National Semiconductor Application Note 2107 Michael Hartshorne March 21, 2011 Introduction The LM21212-1 evaluation board has been optimized to work from 2.95V to 5.5V, achieving a balance between overall solution size and regulator efficiency. The evaluation board measures just under 2” x 2” on a four layer PCB, and exhibits a junction-to-ambient thermal impedance (θJA) of 24°C/W with no air flow. The power stage and compensation components of the LM21212-1 evaluation board have been optimized for an input voltage of 5V, but for testing purposes, the input can be varied across the entire operating range. The output voltage of the evaluation board is nominally 1.2V, but this voltage can be easily changed to any voltage between 0.6V and VIN by modifying the feedback resistor network. This evaluation board provides a solution to examine the high efficiency LM21212-1 buck switching regulator. The LM21212-1 is capable of driving up to 12A of continuous load current with excellent output voltage accuracy due to its ±1% internal reference. This device also features a clock synchronization input that allows the switching frequency to be synchronized to an external clock source. The 300 kHz to 1.5 MHz frequency synchronization range enables the user to minimize the power stage component size, while still allowing for high efficiency. The LM21212-1 is capable of down converting from an input voltage between 2.95V and 5.5V. Fault protection features include current limit, output power good, and output over-voltage protection. The dual function softstart/tracking pin can be used to control the startup response of the LM21212-1, and the precision enable pin can be used to easily sequence the LM21212-1 in applications with sequencing requirements. LM21212-1 Evaluation Board LM21212-1 Evaluation Board Evaluation Board Schematic 30144801 AN-2107 © 2011 National Semiconductor Corporation 301448 www.national.com AN-2107 Powering and Loading Considerations Step 7: The frequency of operation can be varied as desired by connecting a 2.0V square-wave positive signal between SYNC and GND. Read this entire page prior to attempting to power the evaluation board. POWERING UP It is suggested that the load power be kept low during the first power up. Once the device is powered up, immediately check for 1.2V at the output. A quick efficiency check is the best way to confirm that everything is operating properly. If something is amiss you can be reasonably sure that it will affect the efficiency adversely. Few parameters can be incorrect in a switching power supply without creating losses and potentially damaging heat. Some voltage supplies can exhibit severe voltage overshoot during high current transients. If a supply overshoots above 6.0V, damage to the LM21212-1 can occur. For these supplies, a large capacitor across the terminals of the supply (1000µF) can alleviate this problem. QUICK SETUP PROCEDURE Step 1: Set the input source current limit to 10A. Turn off the input source. Connect the positive output of the input source to VIN and the negative output to the corresponding GND. Step 2: Connect the load (with 12A capability) to VOUT for the positive connection and GND for the negative connection. Step 3: The ENABLE pin should be left open for normal operation. Step 4: Set the input source voltage to 5V. The load voltage should be in regulation with a nominal 1.2V output. Step 5: Slowly increase the load while monitoring the load voltage at VOUT. It should remain in regulation with a nominal 1.2V output as the load is increased up to 12A. Step 6: Slowly sweep the input source voltage from 2.95V to 5.5V. The load voltage should remain in regulation with a nominal 1.2V output. If desired, the output of the device can be disabled by connecting the ENABLE pin to GND. OVER CURRENT PROTECTION The evaluation board is configured with over-current protection. This function is completely contained in the LM21212-1. The peak current is limited to approximately 17A. Connection Descriptions Terminal Silkscreen Description VIN This terminal is the input voltage to the device. The evaluation board will operate over the input voltage range of 2.95V to 5.5V. GND These terminals are the ground connections to the device. The