Wide Input Range, Full Bridge Phase Shifted topology using ADP1046A 48V/600W PRD1404 FEATURES 600W Phase Shifted Full Bridge Topology Wide Input Range to minimize hold up capacitor Wide ZVS range down to 10% rated load Short circuit and Fast Over Voltage protection Remote voltage sensing Line voltage feedforward I2C serial interface to PC Software GUI Programmable digital filters for DCM and CCM 7 PWM outputs including Auxiliary PWM Digital Trimming Current, voltage, and temperature sense through GUI Calibration and trimming CAUTION This evaluation board uses high voltages and currents. Extreme caution must be taken especially on the primary side, to ensure safety for the user. It is strongly advised to power down the evaluation board when not in use. A current limited power supply is recommended as input as no fuse is present on the board. ADP1046A EVALUATION BOARD OVERVIEW This evaluation board features the ADP1046A in a switching power supply application. With the evaluation board and software, the ADP1046A can be interfaced to any PC running Windows 2000/XP/Vista/NT/7 via the computer's USB port. The software allows control and monitoring of the ADP1046A internal registers. The board is set up for the ADP1046A to act as an isolated switching power supply with a rated load of 48V/12.5A from an input voltage ranging from a 340VDC to 400VDC. Figure 1 – Prototype Rev. 1.0 Reference designs are as supplied “as is” and without warranties of any kind, express, implied, or statutory including, but not limited to, any implied warranty of merchantability or fitness for a particular purpose. No license is granted by implication or otherwise under any patents or other intellectual property by application or use of reference designs. 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. Analog Devices reserves the right to change devices or specifications at any time without notice. Trademarks and registered trademarks are the property of their respective owners. Reference designs are not authorized to be used in life support devices or systems. One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106, U.S.A. Tel: 781.329.4700 Fax: 781.461.3113 ©2009 Analog Devices, Inc. All rights reserved. Phase Shifted Full Bridge 48V/600W PRD1404 TABLE OF CONTENTS Features ....................................................................................................................................................................................... 1 CAUTION ..................................................................................................................................................................................... 1 TOPOLOGY AND circuit description ............................................................................................................................................ 3 CONNECTORS ............................................................................................................................................................................ 4 SETTING FILES AND EEPROM .................................................................................................................................................. 7 BOARD EVALUATION ................................................................................................................................................................. 8 EQUIPMENT ............................................................................................................................................................................ 8 SETUP...................................................................................................................................................................................... 8 BOARD SETTINGS ................................................................................................................................................................ 