TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 1 INTRODUCTION 1.1 FEATURES • VDD From 4.5 V to 15 V, With Internal 5-V Regulator VOUT From 0.7 V to 5.8 V Converts From 15V Input to 0.7V Output at 1MHz Dual-Output or 2-Phase Interleaved Operation, Stackable to 16 Phases Supports Pre-Biased Outputs Programmable Switching Frequency Up to 1 MHz/Phase 0.5% Internally Trimmed 0.7-V Reference 10-µA Shutdown Current Current Mode Control with Forced Current Sharing (1) 1V to 40V Power Stage Operation Range Power Sharing from Different Input Voltage Rails, (e.g. Master From 5 V, Slave From 12 V) True Remote Sensing Differential Amplifier Programmable Input Undervoltage Lockout Resistive or Inductor DCR Current Sensing Provide a 6-Bit Digitally-Controlled Output When Used With TPS40120 36-pin QFN Package • • • • • • • • • • • • • • VIN CSRT1 TPS40140 HDRV1 LDRV1 L1 VIN CSRT2 CS2 HDRV2 VOUT2 SW2 LDRV2 L2 UDG−06016 1.3 DESCRIPTION The TPS40140 is a multifunctional synchronous buck controller that can be configured to provide either a single-output two-phase power supply or a power supply that supports two independent outputs. Several TPS40140 controllers can be stacked up to a 16-phase multiphase single output power supply. Alternatively, several controllers providing multiple independent outputs can be synchronized in an interleaving pattern for improved input ripple current. Graphic Cards Internet Servers Networking Equipment Telecommunications Equipment DC Power Distributed Systems (1) VOUT1 SW1 1.2 APPLICATIONS • • • • • CS1 The TPS40140 is capable of converting from a 15-V input to a 0.7-V output at 1MHz. Each phase operates at a switching frequency of up to 1 MHz. The two phases in one device operate 180° out-of-phase. In a multiple device stackable configuration, the phase shift of the slaves, relative to a master, is programmable. Patents Pending 1.4 ORDERING INFORMATION PACKAGE Plastic Quad Flatpack 36-pin RHH (PQFP) TAPE AND REEL QTY. PART NUMBER 250 TPS40140RHHT 3000 TPS40140RHHR Please be aware that an important notice concerning availability, standard warranty, and use in critical applications of Texas Instruments semiconductor products and disclaimers thereto appears at the end of this document. PowerPAD is a trademark of Texas Instruments. PRODUCTION DATA information is current as of publication date. Products conform to specifications per the terms of the Texas Instruments standard warranty. Production processing does not necessarily include testing of all parameters. Copyright © 2005–2006 , Texas Instruments Incorporated TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 Contents 1 INTRODUCTION .......................................... 1 5.14 OUTPUT OVERVOLTAGE PROTECTION ......... 19 1.1 FEATURES ........................................... 1 5.15 CLKFLT, CLKIO PIN FAULT ........................ 19 1.2 APPLICATIONS ...................................... 1 5.16 PHSEL PIN FAULT 19 1 5.17 OVERTEMPERATURE 20 1 5.18 3 5.19 3 5.20 5.21 ....................................... 1.4 ORDERING INFORMATION ......................... DEVICE RATINGS ........................................ 2.1 ABSOLUTE MAXIMUM RATINGS ................... 2.2 RECOMMENDED OPERATING CONDITIONS ..... 1.3 2 3 4 DESCRIPTION 20 20 SYNCHRONIZING A SINGLE CONTROLLER TO AN EXTERNAL CLOCK ............................. 21 3 ELECTROSTATIC DISCHARGE (ESD) PROTECTION ........................................ 3 5.22 SPLIT INPUT VOLTAGE OPERATION ............. 22 2.4 PACKAGE DISSIPATION RATINGS ................. 3 5.23 CURRENT SENSE 2.5 ELECTRICAL CHARACTERISTICS.................. 4 5.24 5.25 CURRENT SENSING AND BALANCING ........... 24 OVERCURRENT DETECTION AND HICCUP MODE ............................................... 24 CALCULATING OVERCURRENT PROTECTION LEVEL ............................................... 25 TYPICAL CHARACTERISTICS......................... 6 DEVICE INFORMATION ............................... 11 ..................... 4.2 CLOCK MASTER AND CLOCK SLAVE ............ 4.3 VOLTAGE MASTER AND VOLTAGE SLAVE ...... 4.4 FUNCTIONAL BLOCK DIAGRAM .................. APPLICATION INFORMATION ....................... 5.1 FUNCTIONAL DESCRIPTION ...................... 5.2 DATA SHEET ORGANIZATION .................... 5.3 TYPICAL START UP SEQUENCE.................. TERMINAL CONFIGURATION 5.26 11 11 12 14 15 15 6 CONFIGURING SINGLE AND MULTIPLE ICS ..... 28 DIGITAL CLOCK SYNCHRONIZATION ............ 39 5.29 DESIGN EXAMPLES INFORMATION .............. 41 DESIGN EXAMPLES ................................... 42 6.1 15 6.2 5.5 5.6 SOFT-START WITH PRE-BIASED OUTPUTS ..... 16 TRACK FUNCTION IN CONFIGURING A SLAVE CHANNEL ........................................... 17 6.3 5.7 DIFFERENTIAL AMPLIFER, U9 .................... 18 5.8 POWER GOOD 5.11 5.12 5.13 18 18 PROGRAMMABLE INPUT UNDERVOLTAGE LOCK OUT PROTECTION .......................... 19 POWER ON RESET (POR) ......................... 19 OVERCURRENT .................................... 19 OUTPUT UNDERVOLTAGE PROTECTION Contents ....... 19 7 23 5.28 15 TRACK (SOFT-START WITHOUT PRE-BIASED OUTPUT) ............................................ 16 ..................................... SETTING THE OUTPUT VOLTAGE ................ ................................. 5.27 5.4 5.9 5.10 2 20 2.3 4.1 5 ................................. ............................. FAULT MASKING OPERATION .................... PROTECTION AND FAULT MODES ............... SETTING THE SWITCHING FREQUENCY ........ Example 1: Dual-Output Configuration from 12 V to 3.3 V and 1.5 V DC-to-DC Converter Using a TPS40140 ........................................... 42 Example 2: Two-Phase Single Output Configuration From 12 V to 1.5 V DC/DC Converter Using a TPS40140 ........................................... 49 Example 3: Four-Phase Single Output Configuration From 12 V to 1.8 V DC-to-DC Converter Using Two TPS40140 ........................................... 52 6.4 ABBREVIATIONS ................................... 58 6.5 LAYOUT CONSIDERATIONS ...................... 59 ADDITIONAL REFERENCES ......................... 60 7.1 7.2 7.3 7.4 ....................................... References ......................................... Package Outline ..................................... Recommended PCB Footprint ...................... Related Parts 60 60 60 60 Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 2 DEVICE RATINGS 2.1 ABSOLUTE MAXIMUM RATINGS over operating free-air temperature range (unless otherwise noted) VALUE VDD, UVLO_CE1, UVLO_CE2 –0.3 to 16 SW1, SW2 Input voltage range UNIT –1 to 44 SW1, SW2, transient < 50ns –5 BOOT1, BOOT2, HDRV1, HDRV2 V VSW + 6.0 All other pins –0.3 to 6.0 Output current RT 200 µA Junction Temperature, TJ Operating –40 to 125 °C Junction Temperature, TJ Storage –55 to 150 °C 2.2 RECOMMENDED OPERATING CONDITIONS over operating free-air temperature range (unless otherwise noted) VDD, UVLO_CE1, UVLO_CE1 SW1, SW2 Input voltage TYP MAX 15 –1 BOOT1, BOOT2, HDRV1, HDRV2 All other pins Maximum output current 40 VSW+5.5 –0.3 UNIT V 5.5 RT µA 25 Operating free-air temperature 2.3 MIN –0.3 –40 85 °C ELECTROSTATIC DISCHARGE (ESD) PROTECTION PARAMETER MIN TYP MAX UNIT Human body model 3000 V CDM 1500 V 2.4 (1) PACKAGE DISSIPATION RATINGS (1) THERMAL IMPEDANCE JUNCTION-TO-AMBIENT (°C/W) TA = 25°C POWER RATING (W) TA = 85°C POWER RATING (W) 48 2 0.8 For more information on the RHH package and the test method, refer to TI technical brief, literature number SLUA271. Submit Documentation Feedback DEVICE RATINGS 3 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 2.5 ELECTRICAL CHARACTERISTICS TJ = –40°C to 85°C, (unless otherwise noted), VVDD = 7 V, VBP5 = 5 V, UVLO_CE1, UCLO_CE2: 10 kΩ, Pullup to BP5, f SW = 300 kHz, unless otherwise noted PARAMETER TEST CONDITIONS MIN TYP MAX UNIT 4.5 12 15 V 1 10 µA 4.5 5.0 5.5 2 3 5 4.0 4.25 4.45 V 100 220 400 mV VDD INPUT SUPPLY Operating Voltage Range Shutdown Current UVLO_CE1 = UVLO_CE2 =GND BP5 INPUT SUPPLY Operating Voltage Range BP5 Operating Current Rising BP5 Turn-On BP5 Turn-Off Hysteresis Standby Mode Current (1) UVLO_CEx =1.7V 2.8 V mA mA VREG 7 V < VDD <15 V Output current 4.5 5.1 0 5.5 V 100 mA OSCILLATOR, RT Phase Frequency Accuracy RRT= 110 kΩ Phase Frequency Set Range 300 150 25 kΩ≤ RRT≤ 500 kΩ RT (1) kHz 1000 0.7 kHz V UNDERVOLTAGE LOCKOUT (UVLO_CE1, UVLO_CE2) Enable threshold, standby mode Internal 5VREG regulator enabled 0.5 1.0 1.5 UVLO threshold PWM Switching enabled 1.9 2 2.1 UVLO hysteresis At the UVLO_CEx pin 40 UVLO_CE1, UVLO_CE2 bias current (1) V V mV 1 µA PWM D Maximum duty cycle per channel (1) 2-phase, 4-phase, 8-phase or 16-phase 87.5% 3-phase, 6-phase, or 12-phase 83.3% VSHARE (1) IVSHR = 0 1.785 1.8 1.815 V -30µA<iVSHR < 50µA 1.785 1.8 1.815 V 0 0.7 2.0 V 0.6965 0.700 ERROR AMPLIFIER CH1, ERROR AMPLIFIER CH2 Input Common Mode Range (1) Input Bias Current (1) VFB = 0.7 V FBx Voltage (1) 10 nA 0.7035 V Output Source Current VCOMP = 1.1 V, VFB = 0.6 V 1 2 mA Output Sink Current VCOMP = 1.1V, VFB = BP5 1 2 mA 8 12 MHz 60 90 dB BW (1) Open Loop Gain (1) VOLTAGE TRACKING (TRK1, TRK2) SS source current After EN, before PWM and during hiccup mode After first PWM pulse Fault Enable Threshold (1) Internal Clamp (1) 4 6.0 7.3 µA 12.5 15 µA 1.4 Voltage (1) SS sink resistance (1) 5 10 V 2.4 Pull-down resistance V 1 kΩ Ensured by design. Not 100% production tested. DEVICE RATINGS Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 ELECTRICAL CHARACTERISTICS (continued) TJ = –40°C to 85°C, (unless otherwise noted), VVDD = 7 V, VBP5 = 5 V, UVLO_CE1, UCLO_CE2: 10 kΩ, Pullup to BP5, f SW = 300 kHz, unless otherwise noted PARAMETER TEST CONDITIONS MIN TYP MAX UNIT -2.0 0 2.0 mV 12 13 14 V/V CURRENT SENSE AMPLIFIERS (CS1, CS2) Differential input voltage Ac -60 Input offset voltage CS1, CS2, Trimmed Gain transfer to PWM COMP 5 mV < VCS < 60 mV, VCSRT = 1.5 V Input common mode (1) CSA 60 0 Input bias current 5.8 100 mV V nA DIFFERENTIAL AMPLIFIER (DIFFO) Gain 1.0 V < VOUT < 5.8 V Input Common Mode Range (1) 0.997 1 0 1.003 5.8 Output Source Current (1) VOUT– VVGSNS = 2 V, VDIFFO > 1.98 V, VDD-VOUT > 2 V 2 Output Source Current (1) VOUT– VVGSNS = 2 V, VDIFFO > 2.02 V VDD-VOUT =1 V 1 VOUT– VVGSNS = 2 V, VDIFFO > 2.02 V 2 Output Sink Current (1) Unity gain bandwidth (1) 5 8 Input Impedance, non inverting (1) VOUT to GND 60 Input Impedance, inverting (1) 60 GSNS to DIFFO V/V V mA MHz kΩ GATE DRIVERS HDRV1, HDRV2 Source On Resistance VBOOT1, VBOOT2 = 5 V, VSW1 = VSW2 = 0 V, Sourcing 100 mA 1 2 3 HDRV1, HDRV2 Sink On Resistance VVREG = 5 V, VSW1 = VSW2 = 0 V, Sinking 100 mA 0.5 1.2 2 LDRV1, LDRV2 Source On Resistance VVREG = 5 V, VSW1 = VSW2 = 0 V, Sourcing 100 mA 1 2 3 LDRV1, LDRV2 Sink On Resistance VVREG = 5V, VSW1 = VSW2 = 0 V, Sinking 100 mA 0.3 0.65 1 tRISE HDRVx rise time (1) CLOAD= 3.3 nF 25 75 tFALL HDRVx fall time (1) CLOAD= 3.3nF 25 75 tRISE LDRVx rise time (1) CLOAD= 3.3nF 25 75 tFALL LDRVx fall time (1) CLOAD= 3.3nF 20 60 Minimum Controllable On-Time CLOAD= 3.3nF 50 Ω ns OUTPUT UNDERVOLTAGE FAULT VFB relative to VREF -19% Undervoltage delay (1) -16.5% -14% µs 3 CURRENT LIMIT IILIM Output current 18.8 20 21.2 µA POWER GOOD PGOOD transition low threshold VFB rising relative to VREF 10% 12.5% 15% PGOOD transition low threshold VFB falling relative to VREF -15% -12.5% -10% PGOOD trip hysteresis 2% PGOOD Delay (1) (1) 5% µs 10 Low level output voltage, VOL IPGOOD = 4 mA PGOOD Bias Current VPGOOD= 5.0 V -2 0.35 0.4 V 1 2 µA Ensured by design. Not 100% production tested. Submit Documentation Feedback DEVICE RATINGS 5 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 ELECTRICAL CHARACTERISTICS (continued) TJ = –40°C to 85°C, (unless otherwise noted), VVDD = 7 V, VBP5 = 5 V, UVLO_CE1, UCLO_CE2: 10 kΩ, Pullup to BP5, f SW = 300 kHz, unless otherwise noted PARAMETER TEST CONDITIONS MIN TYP MAX UNIT 0.421 0.5 0.526 V 0.23 0.25 0.27 V/V RAMP Ramp Amplitude (1) VIN BALANCE VIN Balance Gain, AVB THERMAL SHUTDOWN Shutdown Temperature (1) 155 Hysteresis (1) °C 30 DIGITAL CLOCK SIGNAL (CLKIO) (1) Pull-up resistance (1) IOH = 5 mA 27 Pull-down resistance (1) IOL = 10 mA 27 Output leakage (1) Three-state Ω Ω 1 µA Ensured by design. Not 100% production tested. 3 TYPICAL CHARACTERISTICS BP5 TURNOFF HYSTERESIS VOLTAGE vs TEMPERATURE BP5 TURNON THRESHOLD VOLTAGE vs TEMPERATURE 4.2660 VBP5 − BP5 Turnon Threshold Voltage − V VBP5 − BP5 Turnoff Hysteresis Voltage − mV 230.4 230.2 230.0 229.8 229.6 229.4 229.2 4.2650 4.2645 4.2640 4.2635 4.2630 4.2625 4.2620 4.2615 229.0 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-1. 