ADP1043A 100 Watt Evaluation Kit ADP1043AFB100EVALZ PRD1266 FEATURES 100W Full Bridge Topology Advanced Voltage mode Control with integrated Volt-Second Balance I2C serial interface to PC Software GUI Programmable digital filters 7 PWM outputs including Auxiliary PWM Digital Trimming OrFET Control for Hot swap and Redundancy Current, voltage, and temperature sense through GUI Calibration and trimming Analog/Digital current sharing CAUTION This evaluation board uses high voltages and currents. Extreme caution must be taken especially on the primary side, to ensure safety for the user. It is strongly advised to power down the evaluation board when not in use. A current limited power supply is recommended as input as no fuse is present on the board. ADP1043A EVALUATION BOARD OVERVIEW This evaluation board features the ADP1043A in a switching power supply application. With the evaluation board and software, the ADP1043A can be interfaced to any PC running Windows 2000/XP/Vista/NT via the computer's USB port. The software allows control and monitoring of the ADP1043A internal registers. The board is set up for the ADP1043A to act as an isolated switching power supply with a rated load of 12V/8A from an input voltage ranging from a 36 to 60VDC. EVALUATION SYSTEM CONTENTS The evaluation system package contains the following items: * Application note EVAL-ADP1043AEB (order code: ADP1043AFB100EVALZ) * ADP1043A evaluation board The USB/I2C dongle for serial communication and software CD need to be ordered separately. Order code: ADP1043A-USB-Z. Rev. 1.3 Reference designs are as supplied as is and without warranties of any kind, express, implied, or statutory including, but not limited to, any implied warranty of merchantability or fitness for a particular purpose. No license is granted by implication or otherwise under any patents or other intellectual property by application or use of reference designs. Information furnished by Analog Devices is believed to be accurate and reliable. However, no responsibility is assumed by Analog Devices for its use, nor for any infringements of patents or other rights of third parties that may result from its use. Analog Devices reserves the right to change devices or specifications at any time without notice. Trademarks and registered trademarks are the property of their respective owners. Reference designs are not authorized to be used in life support devices or systems. One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106, U.S.A. Tel: 781.329.4700 Fax: 781.461.3113 (c)2009 Analog Devices, Inc. All rights reserved. ADP1043A 100Watt PRD1266 TABLE OF CONTENTS Features ....................................................................................................................................................................................... 1 CAUTION ..................................................................................................................................................................................... 1 TOPOLOGY AND circuit description ............................................................................................................................................ 4 CONNECTORS ............................................................................................................................................................................ 4 SETTING FILES AND EEPROM .............................................................................................................................................. 6 BOARD EVALUATION ................................................................................................................................................................. 7 EQUIPMENT ............................................................................................................................................................................ 7 SETUP ...................................................................................................................................................................................... 8 ADP1043A PROGRAMMING SOFTWARE ............................................................................................................................ 10 FLAGS SETTINGS CONFIGURATIONS ................................................................................................................................ 11 GENERAL SETTINGS AND SOFTSTART ................................................................................................................................. 13 PWM AND SR SETTINGS ......................................................................................................................................................... 16 CS1 OR INPUT CURRENT SETTING ....................................................................................................................................... 