10 Theory of operation during startup ............................................................................................................................................. 10 FLAGS SETTINGS CONFIGURATIONS ................................................................................................................................ 11 PWM SETTINGS ....................................................................................................................................................................... 12 BOARD EVALUATION AND TEST DATA ................................................................................................................................... 13 STARTUP ............................................................................................................................................................................... 13 OVERCURRENT AND SHORT CIRCUI PROTECTION......................................................................................................... 14 PRIMARY GATE DRIVER DEADTIME ................................................................................................................................... 15 CS1 PIN VOLTAGE (PRIMARY CURRENT) .......................................................................................................................... 17 SYnchronous rectifier peak inverse voltage ............................................................................................................................ 17 OUTPUT VOLTAGE RIPPLE .................................................................................................................................................. 18 TRANSIENT Voltage at 385VDC (NOMINAL VOLTAGE) ....................................................................................................... 18 HOLD UP TIME AND VOLTAGE DROP OUT ......................................................................................................................... 20 LINE VOltage FEEDFORWARD ............................................................................................................................................. 20 ZVS WAVEFORMS FOR QA (PASSIVE TO ACTIVE TRANSITION)...................................................................................... 21 ZVS WAVEFORMS FOR QB (PASSIVE TO ACTIVE TRANSITION) ..................................................................................... 23 ZVS WAVEFORMS FOR QC (Active TO PaSSIVE TRANSITION) ........................................................................................ 24 ZVS WAVEFORMS FOR QD (Active TO PaSSIVE TRANSITION) ........................................................................................ 24 CLOSED LOOP FREQUENCY RESPONSE .......................................................................................................................... 25 EFFICIENCY .......................................................................................................................................................................... 26 TRANSFORMER SPECIFICATION ........................................................................................................................................... 27 Thermal TEST DATA .................................................................................................................................................................. 29 APPENDIX I – SCHEMATIC ...................................................................................................................................................... 32 APPENDIX IV – LAYOUT ........................................................................................................................................................... 36 NOTES ....................................................................................................................................................................................... 