ADP1043A Evaluation Board Two Stage Buck + Full Bridge PRD 1152 Reference Design FEATURES Voltage-Fed Buck+Full Bridge with Synchronous Rectifier Voltage Feedback Loop Dimensions: 116.8mm×61mm×12.7mm (Full Brick) Input Voltage Range: -36V to -60VDC 28V/14A DC Output from -48V DC Input 94% Max. Efficiency I2C serial interface Software GUI PRD 1152 OVERVIEW This Evaluation Board allows the ADP1043A to be quickly evaluated in a switching power supply application. Using the evaluation board and its accompanying software, the ADP1043A can be interfaced to any PC running Windows 2000, Windows NT, Windows XP and Windows Vista via the computer's USB port. The software allows control and monitoring of the ADP1043A internal registers. The board is set up for the ADP1043A to act as an isolated switching power supply, outputting a 28V/14A DC voltage from a -36 to -60VDC input. EVALUATION EQUIPMENT To evaluate this demo board, a PC, oscilloscope, electronic load and a DC power source are required. Figure 1 Voltage-Fed Buck+ Full Bridge Converter. CS+ L Q1 Q5 Q3 Lo Vin -36V ~ -60V SR2 Cin Q2 Cb Co Q4 5V’ Driver Driver 12V Q6 5V’ SR1 ADuM3200 ADuM3201 Vo 28V/14A Co’ Rs ADP3634 3.3V OUTA SR1 SR2 CS2- CS2+ OUTB VS3+ 3.3V OUTAUX PSON 3.3V 12V R1 R2 ADP1043A VS3- ADP1720 Aux Power VDD CS1 DGND AGND CS+ 12V’ 5V’ SCL SDA Rev. Prelim.A, Oct 2009 10/30/2009 4:15:00 PM Information furnished by Analog Devices is believed to be accurate and reliable. However, no responsibility is assumed by Analog Devices for its use, nor for any infringements of patents or other rights of third parties that may result from its use. Specifications subject to change without notice. No license is granted by implication or otherwise under any patent or patent rights of Analog Devices. Trademarks and registered trademarks are the property of their respective owners. One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106 U.S.A. Tel: 781.329.4700 www.analog.com Fax: 781.326.8703 © 2009 Analog Devices, Inc. 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Reference Design PRD 1152 TABLE OF CONTENTS Features ......................................................................................................................................................................................................... 1 PRD 1152 Overview ..................................................................................................................................................................................... 1 Evaluation Equipment ................................................................................................................................................................................... 1 Evaluation Board Hardware .......................................................................................................................................................................... 4 Specifications ............................................................................................................................................................................................ 4 Topology and operation waveforms .......................................................................................................................................................... 4 Connectors................................................................................................................................................................................................. 5 Interface Connector ................................................................................................................................................................................... 5 Test Results ................................................................................................................................................................................................... 7 Getting Started............................................................................................................................................................................................. 10 Equipment ............................................................................................................................................................................................... 10 Setup........................................................................................................................................................................................................ 10 Board Evaluation ......................................................................................................................................................................................... 12 Line and Load Voltage Regulation .......................................................................................................................................................... 12 Output Voltage Setting ............................................................................................................................................................................ 12 Soft Start.................................................................................................................................................................................................. 