DEMO MANUAL DC1523A LTC3789EGN: High Efficiency Synchronous 4-Switch Step-Up/Step-Down DC/DC Converter DESCRIPTION Demonstration circuit 1523A features the LTC®3789EGN, a high efficiency switching step-up/down controller. The DC1523A input range is from 5V to 36V. The output voltage is 12V. The board is capable of delivering up to 5A of output current over the input voltage range. The LTC3789EGN is a high performance switching regulator controller designed to regulate the output using input voltages above, below or equal to the output voltage. Synchronous operation provides very high efficiency, up to 97%. Constant frequency current mode architecture allows phase-lockable frequency from 200kHz to 600kHz. An accurate output current limit provides support for battery charging. A wide input and output range with smooth transfer function through all operating modes makes the product ideal for automotive, telecom and battery systems. The MODE/PLLIN pin can select between pulse skipping mode and forced continuous mode operation and allows the IC to be synchronized to an external clock. A Power Good output pin indicates when the output is within 7.5% of its set point. 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 PARAMETER CONDITIONS/ NOTES VALUE Minimum Input Voltage 5V Maximum Input Voltage 36V Output Voltage VOUT Regulation VIN = 5V to 36V, IOUT = 0A to 5A 12V ±2% Maximum Continuous Output Current Some Airflow May be Needed at Low Input Voltage and Continuous Full Load 5A DC Default Operating Frequency R3 = 121k External Clock Synchronous Frequency Range Efficiency Load Transient 400kHz 200kHz to 600kHz VIN = 5V to 36V, IOUT = 5A 88% to 97%. See Figures 3 and 6 See Figure 5 dc1523af 1 DEMO MANUAL DC1523A QUICK START PROCEDURE Demonstration circuit 1523A is easy to set up to evaluate the performance of the LTC3789EGN. Please refer to Figure 1 for proper measurement equipment setup and follow the procedure below. 4. Turn on the power at the input. Increase VIN to between 5V and 36V. The circuit will start and the output voltage will regulate at 12V ±2%. The current draw at no load is 20mA to 60mA depending on the input voltage. 1. With power off, connect the input supply, load and meters as shown in Figure 1. Preset the load to 0A and VIN supply to 0V. 5. Apply load and observe output voltage regulation, ripple voltage, efficiency and other parameters. Efficiency and power loss at full load is shown in Figure 3. Continuous operation with full power and low input voltage may require some airflow. 2. Set the current limit of the input supply high enough so that the bench supply does not go into current limit mode. Figure 2 shows input current as a function of input voltage, at full load. Input current can reach 13A at 5V input voltage. 