39 REVISION HISTORY 04/28/2013—Revision 1.0: SPM 05/02/2013—Revision 2.0: SPM Phase Shifted Full Bridge 48V/600W PRD1404 BOARD SPECIFICATIONS Specification VIN MIN TYP MAX Units 340 385 400 V VOUT IOUT 48 0.0 12.5 Switching frequency Output Voltage Ripple V 15 A With 400 LFM air flow. 15 A OCP set to shutdown PSU after~10ms 96.35% % Typical reading at 385Vin, 12.5A load 111.6 KHz 550 mV Overload current (OCP limit) Efficiency Notes At 12.5A load TOPOLOGY AND CIRCUIT DESCRIPTION This application note consists of the ADP1046A in a typical isolated DC/DC switching power supply in a full bridge phase shifted topology with synchronous rectification. The circuit is designed to provide a rated output load of 48V/12.5A from a nominal input voltage of 385VDC operated in CCM at all times. The ADP1046A is can provide functions such as the output voltage regulation, output over voltage protection, input and output current protection, primary cycle by cycle protection, and over temperature protection. provides a top level schematic that describes the power flow and auxiliary power supply that starts up at 50VDC and provides power to the ADP1046A through a 3.3V LDO, the iCoupler isolation plus gate drivers, the on board fan, and the synchronous rectifier drivers. The transformer is designed to provide a wide input voltage range (340-410VDC) and the circuit has wide ZVS (Zero Voltage Switching) range down to 10% of the rated load. The auxiliary power supply using transformer (T3) and IC (U10) generates a 12V rail on the primary side and a 13V rail on the secondary side to power the iCoupler isolation devices (MOSFET drivers), synchronous rectifier driver and the ADP1046A using the 3.3V LDO. This auxiliary supply starts up at approximately 50VDC. The primary side consists of the input terminals (JP8, JP9), switches (Q1-Q4), the current sense transformer (T5) and the main transformer (T1). There is also an resonant inductor that aids in zero voltage switching at lighter load conditions. The ADP1046A is situated on the secondary side and is powered via the auxiliary power supply or the USB connector via the LDO. The gate signal for the primary switches is generated by the ADP1046A through the iCouplers and fed into the MOSFET drivers (U17, U18). Bypass capacitors (C71, C72, C114-116) are placed closed to the primary switches. Diodes (D36-37) clamp the resonance between the resonant inductor and the output capacitance (COSS) of the output rectifiers. The secondary (isolated) side of the transformer consists of a center tapped winding. The synchronous rectifier driver (U7) provides the drive signals for the switches (Q9, Q23). The output inductor (L8) and output capacitor (C11, C41) act as a low pass filter for the output voltage. The output voltage is fed back to the ADP1046A using a voltage divider and has a nominal voltage of 1V which is differentially sensed. Output current measured using a sense resistor (R2) which is also differentially sensed. To protect the synchronous rectifiers from exceeding the peak reverse voltage an RCD clamp is implemented (D58, D59, R112-115, C94) The primary current is sensed through the CS1 pin with a small RC time constant (R44, C22) that act as a low pass filter to remove the high frequency noise on the signal. An additional RC can be placed, but the internal Σ-Δ ADC naturally averages the signal. The position of the current transformer is placed in series with the resonant inductor to avoid saturation. Line voltage feedforward is implemented using an RCD circuit (D13, R59, R64, C38, C43) that detects the peak voltage at the synchronous FET. There are two time constants that can be implemented in series with each other. The time constants must be matched such that it retains the peak value during the switching frequency period but also is not too long in