6 4.2655 TYPICAL CHARACTERISTICS 4.2610 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-2. Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 CURRENT SENSE GAIN vs TEMPERATURE OSCILLATOR FREQUENCY vs TEMPERATURE 13.00 310 RT = 110 kΩ ∆CS = 30 mV 308 12.90 ∆CS = 60 mV 12.85 12.80 ∆CS = 5 mV 12.75 12.70 12.65 fOSC − Oscillator Frequency − kHz AC − Current Sense Gain − V/V 12.95 12.60 306 304 302 300 298 296 294 12.55 −40 −25 −10 5 20 35 50 65 80 292 −40 −25 −10 95 110 125 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C TJ − Junction Temperature − °C Figure 3-3. Figure 3-4. DIFFERENTIAL AMPLIFIER VOLTAGE GAIN vs TEMPERATURE BP5 CURRENT vs TEMPERATURE 1.0055 3.1 1.0050 3.0 1.0045 IBP5 − BP5 Current − mA Voltage Gain 1.0040 1.0035 1.0030 VIN = 0.7 V 1.0025 1.0020 1.0015 VIN = 4.0 V 2.9 2.8 2.7 2.6 1.0010 2.5 1.0005 1.0000 −40 −25 −10 5 20 35 50 65 80 TJ − Junction Temperature − °C Figure 3-5. Submit Documentation Feedback 95 110 125 2.4 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-6. TYPICAL CHARACTERISTICS 7 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 TRKx SOFT START CURRENT vs TEMPERATURE 4.0 14 3.5 12 ISS − Soft Start Current − µA IDDQ − Shutdown Quiescent Current − mA SHUTDOWN QUIESCENT CURRENT vs TEMPERATURE 3.0 2.5 2.0 1.5 1.0 After First PWM 10 8 6 Prior to PWM 4 2 0.5 0 −40 −25 −10 5 20 35 50 65 80 0 −40 −25 −10 95 110 125 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C TJ − Junction Temperature − °C Figure 3-7. Figure 3-8. DIFFERENTIAL AMPLIFIER INPUT OFFSET VOLTAGE vs TEMPERATURE HDRV SOURCE AND SINK RESISTANCE vs TEMPERATURE 3.5 4.0 3.0 RHDRV − Drive Resistance − Ω DIFFAMP Input Offset Voltage − mV 3.5 3.0 2.5 2.0 1.5 1.0 Source 2.5 2.0 Sink 1.5 0.5 0 −40 −25 −10 8 5 20 35 50 65 80 95 110 125 1.0 −40 −25 −10 5 20 35 50 65 80 TJ − Junction Temperature − °C TJ − Junction Temperature − °C Figure 3-9. Figure 3-10. TYPICAL CHARACTERISTICS 95 110 125 Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 LDRV SINK RESISTANCE vs TEMPERATURE FEEDBACK VOLTAGE vs TEMPERATURE 1.2 701.0 700.8 VFB − Feedback Voltage − mV RLDRV − Sink Resistance − Ω 1.1 1.0 0.9 0.8 700.6 700.4 700.2 700.0 699.8 0.7 699.6 0.6 −40 −25 −10 5 20 35 50 65 80 95 110 125 Figure 3-11. Figure 3-12. VREG OUTPUT VOLTAGE vs TEMPERATURE VSHARE VOLTAGE vs TEMPERATURE 5.30 2.0 5.28 1.8 5.26 1.6 ILOAD = 66 mA 5.24 5.22 5.20 5.18 5.16 No Load 5.14 VVSHARE − VSHARE Voltage − V VVREG − Output Regulation Voltage − V TJ − Junction T emperature − °C 699.4 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C ILOAD = 189 µA 1.4 1.2 No Load 1.0 0.8 0.6 0.4 0.2 5.12 5.10 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-13. Submit Documentation Feedback 0.0 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-14. TYPICAL CHARACTERISTICS 9 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 UVLO_CEx THRESHOLD VOLTAGE vs TEMPERATURE VUVLO_CEx − UVLO Threshold Voltage − V 2.3 2.1 1.9 1.7 PWM Enabled 1.5 1.3 1.1 VREG Enabled 0.9 0.7 0.5 −40 −25 −10 5 20 35 50 65 80 95 110 125 TJ − Junction Temperature − °C Figure 3-15. 10 TYPICAL CHARACTERISTICS Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 4 DEVICE INFORMATION 4.1 TERMINAL CONFIGURATION The package is an 36-pin PQFP (RHH) package. Note: The thermal pad is an electrical ground connection. FB1 COMP1 ILIM1 TRK1 CSRT1 CS1 PGOOD1 UVLO_CE1 CLKIO 36 35 34 33 32 31 30 29 28 RHH PACKAGE (TOP VIEW) PGND VSHARE 6 22 LDRV2 GND 7 21 VREG BP5 8 20 SW2 FB2 9 19 HDRV2 18 23 BOOT2 5 17 RT VDD LDRV1 16 24 UVLO−CE2 4 15 PHSEL 14 SW1 CS2 25 PGOOD2 3 13 GSNS CSRT2 HDRV1 12 26 TRK2 2 11 BOOT1 ILIM2 27 10 1 VOUT COMP2 DIFFO The TPS40140 is a versatile controller that can operate as a single controller or 'stacked' in a multi-controller configuration. A TPS40140 has two channels that may be configured as a multi-phase (single output) or as a dual, with two independent output voltages. The two channels of a single controller always switch 180 degrees out of phase. See below for further discussion on the Clock and Voltage Master and Clock and Voltage Slave. Some pins are used to set the operating mode, and other pins' definition change based on the mode selected. It is often necessary to refer to a pin or pins that are used in CH1 and/or CH2. The short cut nomenclature used is the pin name with a lower case 'x' to mean either or both channels. For example, TRKx refers to TRK1 and/or TRK2. 4.2 CLOCK MASTER AND CLOCK SLAVE A controller may function as a 'Clock Master' or a 'Clock Slave'. The term ' Clock Master' designates the controller, in a multi-controller configuration, that generates the CLKIO signal for clock synchronization between the Clock Master and the Clock Slaves. The CLKIO signal is generated when the 'RT' pin of the Clock Master is terminated with a resistor to ground and the PHSEL pin of the Clock Master is terminated with a resistor, or resistor string, to ground. The 'Clock Slave' is configured by connecting the RT pin to BP5. Then the Clock Slave receives the CLKIO signal from the Clock Master. The phasing of the Slave is accomplished with a resistor string tied to the PHSEL pin. More information is covered in the CLOCK MASTER, PHSEL AND CLKIO CONFIGURATIONS section. Submit Documentation Feedback DEVICE INFORMATION 11 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 4.3 VOLTAGE MASTER AND VOLTAGE SLAVE A Voltage Master has the channel that monitors the output voltage and generates the 'COMP' signal for voltage regulation. A Voltage Slave channel is configured by connecting the TRKx pin to BP5. Then the COMP signal from the Master is connected to the COMPx pin on the Voltage Slave. When the TRKx pin is connected to BP5 the COMPx output for that channel is put in a high impedance state, allowing the regulation for that channel to be controlled by the Voltage Master COMP signal. 4.3.1 TERMINAL FUNCTIONS Table 4-1. TERMINAL FUNCTIONS TERMINAL NAME NO. I/O DESCRIPTION BP5 8 O Filtered input from the VREG pin. A 10-Ω resistor should be connected between VREG and BP5 and a 1.0-µF ceramic capacitor should be connected from BP5 to ground. GND 7 - Low noise ground connection to the device. BOOT1 27 I BOOT1 provides a bootstrapped supply for the high side FET driver for PWM1, enabling the gate of the high side FET to be driven above the input supply rail. Connect a capacitor from BOOT1 to SW1 pin and a Schottky diode from this pin to VREG. BOOT2 18 I BOOT2 provides a bootstrapped supply for the high side FET driver for PWM2, enabling the gate of the high side FET to be driven above the input supply rail. Connect a capacitor from BOOT2 to SW2 pin and a Schottky diode from this pin to VREG. CLKIO 28 O Digital clock signal for synchronizing slave controllers to the master CLKIO frequency and is either 6 or 8 times the PWM switching frequency. COMP1 35 O Output of the error amplifier, CH1. The voltage at this pin determines the duty cycle for the PWM1. COMP2 10 O Output of the error amplifier, CH2. The voltage at this pin determines the duty cycle for the PWM2. CS1 31 I These pins are used to sense the CH1 phase current. Inductor current can be sensed with an external current sense resistor or by using an external R-C circuit and the inductor’s DC resistance. The traces for these signals must be connected directly at the current sense element. CS2 14 I These pins are used to sense the CH2 phase current. Inductor current can be sensed with an external current sense resistor or by using an external R-C circuit and the inductor’s DC resistance. The traces for these signals must be connected directly at the current sense element. CSRT1 32 O Return point of CH1 current sense voltage. The trace for this signal must be connected directly at the current sense element. CSRT2 13 O Return point of CH1 current sense voltage. The trace for this signal must be connected directly at the current sense element. DIFFO 1 O Output of the differential amplifier. The output voltage of the differential amplifier is limited to 5.8 V. For remote sensing, the voltage at this pin represents the true output voltage without I × R drops that result from high current in the PCB traces. The VOUT and GSNS pins must be connected directly at the point of load where regulation is required. See Layout Guidelines for more information. FB1 36 I Inverting input of the error amplifier for CH1. In closed loop operation, the voltage at this pin is nominally 700 mV. This pin is also monitored for PGOOD1 and undervoltage on CH1. FB2 9 I Inverting input of the error amplifier for CH2. In closed loop operation, the voltage at this pin is nominally 700 mV. This pin is also monitored for PGOOD2 and undervoltage on CH2. GSNS 3 I Inverting input of the differential amplifier. This pin should be connected to ground at the load. If the differential amplifier is not used, tie this pin to GND or leave open. HDRV1 26 O Gate drive output for the high side N-channel MOSFET switch for CH1. Output is referenced to SW1 and is bootstrapped for enhancement of the high side switch. HRDV2 19 O Gate drive output for the high side N-channel MOSFET switch for CH2. Output is referenced to SW2 and is bootstrapped for enhancement of the high side switch. ILIM1 34 I Used to set the cycle-by-cycle current limit threshold for CH1. If the ILIM1 threshold is reached, the PWM pulse is terminated and the converter delivers limited current to the output. ILIM2 11 I Used to set the cycle-by-cycle current limit threshold for CH2. If the ILIM2 threshold is reached, the PWM pulse is terminated and the converter delivers limited current to the output. LRDV1 24 O Gate drive output for the low side synchronous rectifier (SR) N-channel MOSFET for CH1. LRDV2 22 O Gate drive output for the low side synchronous rectifier (SR) N-channel MOSFET for CH2. 12 DEVICE INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 Table 4-1. TERMINAL FUNCTIONS (continued) TERMINAL NAME NO. I/O DESCRIPTION PGOOD1 30 O Power good indicators for CH1 output voltage. This open-drain output connects to a voltage via an external resistor PGOOD2 15 O Power good indicators for CH2 output voltage. This open-drain output connects to a voltage via an external resistor PGND 23 - Power ground reference for the controller lower gate drivers. There should be a high current return path from the sources of the lower MOSFETs to this pin. PHSEL 4 O A 20µA current flows from this pin. In a single controller design, this pin should be grounded. In a multi controller configuration, a 39- kΩ resistor string sets the voltage on this pin determines the proper phasing for the slaves. See the section on ' CLOCK MASTER, PHSEL AND CLKIO CONFIGURATIONS' VREG 21 O The output of the internal 5-V regulator. A 4.7-µF ceramic capacitor should be connected from this pin to PGND. RT 6 I Connecting a resistor from this pin to ground sets the oscillator frequency. SW1 25 I Connect to the switched node on converter CH1. It is the return for the CH 1 upper gate driver. There should be a high current return path from the source of the upper MOSFET to this pin. This pin is also used by the adaptive gate drive circuits to minimize the dead time between upper and lower MOSFET conduction. SW2 20 I Connect to the switched node on converter CH2. It is the return for the CH 2 upper gate driver. There should be a high current return path from the source of the upper MOSFET to this pin. This pin is also used by the adaptive gate drive circuits to minimize the dead time between upper and lower MOSFET conduction. TRK1 33 O This is an input to the non-inverting input of the error amplifier CH1. This pin is normally connected to the soft-start capacitor or to another voltage that is tracked. TRK2 12 O This is an input to the non-inverting input of the error amplifier CH2. This pin is normally connected to the soft-start capacitor or to another voltage that is tracked. UVLO_CE1 29 I A voltage divider from VIN to this pin determines the input voltage that CH1 starts. When the voltage is between 0.5 V and 1.5 V the VREG regulator is enabled . When the voltage is 2.1 V or above CH1 soft start is allowed to begin. UVLO_CE2 16 I A voltage divider from VIN to this pin determines the input voltage that CH2 starts. When the voltage is between 0.5 V and 1.5 V the VREG regulator is enabled . When the voltage is 2.1 V or above CH2 soft start is allowed to begin. VDD 17 I Power input for the controller 5V regulator and differential amplifier. A 1.0-µF ceramic capacitor should be connected from this pin to ground. VOUT 2 I Non-inverting input of