3. Place jumpers in the following positions: JP1 JP2 RUN MODE ON CCM + POWER SUPPLY A A V V – + LOAD – DC1523A F01 Figure 1. Proper Measurement Equipment Setup dc1523af 2 DEMO MANUAL DC1523A QUICK START PROCEDURE 14 100 8 12 98 7 96 EFFICIENCY (%) CURRENT (A) 8 IIN 6 IOUT 4 2 0 5 10 15 25 20 VIN (V) 35 30 94 5 92 4 90 3 POWER LOSS 88 2 86 1 84 40 6 EFFICIENCY 0 5 10 15 20 25 30 35 40 POWER LOSS (W) 10 0 VIN (V) DC1523A F03 DC1523A F02 Figure 2. Input Current at Full Load (12V at 5A Out) Figure 3. Efficiency and Power Loss at Full Load. The Power Loss is Highest in Boost Mode Due to the High Inductor Current, and Drops as Input Voltage Increases. Switching Losses Again Increase when VIN > VOUT. All Four MOSFETs are Switching in Buck-Boost Mode and This Shows Up as a Small Increase in Losses When VIN = 11V to 15.5V Figure 4. Output Ripple Voltage at 24VIN (Top), 12VIN (Middle), 6VIN (Bottom). Measured Across COUT1, BW = 20MHz, 100mV/Div 98 Figure 5. Load Transient Response 96 94 12 10 92 88 24V 30V 36V 6V 9V 12V 18V 90 0 1 3 2 LOAD (A) VOUT (V) EFFICIENCY (%) 14 4 5 8 6 4 2 DC1523 F06 Figure 6. Efficiency at Various Input Voltages 0 0 1 2 4 3 LOAD (A) 5 6 DC1523A F07 Figure 7. Output Current Limit. (VIN = 12V. The Easiest Way to Do This Test is with an Active Load in Voltage Mode) dc1523af 3 DEMO MANUAL DC1523A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER AVX, 06035A102KAT2A Required Circuit Components 1 1 CC1 CAP., C0G, 1000pF, 50V, 10% 0603 2 2 CC2, CSS CAP., X7R, 0.01μF, 50V, 10% 0603 AVX, 06035C103KAT2A 3 1 CIN1 CAP., Alum, 270μF, 50V, 20% SANYO, 50ME270WX+T 4 1 COUT1 CAP., OS-CON, 330μF, 16V, 20% SANYO, 16SEP330M+T 5 4 C1, C2, C16, C17 CAP., X7R, 22μF, 16V, 20% 1210 AVX, 1210YC226MAT2A 6 2 C4, C22 CAP., X7R, 0.22μF, 16V, 20% 0603 TAIYO YUDEN, EMK107BJ224MA 7 4 C5, C6, C9, C25 CAP., X7R, 3.3μF, 50V, 20% 1210 AVX, 12105C335MAT2A 8 1 C10 CAP., X7R, 2.2μF, 10V, 10% 0603 MURATA, GRM188R71A225K 9 1 C12 CAP., NPO, 390pF, 100V, 10% 1206 AVX, 12061A391KAT2A 10 1 C13 CAP., NPO, 1800pF, 100V, 10% 1206 AVX, 12061A182KAT2A 11 1 C14 CAP., X7R, 0.1μF, 50V, 10% 0603 AVX, 06035C104KAT2A 12 1 C15 CAP., X7R, 1μF, 50V, 20% 1206-1210 AVX, 12065C105MAT2A 13 1 C18 CAP., X7R, 10μF, 10V, 20% 1206 AVX, 1206ZC106MAT2A 14 1 C24 CAP., X7R, 1μF, 16V, 20% 0603 AVX, 0603YC105MAT2A 15 1 D2 DIODE, BAS16, SOT23 DIODES, BAS16 16 2 D7, D4 SCHOTTKY REC., DFLS160, PowerDI-123 DIODES INC., DFLS160 17 2 D5, D6 SCHOTTKY RECT., B240A SMA DIODES INC. B240A-13-F 18 1 D8 ZENER DIODE, 5.1V, BZX84C5V1, SOT23 DIODES INC. BZX84C5V1-7-F 19 1 L1 INDUCTOR, 4.7μH TOKO, FDA1254-4R7M 20 1 Q2 MOSFET N-CHAN., 40V VISHAY, Si7884BDP-T1-E3 21 1 Q4 MOSFET N-CHAN., 40V