DEMO MANUAL DC1961A LT8309 No-Opto Flyback Converter with Synchronous Rectifier Description Demonstration circuit 1961A features the LT®8309, a secondary synchronous driver in an isolated, no optocoupler, flyback converter. It regulates a 12V, 5A output from a 36V to 72V input source. configuration allows the synchronous MOSFET to remain conducting at all times, even when output is shorted to ground, so as to provide a very robust short circuit performance. Output regulation is handled on the primary side by the LT3748, a boundary conduction mode flyback controller which senses output voltage directly from the primary, resulting in a simple flyback schematic with no opto-coupler. The Performance Summary table summarizes the performance of the demo board at room temperature. For thermally critical applications, proper amount of air flow can help to reduce power components’ temperature rise, therefore greatly improving circuit reliability. The LT8309 synchronous rectifier driver replicates the behavior of a diode by sensing the synchronous MOSFET drain-to-source voltage to determine its turn on period. By replacing the diode with a N-channel MOSFET, applications are no longer restricted by the heat constraints of the rectifier diode. On the DC1961A, the LT8309 is biased from the rectified drain voltage node of secondary side synchronous MOSFET, not directly connecting to output voltage. This The LT8309 data sheet gives a complete description of the part, operation and application information. The data sheet must be read in conjunction with this quick start guide for demo circuit 1961A. Design files for this circuit board are available at http://www.linear.com/demo L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks of Linear Technology Corporation. All other trademarks are the property of their respective owners. Performance Summary Specifications are at TA = 25°C PARAMETER CONDITIONS Input Voltage Output Voltage VIN = 36V to 72V, IOUT = 0.15A to 5A Maximum Output Current MIN TYP MAX 36 48 72 V 11.4 12 12.6 V 5 UNITS A Output Voltage Ripple (Peak to Peak) VIN = 36V to 72V, IOUT = 5A (20MHz BW) 150 mV Boundary Mode Switching Frequency VIN = 48V, IOUT = 5A 133 kHz Minimum Switching Frequency IOUT = 0mA 42 kHz Efficiency VIN = 36V, IOUT = 5A 91 % VIN = 48V, IOUT = 5A 91.5 % VIN = 72V, IOUT = 5A 91.5 % dc1961af 1 DEMO MANUAL DC1961A Quick Start Procedure Demonstration circuit 1961A is easy to set up to evaluate the performance of the LT8309. Refer to Figure 1 for proper measurement equipment setup and follow the procedure below: 1. With power off, connect the input power supply to the board through VIN and GND terminals. Connect the load to the terminals VOUT+ and VOUT– on the board. 2. Turn on the power at the input. NOTE: Make sure that the input voltage does not exceed 72V. To operate the board with higher input/output voltage, input capacitor, output capacitor and MOSFETs with higher voltage ratings are needed. POWER SUPPLY + – – VIN + 3. Check for the proper output voltages. The output should be regulated at 12V (±5%). NOTE: The LT3748 requires a minimum load to maintain good output voltage regulation. On the DC1961A, in order to avoid pre-loading, a Zener diode is placed between its VOUT+ and VOUT– to serve as a minimum load. 4. Once the proper output voltage is established, adjust the input voltage and load current within the operating range and observe the output voltage regulation, ripple voltage, efficiency and other parameters. NOTE: When measuring the input or output voltage ripples, care must be taken to avoid a long ground lead on the oscilloscope probe. Measure the input or output voltage ripple by touching the probe tip directly across the