17 CS2 OR OUTPUT CURRENT SETTING ................................................................................................................................... 20 LIGHT LOAD MODE ............................................................................................................................................................... 22 OUTPUT VOLTAGE SETTINGS ................................................................................................................................................ 24 DIGITAL FILTER SETTINGS AND TRANSIENT ANALYSIS ...................................................................................................... 26 ORFET SETTINGS .................................................................................................................................................................... 29 APPENDIX I - SCHEMATIC (MAIN BOARD) ............................................................................................................................ 31 APPENDIX II - SCHEMATIC (DAUGHTER CARD) ................................................................................................................... 32 APPENDIX III - LAYOUT (MAIN BOARD) ................................................................................................................................. 33 APPENDIX IV - LAYOUT (DAUGHTER CARD) ........................................................................................................................ 36 APPENDIX V - TRANSFORMER SPECIFICATION ................................................................................................................... 39 APPENDIX V - TRANSFORMER SPECIFICATION ................................................................................................................... 39 APPENDIX VI - OUTPUT INDUCTOR SPECIFICATION ........................................................................................................... 41 APPENDIX VII - THERMAL PERFORMANCE ........................................................................................................................... 42 APPENDIX VII - THERMAL PERFORMANCE ........................................................................................................................... 42 APPENDIX VIII - STEADY STATE WAVEFORMS .................................................................................................................... 43 APPENDIX IX - EFFICIENCY and VOLTAGE REGULATION ................................................................................................... 47 APPENDIX X - BILL OF MATERIALS (MAIN BOARD).............................................................................................................. 49 APPENDIX XI - BILL OF MATERIALS (DAUGHTER CARD) .................................................................................................... 52 APPENDIX XII - REGISTER FILE (ADP1043AFB100_I_0710.43R) ......................................................................................... 53 APPENDIX XIII - BOARD FILE (ADP1043AFB100_I_0710.43b) .............................................................................................. 55 APPENDIX XIV - CS1 AND CS2 MEASUREMENT vs GUI READING ..................................................................................... 56 Notes .......................................................................................................................................................................................... 57 REVISION HISTORY 07/15/2010--Revision 1.0: SPM 07/29/2010--Revision 1.1: SPM with MS feedback. 08/03/2010--Revision 1.2: SPM with MS and NSD feedback. 08/20/2010--Revision 1.3: Revisions to rev 1.2 ADP1043A 100Watt PRD1266 DEMO BOARD SPECIFICATIONS Specification VIN MIN TYP MAX Units 36 48 60 V VOUT IOUT TAMBIENT 12 Switching frequency Output Voltage Ripple V 0.0 8.0 10 A 0 30 65 C 87.25 89.4 % 100.8 200 KHz 1.0 V Efficiency 80 Notes Typical reading at 48V/8A load At 8A load ADP1043A 100Watt PRD1266 TOPOLOGY AND CIRCUIT DESCRIPTION This evaluation board features the ADP1043A in a typical DC/DC switching power supply in a full bridge topology with synchronous rectification. Figure 1 gives a block diagram of the main components on the board. The circuit is designed to provide a rated load of 12V/8A from an input voltage source of 36 to 60VDC. The ADP1043A provides functions such as the output voltage regulation, over current protection, load current sharing with multiple power supplies over the share bus, over temperature protection, and power supply shutdown. Please refer to the appendix for the detailed schematic. The primary side consists of the input terminals, full bridge switches (QA to QD), the current sense transformer (T4) and the main transformer (T2). The ADP1043A (U1, on daughter card) resides on the secondary side and is powered via the USB 5V via an ADP3303 LDO (U2, on daughter card) present on the same daughter card. The gate signal for the primary switches comes from