case there is a step down change in the input voltage. This peak voltage is further ratioed and fed in the ACSNS pin of the controller (ADP1046A). A thermistor (RT1) is placed on the secondary side close to synchronous FET and acts thermal protection for the power supply. A 16.5k resistor is placed in parallel with the thermistor that allows the software GUI to read the temperature directly in degrees Celsius. Capacitor (C69) is a YCAP that reduces common mode noise from the transformer. Phase Shifted Full Bridge 48V/600W PRD1404 Also present on the secondary is a 4 pin connector for I2C communication. This allows the PC software to communicate with the IC through the USB port of the PC. The user can easily change register settings on the ADP1046A, and monitor the status registers. It is recommended that the USB dongle be connected directly to the PC, not via external hub. Switch (SW2) acts as a hardware PS_OFF switch. The polarity is configured using the GUI to be active high. CONNECTORS The following table lists the connectors on the board: Connector Evaluation Board Function J8 DC Input positive terminal J9 DC Input negative terminal J11 Output voltage positive terminal J12 Output voltage negative terminal J16 Socket for auxiliary power supply J18 I2C connector The pin outs of the USB dongle are given below: Pin (left to right) Figure 2 – I2C connector (pin1 on left) Function 1 5V 2 SCL 3 SDA 4 Ground Phase Shifted Full Bridge 48V/600W PRD1404 Figure 3 – PCB Side View Phase Shifted Full Bridge 48V/600W PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 SETTING FILES AND EEPROM The ADP1046A communicates with the GUI software using the I2C bus. The register settings (having extension .46r) and the board settings (having extension .46b) are two files that are associated with the ADP1046A software. The register settings file is contains information such as the over voltage and over current limits, softstart timing, PWM settings etc. that govern the functionality of the part. The ADP1046A stores all its settings in the EEPROM. The EEPROM on the ADP1046A does not contain any information about the board, such as current sense resistor, output inductor and capacitor values. This information is stored in board setup file (extension .46b) and is necessary for the GUI to display the correct information in the ‘Monitor’ tab as well as ‘Filter Settings’ window. The entire status of the power supply such as the ORFET and synchronous rectifiers enable/disable, primary current, output voltage and current can be thus digitally monitored and controlled using software only. Always make sure that the correct board file has been loaded for the board currently in use. Each ADP1046A chip has trim registers for the temperature, input current and the output voltage and current, and ACSNS. These can be configured during production and are not overwritten whenever a new register settings file is loaded. This is done in order to retain the trimming of all the ADCs for that corresponding environmental and circuit condition (component tolerances, thermal drift, etc.). A guided wizard called the ‘Auto Trim’ is started which trims the above mentioned quantities so that the measurement value matches the valued displayed in the GUI to allow ease of control through software. Phase Shifted Full Bridge 48V/600W PRD1404 BOARD EVALUATION EQUIPMENT • DC Power Supply (300-400V, 600W) • Electronic Load (60V/600W) • Oscilloscope with differential probes • PC with ADP1046A GUI installed • Precision Digital Voltmeters (HP34401or equivalent - 6 digits) for measuring DC current and voltage SETUP NOTE: DO NOT CONNECT THE USB CABLE TO THE EVALUATION BOARD UNTIL THE SOFTWARE HAS FINISHED INSTALLING 1) Install the ADP1046A software by inserting the installation CD. The software setup will start automatically and a guided process will install the software as well as the USB drivers for communication of the GUI with the IC using the USB dongle. 