA 36mA – 44mA 0.5W to 3.8W 3.8W to 6.5W 6.5W to 12.95W Not defined remove R1, Q6, R12, D3, Q3, Q4, R13 R13 = 953Ω R13 = 536Ω R13 = 340Ω R13 = 270Ω Front End Analog Handshaking Limits: The following are the limits that the evaluation board has been designed to: DESCRIPTION Signature Test (Resistance) Classification Test, Class 3 (Line Current) DC/DC Full Power (Line Current) TEST CONDITION MIN MAX VIN = 2.7V to 10.1V 19KΩ 26.5 KΩ VIN = 14.5V to 20.5V 26mA 30mA VIN = 36V; IOUT=2.5A 229mA 310mA 4 M9999-052402 MIC9130 Power Over Ethernet Flyback Converter Performance VIN = 36V to 60V Efficiency ~ 80% at full load VOUT ripple < 100mV Load Regulation = 1.7% at VIN = 48V Transient Response VOUT Ripple 2.5A 0.5A 100mV/DIV 200mV/DIV Switching Edges Efficiency Efficiency (%) 85 80 75 VIN=37V 70 VIN = 48V 65 VIN = 59V 60 0 1 2 3 4 IOUT (Amps) CH1 = Primary VDS (20V/DIV) CH2 = Gate drive (5V/DIV) Note: Gate rise/fall time is increased by 10Ω resistor to help reduce the frequency of RF emissions. 5 M9999-052402 MIC9130 Power Over Ethernet Bill of Materials Ref. U1 U2 IC2 Q2 Q3 Qty 1 1 1 1 1 Part Description Hi Voltage DC/DC Controller Optocoupler 1.2V Voltage Regulator N channel 100VDS MOSFET NPN med-power transistor 80V,1A Q4 1 Small Signal Transistors NPN Q5 1 N channel 60VDS MOSFET Q6 1 N channel 60VDS MOSFET BR1BR2 2 100V , BRIDGE D1 D2 1 1 LS4148, Fast Switching diodes. 5A, 40V Schottky diode D3 1 Zener Diode, 9.1V D4 1 Voltage Regulator Diode,500mW, 24V Z2 1 Voltage Regultor Diode 500mW,39V C1 1 220pF/50V, 0603. CX 1 Parallel with R18 C3 1 330pF/50V , 0805 C4, C5 2 47uF / 6.3V, X5R,1206 C6 1 33uF/ 100V C7 1 1uF/100V,X7R,1206 C8, C12, C17, C18 4 100nF/ 50V, 0603. C9 1 10uF / 16V, X5R,1206 C10,C11, C16,R5, R6,R20 0 Not fitted ( open location ) C13 1 100nF/100V, 0603 C14 1 100uF / 6.3V C15 1 1000pF/50V , 0603 6 Vendor P/N MIC9130BQS PS2703-1 K TLV431ACDBVR SI3430DV CXT3019 BC846B BC846B Si2308DS 2N7002E CMPDM7002A 2N7002E MB2S HD02 CBRHD-02 LS4148 SBM540 BZX84-C9V1 BZX84C9V1 MSZ5252B ZMM5252B MSZ5259B ZMM5259B VJ0603A221KXAAT VJ0603A221KXAAT C1608COG1H221J 08053D331KAT2A C1608X7R1H333K VJ0805Y331KXAAB C3225X5R0J476MT JMK316BJ476KN-T 517D336M100CC6A GRM32ER72A105KA01L 12101C105KAZ1A HMK325BJ105ML-T C3216X5R2A105KT C1608X7R1H104KT VJ0603Y104KXAAT GRM31CR61C106KC31B C3216X5R1C106KT Vendor Micrel.Inc NEC TI Vishay Siliconix Central Semi Central Semi Vishay Telefunken Vishay Siliconix Vishay Telefunken Central Semi Diodes. Inc Vishay Diodes. Inc Central Semi Vishay Telefunken Diodes. Inc Diodes. Inc Central Semi Diodes. Inc C2012X7R2A104K. VJ0805Y104JXBAT C3225X5R0J107M TPSC107M006R0150 VJ0603Y102KXAAT TDK Vishay Vitramon TDK AVX Vishay Dale Diodes. Inc Vishay Vitramon TDK AVX TDK Vishay Vitramon TDK TAIYO YUDEN Vishay muRata AVX TAIYO YUDEN TDK TDK Vishay Vitramon muRata TDK