the ADP1043A through the iCouplers ADuM5230 (U14, U16) that provide isolation and power. The output of the iCoupler is connected to a buffer as it can source only 10mA of current. This buffer (network consisting of Q5 and Q6, Q7 and Q8, Q9 and Q10, Q11 and Q12) is used to drive the full bridge switches. The secondary side power stage consists of the synchronous rectifiers (Q2 and Q3) and their respective drivers ADP3624 (U1), output inductor (L1), output capacitor (C4, C7), sense resistor (R17), and ORFET (Q1). Diode (D2) and capacitor (C6) form a peak detector that drives the ORFET. Capacitors (C23, C64, C67) provide high frequency decoupling to lower EMI. Diodes (D15-D18) rectify the input current signal to sense the primary current and resistor (R10) converts the current into a voltage. The over current flag trips at 1.2V. Thermistor (RT1) is placed close to the ORFET on the board allowing over temperature protection functionality to be implemented. Also present on the secondary is the current sharing circuitry, flag LEDs (D11-D12), communications port to the software through the I2C bus. CONNECTORS The connections to the evaluation board are shown below. Connector Evaluation Board Function J3 48V DC Input J2 Ground Return for 48V DC Input J4 12V DC Voltage Output J5 Ground Return for 12V DC Voltage Output J8, J9 I2C Connector J10 Share Bus J1 Daughter card There is a 4 pin connector for I2C communication. This allows the software to communicate with the evaluation board through the USB port of the PC. Instead of using an auxiliary supply, the board uses the 5V input from the USB port, and generates 3.3V using an LDO for the ADP1043A. The synchronous rectifier drivers (ADP3624) are also powered by the 5V USB, but are powered from the main 12V output after the output is in regulation. Connectors (J8 and J9) are identical and are connected in parallel to each other to allow multiple boards to be connected to the same I2C bus in a daisy chain configuration. Each board consumes between 150mA and 250mA depending on the conditions. Particular care must be taken not to overload the USB 5V rail. Some USB ports are especially those connected at a hub may shut down if overloaded, causing communication problems. In such cases an external 5V power supply is recommended to power the board between test point TP44(+) and TP21(-). ADP1043A 100Watt PRD1266 Pin Evaluation Board Function 1 5V 2 SCL 3 SDA 4 Ground ADP1043A 100Watt PRD1266 SETTING FILES AND EEPROM The ADP1043A communicates with the GUI software using the I2C bus. The register settings (having extension .43r) and the board settings (having extension .43b) are two files that are associated with the ADP1043A software. The register settings file contains information that govern the functionality of the part such as the over voltage and over current limits, softstart timing, PWM settings etc. The ADP1043A stores all its settings in the EEPROM. When the ADP1043A is connected to the USB dongle the LDO powers the I.C. and the GUI downloads the settings from the registers of the ADP1043A so that the state of the part is known. It is possible to save these settings in a file for later use. Older register settings are overwritten when new files are loaded. The EEPROM on the ADP1043A does not contain any information about the board, such as current sense resistor, output inductor and capacitor values. This information is stored in board setup file (extension .43b) and is necessary for the GUI to display the correct information in the Monitor tab as well as Filter Settings window. The ADP1043A does not need this information in order to operate, but the GUI will need it in order to show the values correctly in the Flags and Settings window. The entire status of the power supply such as the ORFET and synchronous rectifiers enable/disable, primary current, output voltage and current can be thus digitally monitored and controlled using software only. Always make sure that the correct board file has been loaded for the board currently in use. Each ADP1043A chip has trim registers for the temperature, input current and the output voltage and current. These can be configured during production and are not overwritten whenever a new register settings file is loaded. This is done in order to retain the trimming of all the ADCs for that corresponding environmental and circuit condition (component tolerances, thermal drift, etc.). A guided wizard called the Auto Trim is started which trims the above mentioned quantities so that the measurement value matches the valued displayed in the GUI to allow ease of control through software. In the following pages it will be shown that the ADP1043A can be easily programmed to modify the behavior of the PSU under different fault and load conditions without any hardware changes. All the changes are purely through software and do not require desoldering components and replacing them with new values to specify a different operating condition ADP1043A 100Watt BOARD EVALUATION EQUIPMENT * DC Power Supply * Electronic Load * Oscilloscope with differential probes * PC with ADP1043A GUI installed * Precision Digital Multimeters (HP34401or equivalent - 6 digits) for measuring DC current and voltage PRD1266 ADP1043A 100Watt PRD1266 SETUP NOTE: DO NOT CONNECT THE USB CABLE TO THE EVALUATION BOARD UNTIL THE SOFTWARE HAS FINISHED INSTALLING 1) Install the ADP1043A software by inserting the installation CD. The software setup will start automatically and a guided process will install the software as well as the USB drivers for communication of the GUI with the IC using the USB dongle. 