VIN and GND, or VOUT+ and VOUT– terminals. See Figure 2 for proper scope probe technique. + – IIN + IOUT + – + VOUT – LOAD – Figure 1. Proper Measurement Equipment Setup INPUT OR OUTPUT CAPACITOR Figure 2. Proper Scope Probe Placement for Measuring Input/Output Ripple 2 dc1961af DEMO MANUAL DC1961A performance Efficiency Curve 100 95 EFFICIENCY (%) 90 85 80 75 70 36VIN 48VIN 72VIN 65 60 0.15 0.5 1 1.5 2 2.5 3 3.5 4 4.5 DC1961A F03 5 OUTPUT CURRENT (A) Figure 3. Typical Efficiency Curve Output Load and Line Regulation 12.60 OUTPUT VOLTAGE (V) 12.40 12.20 12.00 11.80 36VIN 48VIN 72VIN 11.60 11.40 0.15 0.5 1 1.5 2 2.5 3 3.5 4 4.5 DC1961A F04 5 OUTPUT CURRENT (A) Figure 4. Typical Regulation Curve dc1961af 3 DEMO MANUAL DC1961A performance DRAIN VOLTAGE OF SYNCHRONOUS MOSFET 200mV/DIV GATE OF SYNCHRONOUS MOSFET, 5V/DIV 1µS/DIV DC1961A F05 Figure 5. Synchronous MOSFET Drain and Gate Voltage (VIN = 48V, IOUT = 5A) INTVCC VOLTAGE OF LT8309, 10V/DIV SWITCH NODE VOLTAGE OF PRIMARY MOSFET, 50V/DIV 1mS/DIV DC1961A F06 Figure 6. Output Short Circuit Waveforms (VIN = 48V) Figure 7. Thermal Picture, 48VIN and 5AOUT (TA = 25°C, Air Flow 200LFM) Synchronous MOSFET, 52.5°C; Primary MOSFET, 46.7°C; Transformer, 74.1°C 4 dc1961af DEMO MANUAL DC1961A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Required Circuit Components 1 1 C1 CAP., ALUM, 47µF, 80V, 20%, SMD Nippon Chemi-Con, EMZA800ADA470MJA0G 2 3 C2, C3, C4 Cap., X7S, 4.7µF, 100V, 20%, 1210 TDK, C3225X7S2A475MT 3 1 C5 Cap., U2J, 120pF, 250V, 5%, 0805 Murata, GRM21A7U2E121JW31D 4 1 C6 Cap., X7S, 1µF, 100V, 10%, 0805 TDK, C2012X7S2A105K 5 6 C7-C12 Cap., X5R, 47µF, 16V, 10%, 1210 Murata, GRM32ER61C476KE15L 6 1 C13 Cap., X5R, 4.7µF, 16V, 20%, 0805 TDK, C2012X5R1C475M 7 1 C14 Cap., X7R, 0.22µF, 25V, 10%, 0603 TDK, C1608X7R1E224K 8 1 C15 Cap., NPO, 470pF, 25V, 5%, 0603 AVX, 06033A471JAT2A 9 1 C16 Cap., X7R, 1µF, 100V, 20%, 1206 TDK, C3216X7R2A105M 10 1 C17 Cap., X5R, 4.7µF, 25V, 10%, 0805 TDK, C2012X5R1E475K 11 1 C18 Cap., NPO, 47pF, 25V, 5%, 0603 AVX, 06033A470JAT2A 12 1 C19 Cap., X7R, 0.033µF, 25V, 10%, 0603 AVX, 06033C333KAT2A 13 1 C20 Cap., X7R, 4700pF, 250V, 10%, 1812 Murata, GA343DR7GD472KW01L 14 1 D1 Diode, TVS UNI-DIR 85V, 600W, SMB Diodes Inc., SMBJ85A-13-F 15 1 D2 Diode, 1A/200V, SOD-123 Central Semi., CMMR1U-02 TR 16 1 D3 Diode Zener, 13V SMA Central Semi., CMZ5928B TR 17 2 D4, D5 DIODE, SWITCHING 150V, 0.2A, SOD123 Diodes Inc., BAV20W-7-F 18 1 D6 Zener Diode, 36V, SOD-123 Central Semi., CMHZ5258B TR 19 1 L1 Inductor, 22µH, XAL6060 Coilcraft, XAL6060-223MEC 20 1 L2 Inductor, 1µH, XAL6030 Coilcraft, XAL6030-102MEB 21 1 Q1 MOSFET, N-CH, 80V, 100A, TDSON-8 Infineon, BSC047N08NS3 G 22 1 Q2 MOSFET, N-CH, 200V, 36A, TDSON-8 Infineon, BSC320N20NS3 G 23 1 R1 Res., Chip 100, 0.50W, 5%, 1210 Vishay, CRCW1210100RJNEA 24 1 R3 Res., Chip 1.2M, 0.1W, 5%, 0603 Vishay, CRCW06031M20JNEA 25 1 R4 Res., Chip 51k 0.1W 5% 0603 Vishay, CRCW060351K0JNEA 26 1 R5 Res., Chip 68, 1/8W, 5%, 0805 Vishay, CRCW080568R0JNEA 27 2 R6, R8 Res/Jumper, Chip 0Ω, 0.25W, 5A, 0603 Vishay, CRCW06030000Z0EA 28 1 R7 Res., Chip 160k, 1/8W, 1%, 0805 Vishay, CRCW0805160KFKEA 29 1 R9 Res., Chip 3Ω, 1/8W, 5%, 0805 Vishay, CRCW08053R00JNEA 30 1 R10 Res., Chip 60.4k, 0.1W, 1%, 0603 Vishay, CRCW060360K4FKEA 31 1 R11 Res., Chip 3, 1/10W, 5%, 0603 Vishay, CRCW06033R00JNEA 32 1 R12 Res., Chip 7.50k, 0.1W, 1%, 0603 Vishay, CRCW06037K50FKEA 33 1 R13 Sense Res., RL Vert. 0.010, 1W, 1%, 0815 SUSUMU, RL3720WT-R010-F 34 1 R14 Res., Chip 6.04k, 0.1W, 1%, 0603 Vishay, CRCW06036K04FKEA 35 1 R15 Res., Chip 2.37k, 0.25W, 1%, 1206 Vishay, CRCW12062K37FKEA 36 1 T1 Transformer, ±5%, 20.5µH, EFD20 Platform Pulse Engrng., PA1736NLT 37 1 U1 I.C., Rectifier Driver, TSOT23-S5 Linear