the differential amplifier. This pin should be connected to the output of the converter close to the load point. If the differential amplifier is not used, leave this pin open. VSHARE 6 O The 1.8 V reference output. Submit Documentation Feedback DEVICE INFORMATION 13 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 4.4 FUNCTIONAL BLOCK DIAGRAM U1 VDD VREG V5Reg 17 8 31 32 34 2 3 1 21 BP5 U6 U3 U2 CS1 + ICTLR1 ILIM1 27 U5 OC1 RAMP1 PWM 1 HDRV1 26 U8 SW1 + DIFFO 25 VREG PWM LOGIC VREF 0.7V 36 33 U7 + U9 GSNS FB1 BOOT1 U4 CSRT1 VOUT ANTI CROSS CONDUCTION TRK1 + − + U10 + + U11 LDRV1 24 U12 PGND 23 ANTI CROSS CONDUCTION U13 6−12uA COMP1 BOOT2 18 35 VREF 9 12 0.7V FB2 + − + TRK2 U15 U14 U17 U16 + + + U18 PWM 2 HDRV2 U19 19 SW2 RAMP2 20 U20 6−12uA COMP2 10 14 CS2 CSRT2 + U21 29 16 VREG OC1 ICTLR2 13 11 OC/UV DETECTION U22 LDRV2 U24 OC2 ILIM2 22 U23 FB1 PGOOD1 FB2 UVLO_CE1 30 PGOOD2 UVLO_CE2 15 VSHARE 5 4 U25 RT PHSEL CLOCK MCLK U26 RAMP GEN RAMP1 RAMP2 6 1.8 V GND 7 CLKIO 28 14 DEVICE INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5 APPLICATION INFORMATION 5.1 FUNCTIONAL DESCRIPTION The TPS40140 operates with a programmable fixed switching frequency. It is a current feedback controller with forced phase current balancing. When compared to voltage mode control, the current feedback controller results in a simplified feedback network and reduced input line sensitivity. Phase current is sensed by using either the DCR (direct current resistance) of the filter inductors or current sense resistors installed in series with the output. See the section on INDUCTOR DCR CURRENT SENSE. The current signal is then amplified and superimposed on the amplified voltage error signal to provide current mode PWM control. Other features include programmable input Under Voltage Lock Out (UVLO), differential input amplifier for precise output regulation, user programmable operation frequency, programmable pulse-by-pulse overcurrent protection, output under-voltage shutdown and re-start, capacitor to set soft-start time and power good indicators. 5.2 DATA SHEET ORGANIZATION The Application Information is partitioned into sections to facilitate applying the TPS40140 in various modes and configurations. The first sections describe functions that are used in all configurations. The following sections are specific to the configuration ( i.e., single controller, multiple controllers, Master and Slave). 5.3 TYPICAL START UP SEQUENCE Figure 5-1 shows a typical start up with the VDD applied to the controller and then the UVLO-CEx being enabled. Shut down occurs when the VDD is removed. VDD VREG BP5 UVLO_CEx 2.4 V 1 .4 V 0.7 V TRKx SSWAIT VOUT PGOOD Figure 5-1. Typical Start Up and Shut Down Sequence Submit Documentation Feedback APPLICATION INFORMATION 15 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.4 TRACK (SOFT-START WITHOUT PRE-BIASED OUTPUT) A capacitor connected to the TRKx pins sets the power-up time. When UVLO_CEx is high and the internal power-on reset (POR) is cleared, the calibrated current source, starts charging the external soft start capacitor with 12-µA. The PGOOD pin is held low during the start up. The rising voltage across the capacitor serves as a reference for the error amplifier, U10 and U14. When the soft start voltage reaches the level of the reference voltage, VREF = 0.7 V, the converter’s output reaches the regulation point and further voltage rise of the soft-start voltage has no effect on the output. When the soft start voltage reaches 1.4 V, the powergood (PGOOD) function is cleared to be reported on the PGOOD pin. Normally the PGOOD pin goes high at this time. Equation 1 is used to calculate the value of the soft-start capacitor. Css is in Farads and Tss is given in seconds. T SS + CSS 58 10 3 (1) 5.5 SOFT-START WITH PRE-BIASED OUTPUTS For pre-biased outputs the TPS40140 uses two levels of soft-start current that charge the soft-start capacitor connected to the TRKx pin(s). PWM switching begins when the TRKx voltage rises to the voltage present on the FBx pin. When the first PWM pulse occurs, the charging current is increased to 12 µA. Figure 5-2 shows the typical waveforms present on the TRACKx pin and the output voltage, VOUT when VOUT is pre-biased. TRKx rises due to the 6µA current, until at T1 the voltage on TRKx equals the pre-biased voltage on the FBx pin, at time t1. At this time the soft-start current is increased to 12 µA and TRKx rises with an increase in it's slope. When TRKx reaches 0.7 V, at time t2, the output should be in regulation. The voltage on the TRKx pin continues to rise. When the TRKx voltage is 1.4 V, at time t3, the PGOODx signal is enabled. The TRKx voltage continues to rise to 2.4 V where is is clamped internally. This approach provides for an accurate detection of the threshold where FBx = TRKx. Figure 5-3 is a block diagram of the implementation. The calculation for the soft start time, due to pre-bias, includes the time from t0 to t1, plus the time from t1 to t2, as shown in Equation 2 through Equation 4. C VOUT RBIAS t1 + SS 6 mA R1 ) R BIAS ǒ t2 + CSS 12 mA where • • Ǔ ǒ 0.7 V * ǒ (2) ǓǓ V OUT R BIAS R1 ) RBIAS (3) Css is in Farads Tss is in seconds T SS + t1 ) t2 (4) If there is no pre-bias (VOUT = 0 V), the equation reduces to case without pre-bias. 16 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 2.4 1.4 12 µA FBx 0.7 FBx TRKx 6 µA 0 VREG VPRE−BIAS VOUT 0 t0 t1 t2 t3 Figure 5-2. Soft-Start with PreBiased Output Waveforms From CSx Amplifier VOUT VREF 0.7 V R1 FBx TRKx RBIAS Error Amplifier Ramp1 + COMPx + U3 + + 6 µA 12 µA CEXT PWM Logic + U7 Comparator + UDG−06031 Figure 5-3. Implementation of PreBiased Output DESIGN HINT: If the pre-biased is greater than the regulation voltage, the controller does not start. This is a condition of an overvoltage being applied before the controller starts PWM switching. 5.6 TRACK FUNCTION IN CONFIGURING A SLAVE CHANNEL The TRACKx pin is internally clamped to 2.4 V. To configure a channel as a Slave, the TRACKx pin is pulled up externally to 5 V. This configures the output of the error amplifier, COMPx, for that channel to be a high impedance, allowing the Master COMP signal to control the Slave channel. Submit Documentation Feedback APPLICATION INFORMATION 17 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.7 DIFFERENTIAL AMPLIFER, U9 The unity gain differential amplifier has high bandwidth to achieve improved regulation at user defined point of load and ease layout constrains. The output voltage is sensed between the VOUT and GSNS pins. The output voltage programming divider is connected to the output of the amplifier, the DIFFO pin. 30 kW VOUT + DIFFO − 30 kW 30 kW GSNS 30 kW Figure 5-4. Differential Amplifier Configuration DESIGN HINT: Because of the resistor configuration of the differential amplifier, the input impedance must be kept very low or errors result in setting the output voltage. 5.8 POWER GOOD The PGOOD1, PGOOD2 pins indicate when the inputs and output are within their specified ranges of operation. Also monitored are the UVLO_CE1, UVLO_CE2 and TRK1 and TRK2 pins. The PGOOD has a high impedance when indicating inputs and outputs are within specified limits and is pulled low to indicate an out of limits condition. The PGOOD signal is held low until the respective TRK1 or TRK2 pin voltages exceed 1.4 V, then the undervoltage, overcurrent or overtemperature controls the state of PGOOD. 5.9 SETTING THE OUTPUT VOLTAGE Two resistors, R1 and RBIAS sets the output voltage as shown in Figure 5-5. R1 COMP VOUT VFB + RBIAS 0.7 V Figure 5-5. Setting the Output Voltage with RBIAS RBIAS is calculated in Equation 5. R BIAS + 0.7 18 ǒ R1 Ǔ ǒV OUT * 0.7Ǔ APPLICATION INFORMATION (5) Submit Documentation Feedback www.ti.com TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.10 PROGRAMMABLE INPUT UNDERVOLTAGE LOCK OUT PROTECTION A voltage divider that sets 2 V on the UVLO_CEx pins determines when the controller begins to operate. The internal regulators are enabled when the voltage on the UVLO_CEx pins exceeds 1 V, but switching commences when the voltage is 2 V. 5.11 POWER ON RESET (POR) The internal POR function ensures the VREG and BP5 voltages are within their regulation windows before the controller is allowed to start. 5.12 OVERCURRENT The operation during an overcurrent condition is described in the ‘Overcurrent Detection and Hiccup Mode’ section. In summary, when the controller detects 7 clock cycles of an overcurrent condition, the upper and lower MOSFETs are turned off and the controller enters a 'hiccup' mode'. After seven soft start cycles, normal switching is attempted. If the overcurrent has cleared, normal operation resumes, otherwise the sequence repeats. 5.13 OUTPUT UNDERVOLTAGE PROTECTION If the output voltage, as sensed by U23 of the Functional Block Diagram on the FB pin becomes less than 0.588 V, the undervoltage protection threshold (84% of VREF), the controller enters the hiccup mode as described in the Overcurrent Detection and Hiccup Mode section. 5.14 OUTPUT OVERVOLTAGE PROTECTION Output overvoltage is defined as any voltage greater than the regulation level that appears on the output. Overvoltage protection is accomplished by the feedback loop monitoring the output voltage via the FB pin. If, during operation the output voltage experiences an overvoltage condition the FB pin voltage rises and the control loop turns the upper FET off and the lower FET is turned on until the output returns to set level. This puts the overvoltage channel in a boost mode configuration and tends to cause the input voltage to be boosted up. If the output overvoltage condition exists prior to the controller PWM switching starting, i.e., no switching has commenced, the overvoltaged channel does not start PWM switching. This controller allows for operating with a pre-biased output. Since the output is greater than the regulation voltage, no PWM switching occurs. DESIGN HINT: Care must be taken to insure there is sufficient load on the input voltage to prevent excessive boosting. 5.15 CLKFLT, CLKIO PIN FAULT If the CLKIO signal is to be distributed from the Master to the Slave controllers, and is not there, the Slave controller enters a ‘Standby’ mode. The upper and lower MOSFETs are turned off but the internal 5-V regulator is still active and VREG is present. The CLKIO signal could be turned off at the Master controller or the connection to the Slave CLKIO input could be opened. If the CLKIO signal is restored, normal operation continues. 5.16 PHSEL PIN FAULT The PHSEL pin is normally terminated with a resistor string, or tied directly to ground. If this string becomes open, the PHSEL pin voltage is pulled up internally to greater than 4V. The controller enters a ‘Standby’ mode. The upper and lower MOSFETs are turned off but the internal 5V regulator is still active and VREG is present. If the PHSEL connection is restored, normal operation continues after 64 PWM clock cycles. Submit Documentation Feedback APPLICATION INFORMATION 19 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.17 OVERTEMPERATURE If the temperature of the controller die is detected to be above 155°C, the upper and lower MOSFETs are turned off and the 5-V regulator, VREG, is turned off. When the die temperature decreases 30°C the controller performs a normal start up. 5.18 FAULT MASKING OPERATION If the TRKx pin voltage is externally limited below the 1.4-V threshold, the controller does not respond to an Undervoltage fault and the PGOOD output remains low. Other fault modes remain operational. The overcurrent protection continues to terminate PWM cycle every time the threshold is exceeded, but the hiccup mode is not entered. 5.19 PROTECTION AND FAULT MODES There are modes of normal operation during start up and shut down as well various fault modes that may be detected. It is often necessary to know the state of the upper and lower MOSFETs in these modes. Table xx shows a summary of these modes and the state of the MOSFETs. A description of each mode follows the table. Table 5-1. Fault Mode Summary MODE UPPER MOSFET LOWER MOSFET PROGRAMMABLE UVLO_CEx = LOW OFF OFF POWER ON RESET: FIXED UVLO, BP5 < 4.25V OFF OFF OVERCURRENT OFF, HICCUP MODE OFF, HICCUP MODE OUTPUT UNDERVOLTAGE OFF, HICCUP MODE OFF, HICCUP MODE OUTPUT OVERVOLTAGE, PRIOR TO PWM SWITCHING OFF OFF PWM SWITCHING PWM SWITCHING CLKFLT, MISSING CLKIO AT SLAVE OFF OFF PHSEL VOLTAGE > 4V, or open to ground OFF OFF OVERTEMPERATURE OFF OFF OUTPUT OVERVOLTAGE, WHILE PWM SWITCHING 5.20 SETTING THE SWITCHING FREQUENCY The clock frequency is programmed by the value of the timing resistor connected from the RT pin to ground. See Equation 6. This equation gives the frequency for an 8-phase system. For a 6-phase system the frequency is 1 1/3 times higher. R +1.33 ǒ39.2 103 Ǔ ƒ*1.041*7 ; PH (6) fPH is a single phase frequency, kHz. The Rt resistor value is expressed in kΩ. See Figure 5-6. 