2) Insert the daughter card in connector J5 as shown in Figure 6 3) Ensure that the PS_ON switch (SW1 on schematic) is turned to the OFF position. It is located on the bottom left half of the board. 4) Connect one end of USB dongle to the board and the other end to the board to the USB port on the PC using the “USB to I2C interface” dongle. 5) The software should report that the ADP1046A has been located on the board. Click “Finish” to proceed to the Main Software Interface Window. The serial number reported on the side of the checkbox indicates the USB dongle serial number. The windows also displays the device I2C address. 5. If the software does not detect the part it enters into simulation mode. Ensure that the connecter is connected to the daughter card. Click on ‘Scan for ADP1046A now’ icon (magnifying glass) located on the top right hand corner of the screen. Phase Shifted Full Bridge 48V/600W PRD1404 5. Click on the “Load Board Settings” icon (fourth button from the left) and select the ADP1046A_FBPS_600W_xxxx.46b file. This file contains all the board information including values of shunt and voltage dividers. Note: All board setting files have an extension of .46b 6. The IC on the board comes preprogrammed and this step is optional. The original register configuration is stored in the ADP1046A_FBPS_600W_xxxx.46r register file (Note: All register files have an extension of .46r). The file can be loaded using the second icon from the left in Figure 8. 7. Connect a DC power source (385VDC nominal, current limit to ~2A) and an electronic load at the output set to 1 Ampere. 8. Connect a voltmeter on test points TP26(+) and TP46(-). Ensure that the differential probes are used and the ground of the probes are isolated if oscilloscope measurements are made on the primary side of the transformer. 9. Click on the Dashboard settings (3rd icon in Figure 7 and turn on the software PS_ON) 10. The board should now up and running, and ready for evaluation. The output should now read 12 VDC. 11. Click on the ‘MONITOR’ tab and then on the Flags and readings icon. This window provides a snapshot of the entire state of the PSU in a single user friendly window. Phase Shifted Full Bridge 48V/600W PRD1404 BOARD SETTINGS The following screenshot displays the board settings. THEORY OF OPERATION DURING STARTUP The following steps briefly describe the startup procedure of the ADP1046A and the power supply and the operation of the state machine for the preprogrammed set of registers that are included in the design kit. 1. The on board auxiliary power starts up at approximately 50VDC. This provides a drive voltage on the isolated side to an LDO (3.3V) that powers up the ADP1046A. After VDD (3.3V) is applied to the ADP1046A it takes approximately 20-50µs for VCORE to reach 2.5V. The digital core is now activated and the contents of the registers are downloaded in the EEPROM. The ADP1046A is now ready for operation. 2. PS_ON is applied. The power supply begins the programmed softstart ramp of 50ms (programmable). 3. Since the ‘softstart from pre-charge’ setting is active the output voltage is sensed before the softstart ramp begins. Depending upon the output voltage level of the effective softstart ramp is reduced by the proportional amount. 4. The PSU now is running in steady state. PGOOD1 turns on after the programmed debounce. 