Tech. Corp. LT8309ES5#PBF 38 1 U2 I.C., No-Opto Flyback Converter Linear Tech. Corp. LT3748EMS#PBF 39 1 FAB, PRINTED CIRCUIT BOARD Rev 2 DEMO CIRCUIT #1961A dc1961af 5 DEMO MANUAL DC1961A Parts List ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Additional Demo Board Circuit Components 1 0 C21 Cap., 0805 2 0 R2 Res., 1206 Hardware: For Demo Board Only 1 6 4 E1, E2, E3, E4 Turret, Testpoint Mill Max, 2501-2-00-80-00-00-07-0 dc1961af GND E2 E1 VIN 36V to 72V VIN R10 60.4k 1% C2 4.7µF 100V 1210 C15 470pF C3 4.7µF 100V 1210 C19 33nF R12 7.50k 1% R4 51k R3 1.2M C4 4.7µF 100V 1210 RREF VC TC SS 8 1 VIN GND EN/UVLO R14 6.04k 1% 14 11 12 10 3 U2 LT3748EMS 1. ALL RESISTORS 0603. 2. ALL CAPACITORS 0603. C6 1µF 100V 0805 9 SENSE GND GATE RFB INTVCC NOTE: UNLESS OTHERWISE SPECIFIED. C14 0.22uF 47µF 80V + C1 Coilcraft L1 22µH XAL6060-223MEC 7 6 16 5 R5 C18 47pF 0 Ohm R8 D4 R7 BAV20W-7-F 3 Ohm R11 160k 1% 0805 68 0805 C13 4.7µF 16V 0805 INTVCC D2 CMMR1U-02 D1 SMBJ85A-13-F 6 1 5 2 4 3 R13 0.010 1% 0815 C20 4700pF 250V 1812 T1 PA1736NL Q2 BSC320N20NS3G C5 120pF 250V 0805 R1 100 1210 7 8 9 10 11 12 R9 C8 47µF 16V 1210 R15 2.37k 1% 1206 C9 47µF 16V 1210 R6 C21 (Opt) 0805 C16 1uF 100V 1206 5 4 C10 47µF 16V 1210 C11 47µF 16V 1210 DRAIN VIN GATE GND INTVCC U1 LT8309ES5 0 Ohm Q1 BSC047N08NS3 BAV20W-7-F 3 Ohm 0805 D6 36V D5 C7 47µF 16V 1210 Coilcraft L2 1µH XAL6030-102MEC 1 2 3 C12 47µF 16V 1210 C17 4.7uF 25V 0805 D3 CMZ5928B R2 (Opt) 1206 VOUT E4 E3 VOUT- VOUT+ 12V / 5A DEMO MANUAL DC1961A Schematic Diagram dc1961af Information furnished by Linear Technology Corporation is believed to be accurate and reliable. However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights. 7 DEMO MANUAL DC1961A DEMONSTRATION BOARD IMPORTANT NOTICE Linear Technology Corporation (LTC) provides the enclosed product(s) under the following AS IS conditions: This demonstration board (DEMO BOARD) kit being sold or provided by Linear Technology is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not provided by LTC for commercial use. As such, the DEMO BOARD herein may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety measures typically found in finished commercial goods. As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations. If this evaluation kit does not meet the specifications recited in the DEMO BOARD manual the kit may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY THE SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. EXCEPT TO THE EXTENT OF THIS INDEMNITY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user releases LTC from all claims arising from the handling or use of the goods. Due to the open construction of the product, it is the user’s responsibility to take any and all appropriate precautions with regard to electrostatic discharge. Also be aware that the products herein may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). No License is granted under any patent right or other intellectual property whatsoever. LTC assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind. LTC currently services a variety of customers for products around the world, and therefore this transaction is not exclusive. Please read the DEMO BOARD manual prior to handling the product. Persons handling this product must have electronics training and observe good laboratory practice standards. Common sense is encouraged. This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact a LTC application engineer. Mailing Address: Linear Technology 1630 McCarthy Blvd. Milpitas, CA 95035 Copyright © 2004, Linear Technology Corporation 8 dc1961af Linear Technology Corporation LT 0114 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com LINEAR TECHNOLOGY CORPORATION 2014