12 Digital Filter – Transient Analysis ........................................................................................................................................................... 13 PWM – Switching Frequency ................................................................................................................................................................. 14 Light Load Optimization ......................................................................................................................................................................... 14 Primary Side Current Sense and Secondary Side Current Sense ............................................................................................................. 14 Flags and Fault configurations ................................................................................................................................................................ 15 Flag and Fault Response Configuration: ............................................................................................................................................. 15 Appendix ..................................................................................................................................................................................................... 17 Schematic ................................................................................................................................................................................................ 17 Bill of Materials ...................................................................................................................................................................................... 21 PCB Layout ............................................................................................................................................................................................. 24 Board Setting ........................................................................................................................................................................................... 25 Register Setting ....................................................................................................................................................................................... 26 NOTES ........................................................................................................................................................................................................ 30 Rev. Prelim.A Oct.2009| Page 2 of 30 Reference Design PRD 1152 TABLE OF FIGURES Figure 1 Voltage-Fed Buck+ Full Bridge Converter. .................................................................................................................................... 1 Figure 2 Driver signal ................................................................................................................................................................................... 4 Figure 3 Pin Connection Diagram (Top View) ............................................................................................................................................. 5 Figure 4 Eval Board Picture(Top View)....................................................................................................................................................... 6 Figure 5 Test Configuration for the Evaluation Board .................................................................................................................................. 6 Figure 6 Efficiency ....................................................................................................................................................................................... 7 Figure 7 Output Voltage Response................................................................................................................................................................ 7 Figure 8 Output Voltage Response................................................................................................................................................................ 7 Figure 9 Output Voltage Ripple at No Load Current. ................................................................................................................................... 7 Figure 10 Output Voltage Ripple at Nominal Load Current. ........................................................................................................................ 8 Figure 11 Turn-on Transient at No Load Current.......................................................................................................................................... 8 Figure 12 Turn-on transient at Nominal Load Current. ................................................................................................................................ 8 Figure 13 Output Over Current ..................................................................................................................................................................... 8 Figure 14 Output Short Circuit (Latch Mode) .............................................................................................................................................. 