5. If a fault is activated during the softstart or steady state, the corresponding flag will be set and the programmed action will be taken such as disable PSU and re-enable after 1 sec or ‘Disable SR and OrFET, Disable OUTAUX’ etc. Phase Shifted Full Bridge 48V/600W PRD1404 FLAGS SETTINGS CONFIGURATIONS Basically when a flag is triggered, the ADP1046A state machine waits for a programmable debounce time before taking any action. The response to each flag can be programmed individually. The flags can be programmed in a single window by selecting the FLAG SETTINGS icon in the MONITOR tab in the GUI. This monitor window shows all the fault flags (if any) and the readings in one page. The ‘Get First Flag’ button determines the first flag that was set in case of a fault event. Phase Shifted Full Bridge 48V/600W PRD1404 PWM SETTINGS The ADP1046A has a fully programmable PWM setup that controls 7 PWMs. Due to this flexibility the IC can function in several different topologies such as any isolated buck derived topology, push pull, flyback and also has the control law for resonant converters. Each PWM edge can be moved in 5ns steps to achieve the appropriate deadtime needed and the maximum modulation limit sets the maximum duty cycle. PWM Switching element being controlled OUTA-OUTD Primary switch PWM configured for Phase shifted topology SR1-SR2 Synchronous rectifier PWMs OUTAUX N/A Phase Shifted Full Bridge 48V/600W PRD1404 BOARD EVALUATION AND TEST DATA STARTUP Figure 12 - Startup at 340VDC, 600W load(software PSON) Green trace: Output voltage, 10V/div, 10ms/div Yellow trace: Load current, 2A/div, 10ms/div Red trace: Input voltage, 50V/div, 10ms/div Figure 13 - Startup at 385VDC, 600W load (software PSON) Green trace: Output voltage, 10V/div, 10ms/div Yellow trace: Load current, 2A/div, 10ms/div Red trace: Input voltage, 50V/div, 10ms/div Phase Shifted Full Bridge 48V/600W OVERCURRENT AND SHORT CIRCUI PROTECTION Figure 16 - OCP at 385VDC, 15A load(Action to shutdown after ~10ms) Green trace: Output voltage, 10V/div, 5ms/div Yellow trace: Load current, 5A/div, 5ms/div Red trace: Input voltage, 50V/div, 5ms/div PRD1404 Phase Shifted Full Bridge 48V/600W PRIMARY GATE DRIVER DEADTIME PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 Phase Shifted Full Bridge 48V/600W CS1 PIN VOLTAGE (PRIMARY CURRENT) SYNCHRONOUS RECTIFIER PEAK INVERSE VOLTAGE PRD1404 Phase Shifted Full Bridge 48V/600W OUTPUT VOLTAGE RIPPLE TRANSIENT VOLTAGE AT 385VDC (NOMINAL VOLTAGE) LOAD STEP OF 15-50% PRD1404 Phase Shifted Full Bridge 48V/600W LOAD STEP OF 50-100% LOAD STEP OF 0-50% PRD1404 Phase Shifted Full Bridge 48V/600W HOLD UP TIME AND VOLTAGE DROP OUT LINE VOLTAGE FEEDFORWARD PRD1404 Phase Shifted Full Bridge 48V/600W Figure 42 – Line voltage Feed forward DISABLED, 600W load Red trace: Input voltage step 350-385VDC, 50V/div Green trace: Output voltage (AC Coupled), 200mV/div PRD1404 Figure 43 – Line voltage Feed forward ENABLED, 600W load Red trace: Input voltage step 350-385VDC, 50V/div Green trace: Output voltage (AC Coupled), 200mV/div ZVS WAVEFORMS FOR QA (PASSIVE TO ACTIVE TRANSITION) Phase Shifted Full Bridge 48V/600W PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 ZVS WAVEFORMS FOR QB (PASSIVE TO ACTIVE TRANSITION) Figure 50 –Resonant transition at 300W load, 100us/div Red trace: VDS of QB, 100V/div Yellow trace: VGS of QB, 5V/div Figure 51 –Resonant transition at 600W load, 100us/div Red trace: VDS of QB, 100V/div Yellow trace: VGS of QB, 5V/div Phase Shifted Full Bridge 48V/600W PRD1404 ZVS WAVEFORMS FOR QC (ACTIVE TO PASSIVE TRANSITION) ZVS WAVEFORMS FOR QD (ACTIVE TO PASSIVE TRANSITION) Phase Shifted Full Bridge 48V/600W PRD1404 CLOSED LOOP FREQUENCY RESPONSE A network analyzer (AP200) was used to test the bode plots of the system. A continuous noise signal of 300mV was injected across the entire frequency range across a 10Ω resistor in series (R35) with the output voltage divider using an isolation transformer. The operating condition was 385VDC input and a load condition of 600W with a soaking time of 45 minutes. Phase Shifted Full Bridge 48V/600W EFFICIENCY PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 TRANSFORMER SPECIFICATION PARAMETER MIN TYP MAX UNITS NOTES Core and Bobbin PQ3535, Magnetics Inc R Material or equivalent Primary inductance 3.316 mH Pins 1 to pin 6 Leakage inductance 4 µH Pins 1 to pin 6 with all other windings shorted KHz Pins 