20 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 PHASE FREQUENCY vs TIMING RESISTOR 450 400 Rt − Timing Resistor − k W 350 300 250 200 150 100 50 0 100 200 300 400 500 600 700 800 900 1000 Phase Switching Frequency − kHz Figure 5-6. Phase Switching Frequency vs RT 5.21 SYNCHRONIZING A SINGLE CONTROLLER TO AN EXTERNAL CLOCK The TPS40140 has the ability to synchronize a single controller to an external clock. The clock must be a pulse stream at 6 or 8 times the Master PWM frequency. See Figure 5-7. Synchronizing the single controller to an external clock is similar to synchronizing a clock slave to a clock master. The single controller is put in clock slave mode by connecting the RT pin to BP5, disabling the internal clock generator. If the external CLKIO signal is a clock stream without any missing pulses, the master synchromizes to an arbitrary pulse so there is no determinant phase synchronization. Without a missing pulse, the PWM frequency will be 1/8 of the external clock. If the external CLKIO signal has a missing pulse every 6 cycles or 8 cycles, the controller synchronizes based on the missing pulse which would be in the 6th or 8th position. With the missing pulse, the phase synchronization of the master, to the missing pulse, can be controlled by the voltage on the PHSEL pin. See the section on DIGITAL CLOCK SYNCHRONIZATION. Phase shifting would also be desirable if more than one controller were to be synchronized to the same external clock. Figure 5-7 shows a time slice of the two external clock possibilities and the resulting PWM signal. EXT CLK-A is the continuous clock with no missing pulse and the PWM-A signal could be frequency synchronized anywhere in the clock stream. The PWM signal is at 1/8 of the EXT CLK-A frequency. EXT CLK-S is the external clock stream with a missing pulse every 8 cycles. The phasing of the PWM-S is based on the voltage on the PHSEL pin. For PHSEL grounded, the PWM-S signal is shifted 90 degrees from what would be the falling edge of the missing pulse as shown. Submit Documentation Feedback APPLICATION INFORMATION 21 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 EXT CLK−A 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 PWM −A EXT CLK−S PWM −S UDG−06032 Figure 5-7. Synchronizing a Single Controller to an External Clock 5.22 SPLIT INPUT VOLTAGE OPERATION It may be advantageous to operate a master controller’s power stages from VIN1, different from the Slave controller(s) power stages, VIN2 where VIN1 > VIN2. This enables the system designer to optimize the current taken from the system input voltages. In order to balance the output currents, a programmed offset is applied to ILIM2 of the slave controller(s). The voltage on this pin sets the offset current for channel 2. The ramp offset is determined by a resistor, RSET, connected to the ILIM2 pin of the slave, and is given by: ǒ R SET + VOUT 22 Ǔ 1 * 1 100 kW V IN2 V IN1 APPLICATION INFORMATION (7) Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.23 CURRENT SENSE The current sensing and overcurrent detection architecture is shown in Figure 5-8. RSNS IOUT CSn VOUT CSRTn VC _ + U1 CS gain = 12.5 + ERROR AMP + U3 _ U2 + Ve U4 + PWM RAMP COMP VSHR , 1.8 V U5 + + 0.5 V R1 0 V 20 mA U6 U7 ILIM OVER CURRENT + R2 VOUT Figure 5-8. Output Current Sensing and OverCurrent Detection The output current, IOUT, flows through RSNS and develops a voltage, VC across it, representative of the output current. The voltage, VC, could also be derived from an R-C network in parallel with the output inductor. This voltage is amplified with a gain of 12.5 and then subtracted from the Error Amp output, COMP, to generate the Ve voltage. The Ve signal is compared to the slope-compensation RAMP signal to generate the PWM for the modulator. As the output current is increased, the amplified VC causes the Ve signal to decrease. In order to maintain the proper duty cycle (PWM), the COMP signal must increase. Therefore the magnitude of the COMP signal contains the output current information: COMP = Ve + (IPEAK ´ R SNS ) ´ 12.5 (8) This is integral in the overcurrent detection as can be seen at comparator U7, comparing the ILIM voltage with COMP. In order to have the proper duty cycle at PWM, Ve is: V Ve = RAMP ´ OUT + VSHR VIN (9) Combining equations: COMP = RAMP ´ VOUT + VSHR + (IPEAK ´ R SNS ) ´ 12.5 VIN (10) This equation for COMP shows the reason for resistors R1 and R2 being tied to VSHR and VOUT respectively. Submit Documentation Feedback APPLICATION INFORMATION 23 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.24 CURRENT SENSING AND BALANCING The controller employs peak current mode control scheme, thus naturally provides certain degree of current balancing. With current mode, the level of current feedback should comply with certain guidelines depending on duty factor known as “slope compensation” to avoid the sub-harmonic instability. This requirement can prohibit achieving a higher degree of phase current balance. To avoid the controversy, a separate current loop that forces phase currents to match is added to the proprietary control scheme. This effectively provides high degree of current sharing independent of the controller’s small signal response and is implemented in U3 and U22, ICTLR. High bandwidth current amplifiers, U2 and U21 can accept as an input voltage either the voltage drop across dedicated precise current sense resistors, or inductor’s DCR voltage derived by an RC network, or thermally compensated voltage derived from the inductor’s DCR. The wide range of current sense arrangements ease the cost/complexity constrains and provides superior performance compared to controllers utilizing the low-side MOSFET current sensing. See the Inductor DCR Current Sense sectionfor selecting the values of the RC network. 5.25 OVERCURRENT DETECTION AND HICCUP MODE In order to reduce the input current and component dissipation during on overcurrent event, a hiccup mode is implemented. Hiccup mode refers to a sequence of 7 soft-start cycles where no MOSFET switching occurs and then a re-start is attempted. If the fault has cleared, the re-start results in returning to normal operation and regulation. This is shown in Figure 5-9. 2.4 V TRCKn 1.5 V 0.5 V (A) GND VIN SW NODE GND (B) VOUT, REG VOUT GND (C) ILIM COMP (D) t0 t1 t2 t3 Figure 5-9. Hiccup Mode and Recovery 24 APPLICATION INFORMATION Submit Documentation Feedback www.ti.com TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 In Figure 5-9, normal operation is occurring between t0 and t1 as shown by VOUT being at the regulated voltage, (C) and normal switching on the SW NODE (B) and COMP at it's nominal level, (D). At t1, an overcurrent load is experienced. The increased current forces COMP to increase to the ILIM level as shown in (D). If the COMP voltage is above the ILIM voltage for 7 switching cycles, the controller enters a hiccup mode. During this time the controller is not switching and the switching MOSFETs are turned off. The TRCKn voltage goes through 7 cycles of charging and discharging the soft-start capacitor. At the end of the 7 cycles the controller attempts another normal re-start. If the fault has been cleared, the output voltage comes up to the regulation level as shown at time t3. If the fault has not cleared, the COMP voltage again rises above the ILIM voltage and the hiccup mode repeats. If the overcurrent condition exists for seven (7) PWM clock cycles the converter turns off the upper and lower MOSFETs and initiates a hiccup mode restart. In hiccup mode, the TRKx pin is periodically charged and discharged. After seven hiccup cycles, the controller attempts another soft-start cycle to restore normal operation. If the overload condition persists, the controller returns to the hiccup mode. This condition may continue indefinitely. 5.26 CALCULATING OVERCURRENT PROTECTION LEVEL In order to set the desired overcurrent (IOC), a few variables must be known. The input and output voltage, the output inductor value and it's DC resistance (DCR), as well as the switching frequency. Also known are the ramp voltage which is 0.5 V and the VSHARE voltage, VSH which is 1.8 V. See the list of variables and their values at the end of this section. The overcurrent set point is in terms of the DC output current, but the current sense circuit monitors the peak of the current. Therefore, the current ripple is needed and is calculated from • input voltage (VIN) • output voltage (VOUT) • switching frequency (fSW) • output inductance (L) The ripple current is given by Equation 11. V * VOUT VOUT 1 I RIPPLE + IN L V IN f SW (11) The peak current detected is given by Equation 12, and used in Equation 14. I I PEAK + RIPPLE ) I OC 2 (12) It is this IPEAK current that is detected by the current sense circuit. The two resistors needed to set the peak overcurrent protection threshold and their connection for each channel is shown in Figure 5-10. DESIGN HINT: Resistor R2 may be connected to the output voltage, Vout, or to the output of the differential amplifier, DIFFO, if used. Submit Documentation Feedback APPLICATION INFORMATION 25 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 VOUT TPS40140 R2 ILIMx R1 VSHARE Figure 5-10. Selecting Overcurrent Threshold Resistors, R2 and R1 26 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 The two factors, alpha and beta help simplify the final equations and are given by Equation 13 and Equation 14. V a + RAMP V IN (13) b + DCR AC I PEAK ) ǒ V RAMP 2 Nph Ǔ (14) R1 is shown in Equation 15. b ) a V SH R1 + (1 * a) I LIM (15) R2 is shown in Equation 16. b ) a V SH R2 + a I LIM (16) where (for Equation 13 through Equation 16) • VRAMP(1) is the ramp amplitude (0.5 V typ) • VIN is the input voltage • DCR is the inductor equivalent DC resistance • AC(1) is the gain transfer to comparator • IOC is the single-phase DC overcurrent trip point • IPEAK is the peak single-phase inductor current • Nph is 6 if PHSEL voltage = 1.6 V ±0.2 V, otherwise Nph = 8 • VSHR(1) is the VSHARE reference voltage (typ 1.8 V) • ILIM(1) is the current limit, output current (typ 20 µA) (1) Range of variable is specified in Submit Documentation Feedback APPLICATION INFORMATION 27 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27 CONFIGURING SINGLE AND MULTIPLE ICS The controller may be configured for a single output, 2 Phase mode or a Dual output voltage mode. In the Dual output mode the input voltages and the output voltages are independent of each other. In 2 Phase mode the input voltages and output voltages are tied together, respectively and certain other pins must be configured. The two phases of a single controller are always 180° out of phase. The entry in the following tables that refer to' TO NETWORK' means the normal resistor-capacitor network used for control loop compensation. The other entries refer to components that are typically connected to the Device Pin. 5.27.1 Single Device Operation A single controller may be configured as a 2 Phase or Dual output. A summary of the modes and device pin connections for a single controller is given in Table 5-2. The basic schematic of a single controller operating in a 2 Phase mode is shown in Figure 5-11 . The Dual output schematic is shown in Figure 5-14. Table 5-2. TPS40140 SINGLE device MODE SELECTION AND PIN CONFIGURATION 28 DEVICE PIN FOR 2 PHASE MODE FOR DUAL OUTPUT MODE COMP1 TO NETWORK TO NETWORK COMP2 COMP1 TO NETWORK TRK1 TO SS CAPACITOR TO SS CAPACITOR TRK2 TO BP5 TO SS CAPACITOR ILIM1 TO SET RESISTORS TO SET RESISTORS ILIM2 GND TO SET RESISTORS FB1 TO NETWORK TO NETWORK FB2 GND TO NETWORK PHSEL GND GND PGOOD1 TO PULL-UP RESISTOR TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR TO PULL-UP RESISTOR CLKIO OPEN OPEN APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 CS1 VIN CSRT1 CS2 CSRT2 VIN HDRV1 HDRV 2 Vout SW1 SW2 LDRV1 VREG LDRV2 L2 L1 PGND PGND BOOT1 VREG BOOT2 VLOAD 2 GNDLD 3 CLKIO EN 30 UVLO−CE1 29 CS1 31 CS1 CSRT1 32 CLKIO 28 HDRV 1 26 SW1 25 COMP1 SW1 LDRV1 BOOT2 18 VDD 17 UVLO−CE2 16 23 LDRV2 VREG SW2 HDRV2 HDRV2 19 VIN BOOT2 CS2 FB2 CSRT2 9 PGOOD2 20 15 SW2 BP5 CS2 21 14 VREG CSRT2 GND 13 7 TRK2 LDRV2 22 12 