2) Insert the daughter card in connector J1 as shown in Figure 5. 3) Ensure that the PS_ON switch (SW1 on schematic) is turned to the OFF position. It is located on the bottom left half of the board (Figure 5). 4) Connect the evaluation board to the USB port on the PC using the "USB to I2C interface" dongle as shown in Figure 2. 5) The software should report that the ADP1043A has been located on the board. Click "Finish" to proceed to the Main Software Interface Window. The serial number reported on the side of the checkbox indicates the USB dongle serial number. The windows also displays the device I2C address. 5. If the software does not detect the part it enters into simulation mode. Ensure that the connecter is connected to J8/J9 (on main board) or J7 (on daughter card). Click on Scan for ADP1043A now icon (magnifying glass) located on the top right hand corner of the screen. 5. Click on the "Load Board Settings" icon (fourth button from the left) and select the ADP1043AFB100_I_0710.43b file. This file contains all the board information including values of shunt and voltage dividers. Note: All board setting files have an extension of .43b ADP1043A 100Watt PRD1266 6. The IC on the evaluation board comes preprogrammed and this step is optional. The original register configuration is stored in the ADP1043AFB100_I_0710.43r register file. (I and 0710 stand for the hardware revision number and the month/year date code respectively). Note: All register files have an extension of .43r. The file can be loaded using the second icon from the left in Figure 10. 7. Connect a DC power source (48VDC nominal, current limit to 5A) and an electronic load at the output set to 8 Amperes. 8. Connect a voltmeter on the output (connectors J4 and J5) and a differential scope probes (optional) between test points TP16 and TP17. Ensure that the differential probes are used and the ground of the probes are isolated if measurements are made on the primary and secondary side of the transformer simultaneously). 9. Turn the PS_ON switch (SW1 on schematic) to the ON position. 10. The evaluation board should now up and running, and ready for evaluation. The output should now read 12 VDC. 11. Click on the MONITOR tab and then on the Flags and readings icon. This windows provides a snapshot of the entire state of the PSU in a single user friendly window. During power up, the ADP1043A is connected to the USB port (5V) and the LDO powers the IC. It takes 20sec for VCORE (pin 26) to reach an internal voltage of 2.5V. After this, the I.C. downloads the contents of the registers into the EEPROM. After this the softstart ramp begins. After successful startup and in steady state condition, 5 LEDs on the board to provide to the user the status of the board. All except the D12 (or FLAGIN) LED will be turned ON indicating that there are no faults detected such as over voltage or over current. In case of a fault the POOD1 or PGOOD2 LEDs will be turned OFF indicating that some flag has tripped due to an out of bounds condition. The monitor window will display the appropriate state of the PSU. ADP1043A 100Watt LED D1 (Red) PRD1266 Location Description Bottom left Indicates input voltage is present D10 (Yellow) Bottom right PGOOD1 signal (active low) D11 (Red) Bottom right PGOOD2 signal (active low) D12 (Red) Bottom right FLAGIN signal D13 (Red) Top right Indicates ORFET is turned ON ADP1043A PROGRAMMING SOFTWARE The goal of this evaluation kit is to allow the user to get an insight into the flexibility offered by the extensive programming options offered by the ADP1043A. Several test points on the board allow easy monitoring of the various signals. The user can also use the software to program multiple responses (such as disable power supply or turn off ORFET) for various fault conditions. The following sections give provide a good overview of the software as well as the test data experiments that the user might typically evaluate. There are 9 main windows (blue icons in figure below) where the user can use to program and evaluate the PSU. They can be accessed from the Setup window in the GUI. ADP1043A 100Watt PRD1266 FLAGS SETTINGS CONFIGURATIONS The following state machine diagram provides a graphical idea as to how the flags in the ADP1043A operate and hence gain insight into the working of the IC. Basically when a flag is triggered, the