1 to pin 6 with all other windings open Resonant frequency 850 Table 5 - Transformer specifications 11,12 5T, Copper foil, 10 mil 1 14T, 75 strands, 40AWG, Litz wire 3 14T, 75 strands, 40AWG, Litz wire 6 9,10 5T, Copper foil, 10 mil 7,8 Phase Shifted Full Bridge 48V/600W 6 3 7,8 11,12 7,8 9,10 3 1 PRD1404 Phase Shifted Full Bridge 48V/600W THERMAL TEST DATA A thermal snapshot of the unit was taken after running at 600W with a 45 minute soaking time. PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 Figure 64 – Thermals, Output inductor Figure 65 – Thermals, output current sense resistor Figure 66 – Thermals, Transformer Figure 67 – Thermals, Resonant inductor Phase Shifted Full Bridge 48V/600W Figure 68 – Thermals, Primary MOSFET PRD1404 Figure 69 – Thermals, Transformer Phase Shifted Full Bridge 48V/600W PRD1404 APPENDIX I –SCHEMATICS (MAIN, DAUGHTER CARD, AND TOPLEVEL) FULL BRIDGE PHASE SHIFTED SYNC RECT 48VDC/600W, 720W overload power MOSFET Drivers ADP1046 Daughter CARD Socket MOSFET Drivers 3.3V LDO OR 3.3V VDD_PRI= 12V 340-410VDC ADuM4223 icoupler + driver Auxillary PSU Primary= +12V Secondary= +13V OUTA-D VDD_SEC= 13V Figure 70 – Schematic – Top Level Schematic I2C Interface 5V from USB VIN- J9 VIN+ 1 TP4 Vin+ TP12 Vin- 400V C106 100uF 450V PRI_GND GATE_QB+ R132 4.99 R120 0 GATE_QB- R25 10k TP15 G-QB 1 650V 20.7A QB SPP20N60CFD R34 10k 1 C115 1uF 630V 650V 20.7A QA SPP20N60CFD TP13 G-QA GATE_QA+ R133 4.99 GATE_QA- PRI_GND 250VAC 3A #0875003 450V C71 C72 0.33uF 0.33uF 2 3 2 3 L9 2 PRI_GND LSM-28285-0330,33uH 1 C116 C114 1uF 1uF VDD_PRI VDD_PRI D37 ES1J C21 0.1uF C17 0.1uF 2 650V 20.7A QD 1:100 1 1 25V 25V GATE_QD+ GATE_QDC29 1uF GATE_QC+ GATE_QC- 600V 1A D11 RS1J 1 GATE_QB+ GATE_QBC18 1uF T5 R65 10k 25V C30 0.1uF R129 4.99 25V 16 0 15 14 13 12 11 0 10 9 16 0 15 14 13 12 11 0 10 9 VSS VDDA VOA GNDA NC4 NC3 VDDB VOB GNDB VIA VIB VDD1 GND1 DISABLE NC1 NC2 VDD2 U18 ADuM4223 VIA VIB VDD1 GND1 DISABLE NC1 NC2 VDD2 U17 ADuM4223 VDDA VOA GNDA NC4 NC3 VDDB VOB GNDB PRI_GND 500VAC C69 2200pF 250V 1A D58 ES1D 7 12 9 10 A 1 2 3 4 5 6 7 8 C B 1 2 3 4 5 6 7 8 250V 1A AGND 25V AGND C16 1uF +3.3V 25V C15 1uF +3.3V 200V C94 33nF R114 R113 R112 VSS 0 2 R109 1 Q22 IPB107N20N3 G 1 D62 1N5819 100V C120 0.1uF OUTC VIB_U18 OUTA VIB_U17 90k 90k 90k 1 SR1_out R111 1 200V 88A 3 200V 88A R122 10k 100V C111 2.2uF 25A L8 4.7uH VSS Q23 FQT3P20TF 1 50V C48 1uF 2 50V CS2- CS2+ R118 0 R2 0.002 R119 0 1 TP41 VS3- TP39 VS3+ CSNL1206FT2L00 2 R51 10 C41 680uF VS3+ 63V VS1 R123 0 63V C70 10uF R117 10 VS3- PRI_GND TP47TP48 GNDGND PGND TP49TP50 GNDGND VSS TP52 VSS OUTPUT CURRENT & VOLTAGE SENSING 80V C11 C53 330uF 1uF Not needed in Resonant mode due to softsw itching: R112, R113, R114, D58, D59, C94, L8 Q9, Q22 can be replaced by 200V diodes VS1 Q9 IPB107N20N3 G R116 SR2_out D59 ES1D OUTAUX SECONDARY GATE DRIVERS FOR PRIMARY FETS R45 R49 25V C31 1uF R43 R42 25V C20 1uF 1 2 4 5 6 T12 PQ3230 1.25KVDC C75 0.022UF GATE_QC- GATE_QC+ R131 GATE_QD+ 4.99 R121 0 R68 10k C19 0.1uF R128 4.99 2 R130 4.99 CSTP16 G-QB GATE_QD- 1 CS+ PE-67100 1 TP14 G-QC PRIMARY GATE_QA+ GATE_QA- 600V 1A D10 RS1J PRI_GND 2 QC 650V 20.7A PRI_GND D36 Vin_Aux ES1J 1 2 1 2 3 2 SPP20N60CFD 3 2 SPP20N60CFD 3 4 F2 5A 3 11 8 Vin_400V 2 1 2 1 1 3 2 1 2 1 2 3 J8 63V C68 10uF PGND TP26 VOUT+ 1 TP46 VOUT- C1 1 1 2 PGND VOUT+ VOUT- J12 VOUT J1 J11 Phase Shifted Full Bridge 48V/600W PRD1404 VDD_SEC C74 1nF C44 VSS 0.1uF 4.7uF NC2 VDD OUTB OUTA INB PND NC1 VSS 3 1 4 2 SR1 SR2 R77 DNI R75 0 R79 DNI R78 0 INA U7 ADP3654 PSON 18 17 13 11 9 CS2- 12V AGND 3.3V 5V VS3- VS3+ GATE VS2 VS1 PGND CS2+ SR2 SR1 ACSNS CS1 OUTA OUTB OUTC OUTD OUTAUX PSON 30 29 28 27 26 25 24 23 22 21 20 19 16 15 14 12 10 AGND PGND ACSNS 2 OUTA OUTC OUTAUX R93 2k2 VDD_SEC +3.3V +5V VS3- VS3+ GATE VS2 VS1 CS2+ D49 RED D51 YELLOW AGND 1 1 PGND C43 DNI R66 PGND D20 DNI TP23 CS1 CS1 LED INDICATORS R40 2k22 FLAGIN CS2- PGOOD1 PGOOD2 ADP1046 DAUGHTER CARD CONNECTIONS