VSHARE ILIM2 6 11 PGND 10 COMP2 RT 8 BOOT1 HDRV1 LDRV1 24 PHSEL VLOAD L O A D BOOT1 27 GSNS 5 VREG TRK1 33 VOUT 4 BP5 ILIM1 34 DIFFO PGOOD1 1 COMP1 35 FB1 36 CSRT1 BP5 EN GNDLD ‘ Figure 5-11. Typical Applications Circuit, 2 PHASE Mode Submit Documentation Feedback APPLICATION INFORMATION 29 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 CS1 VIN CSRT1 CS2 CSRT2 VIN HDRV1 HDRV2 Vout1 SW1 LDRV1 VREG Vout2 SW2 LDRV2 L2 L1 PGND PGND BOOT1 VREG BOOT2 CLKIO CLKIO 28 UVLO−CE1 29 PGOOD1 30 EN CS1 GSNS PHSEL LDRV1 24 LDRV1 PGND 23 RT 6 VSHARE 7 GND VREG 21 8 BP5 SW2 20 18 BOOT2 17 VDD 16 UVLO−CE2 15 PGOOD2 14 CS2 13 CSRT2 Vout2 HDRV2 19 CS2 12 TRK2 11 ILIM2 FB2 LDRV2 22 CSRT2 L O A D CS1 31 VOUT 3 9 VLOAD CSRT1 32 2 BOOT1 27 BOOT1 HDRV1 HDRV1 26 SW1 SW1 25 5 BP5 TRK1 33 DIFFO 4 V R E G ILIM1 34 1 10 COMP2 VLOAD GNDLD COMP1 35 FB1 36 CSRT1 BP5 LDRV2 VREG SW2 HDRV2 Vout2 VIN BOOT2 EN BP5 GNDLD ‘ Figure 5-12. Typical Applications Circuit, DUAL Mode 30 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27.2 MULTIPLE ICs In a multiple device system it is often desireable to synchronize the clocks of all the ICs to minimize input ripple current as well as radiated and conducted emissions. This is accomplished by designating one of the controllers as the 'Master' and the other ICs as 'Slaves'. The Master generates the system clock, CLKIO , and it is distributed to the Slaves. This is the most useful configuration of multiple ICs and the one that is demonstrated in this data sheet. It is described in more detail in the ' Clock Master, PHSEL AND CLKIO Configurations' section. To increase the total current capability, or number of outputs, a single Slave controller can be added to a Master controller as shown in Figure 5-15. The configuration of the 2 Phase Master and a 2 Phase Slave controller is also shown in Table 5-3 It is possible to have the Master controller operate on one switching frequency and the Slave controllers on another, independent frequency. In a multi-phase system the Slave controllers would still share load current with the Master. This is not a preferred configuration and is mentioned here only for completeness. Table 5-3. TPS40140 TWO DEVICE, 4 PHASE MODE SELECTION AND PIN CONFIGURATION DEVICE PIN, MASTER MASTER, 2 PHASE DEVICE PIN, SLAVE SLAVE, 2 PHASE COMP1 TO NETWORK COMP1 TO MASTER, COMP1 COMP2 COMP1 COMP2 TO MASTER, COMP1 TRK1 TO SS CAPACITOR TRK1 TO BP5 TRK2 TO BP5 TRK2 TO BP5 ILIM1 TO SET RESISTORS ILIM1 GND ILIM2 GND ILIM2 GND FB1 TO NETWORK FB1 GND FB2 GND FB2 GND PHSEL 39KΩ TO GND PHSEL GND PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR CLKIO TO SLAVE, CLKIO CLKIO Submit Documentation Feedback TO MASTER, CLKIO APPLICATION INFORMATION 31 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 CLKIO−MST 28 CLKIO EN 29 UVLO−CE1 30 PGOOD1 31 CS1 32 CSRT1 3 GSNS SW1 LDRV1 24 LDRV1 PHSEL MASTER 9 FB2 HDRV2 19 BOOT2 18 17 LDRV2 SW2 HDRV2 VIN BOOT2 CS2 CSRT2 A D VDD 20 UVLO−CE2 SW2 16 BP5 PGOOD2 21 8 15 VREG CS2 GND 14 7 CSRT2 22 13 VSHARE TRK2 23 12 PGND LDRV2 ILIM2 RT 6 COMP1−MST O CS1 CSRT1 33 HDRV1 VLOAD L 34 VOUT 5 BP5 TRK1 2 4 VSHR ILIM1 DIFFO 11 GNDLD 27 BOOT1 HDRV1 26 SW1 25 BOOT1 1 10 COMP2 VLOAD COMP1 35 COMP1−MST FB1 36 BP5 EN 28 31 CS1 CLKIO 32 CSRT1 29 33 TRK1 30 34 ILIM1 PGOOD1 35 UVLO−CE1 27 DIFFO 2 VOUT HDRV1 26 3 GSNS SW1 25 LDRV1 24 SLAVE PHSEL SW2 20 HDRV2 19 COMP1−MST 18 FB2 17 9 BOOT2 BP5 VDD 8 UVLO−CE2 21 16 VREG PGOOD2 GND 15 7 CS2 22 14 LDRV2 CSRT2 VSHARE 13 6 TRK2 23 BP5 12 PGND ILIM2 RT 11 5 10 COMP2 VSHR BOOT1 1 4 BP5 36 ‘ FB1 GNDLD COMP1 CLKIO−MST VIN EN VIN EN Figure 5-13. Typical Applications Circuit, 4 Phase Mode 32 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 In this configuration, the Master senses that there is one Slave controller, by the 39-kΩ resistor on the PHSRL pin, and distributes the CLKIO signal. The Slave controller senses the zero-volt level on its PHSEL pin and delays the proper number of CLKIO pulses to be 90° out of phase with the Master. Two ICs could also be configured as a 2 Phase, single output Master and a Slave which has two independent outputs, but is synchronized with the Master controller clock. The configuration is shown in Table 5-4. Table 5-4. TPS40140 TWO DEVICE, 2 PHASE MASTER AND A DUAL OUTPUT SLAVE CONFIGURATION DEVICE PIN, MASTER MASTER, 2 PHASE DEVICE PIN, SLAVE SLAVE, DUAL OUTPUT COMP1 TO NETWORK COMP1 TO NETWORK COMP2 COMP1 COMP2 TO NETWORK TRK1 TO SS CAPACITOR TRK1 TO SS CAPACITOR TRK2 TO BP5 TRK2 TO SS CAPACITOR ILIM1 TO SET RESISTORS ILIM1 TO SET RESISTORS ILIM2 GND ILIM2 TO SET RESISTORS FB1 TO NETWORK FB1 TO NETWORK FB2 GND FB2 TO NETWORK PHSEL 39-kΩ TO GND PHSEL GND PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR PGOOD1 TO PULL-UP RESISTOR CLKIO TO SLAVE, CLKIO CLKIO TO MASTER, CLKIO 5.27.3 CLOCK MASTER, PHSEL AND CLKIO CONFIGURATIONS The clock synchronization between the Master and the Slave controller(s) is implemented in a simple configuration of series 39-kΩ resistors. There is a 20-µA current source from the PHSEL pin of the Master controller. Depending on the number of Slave controllers connected, the Slave controllers will select the proper delay from the Master CLKIO signal to accomplish phase interleaving. On a given Master or Slave controller, the two phases are always 180° out of phase. The CLKIO signal has either six or eight clocks for each cycle of the switching period. For maximum flexibility the Master and Slave controllers can be either in a 2 Phase configuration or a Dual output configuration 5.27.3.1 One device Operation The basic configuration of a single device is shown in Figure 5-14. TPS40140 MASTER 20 µA PHSEL CLKIO Figure 5-14. Single Controller only, Two Phases Submit Documentation Feedback APPLICATION INFORMATION 33 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27.3.2 Two ICs Operation To increase the total current capability, or number of outputs, a single Slave controller can be added as shown in Figure 5-15 TPS40140 MASTER 20 µA PHSEL CLKIO TPS40140 R1 CLKIO PHSEL SLAVE1 Figure 5-15. Master Controller and One Slave Controller, Four Phases In this configuration, the Master senses that there is one Slave controller, and distributes the CLKIO signal. The Slave controller senses the zero-volt level on its PHSEL pin and delays the proper number of CLKIO pulses to be 90° out of phase with the Master. 5.27.3.3 Three ICs Operation To increase the total current capability to six phases, or to increase the number of outputs, two Slave controllers can be added as shown in Figure 5-16. In this configuration for perfect interleaving, the Master and Slaves are 120° out of phase. The CLKIO signal has six clocks for each cycle of the switching period; therefore, the switching period is reduced. In this six-phase mode, the switching frequency is increased 33%. 34 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 TPS40140 MASTER 20 µA PHSEL CLKIO TPS40140 R2 CLKIO PHSEL SLAVE2 TPS40140 R1 CLKIO PHSEL SLAVE1 Figure 5-16. Master Controller and Two Slave Controllers, Six Phases In this configuration, the Master senses that there are two Slave controllers, and distributes a six-phase CLKIO signal. The Slave controllers sense the voltage on their PHSEL pins, and delay the proper number of CLKIO pulses to be 60° or 120° out of phase with the Master. Submit Documentation Feedback APPLICATION INFORMATION 35 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27.3.4 Four ICs Operation To further increase the total current capability to eight phases, or to increase the number of outputs, three Slave controllers can be added as shown in Figure 5-17 TPS40140 MASTER 20 µA PHSEL CLKIO TPS40140 R3 CLKIO PHSEL SLAVE3 TPS40140 R2 CLKIO PHSEL SLAVE2 TPS40140 R1 CLKIO PHSEL SLAVE1 Figure 5-17. Master Controller and Three Slave Controllers, 8 Phases In this configuration, the Master senses that there are three Slave controllers, and distributes a eight-phase CLKIO signal. The Slave controllers sense the voltage on their PHSEL pins and delay the proper number of CLKIO pulses to be 45° or 90° out of phase with the Master. 36 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27.3.5 Six ICs Operation To further increase the total current capability to twelve phases, or to increase the number of outputs, five Slave controllers can be added as shown in Figure 5-18 TPS40140 MASTER 20 µA BP5 TPS40140 ILIM2 PHSEL CLKIO CLKIO PHSEL SLAVE5 R2 TPS40140 ILIM2 TPS40140 CLKIO CLKIO PHSEL PHSEL SLAVE4 SLAVE2 TPS40140 ILIM2 R1 TPS40140 CLKIO CLKIO PHSEL SLAVE3 PHSEL SLAVE1 Figure 5-18. Master Controller and Five Slave Controllers, 12 Phases In this configuration, the Master senses that there are two Slave controllers (due to the 2 resistors) and distributes a six-phase CLKIO signal. Slaves 1 and 2 are turned on at 60° and 120° respectively, as before with 2 Slaves. However, to get 12 phases with a 6-phase clock, both edges of the CLKIO signal are used to control the slaves. With the ILIM2 tied high on Slaves 3, 4, and 5, they turn on at the rising edge of CLKIO while the Master and Slaves 1 and 2 turn on at the falling edge of CLKIO. If 4 Slaves are desired, just delete one of the Slaves from Figure 5-18. The interleaving will not be perfect because there will be 30 degrees between the Master and 3 Slaves. The deleted Slave will cause 60° between the 2 adjacent Slaves. See Figure 5-20 for phasing details. Submit Documentation Feedback APPLICATION INFORMATION 37 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.27.3.6 Eight ICs Operation To further increase the total current capability to sixteen phases, or to increase the number of outputs, seven Slave controllers can be added as shown in Figure 5-19. TPS40140 MASTER BP5 20 µA TPS40140 ILIM2 PHSEL CLKIO CLKIO PHSEL SLAVE7 TPS40140 ILIM2 R3 TPS40140 CLKIO CLKIO PHSEL PHSEL SLAVE6 SLAVE3 TPS40140 R2 TPS40140 CLKIO ILIM2 CLKIO PHSEL PHSEL SLAVE5 SLAVE2 TPS40140 TPS40140 R1 ILIM2 CLKIO CLKIO PHSEL PHSEL SLAVE4 SLAVE1 Figure 5-19. Master Controller and Seven Slave Controllers, 16 Phases In this configuration, the Master senses that there are three Slave controllers (due to the 3 resistors) and distributes an eight-phase CLKIO signal. Slaves 1, 2 and 3 are turned on at 45° and 90° respectively as before with 3 Slaves. However, to get 16 phases with an 8-phase clock, both edges of the CLKIO signal are used to control the slaves. With the ILIM2 tied high on Slaves 4, 5, 6, and 7 they turn on at the rising edge of CLKIO, while the Master and Slaves 1, 2, and 3 turn on at the falling edge of CLKIO. If 6 Slaves are desired, just delete one of the Slaves from Figure 5-19. The interleaving will not be perfect because there will be 22.5° between the Master and 3 Slaves. The deleted Slave will cause 45° between the 2 adjacent Slaves. See Figure 5-20 for a phasing details. 