controller waits for a programmable debounce time before taking any action. The response to each flag can be programmed individually. The flags can be programmed in a single window by hitting the FLAG SETTINGS icon in the MONITOR tab in the GUI and the state of the power supply can be monitored by clicking on the FLAGS AND READINGS icon in the MONITOR tab. ADP1043A 100Watt PRD1266 This monitor window shows all the fault flags (if any) and the readings in one page. The Get First Flag button determines the first flag that was set in case of a fault event. The ADP1043A is programmed to respond to the various fault conditions in the Flag Settings Window. ACTION: Ignore Flag Completely, Disable Synchronous Rectifiers, Disable ORFET, and Disable power Supply are the operations available in this column. TIMING: This defines if an ACTION is taken immediately or after a debounce. Debounce is a term used for a wait period in digital circuitry. After a flag signal is detected, the debounce routine checks if the flag signal remains in its changed state for the entire programmed debounce period before taking any action. This prevents the ADP1043A from reacting to false positives. RESOLVE ISSUE: This determines the operation of the PSU after the fault is cleared. Hysteretic or latching options are available. ADP1043A 100Watt PRD1266 GENERAL SETTINGS AND SOFTSTART This section programs the PS_ON turn on and softstart timing. The power supply (PSU) can be turned on with a manual switch (hardware PS_ON), a software enabled switch (SW PS_ON), or both with a programmable delay. It contains the capability of adding a soft start to the primary and secondary switches (synchronous rectifiers) and also displays the temperature of the thermistor for the over temperature protection. It is not recommended to use the soft stop ramp as it overrides any protection features such as overcurrent protection. Some test results are provided to better appreciate the flexibility of part. In addition to these some suggestions for further exploration are also provided. A. PS_ON Turn on Delay: Figure 16 and Figure 17 show the startup sequence with a 0.5 second and 2 second delay respectively. This test was conducted by monitoring the PSON signal (TP29), the output voltage (J4 and J5) and setting a programmable delay using the drop down menu. Monitoring the synchronous rectifier (test point SR1 and SR2) is optional. ADP1043A 100Watt B. PRD1266 Softstart ramp and SR blanking: Figure 18 and Figure 19 show the startup sequence with the synchronous rectifiers enabled/disabled with a 20ms and 40ms softstart ramp respectively. This test was conducted by monitoring the output voltage (J4 and J5) and the test points SR1/SR2 during a startup condition. The Blank SR during softstart check box and the Softstart ramp rate dropdown menu were appropriately selected. C. SR enable during softstart: Figure 20 shows the startup sequence with the synchronous rectifiers enabled during softstart. This test was conducted by monitoring the output voltage (J4 and J5) and the synchronous rectifier test points test points (SR1, SR2) during a startup condition. The Blank SR during softstart check box was left unchecked. ADP1043A 100Watt D. PRD1266 SR softstart: This test shows the capability of the softstart ramp or fade in sequence applied to the synchronous rectifiers. The Enable SR softstart button was checked. Figure 21 and Figure 22 show a zoomed in snapshot of the duty cycle at the beginning and end of the softstart ramp Additional things to try: a) Implementation of different softstart timings in combination with different PS_ON delays. b) Disabling Soft Start Always and evaluating the performance after a fault like UVP/OVP disables the PSU. c) Trimming the RTD register by measuring the temperature at the OrFET and changing the trim setting. d) Disable the OrFET allowing its body diode to conduct the output current. Then set different OTP thresholds. e) Enable Softstart always and see the PSU start a softstart ramp everytime a fault such as a temporary short circuit. ADP1043A 100Watt PRD1266 PWM AND SR SETTINGS The switches on the primary and the synchronous rectifier timings are controlled in this window. This window programs the switching frequency, timings of the synchronous rectifier, the type of modulating edge (rising or falling), modulation type (positive or negative). The IC can be programmed to run at a fixed duty cycle. The Pulse Skipping mode is activated when the controller requires a duty cycle less than the modulation low limit to maintain output regulation. Note 1: All the signals shown below represent the gate drive signals at the output pins of the IC. Note 2: Although the switching frequency can be increased, the software does not account for the dead times and these have to be programmed manually by measuring the propagation delays between the output of the ADP1043A and the gate of the MOSFET. A 200nsec delay is conservative for the evaluation