M9999-052402 MIC9130 Power Over Ethernet Ref. PL1 Qty 1 Part Description Header 1 x 2 L1 1 12uH R1 R2 R3 R4 R7 R8,R21 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R20 R22 R23 RJ45_1, RJ45_2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1M (0603size), 1% 15K (0805 size), 1% 9.09K (0603size), 1% 0.25 ohms (1206 size), 1% 10 (0805 size), 1% 30K1 (0603 size), 1% 243K (0805 size), 1% 10K (0603 size), 1% 24.9K (0603 size), 1% 5.6K (0805 size), 5% 340 (0805), 1% 68K (0603 size), 5% 51K (0603 size), 5% 5.1K (0603 size), 5% 422K (0603 size), 1% 8.06K (0603 size), 1% 909 Ohm , (0603) , 1%. 806 (0603), 1% 100 (0603 size), 1% 2 Connector 8 pins T1 1 PoE Magnetic T2 1 Flyback transformer Vendor P/N Vendor 1812LS-123XJBC NL453232T-120J CRCW06031004FRT1 CRCW08051502FRT1 CRCW06039091FRT1 WSL1210-R250-F CRCW080510R0FRT1 CRCW06033013FRT1 CRCW08052433FRT1 CRCW06031002FRT1 CRCW06032492FRT1 CRCW0805562JRT1 See list…Classification CRCW0603683JRT1 CRCW0603513JRT1 CRCW0603512JRT1 CRCW06034223FRT1 CRCW06038061FRT1 CRCW06039090FRT1 CRCW06038060FRT1 CRCW06031000FRT1 SS-640810S-A-NF-1-01A111 H2019 TLA-6T127LF PF0606 Coilcraft TDK Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Vishay Dale Belfuse/Stewart Pulse TDK Pulse Vendor Phone Numbers Micrel.Inc Vishay corp Diodes.inc muRata Sumida Micro Commercial Components AVX NEC ( CEL ) Coilcraft Pulse Central Semi TAIYO YUDEN Belfuse/Stewart TDK 408-944-0800 206-452-5664 805-446-4800 800-831-9172 408-321-9660 800-346-3371 843-448-9411 408-588-2247 847-639-2361 619-674-8100 631435-1110 408-573-4150 1-800-235-3873 847-803-6100 7 M9999-052402 MIC9130 Power Over Ethernet PCB Layout Top Silkscreen Top Layer Bottom Silkscreen Bottom Layer MICREL, INC. 2180 FORTUNE DRIVE SAN JOSE, CA 95131 USA TEL +1 (408) 944-0800 FAX +1 (408) 944-0970 WEB http:/www.micrel.com The information furnished by Micrel in this data sheet is believed to be accurate and reliable. However, no responsibility is assumed by Micrel for its use. Micrel reserves the right to change circuitry and specifications at any time without notification to the customer. Micrel Products are not designed or authorized for use as components in life support appliances, devices or systems where malfunction of a product can reasonably be expected to result in personal injury. Life support devices or systems are devices or systems that (a) are intended for surgical implant into the body or (b) support or sustain life, and whose failure to perform can be reasonably expected to result in a significant injury to the user. A Purchaser’s use or sale of Micrel Products for use in life support appliances, devices or systems is a Purchaser’s own risk and Purchaser agrees to fully indemnify Micrel for any damages resulting from such use or sale. © 2004 Micrel, 8 Incorporated. M9999-052402