9 Figure 15 Output Short Circuit (Recovery Mode). ....................................................................................................................................... 9 Figure 16 Connection with Computer ......................................................................................................................................................... 10 Figure 17 Getting Started ............................................................................................................................................................................ 10 Figure 18 Load Board Setting ......................................................................................................................................................................11 Figure 19 Graphical User Interface............................................................................................................................................................. 12 Figure 20 General Settings Window ........................................................................................................................................................... 13 Figure 21 Digital Filter Window ................................................................................................................................................................. 13 Figure 22 Timing Window .......................................................................................................................................................................... 14 Figure 23 Light Load Current Threshold .................................................................................................................................................... 14 Figure 24 Flags ........................................................................................................................................................................................... 15 Figure 25 Fault Configurations ................................................................................................................................................................... 16 Figure 26 Primary Main Circuit .................................................................................................................................................................. 17 Figure 27 Secondary Main Circuit .............................................................................................................................................................. 18 Figure 28 ADP1043A Control Circuit ........................................................................................................................................................ 19 Figure 29 ON/OFF Circuit .......................................................................................................................................................................... 19 Figure 30 Aux. Power Circuit ..................................................................................................................................................................... 20 Figure 31 Top View of Board...................................................................................................................................................................... 24 Figure 32 Bottom View of Board ................................................................................................................................................................ 24 Rev. Prelim.A Oct.2009| Page 3 of 30 Reference Design PRD 1152 EVALUATION BOARD HARDWARE SPECIFICATIONS • Nominal input voltage: -48 DC • Input voltage range: -36~-60V DC • Nominal output voltage: 28V DC • Nominal output current: 14A DC • Buck stage switching frequency: 300kHz • Full bridge switching frequency: 150kHz • Efficiency: 93% at full load TOPOLOGY AND OPERATION WAVEFORMS A typical DC/DC switching power supply is the basis for the eval board. It is a voltage-fed buck + full bridge topology, shown as Figure 1.The buck converter, as the first stage, regulates the output voltage. The full bridge is an isolated converter, which operates with 50% duty cycle. The primary side consists of the input terminals, buck and full bridge switches and the inductor and main transformer. The gate driver signal for the switches comes from the ADP1043A, through the iCoupler and the drivers. There is also a current transformer (CT), to transmit the primary side current information to the ADP1043A on the secondary side. Figure 2 Driver Signal The secondary side power stage consists of the synchronous rectifiers, output capacitor, sensing resistor. This provides 28V @ 14A at the output. The ADP1043A is located on the secondary side. The ADP1043A provides the feedback signal that is used to regulate the voltage, limit the current, and allow current sharing and shutdown to be implemented. Low side current sensing is used. There is a 8pins connector on the board. 