board. Things to try: a) Referring to the schematic, turning on QA and QB for the entire period of Ts/2 (with appropriate deadtimes) and modulating only the bottom MOSFETs. b) Enabling/Disabling Pulse skipping mode and measuring standby power (by disabling the LEDs on the board additional power can be saved). c) Doubling the switching frequency (see accompanying file 200KHz with VS balance.43r) Note: The board is designed to operate at switching frequencies of up to 200kHz with air flow cooling (i.e. a fan). Beyond that, frequency damage to the FETs may occur. d) Programming an imbalance in the ON times of the MOSFETs of each branch and evaluating Volt-Second balance. e) Measuring the effect on standby power by reducing the Modulation Low Limit with/without pulse skipping. f) Run the software in simulation mode and program the PWM settings for a different topology. ADP1043A 100Watt PRD1266 CS1 OR INPUT CURRENT SETTING The input current settings are accessed using the CS1 Settings block. It is used to program the fast and accurate ADCs for pulse by pulse current limiting, leading edge blanking, and enable the volt-sec balance correction to the bottom MOSFETs of the full bridge converter and/or the synchronous rectifiers. Some tests are provided to better appreciate the flexibility of part. In addition to these, some suggestions for further evaluation are also provided. A. CS1 Accurate OCP: Figure 25 shows the CS1 accurate OCP flag and a reenable after 1 second This test was conducted by setting the CS1 accurate OCP limit of 2.76A (drop down menu in the GUI) which is lower than the current at minimum voltage. Then the input voltage was ramped down from 60V until the OCP limit was triggered. . Monitoring the PWM signal at test point OUTA clearly shows the shutdown of the PWM. ADP1043A 100Watt B. PRD1266 Volt Second Balance feature: The CS1 settings window has the volt second feature that measures the average current in each leg of the full bridge topology. The algorithm reduces (or increases) the conduction time of each branch by varying the pulse width of the MOSFET gate signals applied to OUTB and OUTD depending if there was an increase (or decrease) of current in the corresponding branch. A maximum of 80nsec can be accounted for by this algorithm. This test was conducted by purposely introducing a mismatch of 75nsec in the PWM settings window. This mismatch clearly shows that the transformer is close to saturation on one end. Figure 27 shows the imbalance and Figure 28 shows the corrected imbalance after the feature was turned on in the GUI by closing the switch. The primary current can be measured using a current probe and by using a small loop of wire in place of jumper L3 or C10 on the board. ADP1043A 100Watt C. PRD1266 CS1 Fast OCP: Figure 29 and Figure 30 show the CS1 fast OCP tripping under a shorted output. In this test the CS1 pulse by pulse current limit was tested during a shorted output. A shutdown was programmed after 4 repetitive OCP limits were triggered. Additional things to try: a) Programming an external FLAGIN to trip the CS1 fast OCP comparator. b) Enabling/Disabling Volt-Second balance and its associated gain. c) Measuring peak output power at maximum input voltage and by decreasing/increasing the debounce value. d) Use a blocking capacitor (0.47F/100V, metal film) and check the effect of changing the gain in the Volt-second balance on the current waveform. e) Choosing a different value of R10 (on schematic) to get a different range of protection. ADP1043A 100Watt PRD1266 CS2 OR OUTPUT CURRENT SETTING The output current settings window is accessed using the CS2 Settings block. This window also features trimming registers , line impedance feature, threshold for over current protection (OCP), the light load threshold, and constant current mode. The following waveforms display some of the features that can be programmed using this window. A. Over Current Protection (OCP): Figure 32 and Figure 33 show hysteretic and latching OCP respectively. An over current condition can be easily created by shorting the load or increasing the output current beyond the OCP limt. Different reactions to the fault can be programmed by either re-enabling the PSU after 1 second or a complete shutdown through the drop down menus in the GUI. ADP1043A 100Watt B. PRD1266 Constant Current Mode: Figure 34 shows the output voltage ramping down linearly by 60% during constant current mode. Closing the switch on the trace connected to the Constant Current Block enables CC mode. In this the output voltage linearly drops by 60% of its nominal value when the load current reaches 90% of the OCP limit. In this example, the IC enters CC mode when the load was set to 9.5A which is 94.7% of the OCP limit and output voltage drops to 7 Volts in during CC. Additional things to try: a) Setting a different light load thresholds and measuring its effect on efficiency b) Using the line impedance feature to simulate the voltage drop through a 