input power ground should be connected next to the input VIN connection, and the output power ground next to the VOUT connection. VOUT This terminal connects to the output voltage of the power supply and should be connected to the load. ENABLE This terminal connects to the enable pin of the device. This terminal can be left floating or driven externally. If left floating, a 2µA current source will pull the pin high, thereby enabling the device. If driven externally, a voltage typically less than 1.2V will disable the device. SS/TRK This terminal provides access to the SS/TRK pin of the device. Connections to this terminal are not needed for most applications. The feedback pin of the device will track the voltage on the SS/TRK pin if it is driven with an external voltage source that is below the 0.6V reference. PGOOD This terminal connects to the power good output of the device. This pin is pulled up through a 10 kΩ pull-up resistor to VIN. AC INJ This terminal block allows the user to insert an AC injection signal across a 49.9Ω resistor for openloop gain bode measurements. A jumper shorts out this resistor when it is not needed. SWITCH This terminal allows easy probing of the switch node. Do not apply any external voltage source to this pin. SYNC This terminal connects to the SYNC pin of the device. The LM21212-1 can sychronize the SWITCH pin to a SYNC signal with a frequency between 300kHz and 1.5MHz. If this pin is left open, the switching frequency will default to 1MHz. VIN_SENSE+, VIN_SENSEVOUT_SENSE+, VOUT_SENSE- www.national.com These terminals allow a sense connection on the board for accurate VIN and VOUT measurements, respectively. 2 EFFICIENCY PLOTS Figure 1 shows the conversion efficiency versus output current for a 5V input voltage for 500kHz, 1MHz, and 1.5MHz fSW. 96 500kHz 1MHz 1.5MHz EFFICIENCY (%) 94 92 90 88 86 84 82 80 0 2 4 6 8 10 OUTPUT CURRENT (A) 30144804 12 FIGURE 3. (1 µs/DIV) 30144835 FIGURE 1. PRIMARY SWITCHNODE WAVEFORM Figure 4 shows the typical SW pin voltage while synchronizing to an external source. TURN-ON WAVEFORM A soft-start sequence occurs when applying power to the LM21212-1 evaluation board. Figure 2 shows the output voltage during a typical start-up sequence. 30144805 FIGURE 4. (1 µs/DIV) 30144803 FIGURE 2. (2 ms/DIV) 3 www.national.com AN-2107 OUTPUT RIPPLE WAVEFORM Figure 3 shows the output voltage ripple. This measurement was taken with the scope probe tip placed on the output capacitor C9 VOUT connection and the scope probe ground "barrel" wired to the GND connection of C9. The scope bandwidth is set to 20 MHz. Performance Characteristics 100 160 120 60 100 40 80 60 20 40 0 -20 100 30144834 FIGURE 5. (100 µs/DIV) 20 GAIN PHASE MARGIN 1k 10k 100k FREQUENCY (Hz) PHASE MARGIN (°) 140 80 GAIN (dB) AN-2107 OPEN LOOP BODE RESPONSE Figure 7 shows the open loop bode response generated by inserting a stimulus signal across RAC and using a network analyzer to plot the gain and phase. OUTPUT TRANSIENT RESPONSE Figure 5 shows the VOUT deviation for a 3A to 12A output current transient condition. 0 1M 30144842 OUTPUT CURRENT LIMIT Figure 6 shows the VOUT output response to an output current limit condition. FIGURE 7. 30144841 FIGURE 6. (100 µs/DIV) www.national.com 4 AN-2107 Bill of Materials The Bill of Materials is shown below, including the manufacturer and part number. ID DESCRIPTION VENDOR AC INJ Header, TH, 100mil, 2x1, Gold plated, 230 mil above insulator Samtec Inc. C1 CAP, CERM, 1 uF, 10V, +/-10%, MuRata X7R, 0603 PART NUMBER QUANTITY TSW-102-07-G-S 1 GRM188R71A105KA61D 1 C3, C4, C5, C6, C7, CAP, CERM, 100 uF, 6.3V, C8 +/-20%, X5R, 1206 MuRata GRM31CR60J107ME39L 6 C9 CAP, CERM, 0.1 uF, 50V, +/-10%, X7R, 0603 TDK C1608X7R1H104K 1 CC1 CAP, CERM, 2700 pF, 50V, +/-5%, C0G/NP0, 0603 MuRata GRM1885C1H272JA01D 1 CC2 CAP, CERM, 82 pF, 50V, +/-5%, MuRata C0G/NP0, 0603 GRM1885C1H820JA01D 1 CC3 CAP, CERM, 820 pF, 50V, +/-5%, MuRata C0G/NP0, 0603 GRM1885C1H821JA01D 1 CSS CAP, CERM, 0.033 uF, 16V, +/-10%, X7R, 0603 MuRata GRM188R71C333KA01D 1 GND_FI, GND_FO, Standard Banana Jack, VIN_F, VOUT_F Uninsulated, 15A Johnson Components 108-0740-001 4 L1 Inductor, Shielded Drum Core, Powdered Iron, 560nH, 27.5A, 0.0018 ohm, SMD Vishay-Dale IHLP4040DZERR56M01 1 R1 RES, 