4pins of the connector is for I2C. This allows the PC software to communicate with the eval board through the USB port of the PC. The user can readily change register settings on the ADP1043A this way, and also monitor the status registers. The eval board is designed with a 2mOhm RSENSE resistor. The power supply support a maximum continuous output of 14 A. A variable load is required to perform a thorough evaluation. The output voltage is available between P4, P5, P6 and P7, P8, P9. This is also where the load should be connected. Rev. Prelim.A Oct.2009| Page 4 of 30 Reference Design PRD 1152 The power supply will be in Continuous Conduction Mode. If the synchronous rectifiers are enabled, the power supply will remain in CCM mode over the full load range. Figure 3 Pin Connection Diagram (Top View) CONNECTORS The connections to the eval board are shown in Table 1. Table 1. Power module pin assignment Pin Designation Eval Board Function P1 On/Off Remote Control P2 Vin+ Positive Input P3 Vin- Negative Input P4-P6 Vo+ Positive Output P7-P10 Vo- Negative Output P10 Interface Interface INTERFACE CONNECTOR The signal pins are P10.1~P10.8 as shown in Table 2. Among them P10.7, P10.5, P10.3 and P10.1 are connected to USB dongle. Table 2. Signal pins Pin Designation Pin Designation P10.1 GND P10.5 SCL P10.2 PGOOD P10.6 Vsen- P10.3 SDA P10.7 5V P10.4 Vsen+ P10.8 Share Rev. Prelim.A Oct.2009| Page 5 of 30 Reference Design PRD 1152 Figure 4 shows the photo of eval board. Figure 5 provides a typical circuit diagram which details the filtering for normal operation and output ripple test. Figure 4 Eval Board Picture(Top View) Figure 5 Test Configuration for the Evaluation Board Rev. Prelim.A Oct.2009| Page 6 of 30 Reference Design PRD 1152 TEST RESULTS Figure 6 Efficiency at nominal output voltage vs. load current for minimum, nominal, and maximum input voltage at 25°C. Figure 7 Output voltage response to step-change in load current (25%50% of Iout(max): dI/dt = 1A/μs). Ch 2: Vout (200mV/div), Ch 4: Iout (5A/div). Figure 8 Output voltage response to step-change in load current (50%- Figure 9 Output voltage ripple at nominal input voltage and no load current . Ch 1: Vout (50mV/div), Bandwidth: 20 MHz. 25% of Iout(max): dI/dt = 1A/μs). Ch 2: Vout (200mV/div), Ch 4: Iout (5A/div). Rev. Prelim.A Oct.2009| Page 7 of 30 Reference Design PRD 1152 Figure 10 Output voltage ripple at nominal input voltage and nominal load current. Ch 1: Vout (50mV/div), Bandwidth: 20 MHz Figure 11 Turn-on transient at nominal input voltage and no load current. Ch 1: Vout (10V/div), Ch 4: Load Current Figure 12 Turn-on transient at nominal input voltage and nominal load Figure 13 Output over current protection function. Increase load current. Ch 1: Vout (10V/div), Ch 4: Load Current (10A/div). current at nominal input voltage to over current limit. Ch 3: Vout (10V/div), Ch 4: Load Current (10A/div). Rev. Prelim.A Oct.2009| Page 8 of 30 Reference Design PRD 1152 Figure 14 Output short circuit protection function (Latch Mode). Turn Figure 15 Output short circuit protection function (Recovery Mode). on at nominal input voltage and nominal load current then short circuit. Turn on at nominal input voltage and nominal load current then short Ch 3: Vout (10V/div), Ch 4: Load Current (10A/div). circuit. Ch 3: Vout (10V/div), Ch 4: Load Current (10A/div). Rev. Prelim.A Oct.2009| Page 9 of 30 Reference Design PRD 1152 GETTING STARTED EQUIPMENT • • • • • • DC Power Supply 0-60V (Sorensen DLM150-20E) Electronic Load capable of 28V/14A (Chroma 63112) Oscilloscope (Tektronix TDS5054B) PC with ADP1043A GUI installed Precision Digital Multi-meters (Agilent 34401A) Current Probe for measuring up to 14A DC (Tektronix TCP202) SETUP NOTE: DO NOT CONNECT THE USB CABLE TO THE EVAL BOARD UNTIL AFTER THE SOFTWARE HAS BEEN INSTALLED. Figure 16 Connection with Computer 1. Install the ADP1043A software. Refer to the Quick Start Guide that comes on the CD (If already installed, skip to the next step). 2. Connect the evaluation board to the USB port on the computer, using the “USB to I2C interface” dongle. If the dongle driver was not previously installed, run the software from the Start Menu under “Programs/Analog Devices/ADP1043A”. 3. The software should report that the ADP1043A has been located on the board. Click Finish to proceed to the Main Software Interface Window. Figure 17 Getting Started 4. Click on the icon and “Load Board Setting”: select the “PRD1152.43b” file. This file contains all the board information including values of shunt and voltage dividers. Rev. Prelim.A Oct.2009| Page 10 of 30 Reference Design PRD 1152 Figure 18 Load Board Setting 5. The ADP1043A is pre-programmed and calibrated, so there is no programming necessary. 6. Connect an electronic load at the output. 7. For the input voltage source, a DC power supply can be used. The input voltage range is -36V to -60 VDC (-48VDC is recommended). This input voltage is the signal which will be regulated to provide a 28V/14A supply at the output. Set the voltage to -48VDC 8. The evaluation board should now up and running, and ready to evaluate. The output should be 28 VDC. Rev. Prelim.A Oct.2009| Page 11 of 30 Reference Design PRD 1152 BOARD EVALUATION The ADP1043A is optimized for improving the power supply design and evaluation process. The goal of this eval kit is to allow the user to get an insight into the flexibility offered by the extensive programming options offered by the ADP1043A. The ADP1043A performs many monitoring and housekeeping functions in the power supply. The eval board allows the user to simulate various events that could affect the ADP1043A in a working