GATE DRIVERS FOR SR 8 6 5 7 VIB_U18 VIB_U17 AGND C82 SR2_out SR1_out +3.3V SW2 PSON 1 2 2.5V D19 C38 DNI R64 0 DNI 1 2 D13 1N4148 1 2 1 2 B AGND D63 BAV99 3 D64 BAV99 3 Q10 DNI RTD D13= DNI for Resonant mode R66= 0ohm for Resonant mode change ACSNS resistor div ider accordingly to giv e >0.45V on DC LINE FEED-FORWARD R59 200 C CS1 SENSING MMSZ5222BT1G C22 R76 1000pF 51 R44 0 1 R74 0 R70 16.5k R71 0 TEMP SENSING RTD 100k 2 3 SCL 1 2 CS- CS+ AGND PGND R73 0 R52 22K OUTAUX R87 100 2 VDD_SEC J28 1 1 2 2 3 Q21 BSS138 C61 100 33pF R96 C63 100 33pF R95 AGND C62 33pF AGND C60 33pF +5V 120X120X25MM 48VDC FAN CONTROL Part #: 3106KL-04W-B50-B01 D47 1N4148 I2C INTERFACE AND FILTERING SDA SCL PGND 1 1 2 SDA 2 1 SHAREI AGND +5V J18 VIN_AUX1 VIN_AUX2 PRI_GND1 PRI_GND2 PRI_GND3 PRI_GND4 VDD_PRI1 VDD_PRI2 NC1 NC2 NC3 NC4 PGND1 PGND2 VDD_SEC1 VDD_SEC2 PGND 13 14 PRI_GND 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 Miro MaTch SCL GND A SDA VBUS SPI MISO NC SPI SCLK SPI MOSI SPI CS A GND B J17 COM2 5V SCL SDA GND J16 COM1 AUXILLARU PSU PRIMARY +12V SECONDARY +12V 15 16 7 8 9 10 11 12 1 2 AGND 400V D50 BAW56 D48 BAV70 VDD_SEC VDD_PRI Vin_Aux 1 2 SHAREO 3 3 J15 ADP1046_DC 1 SHAREO 2 SHAREI 3 SDA 4 SCL 5 RTD 6 FLAGIN 7 PGOOD2 8 PGOOD1 Phase Shifted Full Bridge 48V/600W PRD1404 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 None-Inverting Remote Voltage Sense Input OrFET Gate Drive Output OrFET Drain Sense Input Local Voltage Sense Input Power GND None Inverting Differential Current Sense Input Inverting Differential Current Sense Input Synchronous Rectifier Output Synchronous Rectifier Output AC Sense Input Primary Side Differential Current Sense Input PWM Output for Primary Side Switch PWM Output for Primary Side Switch PWM Output for Primary Side Switch PWM Output for Primary Side Switch Auxiliary PWM Output Power Supply On Input Power Good Output (Open Drain) Power Good Output (Open Drain) Flag Input 2 1 Analog Share Bus Feedback Pin Share Bus Output Voltage NOTES: 3 I2C Serial Clock Input I2C Serial Data Input and Output C26 = 330pF 50V X7R VCORE DNI DNI Low Side 4.99k 4.99k DNI High Side 110k 110k DNI DNI 33pF 33pF DNI C10 C13 C16 C17 R14, R15 = 2.2k 1% PGOOD1/2 R4 R33, R32 = 2.2k 1% SHARE O/I R3 R19 = 10k 1% ADD 1: R3, R4, R5, R6, R7, R8, R10, R11,R20 ARE 0.1% 25ppm UNLESS OTHERWISE SPECIFIED. 2 3 SHARE0 SHAREi SDA SCL RTD FLAGIN PGOOD2 PGOOD1 PSON OUTAUX OUTD OUTC OUTB OUTA CS1 ACSNS SR1 SR2 CS2- CS2+ VS1 VS2 GATE VS3+ VS3- +5V +3.3V Short trace from pin 25 DGND to pin 2 AGND 4 Thermistor Input 4 5 6 26 Inverting Remote Voltage Sense Input 27 +12V C18 DNI R2 1k R1 65 C10 100pF ACSNS C5 1.0uF 50V DNI D1 +12V 2 C17 R4 DNI 4.99k CS2+ 5 6 8 7 2 GND NR OUT1 OUT2 U2 ADP3303 SD ERR IN1 IN2 R6 1k R5 46.4k VS1 R3 4.99k D2 1N4148 +5V C13 100pF C16 DNI CS2- 4 3 1 2 C8 0.1uF C2 DNI C1 DNI C15 1000pF C4 DNI C3 DNI R11 1k C12 4.7uF R21 5.1K +3.3V CS1 R8 1k R7 46.4k VS2 R10 46.4k D6 LED RED 8 7 6 5 4 3 2 1 C14 0.1uF VS3+ PGND CS1 ACSNS CS2+ CS2- VS1 AGND VS2 C9 DNI C7 DNI VS3- 2 10k 29 R19 3 RTD 3 C11 +3.3V U1 ADP1046A ADD 28 PGND R13 0 Ohm 4 AGND DGND SCL SDA PSON FLAGIN PGOOD2 PGOOD1 SHAREO SHAREI 0.1uF 25 DGND 29 2 1 33 PAD 31 32 VS3+ 10 SR1 9 SR1 28 RTD C6 330pF 26 VCORE 10k 11 VS3- 30 R20 RES OUTA OUTA OUTB 12 OUTB OUTC 13 OUTC R29 2.2k 17 18 19 20 21 22 23 24 R33 2.2k 3 +3.3V R24 2.2k 2.2k R32 30 2 1 14 SR2 SR2 27 VDD OUTD OUTD GATE 16 GATE OUTAUX 15 OUTAUX 2.2k R15 Analog GND 2 1 J1 SDA SCL +5V R14 2.2k +3.3V 4 3 2 1 SCL SDA PSON J7 FLAGIN PGOOD2 PGOOD1 SHARE0 SHAREi Phase Shifted Full Bridge 48V/600W PRD1404 Phase Shifted Full Bridge 48V/600W PRD1404 APPENDIX IV – LAYOUT Figure 75 – Bottom side placement of components Phase Shifted Full Bridge 48V/600W PRD1404 Figure 77 – Layout Layer 2 Phase Shifted Full Bridge 48V/600W PRD1404 Phase Shifted Full Bridge 48V/600W NOTES PRD1404 ©2009 Analog Devices, Inc. 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