1.0 ohm, 5%, 0.1W, 0603 Vishay-Dale CRCW06031R00JNEA 1 RAC RES, 49.9 ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW060349R9FKEA 1 RC1 RES, 7.32 kohm, 1%, 0.1W, 0603 Vishay-Dale CRCW06037K32FKEA 1 RC2 RES, 165 ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW0603165RFKEA 1 RFB1, RFB2, RPG RES, 10 kohm, 1%, 0.1W, 0603 Vishay-Dale CRCW060310K0JKEA 3 SH-J1 Shunt, 100mil, Gold plated, Black Samtec Inc. SNT-100-BK-G 1 U1 12A Buck DC/DC Converter LM21212MH-1 1 National Semiconductor 5 www.national.com AN-2107 ple (ΔIP-P) the output voltage ripple can be approximated by the equation: Component Selection This section provides a walk-through of the design process of the LM21212-1 evaluation board. Unless otherwise indicated all equations assume units of amps (A) for current, farads (F) for capacitance, henries (H) for inductance, and volts (V) for voltages. The variable RESR above refers to the ESR of the output capacitor. As can be seen in the above equation, the ripple voltage on the output can be divided into two parts, one of which is attributed to the AC ripple current flowing through the ESR of the output capacitor and another due to the AC ripple current actually charging and discharging the output capacitor. The output capacitor also has an effect on the amount of droop that is seen on the output voltage in response to a load transient event. For the evaluation board, three 100µF ceramic capacitors were selected to provide good transient and DC performance. Ceramic capacitors give the lowest RESR of any standard capacitor chemistries, resulting in the lowest output ripple for the given ripple current. Ceramic capacitors (especially high capacitance, small package multi-layer types, or MLCC) lose thier capacitance as the DC voltage is increased. For this configuration, the actual capacitance value was approximated to be 50 µF per capacitor, or 150 µF total. This is lower than measured capacitance values for 1.2V, but will allow the user to change the output voltage up to 3.3V and maintain stability. INPUT CAPACITORS: C1, C2, C3 The required RMS current rating of the input capacitor for a buck regulator can be estimated by the following equation: The variable D refers to the duty cycle, and can be approximated by: From this equation, it follows that the maximum ICIN(RMS) requirement will occur at a full 12A load current with the system operating at 50% duty cycle. Under this condition, the maximum ICIN(RMS) is given by: SOFT-START CAPACITOR: CSS A soft-start capacitor can be used to control the startup time of the LM21212-1 voltage regulator. The startup time of the regulator when using a soft-start capacitor can be estimated by the following equation: Ceramic capacitors feature a very large IRMS rating in a small footprint, making a ceramic capacitor ideal for this application. The input capacitors also keep the input stable during load transient conditions. If the input capacitance is too low, the input can drop below the UVLO threshold and cause the device to disable the output. This may result in repetitive dropout and re-enable oscillation, or "motorboating". To give the user the ability to operate with a low VIN voltage, three 100 µF ceramic capacitors were used on the input. For the LM21212-1, ISS is nominally 5 µA. For the evaluation board, the soft-start time has been designed to be roughly 10 ms, resulting in a CSS capacitor value of 33 nF. INDUCTOR: L1 The value of the inductor was selected to allow the device to achieve a 5V to 1.2V conversion at 500kHz to provide a peak to peak ripple current of 3.2A, which is about 27% of the maximum output current. To have an optimized design, generally the peak to peak inductor ripple current should be kept to within 20% to 40% of the rated output current for a given input voltage, output voltage and operating frequency. The peak to peak inductor ripple current can be calculated by the equation: COMPENSATION COMPONENTS: CC1, CC2, CC3, RC1, RC2 These components are used in conjunction with the error amplifier to create a type 3 voltage-mode compensation network. The analysis of type 3 compensation is outside the scope of this document, but an example of the step-by-step procedure to generate comensation component values is given. The