system. The user can monitor how the ADP1043A handles this event in many ways. One way is to use an oscilloscope and/or multi-meter, and probe the eval board, to see various conditions in the system. The user can also use the software to monitor the conditions of the ADP1043A, and how it has reacted to the event. The following section gives some experiments that the user might typically evaluate. LINE AND LOAD VOLTAGE REGULATION Vary the input voltage from -36 VDC to -60VDC. The output voltage remains 28V. Vary the load current from 0 to 14A. The output voltage remains 28V. The line and load regulation are less than ±0.5%. Figure 19 Graphical User Interface OUTPUT VOLTAGE SETTING The output voltage setting is programmable. Using the Voltage Setting window in the software, adjust the output voltage (using the o/p trim menu). Monitor the actual output voltage of the power supply using the software or a multi-meter, or looking at the output voltage reading on the electronic load. It should match the programmed value. This will be used to calibrate the power supply in the production environment. By doing this evaluation, the user can see how the ADP1043A can be trimmed digitally to adjust the output voltage. SOFT START Once the input voltage is applied it is possible to test the Soft Start of the ADP1043A. The settings are located in the General Settings Window. Please refer to the Software Reference Guide for a detailed explanation of all the controls (EVAL-ADP1043A-GUI-RG). Rev. Prelim.A Oct.2009| Page 12 of 30 Reference Design PRD 1152 Figure 20 General Settings Window Soft Start is enabled and set to 40ms. You can experiment with different times. DIGITAL FILTER – TRANSIENT ANALYSIS The digital filter can be changed using the software. The effect on transient analysis can be evaluated this way. Connect a switching electronic load to the output of the eval board. The load should be set to switch between 25%-50%, changing every 10msecs. Set up an oscilloscope to capture the transient waveform of the power supply output. Use a differential probe on the scope, connecting it to the eval board output. Turn on the load, and note the waveform response. Now, vary the digital filter using the software. Click on “Filter Settings” the window shows the filter settings for Normal mode. Click on the curve to move position of poles, zeroes and gains. Figure 21 Digital Filter Window The transient response will change. This evaluation shows the user how the digital filter can easily be programmed to optimize the transient response of the power supply. Rev. Prelim.A Oct.2009| Page 13 of 30 Reference Design PRD 1152 PWM – SWITCHING FREQUENCY The converter switching frequency is programmable. In the “PWM & SR Settings” change the switching frequency. The minimum and maximum modulation limits can also be modified. Figure 22 Timing Window NOTE: It is recommended to evaluate this feature with the power supply turned off. This prevents the chance of damaging the power supply by introducing shoot-through. LIGHT LOAD OPTIMIZATION The ADP1043A can be programmed to optimize performance when an output current drops below a certain level. The threshold for light load mode can be programmed in the digital filter window. Once the current will drop below this level the sync rectifiers (SR1 and SR2) will be disabled. The “Light Load Mode Settings” will be used. The response time for the ADP1043A to switch from one mode to another is between 10 and 20ms. The light load mode can be disabled by selecting a Light Load Current Threshold of 0%. Figure 23 Light Load Current Threshold PRIMARY SIDE CURRENT SENSE AND SECONDARY SIDE CURRENT SENSE Current sensing is available for both the primary side current and the secondary side current. Primary side current sensing is performed using the current transformer, T1. Secondary side current sensing uses a low-side sense resistor. Rev. Prelim.A Oct.2009| Page 14 of 30 Reference Design PRD 1152 Open the Monitor window in the software. Click on the Flags and Readings tab. Adjust the load current from 0A to 14A. The input current and output current values will change in the software, matching the changes being made at the load. FLAGS AND FAULT CONFIGURATIONS Open the Monitor window in the software. Click on the Flags and Readings tab. The window will show all of the fault flags. If a flag is set, then there is a red box next to the flag. If the flag is ok, then there is a green box next to the flag. Set the load current to 0.3A. The CS2 OCP flag should be green. Figure 24 Flags Now change the load to 17 A. The CS2 OCP flag should now have turned red, because the CS2 OCP threshold has been reached. The board wills ender in hiccup mode and try and restart. Set the load back to 2A, and the flag turns green again. This shows how the user can easily monitor the health of the power supply by monitoring the status of the various flags. Flag and Fault Response Configuration: The ADP1043A is programmed to respond to the various fault conditions in the Fault Configuration Tab. Rev. Prelim.A Oct.2009| Page 15 of 30 Reference Design PRD 1152 Figure 25 Fault Configurations You can change the resolve issue to “Remain Disabled”. If the over current is applied again the ADP1043A will shut down and remain off until PSON is cycled. This evaluation shows how it is