38 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.28 DIGITAL CLOCK SYNCHRONIZATION Figure 5-20 is a summary of the Master and Slave clock phasing. The Master and the Slaves can be selected to be a multi-phase, single output configuration and/or several independent output voltage rails, independent of the clocking. Phase PHSEL connection Clock scheme M M_CH2 M_CH1 (A) Two Phase Master 1 2 3 4 5 6 1 2 3 4 5 6 7 8 S_CH1 (E) ‘Missing’ Pulse with six and eight CLKIO pulses M R M_CH2 M_CH1 S PHSEL connection S_CH2 (B) Four Phase, Master and one Slave ILIM2= S1_CH1 M S2_CH1 M h i Phase S3_CH1 S5 S1_CH1 R R S2 S2_CH1 S5_CH1 S4_CH1 S4 M_CH2 M_CH2 S2 M_CH1 M_CH1 R S4_CH2 R S1 S5_CH2 S3 S2_CH2 S1 S2_CH2 S1_CH2 S3_CH2 S1_CH2 (F) Twelve Phase , Master and five Slaves (C) SixPhase, Master and two Slaves S1_CH1 S4_CH1 S6_CH1 S1_CH1 M S3_CH1 S2_CH1 M R S3_CH1 S7 R S3 S3 M_CH2 S2_CH1 S7_CH2 S5_CH1 S6 M_CH1 M_CH2 M_CH1 R R S5_CH2 S2 S2 R S2_CH2 S2_CH2 R S3_CH2 (D) Eight Phase, Master and three Slaves S3_CH2 S4_CH2 S1_CH2 S1 S7_CH1 S5 S1 S4 S6_CH2 S1_CH2 (G) Sixteen Phase, Master and seven Slaves Figure 5-20. Clock Phasing Summary Submit Documentation Feedback APPLICATION INFORMATION 39 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 5.28.1 BASIC CONFIGURATIONS FOR 2, 4, 6, 8, 12 OR 16 PHASES The solid square boxes in Figure 5-20 represent the PHSEL pin of the Master (M) controller or a numbered Slave controller (S1-S7). The labels on the spokes of the wheels indicate a Master Channel 1 and Master Channel 2 (M_CH1 and M_CH2) and numbered Slaves Channel 1 and Slave Channel 2 (Sn_CH1 and Sn_CH2). The Channel 1 and Channel 2 of a given Master or Slave is always 180° out of phase. The Master and Slaves are automatically configured for proper phasing based on the resistor string from the Master to the Slaves. All the resistors are 39 kΩ to 41.2 kΩ. Part (A) above shows a single controller operating two phases 180° out of phase. Part (B) above shows four phase operation. This is configured by connecting a single resistor from the Master PHSEL to GND and grounding the Slave PHSEL pin. The individual channels are 90° out of phase. Part (C) above shows six phase operation. This is configured by connecting two resistors from the Master PHSEL to GND. The first resistor tap is connected to Slave2 PHSEL pin and then grounding the Slave1 PHSEL pin. The individual channels are 60°out of phase. Part (D) above shows eight phase operation. This is configured by connecting three resistors from the Master PHSEL to GND. The first resistor tap is connected to Slave3 PHSEL pin. The second resistor tap is connected to Slave2 PHSEL pin and then grounding the Slave1 PHSEL pin. The individual channels are 45° out of phase. Part (F) above shows twelve phase operation. This is configured by connecting two resistors from the Master PHSEL to GND. The Master PHSEL pin is also connected to Slave5 PHSEL pin. The first resistor tap is connected to Slave2 and Slave4 PHSEL pins and then grounding the Slave1 and Slave3 PHSEL pins. The individual channels are 30° out of phase. Additionally, the ILIM2 pins of Slave5, Slave4 and Slave3 are left open (internal pull-up) or externally connected to BP5. Part (G) above shows sixteen phase operation. This is configured by connecting three resistors from the Master PHSEL to GND. The Master PHSEL pin is also connected to Slave7 PHSEL pin. The first resistor tap is connected to Slave3 and Slave6 PHSEL pins. The second resistor tap is connected to Slave2 and Slave5 PHSEL pins and then grounding the Slave1 and Slave4 PHSEL pins. The individual channels are 22.5° out of phase. Additionally, the ILIM2 pins of Slave7, Slave6, Slave5 and Slave4 are left open (internal pull-up) or externally connected to BP5. 5.28.2 CONFIGURING FOR OTHER NUMBER OF PHASES Configuring for other than 2, 4, 6, 8, 12 or 16 phases is simply a matter of not attaching one or more Slave controllers. The phasing between Master and populated Slaves is as shown above. For example a 3-phase system could be configured with a Master CH1 and Master CH2 and 1 phase of a Slave. Referring to part (B) above, the 3 phases could be Master CH1, Master CH2 and Slave CH1 or Slave CH2 as shown in Figure 5-21. S_CH1 M R S M_CH2 M_CH1 S_CH2− NOT USED IN3PH Figure 5-21. Phase System: 2 Channels of the Master and 1 Channel of the Slave The 3-phase system could also be configured with 1 channel of the Master and 2 channels of the Slave. Referring to part (B) above, the 3 phases could be Master CH1 or Master CH2 and Slave CH1 and Slave CH2. In either of these configurations there will be 90° between two of the channels and 180° between the other channel. The unused channel could be another independent output voltage whose clocking would occupy the phase not used in the 3-phase system. This philosophy can be used for any number of phases not shown in Figure 5-20, Clock Phasing Summary. For example, a 10-phase system could be configured as shown in Figure 5-22. 40 APPLICATION INFORMATION Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 PHSEL connection Phase ILIM 2 = hi M S1_CH1 S4 S4_CH1 M_CH2 R S1 S2_CH1 S5_CH1 NOT USED R S2 S3_CH1 M_CH1 S5_CH2 NOT USED S4_CH2 S3 S2_CH2 S3_CH2 S1_CH2 Figure 5-22. Ten-Phase System with Slave5 Not Attached Clocking between the attached slave channels is as shown. 5.29 DESIGN EXAMPLES INFORMATION 5.29.1 INDUCTOR DCR CURRENT SENSE The preferred method for sampling the output current for the TPS40140 is known as the inductor DCR method. This is a lossless approach, as opposed to using a discrete current sense resistor which occupies board area and impacts efficiency as well. The inductor DCR implementation is shown in Figure 5-23. VIN L1 DCR VOUT C1 R1 + VC − To CSRTx To CSx Figure 5-23. Inductor DCR Current Sense Approach The inductor L1 consists of inductance, L, and resistance, DCR. The time constant of the inductor: L / DCR should equal the R1×C1 time constant. Then choosing a value for C1 (0.1 µF is a good choice) solving for R1 is shown in Equation 17. L1 R1 + DCR C1 (17) The voltage into the current sense amplifier of the controller , VC, is calculated in Equation 18. V OUT V C + ǒVIN * VOUTǓ ) I OC DCR R1 C1 f SW V IN (18) As the DC load increases the majority of the voltage, VC, is determined by (IOC× DCR), where IOC is the per phase DC output current. It is important that at the overcurrent set point that the peak voltage of VC does not exceed 60 mV, the maximum differential input voltage. If the voltage VC exceeds 60 mV, a resistor, R2,can be added in parallel with C1 as shown in Figure 5-24. Adding R2 reduces the equivalent inductor DCR by the ratio shown in Equation 20 Submit Documentation Feedback APPLICATION INFORMATION 41 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 VIN L1 DCR VOUT C1 R1 R2 + VC − To CSRTx To CSx Figure 5-24. Using Resistor R2 to Reduce the Current Sense Amplifier Voltage The parallel combination of R1 and R2 is shown in Equation 19. L1 R1 ø R2 + DCR C1 (19) The ratio shown in Equation 20 provides the required voltage attenuation. R2 R1 ) R2 (20) 6 DESIGN EXAMPLES 6.1 Example 1: Dual-Output Configuration from 12 V to 3.3 V and 1.5 V DC-to-DC Converter Using a TPS40140 The following example illustrates the design process and component selection for a dual output synchronous buck converter using TPS40140. The design goal parameters are given in Table 6-1. Only the calculated numbers for the 1.5-V output are shown, however, the equations are suitable for both channel design. A list of symbol definitions is found at the end of this section. Table 6-1. Design Goal Parameters PARAMETER TEST CONDITION MIN TYP MAX UNIT 10.8 12 13.2 V VIN Input voltage VOUT1 Output voltage 1 1.5 V VOUT2 Output voltage 2 3.3 V VRIPPLE Output ripple 2%Vo V IOUT1 Output current 1 20 A IOUT2 Output current 2 fsw Switching frequency 6.1.1 IO = 20 A 20 A 500 kHz Step 1: Inductor Selection The inductor is determined by the desired ripple current. The required inductor is calculated by: VIN(max) - VOUT VOUT 1 L= × × IRIPPLE VIN(max) fSW (1) Typically the peak-to-peak inductor current, IRIPPLE is selected to be around 20% of the rated output current. In this design, IRIPPLE is targeted at 15% of IOUT1. The calculated inductor is 0.89 µH and in practical a 1-µH, 32-A inductor from Vishay is selected. So, the inductor ripple current is 2.66 A. 42 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.1.2 Step 2: Output Capacitor Selection The output capacitor is typically selected by the output load transient response requirement. Equation 2 estimates the minimum capacitor to reach the undervoltage requirement with load step up. Equation 3 estimates the minimum capacitor for overvoltage requirement with load step down. When VIN(min) < 2 ×VOUT, the minimum output capacitance can be calculated using Equation 2. Otherwise, Equation 3 is used. ITRAN(MAX)2 × L COUT(MIN) = VIN(min) - VOUT × VUNDER (2) ( ) when VIN(min) < 2 × VOUT COUT(MIN) = ITRAN(MAX)2 × L VOUT × VOVER (3) when VIN(min) > 2×VOUT In this design, VIN(min) is much larger than 2 × VOUT, so Equation 3 is used to determine the minimum capacitance. Based on a 10-A load transient with a maximum of 80-mV deviation, a minimum 833-µF output capacitor is required. In the design, four 220-µF, 4-V, SP capacitor are selected to meet this requirement. Each capacitor has an ESR of 5 mΩ. Another criterion for capacitor selection is the output ripple voltage. The output ripple is determined mainly by the capacitance and the ESR. ESRCo = VRIPPLE(TotOUT) - VRIPPLE(COUT) IRIPPLE æ ö IRIPPLE VRIPPLE(TotOUT) - ç ÷ 8×COUT × fSW ø è = IRIPPLE (4) With 880-µF output capacitance, the ripple voltage at the capacitor is calculated to be 863-µV. In the specification, the output ripple voltage should be less than 30 mV, so based on Equation 4, the required maximum ESR is 9.5 mΩ. The selected capacitors can meet this requirement. 6.1.3 Step 3: Input Capacitor Selection The input voltage ripple depends on the input capacitance and the ESR. The minimum capacitor and the maximum ESR can be estimated by: IOUT × VOUT CIN(min) = VRIPPLE(CIN) × VIN × fSW (5) VRIPPLE(CinESR) ESRCin = IOUT + 1 IRIPPLE 2 (6) For this design, assume VRIPPLE(CIN) is 100 mV and VRIPPLE(CinESR) is 50 mV, so the calculated minimum capacitance is 50µF and the maximum ESR is 2.3 mΩ. Choosing four 22-µF, 16-V, 2-mΩ ESR ceramic capacitors meets this requirement. Another important consideration for the input capacitor is the RMS ripple current rating. The RMS current in the input capacitor is estimated by: IRMS_CIN = D × (1 - D) × IOUT (7) D is the duty cycle. The calculated RMS current is 6.6 A. Each selected ceramic capacitor has a RMS current rating of 4.3 A, so it is sufficient to reach this requirement. Submit Documentation Feedback DESIGN EXAMPLES 43 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.1.4 Step 4: MOSFET Selection The MOSFET selection determines the converter efficiency. In this design, the duty cycle is very small so that the high-side MOSFET is dominated with switching losses and the low-side MOSFET is dominated with conduction loss. To optimize the efficiency, choose smaller gate charge for the high-side MOSFET and smaller RDS(on) for the low-side MOSFET. The RENESAS RJK0305 and RJK0301 are selected as the high-side and low-side MOSFETs respectively. To reduce the conduction loss, two RJK0301 components are used. The power losses in the high-side MOSFET is calculated with the following equations: The RMS current in the high side MOSFET is show in Equation 8. Ǹ I SWrms + D ǒ I OUT 2 I ) RIPPLE 12 2 Ǔ + 7.07 A (8) The RDS(on) is 13 mΩ when the MOSFET gate voltage is 4.5 V. The conduction loss is: P SWcond + ǒI SWrmsǓ 2 R DS(on) (sw) + 0.65 W (9) The switching loss is: Psw sw = Ipk × Vin × fsw × Rdrv × (Qgdsw + Qgssw ) = 0.26W Vgtdrv The calculated total loss in the high-side MOSFET is: P SWtot + PSWcond ) PSWsw + 0.91 W (10) (11) The power losses in the low-side SR MOSFET is calculated by: The RMS current in the low side MOSFET is shown in Equation 12. I SRrms + Ǹ (1 * D) ǒ 2 I OUT ) I RIPPLE 12 2 Ǔ + 18.7 A (12) The RDS(on) is 4mΩ when the MOSFET gate voltage is 4.5V. The total conduction loss in the two low-side MOSFETs is: R DS(on) (sr) 2 P SRcond + ǒI SRrmsǓ + 0.7 W N (13) N is the number of MOSFET. Here, it is equal to 2. The total power loss in the body diode is: Pdiode = 2 × IOUT × t d × Vf × fsw = 0.77W So the calculated total loss in the SR MOSFET is: P SRtot + PSRcond ) PDIODE + 1.47 W 6.1.5 44 (14) (15) Step 5: Peripheral Component Design DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.1.5.1 Switching Frequency Setting (RT pin 5): ǒ39.2 R + 1.33 10 3 Ǔ f *1.041 * 7 + 71.5 kW SW (16) In the design, a 62-kΩ resistor is selected. The actual switching frequency is 510kHz. 6.1.5.2 Output Voltage Setting (FB1 pin 36): Substitute R1 with 10 kΩ and then calculate RBIAS. R1 = 8.75kΩ VOUT - 0.7 RBIAS = 0.7 × (17) 6.1.5.3 Current Sensing Network Design (CS1 pin 31 and CSRT1 pin32) For small pulse width, to avoid the sub-harmonics brought by the loop delay, a resistor divider is usually used to attenuate the current feedback information as described in the Inductor DCR Current Sense section. Choosing C1 a value for 0.1-µF, and let R1 and R2 be equal, calculating R1 and R2 with the following equations: R1//R2 = L = 5kΩ DCR × C1 (18) R1 = R2 = 10k (19) There is a simplified equation to check if the design will have sub-harmonics or not. VIN × Ac L > DCR(eqv) 2 × Vramp × fsw DCR (eqv) = (20) R2 DCR × DCR = R1+ R2 2 (21) In this design, a 1-µF capacitor is placed at the CSRT1 pin for the purpose of eliminating noise. It can be removed without degrading performance. 6.1.5.4 Overcurrent Protection (ILIM1 pin 34) The resistor selection equations in the CALCULATING OVERCURRENT PROTECTION LEVELsection are simplified to calculate the over current setting resistors. Set the DC over current rating at 25A. I PK DCR eqv Ac ) VOS ) 0.9 VIN R1 + + 22.5 kW 0.5 *6 1* 20 10 V IN ǒ I PK R2 + Ǔ DCR eqv ǒ Ǔ 0.5 VIN (22) Ac ) VOS ) 0.9 VIN 20 + 510 kW 10 *6 (23) VOS is defined as the internal offset, which is typically about 50 mV. 6.1.5.5 VREG (pin 21) A 4.7-µF capacitor is connected to VREG pin to filter noise. 