parameters needed for the compensation values are given in the table below. Once an inductance value is calculated, an actual inductor needs to be selected based on a trade-off between physical size, efficiency, and current carrying capability. For the LM21212-1 evaluation board, a Vishay IHLP4040DZERR56M01 inductor offers a good balance between efficiency (1.8 mΩ DCR) and size. OUTPUT CAPACITOR: C3, C4, C5, C9 The value of the output capacitor in a buck regulator influences the voltage ripple that will be present on the output voltage as well as the large signal output voltage response to a load transient. Given the peak-to-peak inductor current rip- www.national.com 6 Parameter Value VIN 5.0V VOUT 1.2V IOUT 12A fCROSSOVER 80 kHz L 0.56 µH RDCR 1.8 mΩ CO 150 µF RESR 1.0 mΩ ΔVRAMP 0.8V fSW 500 kHz Last, CC3 can be calculated to place a pole at the same frequency as the zero created by the output capacitor ESR. The standard values used for the above calculations are given in the Bill of Materials. FEEDBACK RESISTORS: RFB1, RFB2, and RAC The resistors labeled RFB1 and RFB2 create a voltage divider from VOUT to the feedback pin that is used to set the output of the voltage regulator. Nominally, the output of the LM21212-1 evaluation board is set to 1.2V, giving resistor values of RFB1= RFB2 = 10kΩ. If a different output voltage is required, the value of RFB2 can be adjusted according to the equation: RFB1 does not need to be changed from its value of 10kΩ. Resistor RAC has a value of 49.9Ω and is provided as an injection point for loop stability measurements, as well as, a way to further tweak the output voltage accuracy to account for resistor tolerance values differing from ideal calculated values. The jumper is used to short out RAC when not needed. PROGRAMMABLE UVLO: REN1 and REN2 The resistors labeled REN1 and REN2 create a voltage divider from VIN to the enable pin that can be used to enable the device above a programmed VIN, effectively creating a programmable UVLO voltage above the device's internal UVLO (nominally 2.7V). To allow evaluation of the device down to 2.95V, these components are not installed. To change the turn-on threshold of the device a 10 kΩ resistor is recommended for REN1 and the value of REN2 can be calculated using the equation: Next, the value of CC1 can be calculated by placing a zero at half of the LC double pole frequency. Now the value of CC2 can be calculated to place a pole at half of the switching frequency. where VTO is the desired VIN voltage at which the device will enable. RC2 can then be calculated to set the second zero at the LC double pole frequency. 7 www.national.com AN-2107 where ΔVRAMP is the oscillator peak-to-peak ramp voltage (nominally 0.8 V), fCROSSOVER is the frequency at which the open-loop gain is a magnitude of 1, RDCR is the effective DC resistance of the inductor, RESR is the effective resistance of the output capacitor, and CO is the effective output capacitance at the programmed output voltage. It is recommended that fCROSSOVER not exceed one-fifth of the switching frequency. The output capacitance, CO, depends on capacitor chemistry and bias voltage. For Multi-Layer Ceramic Capacitors (MLCC), the total capacitance will degrade as the DC bias voltage is increased. Measuring the actual capacitance value for the output capacitors at the output voltage is recommended to accurately calculate the compensation network. Note that it is more conservative, from a stability standpoint, to err on the side of a smaller output capacitance value in the compensation calculations rather than a larger, as this will result in a lower bandwidth but increased phase margin. First, the value of RFB1 should be chosen. A typical value is 10kΩ. From this, the value of RC1 can be calculated to set the mid-band gain so that the desired crossover frequency is achieved. AN-2107 PCB Layout The PCB was manufactured with 2oz. copper outer layers, and 1oz. copper inner layers. Twenty 8 mil. diameter vias placed underneath the device, along with addional vias placed throughout the ground plane around the device, help improve the thermal dissipation of the board. 