quite easy to configure the response to a fault condition. Change the load back to 2A, then toggle the PS_ON switch to restart the power supply. Rev. Prelim.A Oct.2009| Page 16 of 30 Reference Design PRD 1152 APPENDIX SCHEMATIC 3 CS+ JP1 1 1 1 AGND Figure 26 Primary Main Circuit Vin+ Q1 RJK1053DPB L2 12uH SW1 2 1 D2 1N5819 Gate1 C13 1uF C12 1uF SW1 VDD HB HO HS LO VSS LI HI 8 7 6 5 C16 470pF 1 C75 470pF 10K 10K R19 5V_PRI Gate3 C19 1uF C18 0.1uF SW2 1 2 3 4 VDD HB HO HS U3 R20 1.2KOhm 1 2 3 4 Ven C15 0.1uF VDD1 VOA VIB GND1 VDD2 VIA VOB GND2 U6 SW3 C23 1uF C22 0.1uF 1 2 3 4 HIP2101 R22 200Ohm ADUM3201 CS+ AGND 12V_PRI C17 0.1uF 5V_PRI 8 7 6 5 12V_SEC 3.6V_SEC R25 0Ohm 5V_PRI 3.6V_SEC U5 8 7 6 5 R24 0Ohm LO VSS LI HI OUTAUX PSON 0 C20 0.1uF Gate6 VDD HB HO HS Vin- 8 7 6 5 R23 560Ohm HIP2101 12V_PRI Gate5 LO VSS LI HI Vin+ 3.6V_SEC 1 2 Gate4 8 7 6 5 TR3 Gate6 1 2 D9 1N4148WS U4 R15 10K TR4 8 U2 NC7SZU04 4 HIP2101 12V_PRI R14 2Ohm TR5 6 Q9 ERJK0653DPB 10K R18 Gate4 Q8 ERJK0653DPB 2 1 D6 R13 10K 4 5 5V_PRI D7 1N4148WS 1 2 Gate2 U1 1 2 3 4 R12 2Ohm 10nF 5 D30 2 MURA110T3 12V_PRI 1 T2 PQ32 1 SW3 C11 3 1 Vin- R6 10K Gate5 D4 MURA110T3 R17 MMBT4403 JP2 R16 10K R10 10K MMBT4403 D5 1N5819 1 2 Q10 Vin- Q6 RJK1053DPB Gate2 1 Q5 Q7 R11 2Ohm R5 2Ohm SW2 D3 1N5819 1 2 RJK1053DPB 2 B2100 1.5uF/100V 1.5uF/100V 1.5uF/100V 1.5uF/100V R9 2Ohm R4 10K Gate3 C7 C8 C9 C10 1.5uF/100V 1.5uF/100V C5 C6 R3 2Ohm Q3 ERJK0653DPB C4 1.5uF/100V 10K C3 1.5uF/100V R8 Gate1 1.5uF/100V R7 5.1Ohm C2 1.5uF/100V 1 C1 R2 5.1Ohm D1 1N5819 Q2 ERJK0653DPB R1 10K Q4 RJK1053DPB PA1005.100NL 2 T1 8 7 Vin+ VDD2 VOA VOB GND2 VDD1 VIA VIB GND1 1 2 3 4 ADUM3200 R26 0Ohm OUTA OUTB C21 0.1uF 0 R27 0Ohm Rev. Prelim.A Oct.2009| Page 17 of 30 Vin+ VinCS+ AGND 12V_PRI 5V_PRI 12V_SEC 3.6V_SEC Reference Design PRD 1152 Figure 27 Secondary Main Circuit JP3 Vout+ TR4 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V C79 C78 C26 C27 C76 C77 R28 D10 MMSD914 1 2 TR5 1 1 Vout+ 10K JP9 C24 10nF R29 10K R30 10K R31 10K 1 1 Vout+ M1 RJK1053DPB JP8 1 R32 10K R34 10K 1 Vout+ M2 RJK1053DPB 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V 3.3uF/50V 10K Vout+ VoutPGND R39 10K C35 10K C34 R38 C33 10nF PSON 12V_SEC M3 RJK1053DPB TR3 R37 C32 C25 10K C31 2 MMSD914 R36 C30 D13 1 D12 1N5819 C29 R35 2Ohm C28 D11 1N5819 3.3uF/50V 1 1 2 3V3_SEC M4 RJK1053DPB R40 10K R41 10K R43 2Ohm 2 R42 2Ohm 1 1 D14 1N5819 R100 NC D15 1N5819 R44 2mOhm 2 2 3.3uF/50V R33 2Ohm PGND JP4 Vout- 1 1 Vout- 3V3_SEC R45 2.2K D16 RED JP10 1 PSON R46 NC 8 7 6 5 12V_SEC OTW EN OUTA INA VDD PGND OUTB INB 1 Vout- U7 1 2 3 4 R47 0Ohm SR1 SR2 ADP3634 C36 1uF Rev. Prelim.A Oct.2009| Page 18 of 30 JP11 1 1 Vout- Vout+ VoutPGND PSON 12V_SEC 3V3_SEC Reference Design PRD 1152 D17 BAV70WT1 R48 680Ohm R49 27k R53 12Ohm R52 12Ohm R50 10Ohm R54 10K C38 100pF Vout+ Vout+ C74 100pF CS+ R51 4.7K Vout- TR4 PGND Figure 28 ADP1043A Control Circuit R55 10K C37 NC R56 27k Vsen+ R57 1k AGND C40 NC R59 1k 0 GATE 1 VS2 VS1 3 8 PGND CS2+ 16 CS2+ CS2CS2- VS3+ VCORE 32 VDD 31 OUTC AGND 14 OUTD TPAD 15 OUTAUX DGND ADP1043A PGOOD1 C42 0.1uF C43 0.1uF 25 R104 R67 2.2K 3V3_SEC R69 NC 5.1K 0 R103 NC R70 10K 33 0 0 D22 RED 0 0 R63 2.2K 24 R64 100Ohm Share 3V3_SEC D18 BAV70WT1 R65 2.2K R66 100Ohm C46 33pF R71 R72 2.2K JP5 Vout- 1 3 5 7 C47 33pF 0 R74 C48 33pF 0 2 4 6 8 D19 BAW56WT1 D20 1N4148WS R75 0 12V_SEC 2Ohm 0 2 JP6 SHORTPIN 0 Figure 29 ON/OFF Circuit Ven R79 100k 5V_PRI R77 220k R81 10k R78 1k R80 5.1k Vin+ Q12 MMBT2907AW1 Vin+ Vin- R83 8.2k D24 TLV431 Ven Ven CS+ R86 200Ohm JP7 1 D25 BAV70WT1 R84 5.1k C52 1uF C53 10nF 5V_PRI 3V3_SEC EN_LDO 1 ON/OFF AGND C55 10nF ON/OFF&UVP CIRCUIT Rev. Prelim.A Oct.2009| Page 19 of 30 PGOOD Vsen+ VsenShare Connector 0 100Ohm C49 33pF 0 RT1 100KOhm 0 12V_SEC 3V3_SEC 23 0 D21 GREEN TR4 12V_SEC SCL 0 3V3_SEC TR4 2 49.9K 0.1% R73 NC Q13 NC PGND1 R68 2.2K PGOOD PSON 3V3_SEC C44 0.1uF SDA C45 10nF CS+ PSON 27 SDA PSON PGND CS+ 3V3_SEC 18 17 30 SCL RES ADD RTD 29 3V3_SEC 28 22 PGOOD2 21 FLAGIN 20 PSON 19 SHAREi AGND PGND 26 OUTAUX SHAREo CS+ AGND 0 OUTB 13 Vout- CS+ Vout- Vsen- OUTA 12 OUTB Vout+ Vout- CS1 11 Vout+ R62 10Ohm 3V3_SEC OUTA R61 1k C41 10nF VS37 R58 27k R60 0Ohm 5 4 10 SR2 SR1 ACSNS U8 SR2 9 6 SR1 C39 10nF Vin+ VinVen CS+ 5V_PRI 3V3_SEC EN_LDO AGND Reference Design PRD 1152 Figure 30 Aux. Power Circuit T3 2 3 5 R92 1M 12V_SEC R21 1K 3.6V_SEC 3 D26 EGL34B 1 2 10uF/16V R90 20k 6 10uF/16V R89 20k C57 0.1uF D27 MMBD1504A C56 470pF/250V C59 1 C58 Vin+ ER14.5/6 D32 MMBZ5227BL/3.6V 10uF/16V R93 20k 10uF/16V 1 2 3 4 R94 680Ohm R95 680Ohm Vin+ Vin- R96 10K 12V_PRI 3 R97 5.1K 5V_PRI C69 0.1uF 1 R98 55k 5V_PRI C65 0.1uF 2 C66 NCP1031A C68 VD GND VCC CT UV VFB OV COM 0 C63 560pF C67 8 7 6 5 2 1 2 1 U12 1nF 1N4148SW C64 1uF EGL34B 12V_PRI 2 D33 1 4 D28 C70 PGND 1000pF/2000V 12V_SEC 3V3_SEC EN_LDO C71 220pF D29 MMBZ5231BLT/5.1V R99 36k AGND PGND 3.6V_SEC 3V3_SEC 12V_SEC U11 1uF 0.1uF 1uF C61 C62 C60 1 2 3 EN_LDO 4 R91 10K GND IN OUT EN GND4 GND3 GND2 GND1 8 7 6 5 ADP1720ARMZ-3.3-R7 0 Rev. Prelim.A Oct.2009| Page 20 of 30 Vin+ Vin12V_PRI 5V_PRI 12V_SEC 3V3_SEC EN_LDO AGND PGND 3.6V_SEC Reference Design PRD 1152 BILL OF MATERIALS Item Reference C1,C2,C3,C4,C5,C6 1 C7,C8,C9,C10 2 C11,C24,C25 3 C12 4 C13,C19,C23,C36 C15,C17,C18,C20,C21,C22 5 C42,C43,C44,C62,C65,C69 6 C16,C75 C26,C27,C28,C29,C30,C31,C32 7 C33,C34,C35,C76,C77,C78,C79 8 C37,C40 9 