VISHAY, Si4840BDY-T1-E3 22 2 Q3, Q5 MOSFET N-CHAN., SiR496DP, 20V VISHAY, SiR496DP-T1-GE3 23 1 RC RES., CHIP., 14.7k, 0.1W, 1% 0603 VISHAY, CRCW060314K7FKEA 24 1 RFB1 RES., CHIP., 113k, 0.1W, 1% 0603 VISHAY, CRCW0603113KFKEA 25 1 RFB2 RES., CHIP., 8.06k, 0.1W, 1% 0603 VISHAY, CRCW06038K06FKEA 26 1 R1 RES., CHIP., 5.6Ω, 0.1W, 1% 0603 VISHAY, CRCW06035R60FKEA 27 2 R2, R18 Sensor Res., 0.01Ω, 1W, 2%, RL3720W Thin Film Tech., RL3720WT-R010-G-C 28 4 R3, R4, R13, R14 RES., CHIP., 100Ω, 0.1W, 5%, 0603 VISHAY, CRCW0603100RJNEA 29 1 R5 RES., CHIP., 15Ω, 0.125W, 1% 0603 VISHAY, CRCW060315R0FKEA 30 1 R7 RES., CHIP., 100k, 0.1W, 1% 0603 VISHAY, CRCW0603100KFKEA 31 3 R8, R11, R26 RES., CHIP., 10Ω, 0.1W, 5% 0603 VISHAY, CRCW060310R0JNEA 32 2 R10, R9 RES., CHIP., 1.24k, 0.1W, 1% 0603 VISHAY, CRCW06031K24FKEA 33 1 R20 Sensor Res., 0.004Ω, 1W, 2%, RL3720W Thin Film Tech., RL3720WT-R004-G-C 34 1 R21 RES., CHIP., 121k, 0.1W, 1% 0603 VISHAY, CRCW0603121K0FKEA 35 1 R24 RES., CHIP., 10k, 0.1W, 1% 0603 VISHAY, CRCW060310K0FKEA 36 1 R25 RES., CHIP., 0Ω, 0.125W, 0805 VISHAY, CRCW08050000Z0EA 37 1 R28 RES., CHIP., 5.6Ω, 1% 1206 VISHAY, CRCW12065R60FNEA 38 1 R29 RES., CHIP., 3.6Ω, 1% 1206 VISHAY, CRCW12063R60FNEA 39 1 R30 RES., CHIP., 33.2k, 0.1W, 1% 0603 VISHAY, CRCW060333K2FKEA 40 1 R31 RES., CHIP., 12.1k, 0.1W, 1% 0603 VISHAY, CRCW060312K1FKEA 41 1 U1 I.C.,VOLT. REG. Linear Tech. Corp.LTC3789EGN dc1523af 4 DEMO MANUAL DC1523A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER Additional Demo Board Circuit Components 42 0 C3, C23, C26, C27 OPT CAP., 1210 43 1 CIN2 CAP., Alum, OPT 44 0 CF1, C11, CF, C7, C8 OPT CAP., 0603 45 0 COUT2 OPT 46 0 Q6 OPT 47 0 Q7 OPT Dual N-CHAN., Si7958DP, 40V 48 0 R6, R12, R22, R27 OPT RES., OPT Dual N-CHAN., Si7948DP, 60V Hardware for Demo Board Only 49 4 TP1, TP2, TP3, TP7 TESTPOINT, TURRET, 0.061" PBF MILL-MAX, 2308-2-00-80-00-00-07-0 50 7 TP4-TP6, TP8, TP10-TP12 TESTPOINT, TURRET, 0.094" PBF MILL-MAX, 2501-2-00-80-00-00-07-0 51 1 JP1 3-PIN 0.079 SINGLE ROW HEADER SAMTEC, TMM103-02-L-S 52 2 JP2C, JP2B 2-PIN 0.079 SINGLE ROW HEADER SAMTEC, TMM102-02-L-S 53 2 XJP1, XJP2B SHUNT, 0.079" CENTER SAMTEC, 2SN-BK-G 54 4 J1, J2, J3, J4 CONNECTOR, BANANA JACK KEYSTONE, 575-4 55 4 (STAND-OFF) STAND-OFF, NYLON 0.25" KEYSTONE, 8831(SNAP ON) dc1523af 5 6 A B C D OFF EXTVCC PLLIN TP4 TP6 TP8 R27 OPT TP12 TP10 3 MODE JP2C CCM JP2B PULSE SKIP R25 0 R22 OPT INTVCC CF OPT 5 2. INSTALL SHUNTS AS SHOWN. 