2 foot output cable. c) Reducing the current sense resistor value (R17) and changing the range of the full scale voltage drop on CS2+ and CS2- d) Increasing the debounce time on CS2 OCP limit and measuring the peak output power during a short circuit test. e) Setting different OCP limits and setting a different response such as disable SyncRec ADP1043A 100Watt PRD1266 LIGHT LOAD MODE The ADP1043A can be programmed to optimize performance when the output current drops below a certain level. The light load threshold is set in a manner to reduce the losses in the synchronous rectifiers to enter into DCM and reduce the power loss in the SR drivers and increase efficiency. A hysteresis is provided on this threshold to avoid oscillations. When operating in light load mode the corresponding flag will be set as well as the SR off flag as shown in the monitor window (Synchronous rectifiers turned red in figure below), and the light load filter settings will be used. Using this in combination with Pulse Skipping aids in reducing standby power consumption. The ACSNS flag is used to sense the voltage at the front side of the inductor connected to the transformer (T2). ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 OUTPUT VOLTAGE SETTINGS This window sets all the parameters related to the output voltage, including trimming, overvoltage protection (OVP) and undervoltage protection (UVP) protection. There are three points where the output voltage is sensed using the ADP1043A namely, before the ORFET (local OVP), after the ORFET (also local OVP), and at the load (remote OVP). An over voltage condition at the load is termed as remote OVP whereas at the other two locations is termed as local OVP. The following waveforms display some of the features that can be changed using this window. A. Under Voltage Protection (UVP): Figure 39 and Figure 40 show latching and hysteretic UVP respectively. This test can be conducted in a number of ways, the simplest of which would be to set the VS3 Output Voltage Setting under the programmed UVP threshold using the drop down menu in the GUI. Alternately, the duty cycle can be clamped to a lower value than its required value. Under certain conditions even a shorted load or an internal short (shorting the synchronous rectifiers) can cause a UVP condition. Hysteretic (enable after 1 sec) and latching (remain disabled, only PS_ON can reenable) are the programmed choices for the faults. ADP1043A 100Watt B. PRD1266 Over Voltage Protection (OVP): Figure 41 and Figure 42 show latching and hysteretic OVP respectively. This test can be easily performed setting the VS3 regulation point beyond the OVP threshold. Another method how an OVP flag can be tripped is by suddenly opening the control loop (open R10 or short R11 on the daughter card). Hysteretic (enable after 1 sec) and latching (remain disabled, only PS_ON can reenable) are the programmed choices for the faults in the drop down menu provided in the GUI. Additional things to try: 1. Using Auto trim to precisely set the voltage at the terminals of the board. 2. Setting OVP and UVP limits to 5% of nominal output voltage and measuring its effect on startup 3. Regulating with VS3 at all times and evaluating the transient response. 4. Use this voltage continuity feature to detect a voltage drop more than 100mV between VS1 and VS2 or VS2 and VS3. ADP1043A 100Watt PRD1266 DIGITAL FILTER SETTINGS AND TRANSIENT ANALYSIS The digital filter can be changed using the software by manipulating the position of the poles and zeros (red and green circles in figure below) in the Laplace domain. The ADP1043A allows two different sets of compensation to be programmed, one at light load and one at heavy load. A type 3 compensation is implemented in the ADP1043A. The first pole (to eliminate steady state error) is indirectly accessed through the placement of the first zero. The second pole can be freely placed, but the third pole (high frequency gain) is fixed at half the switching frequency. There is an additional constraint in moving the poles and zeros and it is that the software allows the poles and zeros to be moved only in a manner that keeps the slopes between them equal to 20dB/dec. WARNING: While varying the compensation parameters is possible while the part is running, the wrong combination of parameters can cause the system to become unstable. The following figures are provided to demonstrate the performance of the PSU as well as the ease with which the GUI can be used to change the dynamic response of the system. A. Closed Loop System: Figure 43 and Figure 44 show the bode plot of the system. The validity of this plot depends highly on the proper characterization of the output inductor and capacitor and their respective parasitic components namely the DC resistance and ESR. The GUI displays the closed loop crossover frequency, phase margin as well as individual gain and phase plots for the LC filter, digital filter and the closed loop scenarios. ADP1043A 