C38,C74 10 C39,C41 11 C45 12 C46,C47,C48,C49 13 C52,C60,C61,C64 14 C53,C55 15 C56 16 C57 17 C58,C59,C67,C68 18 C63 19 C66 Description Part Number Manufacture Qty CAP 1.5uF/100V X7R 1210 C3225X7R2A155K TDK 10 CAP 10nF/100V X7R 0805 CAP 1uF/16V X7R 0603 CAP 1uF/25V X7R 0805 C2012X7R2E103K C2012X7R1E105K TDK TDK TDK 3 1 4 CAP 0.1uF/50V X7R 0603 C1608X7R1H104K TDK 12 CAP 470pF/50V C0G 0603 C1608C0G1H471J TDK 2 CAP 3.3uF/50V X7R 1210 C3225X7R1H335K TDK 14 CAP 100pF/50V C0G 0603 CAP 100pF/50V C0G 0603 CAP 1nF/50V X7R 0603 CAP 33pF/16V X7R 0603 CAP 33pF/16V X7R 0603 CAP 1uF/16V X7R 0603 CAP 10nF/50V X7R 0603 CAP 470pF/250V X7R 0603 CAP 0.1uF/100V X7R 0805 CAP 10uF/16V X7R 1206 CAP 560pF/50V C0G 0603 CAP 1nF/50V X7R 0603 CAP 1000pF/2000V X7R 1808 CAP 220pF/100V C0G 0603 C1608X7R1H101K C1608X7R1H102K C1608COG1H330J C1608COG1H330J C1608X7R1C105K C1608X7R1H103J C1608C0G2E471J C2012X7R2A104K C3216X7R1C106K C1608X7R1H102K TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK TDK 2 2 2 1 4 4 2 1 1 4 1 1 C4520X7R3D102K TDK 1 C1608COG2A221J TDK 1 Diode 1A 40V 1N5819HW Fairchild 8 Diode 1A 100V Diode 1A 100V Diode 150mA 75V Diode 0.2A 100V MURA110T3 B2100 1N4148WS MMSD914 SML‐LXT0805IW‐ TR BAV70WT1 BAW56WT1 1N4148WS SML‐LXT0805IW‐ TR On Semi Diodes Diodes Diodes 1 1 2 2 Lumex 2 ON Semi ON Semi Diodes 3 1 1 Lumex 1 ON Semi 1 Diodes 2 20 C70 21 23 24 25 26 C71 D1,D2,D3,D5,D11 D12,D14,D15 D4 D6 D7,D9 D10,D13 27 D16,D22 RED LED 28 29 30 D17,D18,D25 D19 D20 Diode 200mA 70V Diode 200mA 70V Diode 150mA 75V 31 D21 GREEN LED 32 D24 33 D26,D28 22 Adjustable from Vref=1.25V; ZR431F01 1%; Diode 0.5A 100V EGL34B Rev. Prelim.A Oct.2009| Page 21 of 30 Reference Design 34 35 36 37 38 39 41 42 43 46 47 48 49 50 51 52 53 54 55 56 D27 D29 D30 D32 D33 JP1,JP2,JP6,JP7 JP3,JP8,JP9 JP4,JP10,JP11 JP5 L2 Q1,M1,M2,M3,Q4,M4,Q5,Q6 Q2,Q3,Q8,Q9 Q7,Q10 Q12 Q13 RT1 R1,R4,R6,R8,R10,R13,R15,R16 R32,R34,R40,R41,R81,R91,R96 R2,R7 R3,R5,R9,R11,R12,R14,R33 R35,R42,R43 R17,R18,R19,R28,R29,R30 R31,R36,R37,R38,R39 57 R20 58 R21 59 R22,R86 60 R23 61 62 R24,R25,R26,R27,R47,R60 R44 63 R45,R63,R65,R67,R68,R72 64 R46 65 R48 66 R49,R56,R58 67 R50,R62 68 R51 69 70 R52,R53 R54,R55,R70 PRD 1152 Diode 200mA 200V Zener 5.1V Diode 1A 100V Zener 3.6V Diode 0.5A 100V Vin+, Vin‐, ShortPin, ON/OFF Vout+ Vout‐ 8pin Header Inductor 12uH MOSFET MOSFET PNP ‐600mA ‐40V PNP ‐800mA ‐40V NPN 600mA 40V THERMISTOR 1% RES 10KOHM 5% 1/10W 0603 RES 5.1OHM 5% 1/10W 0603 MMBD1504A MMBZ5231BLT MURA110T3 MMBZ5227BL EGL34B BSC079N10NS BSC079N10NS MMBT4403 MMBT2907AWT1 MMBT4401 ON Semi ON Semi ON Semi ON Semi Diodes Any Any Any Any TDK Infineon Infineon ON Semi ON Semi ON Semi Vishay 1 1 1 1 1 1 3 3 1 1 8 4 2 1 1 1 Generic 15 Generic 2 RES 2OHM 5% 1/10W 0603 Generic 10 RES 10KOHM 5% 1/4W 1206 Generic 11 Generic 1 Generic 1 Generic 2 Generic 1 Generic Vishay 6 1 Generic 6 Generic 1 Generic 1 Generic 3 Generic 2 Generic 1 Generic Generic 2 3 RES 1.2KOHM 5% 1/10W 0603 RES 1KOHM 5% 1/8W 0805 RES 200OHM 5% 1/10W 0603 RES 560OHM 5% 1/10W 0603 RES 0OHM 5% 1/10W 0603 RES 2m OHM 1% 1W 1206 RES 2.2KOHM 5% 1/10W 0603 RES 2OHM 5% 1/10W 0603 RES 680OHM 5% 1/10W 0603 RES 27KOHM 5% 1/10W 0603 RES 10OHM 5% 1/10W 0603 RES 4.7KOHM 5% 1/10W 0603 RES 6OHM 5% 1/8W 0805 RES 10KOHM 1% 1/16W Rev. Prelim.A Oct.2009| Page 22 of 30 Reference Design PRD 1152 0603 71 R57,R59,R61,R78 72 R64,R66,R74 73 R69 74 R71 75 76 R73 R75 77 R77 78 R79 79 R80,R84,R97,R104 80 R83 81 R89,R90 82 R92 83 84 R93 R94,R95 85 R98 86 R99 87 88 89 90 91 92 93 94 95 96 97 R100 R103 T1 T2 T3 U1,U4,U6 U2 U3 U5 U7 U8 RES 1KOHM 5% 1/10W 0603 RES 100OHM 5% 1/10W 0603 RES 5.1KOHM 5% 1/10W 0603 RES 49.9KOHM 0.1% 1/16W 0603 RES 1KOHM 5% 1/10W 0603 RES 2OHM 1% 1/10W 0603 RES 220KOHM 1% 1/10W 0603 RES 100KOHM 5% 1/10W 0603 RES 5.1KOHM 5% 1/10W 0603 RES 8.2KOHM 1% 1/10W 0603 RES 20KOHM 5% 1/8W 0805 RES 1MOHM 5% 1/10W 0603 RES 20KOHM 5% 1/8W 0805 RES 680OHM 5% 1/8W 0805 RES 55KOHM 5% 1/10W 0603 RES 36KOHM 5% 1/10W 0603 RES 2m OHM 1% 1W 1206 RES 0OHM 5% 1/10W 0603 20A 1:100 Main Transformer Aux Transformer Driver IC NOR Gate iCoupler iCoupler Dual channel driver IC Secondary PWM Controller 98 U11 LDO 99 U12 NCP1031 Rev. Prelim.A Oct.2009| Page 23 of 30 Generic 4 Generic 3 Generic 1 Generic 1 Generic Generic 1 1 Generic 1 Generic 1 Generic 4 Generic 1 Generic 2 Generic 1 Generic Generic 1 2 Generic 1 Generic 1 PA1005.100NL PQ32/PC95 ER14.5/6 HIP2101 NC7SZU04 ADuM3201 ADuM3200 ADP3634 ADP1043A ADP1720ARMZ‐ 3.3‐R7 NCP1031A Generic Generic PULSE TDK TDK Intersil ON Semi ADI ADI ADI ADI 1 1 1 1 1 3 1 1 1 1 1 ADI 1 ON Semi 1 Reference Design PRD 1152 PCB LAYOUT Figure 31 Top View of Board Figure 32 Bottom View of Board Rev. Prelim.A Oct.2009| Page 24 of 30 Reference Design PRD 1152 BOARD SETTING Input Voltage = 48 V N1 = 3 N2 = 3 R (CS2) = 2.2 mOhm I (load) = 14 A R1 = 27 KOhm R2 = 1 KOhm C3 = 0.001 uF C4 = 0.001 uF N1 (CS1) = 1 N2 (CS1) = 100 R (CS1) = 6 Ohm ESR (L1) = 3 mOhm L1 = 12 uH C1 = 26.4 uF ESR (C1) = 1 mOhm ESR (L2) = 0 mOhm L2 = 0 uH C2 = 1000 uF ESR (C2) = 20 mOhm R (Normal-Mode) (Load) = 1.96 Ohm R (Light-Load-Mode) (Load) = 28 Ohm Cap Across R1 & R2 = 1 "(1 = Yes: 0 = No)" Topology = 0 (0 = Full Bridge: 1 = Half Bridge: 2 = Two Switch Forward: 3 = Interleaved Two Switch Forward: 4 = Active Clamp Forward: 5 = Resonant Mode: 6 = Custom) Switches / Diodes = 0 (0 = Switches: 1 = Diodes) High