6.1.5.6 BP5 (pin 8) A 4.7Ω and 1µF capacitor is placed between VREG and BP5. Submit Documentation Feedback DESIGN EXAMPLES 45 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.1.5.7 PHSEL (pin 4) For this dual output configuration, the PHSEL pin is directly tied to GND. The channel 1 and channel 2 has a 180° phase shift. 6.1.5.8 VSHARE (pin 6) A 1µF capacitor is tied from VSHARE pin to GND. 6.1.5.9 PGOOD1 (pin 30) The PGOOD1 pin is tied to BP5 with a 10-kΩ resistor. 6.1.5.10 UVLO_CE1 (pin 29) It is connected to the input voltage with a resistor divider. The two resistors have the same value of 10-kΩ. When the input voltage is higher than 2 V, the chip is enabled. 6.1.5.11 CLKIO (pin 28) CLKIO is floating as no clock synchronization required for dual output configuration. 6.1.5.12 BOOT1 and SW1 (pin 27 and 25) A bootstrap capacitor is connected between the BOOT1 and SW1 pin. The bootstrap capacitor depends on the total gate charge of the high side MOSFET and the amount of droop allowed on the bootstrap capacitor. Cboot = Qg 8nc = = 16nF ΔV 0.5V (24) For this application, a 0.1-µF capacitor is selected. 6.1.5.13 TRK1 (pin 33) A 22-nF capacitor is tied to TRK1 pin to provide 1.28 ms soft start time. T ss = C ss × 58 × 10 3 = 22 × 10 -9 × 58 × 10 3 = 1.28m s (25) 6.1.5.14 DIFFO, VOUT and GSNS (pin 1, pin 2 and pin 3) VOUT and GSNS are connected to the remote sensing output connector. DIFFO is connected to the feedback resistor divider. If the differential amplifier is not used, VOUT and GSNS are suggested to be grounded, and DIFFO is left open. 6.1.6 Feedback Compensator Design (COMP1 pin 35) Peak current mode control method is employed in the controller. A small signal model is developed from the COMP signal to the output. Gvc(s) = (s × COUT × ESR + 1) × ROUT 1 1 × × DCR × Ac s × τs + 1 s × COUT × ROUT + 1 (26) The time constant is defined by: T τs = Vramp ln( Vramp T VOUT × DCR × Ac T L ) VIN - VOUT 2 × VOUT × DCR × Ac × DCR × Ac L L - (27) The low frequency pole is calculated by: 46 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 fVCP1 = 1 = 2.36kHz 2 × π × COUT × ROUT (28) The ESR zero is calculated by: fESR = 1 = 176.8kHz 2 × π × COUT × ESR (29) In this design, a Type II compensator is employed to compensate the loop. VREF R2 C1 R1 + C2 Figure 6-1. Type II Compensator The compensator transfer function is: Gc(s) = 1 s × (R1+ R2) × C1+ 1 × R1× C2 s × (s × R2 × C1+ 1) (30) The loop gain transfer function is: Tv(s) = Gc(s) × Gvc(s) (31) Assume the desired crossover frequency is 60 kHz, then set the compensator zero about 1/10 of the crossover frequency and the compensator pole equal to the ESR zero. The compensator gain is then calculated to achieve the desired bandwidth. In this design, the compensator gain, pole and zero are selected as following: 1 = 176.8kHz 2 × π × R2 × C1 1 fz = = 6kHz 2 × π × (R1+ R2) × C1 fp = (32) (33) T v (j × 2 × π × fc) = 1 (34) From the above equation, the compensator gain is solved as 3.978×105. 1 A CM + + 3.978 105 R1 C2 where • • • • (35) C1 = 2.6 nF C2 = 250 pF R2 = 350Ω Set R1 equal to 10-kΩ, and then calculate all the other components In the real laboratory practice, the final components are selected as following to increase the phase margin and reduce PWM jitter. • R1 = 10 kΩ • C2 = 330 pF • R2 = 50Ω • C1 = 2.2 nF Submit Documentation Feedback DESIGN EXAMPLES 47 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.1.7 Design Example Summary + + + + + + + + Figure 6-2 shows the schematic of the dual output converter design. Figure 6-2. Dual Output Converter Schematic 48 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.2 Example 2: Two-Phase Single Output Configuration From 12 V to 1.5 V DC/DC Converter Using a TPS40140 The following example illustrates the design process and component selection for a two phase single output synchronous buck converter using TPS40140. The design goal parameters are given in Table 6-2. The inductor and MOSFET selection equations are quite similar to the dual output converter design, so they will not be repeated here. Table 6-2. Design Goal Parameters PARAMETER VIN Input Voltage VOUT Output voltage VRIPPLE Output ripple IOUT1 Output current fsw Switching frequency 6.2.1 TEST CONDITION IO = 32A MIN TYP MAX UNIT 10.8 12 13.2 V 1.5 V 2%Vo V 32 A 500 kHz Step 1: Output Capacitor Selection The output capacitor is typically selected by the output load transient response requirement. Equation 3 in the dual output design example is used. The inductor L in the equation will be equal to the phase inductance divided by number of phases. Based on a 15-A load transient with a maximum of 30 mV deviation, a minimum 1.32-µF output capacitor is required. In the design, four 330-µF, 2 V, SP capacitor are selected to meet this requirement. Each capacitor has an ESR of 6 mΩ. Another criterion for capacitor selection is the output ripple voltage that is determined mainly by the capacitance and the ESR. Due to the interleaving of channels, the total output ripple current is smaller than the ripple current from a single phase. The ripple cancellation factor is expressed in Equation 36. NPH Õ i-N PH ΔIOUT (NPH, D) = ×D i=1 NPH -1 Õ(i-N PH × D + 1) (36) i=1 Where: D is the duty cycle for a single phase NPH is the number of active phases, here it is equal to 2 Then the maximum output ripple current is calculated by: V OUT I RIPPLE + DI OUTǒNPH, DǓ + 4.374 A L f SW (37) With 1.32 mF output capacitance, the ripple voltage at the capacitor is calculated to be 828 µV. In the specification, the output ripple voltage should be less than 30mV, so based on Equation 4, the required maximum ESR is 6.7 mΩ. The selected capacitors can meet this requirement. 6.2.2 Step 2: Input Capacitor Selection The input voltage ripple depends on the input capacitance and the ESR. The minimum capacitor and the maximum ESR can be estimated by Equation 5 and Equation 6 in the dual output design example. For this design, VRIPPLE(CIN) assume is 100mV and VRIPPLE(CinESR) is 50mV, also the inductor ripple current IRIPPLEwill is 30%, so the calculated minimum capacitance is 40µF and the maximum ESR is 2.7 mΩ. Choosing four 22-µF, 16-V, 2-mΩ ESR ceramic capacitors meet this requirement. Submit Documentation Feedback DESIGN EXAMPLES 49 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 Another important thing for the input capacitor is the RMS ripple current rating. Due to the interleaving of multi-phase, the input RMS current is reduced. The input ripple current RMS value over load current is calculated by: ΔIIN(nom) (NPH, D) = [(D - V × (1- D) 2 k(NPH, D) k(NPH, D) + 1 N )×( - D)] + ( PH 2 ) × [ OUT ] × NPH NPH 12 × D L × fsw × IOUT [(k(NPH, D) + 1)2 × (D where • • • k(NPH, D) 3 k(NPH, D) + 1 ) + k(NPH, D)2 × ( - D)3 ] NPH NPH (38) k(NPH, D) = floor (NPH× D),in this example, k(NPH, D) =0 Floor(x) is the function to return the greatest integer less than or equal to x NPH is the number of active phases, in this example, NPH=2 So in this design, the maximum input ripple RMS current is calculated to be 7.2 A with the minimum input voltage. It is about 34% reduction compared with a 32-A single-phase converter design. Each selected ceramic capacitor has a RMS current rating of 4.3 A and, therefore, sufficient to reach this requirement. 6.2.3 Step 3: Peripheral Component Design 6.2.3.1 Switching Frequency Setting (RT pin 5) R + 1.33 ǒ39.2 10 3 Ǔ f *1.041 * 7 + 71.5 kW SW (39) Here, fswrepresents the phase switching frequency. In the design, a 64.9-kΩ resistor is selected. The actual switching frequency is 490 kHz. 6.2.3.2 COMP1 and COMP2 (pin 35 and pin 10) COMP1 is connected to the compensator network. The selection of compensation components is similar to the dual output design example. COMP2 is directly tied to COMP1. 6.2.3.3 TRK1 and TRK2 (pin 33 and pin 12) A soft start capacitor is connected between TRK1 and GND. TRK2 is directly tied to BP5 to set this channel as a salve. 6.2.3.4 ILIM1 and ILIM2 (pin 34 and pin 11) ILIM1 is connected to the resistor network that has the same design as the dual output example. The peak current in Equation 22 and Equation 23 is the peak current of each phase. ILIM2 is grounded. 6.2.3.5 FB1 and FB2 (pin 36 and pin 9) FB1 is tied to the feedback network. FB2 is connected to GND. 6.2.3.6 PHSEL (pin 4) For this two phase configuration, the PHSEL pin is directly tied to GND. 6.2.3.7 PGOOD1 and PGOOD2 (pin 30 and pin 15) Both of PGOOD1 and PGOOD2 are tied to BP5 with a 10-kΩ resistor. 6.2.3.8 CLKIO (pin 28) CLKIO is open as no clock synchronization required for two phase configuration. 50 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.2.3.9 DIFFO, VOUT and GSNS (pin 1, pin 2 and pin 3) VOUT and GSNS should be connected to the remote sensing output connector. DIFFO is connected to the feedback resistor divider. If the differential amplifier is not used, VOUT and GSNS are suggested to be grounded, and DIFFO is left open. 6.2.4 Design Example Summary + + + + Figure 6-3 shows the schematic of the two phase single output converter design. Figure 6-3. Two phase Single Output Converter Schematic Submit Documentation Feedback DESIGN EXAMPLES 51 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.3 Example 3: Four-Phase Single Output Configuration From 12 V to 1.8 V DC-to-DC Converter Using Two TPS40140 The following example illustrates the design process and component selection for a four phase single output synchronous buck converter using two TPS40140. Here, two modules are designed. One is a master module. The other one is a slave module. Each module contains two phases and each phase handle 5-A. The two modules are stacked together to form a 4-phase converter. More slave modules can be stacked to this converter to get the desired phases. The modules are plugged into a mother board. The design goal parameters are given in Table 6-3. Table 6-3. Design Goal Parameters PARAMETER VIN Input Voltage VOUT Output voltage VRIPPLE Output ripple IPH Phase current fsw Switching frequency NPH Phase number 6.3.1 TEST CONDITION IO = 20A MIN TYP MAX UNIT 10.8 12 13.2 V 1.8 V 1%VO V 5 650 A kHz 4 Step 1: Output Capacitor Selection The output capacitor is typically selected by the output load transient response requirement. Equation 3 in the dual output design example is used. Also, as mentioned in the two phase design example, the inductor L is equivalent to NPH . Based on a 10A load transient with a maximum of 30 mV deviation, a minimum 370µF output capacitor is required. In the design, one 180µF, 6.3V, SP capacitor is placed on the mother board. Four 22-µF, 6,3V ceramic capacitors are placed on each module. The total output capacitance is 356µF. The output ripple current cancellation factor is calculated to be 0.455 based on Equation 36. So the maximum output ripple current is calculated by: IRIPPLE = VOUT × 0.455 = 1.573A L × fsw (40) With 356µF output capacitance, the ripple voltage at the capacitor is calculated to be 850 µV. In the specification, the output ripple voltage should be less than 18 mV, so based on Equation 4, the required maximum ESR is 11 mΩ. The selected capacitors can reach this requirement. 6.3.2 Step 2: Input Capacitor Selection The input voltage ripple depends on the input capacitance and the ESR. The minimum capacitor and the maximum ESR can be estimated by Equation 5 and Equation 6 in the dual output design example. For this design, assume is 50mV and is 30mV, also each phase inductor ripple current is 50%, so the calculated minimum capacitance is 93-µF and the maximum ESR is 4.6 mΩ. In this case, one 33-µF 6.3-V SP-capacitor is placed on the mother board and each module has two 22-µF, 6.3-V ceramic capacitors. The maximum input ripple RMS current is calculated to be 2.57 A with the minimum input voltage based on Equation 38. The selected capacitors are sufficient to meet this requirement. 52 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.3.3 Step 3: Peripheral Component Design 6.3.3.1 Master Module 6.3.3.1.1 RT (pin 5) It is connected to GND with a resistor that sets the switching frequency. R + 1.33 ǒ39.2 10 3 Ǔ f *1.041 * 7 + 52.2 kW SW (41) Here, fswrepresents the phase switching frequency. In the design, a 47-kΩ resistor is selected. The actual switching frequency is 650 kHz. 6.3.3.1.2 COMP1 and COMP2 (pin 35 and pin 10) COMP1 is connected to the compensator network. COMP2 is directly tied to COMP1. 6.3.3.1.3 TRK1 and TRK2 (pin 33 and pin 12) A soft start capacitor is connected between TRK1 and GND. TRK2 is directly tied to BP5 to set this channel as a salve. 