30144830 30144832 Top Layer (Copper planes outlined in grey) Mid Layer2 30144831 30144833 Mid Layer1 www.national.com Bottom Layer 8 AN-2107 9 www.national.com LM21212-1 Evaluation Board Notes For more National Semiconductor product information and proven design tools, visit the following Web sites at: www.national.com Products Design Support Amplifiers www.national.com/amplifiers WEBENCH® Tools www.national.com/webench Audio www.national.com/audio App Notes www.national.com/appnotes Clock and Timing www.national.com/timing Reference Designs www.national.com/refdesigns Data Converters www.national.com/adc Samples www.national.com/samples Interface www.national.com/interface Eval Boards www.national.com/evalboards LVDS www.national.com/lvds Packaging www.national.com/packaging Power Management www.national.com/power Green Compliance www.national.com/quality/green Switching Regulators www.national.com/switchers Distributors www.national.com/contacts LDOs www.national.com/ldo Quality and Reliability www.national.com/quality LED Lighting www.national.com/led Feedback/Support www.national.com/feedback Voltage References www.national.com/vref Design Made Easy www.national.com/easy www.national.com/powerwise Applications & Markets www.national.com/solutions Mil/Aero www.national.com/milaero PowerWise® Solutions Serial Digital Interface (SDI) www.national.com/sdi Temperature Sensors www.national.com/tempsensors SolarMagic™ www.national.com/solarmagic PLL/VCO www.national.com/wireless www.national.com/training PowerWise® Design University THE CONTENTS OF THIS DOCUMENT ARE PROVIDED IN CONNECTION WITH NATIONAL SEMICONDUCTOR CORPORATION (“NATIONAL”) PRODUCTS. NATIONAL MAKES NO REPRESENTATIONS OR WARRANTIES WITH RESPECT TO THE ACCURACY OR COMPLETENESS OF THE CONTENTS OF THIS PUBLICATION AND RESERVES THE RIGHT TO MAKE CHANGES TO SPECIFICATIONS AND PRODUCT DESCRIPTIONS AT ANY TIME WITHOUT NOTICE. NO LICENSE, WHETHER EXPRESS, IMPLIED, ARISING BY ESTOPPEL OR OTHERWISE, TO ANY INTELLECTUAL PROPERTY RIGHTS IS GRANTED BY THIS DOCUMENT. TESTING AND OTHER QUALITY CONTROLS ARE USED TO THE EXTENT NATIONAL DEEMS NECESSARY TO SUPPORT NATIONAL’S PRODUCT WARRANTY. EXCEPT WHERE MANDATED BY GOVERNMENT REQUIREMENTS, TESTING OF ALL PARAMETERS OF EACH PRODUCT IS NOT NECESSARILY PERFORMED. NATIONAL ASSUMES NO LIABILITY FOR APPLICATIONS ASSISTANCE OR BUYER PRODUCT DESIGN. BUYERS ARE RESPONSIBLE FOR THEIR PRODUCTS AND APPLICATIONS USING NATIONAL COMPONENTS. PRIOR TO USING OR DISTRIBUTING ANY PRODUCTS THAT INCLUDE NATIONAL COMPONENTS, BUYERS SHOULD PROVIDE ADEQUATE DESIGN, TESTING AND OPERATING SAFEGUARDS. EXCEPT AS PROVIDED IN NATIONAL’S TERMS AND CONDITIONS OF SALE FOR SUCH PRODUCTS, NATIONAL ASSUMES NO LIABILITY WHATSOEVER, AND NATIONAL DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY RELATING TO THE SALE AND/OR USE OF NATIONAL PRODUCTS INCLUDING LIABILITY OR WARRANTIES RELATING TO FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, OR INFRINGEMENT OF ANY PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT. LIFE SUPPORT POLICY NATIONAL’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS WITHOUT THE EXPRESS PRIOR WRITTEN APPROVAL OF THE CHIEF EXECUTIVE OFFICER AND GENERAL COUNSEL OF NATIONAL SEMICONDUCTOR CORPORATION. As used herein: Life support devices or systems are devices which (a) are intended for surgical implant into the body, or (b) support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided in the labeling can be reasonably expected to result in a significant injury to the user. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system or to affect its safety or effectiveness. National Semiconductor and the National Semiconductor logo are registered trademarks of National Semiconductor Corporation. All other brand or product names may be trademarks or registered trademarks of their respective holders. AN-2107 Copyright© 2010 National Semiconductor Corporation For the most current product information visit us at www.national.com National Semiconductor Americas Technical Support Center Email: [email protected] Tel: 1-800-272-9959 www.national.com National Semiconductor Europe Technical Support Center Email: [email protected] National Semiconductor Asia Pacific Technical Support Center Email: [email protected] National Semiconductor Japan Technical Support Center Email: [email protected]