Side / Low Side Sense (CS2) = 0 (1 = High-Side: 0 = Low-Side Sense) Second LC Stage = 1 (1 = Yes: 0 = No) CS1 Input Type = 0 (1 = AC: 0 = DC) R3 = 0 KOhm R4 = 0 KOhm PWM Main = 6 (0 = OUTA: 1 = OUTB: 2 = OUTC: 3 = OUTD: 4 = SR1: 5 = SR2: 6 = OUTAUX) Rev. Prelim.A Oct.2009| Page 25 of 30 Reference Design PRD 1152 REGISTER SETTING Reg(0h) = F8h - Fault Register 1 Reg(1h) = 20h - Fault Register 2 Reg(2h) = 5h - Fault Register 3 Reg(3h) = 44h - Fault Register 4 Reg(4h) = F8h - Latched Fault Register 1 Reg(5h) = 20h - Latched Fault Register 2 Reg(6h) = 5h - Latched Fault Register 3 Reg(7h) = 45h - Latched Fault Register 4 Reg(8h) = 3Bh - Fault Configuration Register 1 Reg(9h) = BBh - Fault Configuration Register 2 Reg(Ah) = B4h - Fault Configuration Register 3 Reg(Bh) = FCh - Fault Configuration Register 4 Reg(Ch) = CCh - Fault Configuration Register 5 Reg(Dh) = CCh - Fault Configuration Register 6 Reg(Eh) = 1h - Flag Configuration Reg(Fh) = E6h - Soft-Start Flag Blank Reg(10h) = 0h - First Flag ID Reg(11h) = FFh - Reserved Reg(12h) = 0h - VS1 Value Reg(13h) = 0h - CS1 Value Reg(14h) = 0h - CS1 x VS1 Value Reg(15h) = 0h - VS1 Voltage Value Reg(16h) = 0h - VS2 Voltage Value Reg(17h) = A8h - VS3 Voltage Value Reg(18h) = 60h - CS2 Value Reg(19h) = 0h - CS2 x VS3 Value Reg(1Ah) = ADE0h - RTD Temperature Value Reg(1Bh) = FFh - Reserved Reg(1Ch) = FFh - Reserved Reg(1Dh) = 0h - Share Bus Value Reg(1Eh) = 3h - Modulation Value Reg(1Fh) = 0h - Line Impedance Value Reg(20h) = FFh - Reserved Reg(21h) = 14h - CS1 Gain Trim Reg(22h) = 31h - CS1 OCP Limit Reg(23h) = 0h - CS2 Gain Trim Reg(24h) = 1h - CS2 Offset Trim Rev. Prelim.A Oct.2009| Page 26 of 30 Reference Design PRD 1152 Reg(25h) = 6Dh - CS2 Digital Trim Reg(26h) = 8Bh - CS2 OCP Limit Reg(27h) = 3h - CS1 and CS2 OCP Setting Reg(28h) = 3h - VS Balance Gain Setting Reg(29h) = 1Fh - Share Bus Bandwidth Reg(2Ah) = 40h - Share Bus Setting Reg(2Bh) = 16h - Temperature Trim Reg(2Ch) = 43h - PSON/Soft Start Setting Reg(2Dh) = 3Ch - Pin Polarity Setting Reg(2Eh) = 41h - Modulation Limit Reg(2Fh) = Dh - OTP Threshold Reg(30h) = 5h - OrFET Reg(31h) = A4h - VS3 Voltage Setting Reg(32h) = 18h - VS1 Overvoltage Limit Reg(33h) = 18h - VS3 Overvoltage Limit Reg(34h) = 0h - VS1 Undervoltage Limit Reg(35h) = 3h - Line Impedance Limit Reg(36h) = 7h - Load Line Impedance Reg(37h) = FFh - Reserved Reg(38h) = 8Bh - VS1 Trim Reg(39h) = Dh - VS2 Trim Reg(3Ah) = 95h - VS3 Trim Reg(3Bh) = 0h - Light Load Disable Setting Reg(3Ch) = 5h - Silicon Revision ID Reg(3Dh) = 41h - Manufacturer ID Reg(3Eh) = 43h - Device ID Reg(3Fh) = 2Bh - OUTAUX Switching Frequency Setting Reg(40h) = 1Bh - PWM Switching Frequency Setting Reg(41h) = 1h - PWM 1 Positive Edge Timing Reg(42h) = 0h - PWM 1 Positive Edge Setting Reg(43h) = 29h - PWM 1 Negative Edge Timing Reg(44h) = 4h - PWM 1 Negative Edge Setting Reg(45h) = 2Bh - PWM 2 Positive Edge Timing Reg(46h) = 0h - PWM 2 Positive Edge Setting Reg(47h) = 53h - PWM 2 Negative Edge Timing Reg(48h) = 4h - PWM 2 Negative Edge Setting Reg(49h) = 2Bh - PWM 3 Positive Edge Timing Reg(4Ah) = 0h - PWM 3 Positive Edge Setting Reg(4Bh) = 53h - PWM 3 Negative Edge Timing Rev. Prelim.A Oct.2009| Page 27 of 30 Reference Design PRD 1152 Reg(4Ch) = 4h - PWM 3 Negative Edge Setting Reg(4Dh) = 1h - PWM 4 Positive Edge Timing Reg(4Eh) = 0h - PWM 4 Positive Edge Setting Reg(4Fh) = 29h - PWM 4 Negative Edge Timing Reg(50h) = 4h - PWM 4 Negative Edge Setting Reg(51h) = 1h - SR 1 Positive Edge Timing Reg(52h) = 64h - SR 1 Positive Edge Setting Reg(53h) = 29h - SR 1 Negative Edge Timing Reg(54h) = 40h - SR 1 Negative Edge Setting Reg(55h) = 2Bh - SR 2 Positive Edge Timing Reg(56h) = 64h - SR 2 Positive Edge Setting Reg(57h) = 53h - SR 2 Negative Edge Timing Reg(58h) = 40h - SR 2 Negative Edge Setting Reg(59h) = 0h - PWM AUX Positive Edge Timing Reg(5Ah) = 20h - PWM AUX Positive Edge Setting Reg(5Bh) = 15h - PWM AUX Negative Edge Timing Reg(5Ch) = 2Ah - PWM AUX Negative Edge Setting Reg(5Dh) = 0h - PWM and SR Pin Disable Setting Reg(5Eh) = 0h - Password Lock Reg(5Fh) = 3h - Soft-Start Digital Filter LF Gain Setting Reg(60h) = 4h - Normal Mode Digital Filter LF Gain Setting Reg(61h) = F6h - Normal Mode Digital Filter Zero Setting Reg(62h) = CAh - Normal Mode Digital Filter Pole Setting Reg(63h) = Fh - Normal Mode Digital Filter HF Gain Setting Reg(64h) = 1h - Light Load Digital Filter LF Gain Setting Reg(65h) = F8h - Light Load Digital Filter Zero Setting Reg(66h) = D7h - Light Load Digital Filter Pole Setting Reg(67h) = 4h - Light Load Digital Filter HF Gain Setting Reg(68h) = 0h - Dead Time Threshold Reg(69h) = 88h - Dead Time 1 Reg(6Ah) = 88h - Dead Time 2 Reg(6Bh) = 88h - Dead Time 3 Reg(6Ch) = 88h - Dead Time 4 Reg(6Dh) = 88h - Dead Time 5 Reg(6Eh) = 88h - Dead Time 6 Reg(6Fh) = 88h - Dead Time 7 Reg(70h) = 19h Reg(71h) = 1Bh Reg(72h) = 46h Rev. Prelim.A Oct.2009| Page 28 of 30 Reference Design PRD 1152 Reg(73h) = 12h Reg(74h) = 0h Reg(75h) = FFh Reg(76h) = FFh Reg(77h) = 0h Reg(78h) = 0h Reg(79h) = 1Bh Reg(7Ah) = 2h Reg(7Bh) = FFh - Factory Default Settings Reg(7Ch) = 1h - EEPROM X Address Reg(7Dh) = 35h - EEPROM Y Address Reg(7Eh) = 35h - EEPROM Register Reg(7Fh) = FFh Reg(80h) = 35h Reg(81h) = 35h Reg(82h) = 35h - Rev. Prelim.A Oct.2009| Page 29 of 30 Reference Design PRD 1152 NOTES Rev. Prelim.A Oct.2009| Page 30 of 30