6.3.3.1.4 ILIM1 and ILIM2 (pin 34 and pin 11) ILIM1 is connected to the resistor network that has the same design as the dual output example. The peak current in Equation 22 and Equation 23 is the peak current of each phase. ILIM2 is grounded. 6.3.3.1.5 FB1 and FB2 (pin 36 and pin 9) FB1 is tied to the feedback network. FB2 is connected to GND. 6.3.3.1.6 PHSEL (pin 4) For this four phase configuration, the PHSEL pin is tied to GND with a 39-kΩ resistor. 6.3.3.1.7 PGOOD1 and PGOOD2 (pin 30 and pin 15) Both of PGOOD1 and PGOOD2 are tied to BP5 with a 10-kΩ resistor. 6.3.3.1.8 CLKIO (pin 28) CLKIO is connected to the same pin in the salve module. 6.3.3.2 Slave Module: 6.3.3.2.1 RT (pin 5) It is connected to BP5. The slave module receives the clock from the master module. 6.3.3.2.2 COMP1 and COMP2 (pin 35 and pin 10) Both of COMP1 and COMP2 are directly tied together to COMP1 or COMP2 in the master module. 6.3.3.2.3 TRK1 and TRK2 (pin 33 and pin 12) Both TRK1 and TRK2 are directly tied to BP5. 6.3.3.2.4 ILIM1 and ILIM2 ( pin 34 and pin 11) Both ILIM1 and ILIM2 are grounded. 6.3.3.2.5 FB1 and FB2 (pin 36 and pin 9) Both FB1 and FB2 are connected to GND. Submit Documentation Feedback DESIGN EXAMPLES 53 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.3.3.2.6 PHSEL (pin 4) The PHSEL pin is directly tied to GND. 6.3.3.2.7 PGOOD1 & PGOOD2 (pin 30 & pin 15) Both of PGOOD1 and PGOOD2 are tied to BP5 with a 10-kΩ resistor. 6.3.3.2.8 CLKIO (pin 28) CLKIO is connected to the master module CLKIO. 54 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.3.4 Design Example Summary Figure 6-4, Figure 6-5 and Figure 6-6 shows the schematics of the four phase converter design. Figure 6-4. Master Module Schematic Submit Documentation Feedback DESIGN EXAMPLES 55 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 Figure 6-5. Slave Module Schematic 56 DESIGN EXAMPLES Submit Documentation Feedback TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 + + Figure 6-6. Mother Board Schematic Submit Documentation Feedback DESIGN EXAMPLES 57 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.4 ABBREVIATIONS Table 6-4. Definition of Symbols SYMBOL DESCRIPTION VIN(min) Minimum Operating Input voltage VIN(max) Maximum Operating Input Voltage VOUT Output Voltage IRIPPLE Inductor Peak-Peak Ripple Current ITRAN(MAX) Maximum Load Transient VUNDER Output Voltage Undershot VOVER Output Voltage Overshot VRIPPLE(TotOUT) Total Output Ripple VRIPPLE(COUT) Output Voltage Ripple Due to Output Capacitance VRIPPLE(CIN) Input Voltage Ripple Due to Input Capacitance VRIPPLE(CinESR) Input Voltage Ripple Due to the ESR of Input Capacitance Pswcond High Side MOSFET Conduction Loss Iswrms RMS Current in the High Side MOSFET Rdson(sw) ON Drain-Source Resistance of the High Side MOSFET Pswsw High Side MOSFET Switching Loss Ipk Peak Current Through the High Side MOSFET Rdrv Driver Resistance of the High Side MOSFET Qgdsw Gate to Drain Charge of the High Side MOSFET Qgssw Gate to Source Charge of the High Side MOSFET Vgsw Gate Drive Voltage of the High Side MOSFET Pswgate Gate Drive Loss of the High Side MOSFET Qgsw Gate Charge of the High Side MOSFET Pswtot Total Losses of the High Side MOSFET Psrcond Low Side MOSFET Conduction Loss Isrrms RMS Current in the Low Side MOSFET Rdson(sr) ON Drain-Source Resistance of the low Side MOSFET Psrgate Gate Drive Loss of the Low Side MOSFET Qgsr Gate Charge of the Low Side MOSFET Vgsr Gate Drive Voltage of the Low Side MOSFET Pdiode Power Loss in the Diode td Dead Time Between the Conduction of High and Low Side MOSFET Vf Forward Voltage Drop of the Body Diode of the Low Side MOSFET Psrtot Total Losses of the Low Side MOSFET DCR Inductor DC Resistance Ac The Gain of the Current Sensing Amplifier, typically it is 13 ROUT Output Load Resistance Vramp Ramp Amplitude, typically it is 0.5V T Switching Period Gvc(s) Control to Output Transfer Function Gc(s) Compensator Transfer Function Tv(s) Loop Gain Transfer Function Acm Gain of the Compensator fp The Pole Frequency of the Compensator fz The Zero Frequency of the Compensator 58 DESIGN EXAMPLES Submit Documentation Feedback www.ti.com TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 6.5 LAYOUT CONSIDERATIONS 6.5.1 Power Stage A synchronous BUCK power stage has two primary current loops – The input current loop which carries high AC discontinuous current while the output current loop carries high DC continuous current. The input current loop includes the input capacitors, the main switching MOSFET, the inductor, the output capacitors and the ground path back to the input capacitors. To keep this loop as small as possible, it is generally good practice to place some ceramic capacitance directly between the drain of the main switching MOSFET and the source of the synchronous rectifier (SR) through a power ground plane directly under the MOSFETs. The output current loop includes the SR MOSFET, the inductor, the output capacitors, and the ground return between the output capacitors and the source of the SR MOSFET. As with the input current loop, the ground return between the output capacitor ground and the source of the SR MOSFET should be routed under the inductor and SR MOSFET to minimize the power loop area. The SW node area should be as small as possible to reduce the parasitic capacitance and minimize the radiated emissions. The gate drive loop impedance (HDRV-gate-source-SW and LDRV-gate-source- GND) should be kept to as low as possible. The HDRV and LDRV connections should widen to 20mils as soon as possible out from the IC pin. 6.5.2 Device Peripheral The TPS40140 provides separate signal ground (GND) and power ground (PGND) pins. It is required to separate properly the circuit grounds. The return path for the pins associated with the power stage should be through PGND. The other pins especially for those sensitive pins such as FB, RT and ILIM should be through the low noise GND. The GND and PGND plane are suggested to be connected at the output capacitor with single 20 mil trace. A minimum 0.1-µF ceramic capacitor must be placed as close to the VDD pin and GND as possible with at least 15-mil wide trace from the bypass capacitor to the GND. A 4.7-µF ceramic capacitor should be placed as close to VREG pin and GND as possible. BP5 is the filtered input from the VREG pin. A 4.7 -Ω resistor should be connected between VREG and BP5 and a 1-µF ceramic capacitor should be connected from BP5 to GND. Both components should be as close to BP5 pin as possible. When DCR sensing method is applied, the sensing resistor is placed close to the SW node. It is connected to the inductor with Kelvin connection. The sensing traces from the power stage to the chip should be away from the switching components. The sensing capacitor should be placed very close to the CS and CSRT pins. The frequency setting resistor should be placed as close to RT pin and GND as possible. The VOUT and GSNS pins should be directly connected to the point of load where the voltage regulation is required. A parallel pair of 10-mil traces connects the regulated voltage back to the chip. They should be away from the switching components. The PowerPAD should be electrically connected to GND. 6.5.3 PowerPAD™ Layout The PowerPAD™ package provides low thermal impedance for heat removal from the device. The PowerPAD™ derives its name and low thermal impedance from the large bonding pad on the bottom of the device. The circuit board must have an area of solder-tinned-copper underneath the package. The dimensions of this area depend on the size of the PowerPAD™ package. Thermal vias connect this area to internal or external copper planes and should have a drill diameter sufficiently small so that the via hole is effectively plugged when the barrel of the via is plated with copper. This plug is needed to prevent wicking the solder away from the interface between the package body and the solder-tinned area under the device during solder reflow. Drill diameters of 0,33 mm (13 mils) works well when 1-oz copper is plated at the surface of the board while simultaneously plating the barrel of the via. If the thermal vias are not plugged when the copper plating is performed, then a solder mask material should be used to cap the vias with a diameter equal to the via diameter plus 0,1 mm minimum. This capping prevents the solder from being wicked through the thermal vias and potentially creating a solder void under the package. Refer to PowerPAD™ Thermally Enhanced Package for more information on the PowerPAD™ package. Submit Documentation Feedback DESIGN EXAMPLES 59 TPS40140 DUAL OR 2-PHASE, STACKABLE CONTROLLER www.ti.com SLUS660A – SEPTEMBER 2005 – REVISED JULY 2006 7 ADDITIONAL REFERENCES 7.1 Related Parts The following parts have characteristics similar to the TPS40140 and may be of interest. DEVICE DESCRIPTION TPS40130 Two-Phase Synchronous Buck Controller with Integrated MOSFET Drivers TPS40090 4-Channel Multi-Phase DC/DC Controller with Three State TPS40120 Feedback Divider, Digitally Controlled 7.2 References These references may be found on the web at www.power.ti.com under Technical Documents. Many design tools and links to additional references, including design software, may also be found at www.power.ti.com 1. Under The Hood Of Low Voltage DC/DC Converters, SEM1500 Topic 5, 2002 Seminar Series 2. Understanding Buck Power Stages in Switchmode Power Supplies (SLVA057) March 1999 3. Design and Application Guide for High Speed MOSFET Gate Drive Circuits, SEM 1400, 2001 Seminar Series 4. Designing Stable Control Loops, SEM 1400, 2001 Seminar Series 5. Additional PowerPADTM information may be found in Applications Briefs (SLMA002) and (SLMA004) 6. QFN/SON PCB Attachment, Texas Instruments (SLUA271), June 2002 7.3 Package Outline The outlines of the mechanical dimensions of the RHH package are shown. 7.4 Recommended PCB Footprint The outlines the recommended PCB layout are shown. 60 ADDITIONAL REFERENCES Submit Documentation Feedback PACKAGE OPTION ADDENDUM www.ti.com 12-Sep-2006 PACKAGING INFORMATION Orderable Device Status (1) Package Type Package Drawing Pins Package Eco Plan (2) Qty TPS40140RHHR ACTIVE QFN RHH 36 3000 Green (RoHS & no Sb/Br) CU NIPDAU Level-3-260C-168 HR TPS40140RHHRG4 ACTIVE QFN RHH 36 3000 Green (RoHS & no Sb/Br) CU NIPDAU Level-3-260C-168 HR TPS40140RHHT ACTIVE QFN RHH 36 250 Green (RoHS & no Sb/Br) CU NIPDAU Level-3-260C-168 HR TPS40140RHHTG4 ACTIVE QFN RHH 36 250 Green (RoHS & no Sb/Br) CU NIPDAU Level-3-260C-168 HR Lead/Ball Finish MSL Peak Temp (3) (1) The marketing status values are defined as follows: ACTIVE: Product device recommended for new designs. LIFEBUY: TI has announced that the device will be discontinued, and a lifetime-buy period is in effect. NRND: Not recommended for new designs. Device is in production to support existing customers, but TI does not recommend using this part in a new design. PREVIEW: Device has been announced but is not in production. Samples may or may not be available. OBSOLETE: TI has discontinued the production of the device. (2) Eco Plan - The planned eco-friendly classification: Pb-Free (RoHS), Pb-Free (RoHS Exempt), or Green (RoHS & no Sb/Br) - please check http://www.ti.com/productcontent for the latest availability information and additional product content details. TBD: The Pb-Free/Green conversion plan has not been defined. Pb-Free (RoHS): TI's terms "Lead-Free" or "Pb-Free" mean semiconductor products that are compatible with the current RoHS requirements for all 6 substances, including the requirement that lead not exceed 0.1% by weight in homogeneous materials. Where designed to be soldered at high temperatures, TI Pb-Free products are suitable for use in specified lead-free processes. Pb-Free (RoHS Exempt): This component has a RoHS exemption for either 1) lead-based flip-chip solder bumps used between the die and package, or 2) lead-based die adhesive used between the die and leadframe. The component is otherwise considered Pb-Free (RoHS compatible) as defined above. Green (RoHS & no Sb/Br): TI defines "Green" to mean Pb-Free (RoHS compatible), and free of Bromine (Br) and Antimony (Sb) based flame retardants (Br or Sb do not exceed 0.1% by weight in homogeneous material) (3) MSL, Peak Temp. -- The Moisture Sensitivity Level rating according to the JEDEC industry standard classifications, and peak solder temperature. Important Information and Disclaimer:The information provided on this page represents TI's knowledge and belief as of the date that it is provided. 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