1. ALL RESISTORS ARE IN OHMS, 0603. ALL CAPACITORS ARE IN MICROFARADS, 0603. NOTE: UNLESS OTHERWISE SPECIFIED R24 10K RFB1 113K VOS+ INTVCC D8 BZX84C5V1 OPT 8.06K CF1 RFB2 R7 100K INTVCC R31 12.1K 33.2K JP1 VIN+ RUN 1 R30 2 TP5 CSS 0.01uF TP11 ON SS SGND PGOOD VLOGIC INTVCC 5 VIN R14 VOUT 100 C8 OPT C7 OPT 0.01uF C11 OPT 100 R13 4 14 13 12 11 10 9 8 7 6 5 <------ IOSENSE- IOSENSE+ ILIM VOUTSNS VINSNS RUN FREQ MODE/PLLIN SGND ITH SENSE1- SENSE1+ SS VFB R3 100 15 16 17 18 19 20 21 22 23 24 25 26 27 28 D4 10 C18 3 R12 OPT Q4 5.6 D2 BAS16 1 R1 3 Si4840BDY R6 OPT C22 0.22uF 16V Q2 BG1 Si7884BDP 10uF 1206 DFLS160 D7 VIN SW1 TG1 R5 15 Ohm 0805 C4 0.22uF 16V R26 VOUT 10 C24 1uF INTVCC 3 C15 1uF 50V 1210 DFLS160 R11 R4 100 CIRCUITRY ON THIS SIDE MUST CONNECT TO POWER GND GROUNDPLANE ------> NC SW2 TG2 BOOST2 BG2 EXTVCC INTVCC VIN BG1 PGND1 BOOST1 TG1 SW1 PGOOD U1 LTC3789EGN CIRCUITRY ON THIS SIDE MUST CONNECT TO SIGNAL GND GROUNDPLANE C10 2.2uF 121K 1% R21 14.7K RC 4 3 2 1 C14 0.1uF INTVCC CC1 1000pF 1.24K R10 CC2 1.24K R9 4 1210 16V 22uF SW2 TG2 BG2 R29 3.6 1206 C13 1800pF 1206 CUSTOMER NOTICE CS Q5 SiR496DP 4.7uH L1 D6 B240A VOUT1 C9 3.3uF 50V 1210 2 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. 0.004 R20 SCALE = NONE TAGE B. AK APPROVALS C1 C2 C16 C17 LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES. VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. R18 0.010 2% B240A D5 C12 390pF 1206 Q3 C26 OPT 1210 SiR496DP C27 OPT 1210 5.6 Ohm 1206 R28 C25 3.3uF 50V 1210 2 J1 DATE GND VOS- VOS+ 12V @ 5A MAX VOUT GND GND VIN+ 5V - 36V VIN 07-02-10 DATE: 1 LTC3789EGN DEMO CIRCUIT 1523A Friday, November 19, 2010 IC NO. SHEET 1 OF 2 3 REV. 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only J2 TP1 TP2 VOS+ R8 10 J4 TP7 TP3 J3 TAGE B. APPROVED HIGH EFFICIENCY STEP-UP/DOWN DC/DC CONVERTER N/A SIZE + COUT1 COUT2 330uF 330uF 16V 16V OPT + + CIN2 OPT TECHNOLOGY 1210 OPT C23 VOUT CIN1 270uF 50V + 1 DESCRIPTION REVISION HISTORY PRODUCTION VIN+ C3 C6 3.3uF 50V 1210 3 REV TITLE: SCHEMATIC 0.010 2% R2 C5 3.3uF 50V 1210 __ ECO A B C D DEMO MANUAL DC1523A SCHEMATIC DIAGRAMS dc1523af 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. A B C D 5 5 4 CS BG1 SW1 TG1 4 CS BG1 2 SW1 TG1 4 3 1 78 TG2 2 BG2 BG2 4 SW2 3 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. CUSTOMER NOTICE Q7A Si7958DP SW2 TG2 1 Q6B Si7948DP SCALE = NONE AK TAGE B. PCB DES. APP ENG. APPROVALS 3 56 Q6A Si7948DP 78 56 Q7B Si7958DP VOUT1 VIN OPTIONAL CIRCUIT #1 (1.5A OUTPUT) 3 2 2 TECHNOLOGY DATE: LTC3789EGN 1 DEMO CIRCUIT 1523A Thursday, June 17, 2010 IC NO. SHEET 2 HIGH EFFICIENCY STEP-UP/DOWN DC/DC CONVERTER N/A SIZE TITLE: SCHEMATIC OF 2 3 REV. 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only 1 A B C D DEMO MANUAL DC1523A SCHEMATIC DIAGRAMS dc1523af 7 DEMO MANUAL DC1523A 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 dc1523af 8 Linear Technology Corporation LT 1210 • PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 ● FAX: (408) 434-0507 ● www.linear.com © LINEAR TECHNOLOGY CORPORATION 2010