100Watt B. PRD1266 Transient Response for load step: Figure 45 and Figure 46 show the transient response at 36 and 60VDC respectively. A dynamic load from 1-8A (slew rate 1A/s) at a frequency of 20-25Hz can be set up to conduct this test. The output voltage must be measured at the connectors J4 and J5 with very small loop area between the positive and negative of the probes to minimize noise. C. Transient Response under DCM/CCM transition: Figure 47 shows the dynamic response of the system under a load step of 0.2-5A (slew rate1A/s). A low starting current is chosen so that the converter is forced to disable the synchronous rectifiers due to the light load threshold setting in the CS2 window. In contrast, Figure 48 shows the response with the light load threshold set at 0A (SR always on). This forces the output inductor current to be continuous and the converter remains in CCM despite the load condition drawing energy from the output capacitor to charge the inductor. ADP1043A 100Watt PRD1266 Additional things to try: a) Tweaking the light load transient response (0-500mA step load). b) Increasing the crossover frequency and measure transient response c) Measuring transient response under different load steps d) Increasing the phase margin to 60 degrees by cancelling the double pole of the output LC filter by the two zeros of the Type 3 compensation. e) Measuring the transient response (0.2A - 8A) by enabling the light load mode at 0.0A (SR always enabled) thus keeping the output inductor in CCM regardless of the load. f) Measuring the dynamic response at 200KHz switching frequency. ADP1043A 100Watt PRD1266 ORFET SETTINGS The ADP1043A includes features such as hot swapping as well as protection against a reverse current from other PSUs connected on the same bus with the use of active ORing (ORFET). This window sets the turn on condition of the OrFET depending upon the voltage threshold across it as well as its turn off depending upon the reverse current flowing in the current + sense resistor CS2 - CS2 . This enables hot swapping and allows additional PSUs to be connected to the same bus without any interruption with sufficient protection. The following waveforms display some of the features that can be changed using this window. A. Load OVP action on OrFET: Figure 50 shows the OrFET being disabled when a bus voltage is greater than the local voltage. A DC power supply can be connected to the output terminals of the board (J4, J5). Care should be taken to ensure that the output voltage is not beyond the voltage rating of the output capacitor (C7) and the absolute maximum VCC rating of the SR driver (U1). Here the load OVP flag is used to protect the PSU by disabling the OrFET. The body diode of the MOSFET (Q1) is reversed biased during this condition. ADP1043A 100Watt PRD1266 B. Internal short circuit action on OrFET: Figure 51 and Figure 52 shows the OrFET disabled during an internal short circuit and its corresponding flag. An internal short of the synchronous rectifiers can be can be simulated in the PWM settings or by physically shorting the drain pin of Q2 and Q3. The CS1 fast OCP or the UVP flags can be set to disable the OrFET. C. UVP action on OrFET: Figure 53 and Figure 54 show the disabled OrFET signal during a UVP fault and reenable after the flag is cleared. Additional things to try: a) Disable OrFET using CS1 OCP, Load UVP or fast OrFET when an internal short circuit occurs. b) Disable OrFET using VS3 when VOUT> OVP limit. c) Disable ORFET using ACSNS in light load mode to minimize light load standby consumption. QC LO TP7 QC HI TP2 TP6 QD HI C2 330uF 1 2 R3 C14 330uF 25V 1A 100V ELEC T ALU M 1 2 QB HI TP4 TP3 Q8 R76 FMMT589 25V 1A 10K R32 10 25V 1A Q7 FMMT489 QA LO Q6 R74 FMMT589 25V 1A 10K Q10 R41 FMMT589 25V 1A 10K R39 10 25V 1A Q9 FMMT489 Q12 R45 FMMT589 25V 1A 10K R44 10 25V 1A Q11 FMMT489 1 100V 44A 2 2 2 2 2 2 2 2 QB FDD3672 1 100V 44A D1 LED QA FDD3672 RED Q5 FMMT489 R73 10 24.9k 2 1 QA HI TP1 1 + 2 3 2 3 2 1 R43 10 TP51 100V 2A D7 SS2H10 TP52 C41 0.47uF C40 0.47uF R38 10 R37 1 TP49 TP50 TP48 C72 0.47uF R75 10 R46 1 100V 2A TP46 TP23 TP22 TP19 TP18 100V 44A QD FDD3672 1 9 10 3 2 4 1 VOA GNDiso VISO GNDB VOB VDDB 9 10 G-EARTH 16 14 25V C30 4.7UF 11 15 25V C20 0.015UF VOA GNDiso GNDB VISO VOB VDDB U15 ADum5230 16 14 25V C27 4.7UF 15 11 25V TP36 + 5 6 4 3 1 2 U14 ADum5230 C29 + 1UF + T4 T2 100V SPM68280 T2-LO TP17 2 T2-HI TP16 2 C28 + 1UF C10 JUMPER L3 JUMPER C38 0.47uF R72 10 R34 1 D6 SS2H10 1 1 100V 44A QC FDD3672 + C23 4.7uF EN R47 1k 1 8 7 GND2 GND1 GND VIA VIB NC1 NC VADJ 6 5 GND2 GND1 GND VIA VIB NC1 NC VADJ 8 4 1 5 6 25V TP37 R40 8.06k 2 25V 10UF 100V AGND TP21 TP30 TP43 OUTD OUTC TP42 C71 0.47uF OUTB TP41 OUTA TP40 2 2 R71 0 +5V +5V 1 D16 D18 1 PGND 4 5 C70 0.47uF PGND INA INB PGND C26 DNI 3 BAV70 BAV70 3 25V TP31 + 2 1 2 t C24 0.1UF 5 15 12 11 17 16V RTD CS1 OUTC OUTD SR1 SR2 2 18 2 J14 1 J13 PGND TP25 1 C31 DNI +3.3V L1 J15 10uH 10A 1 4 3 C4 + C11 DNI 1500uF PGND RT1 NTC SR2 SR1 TP9 TP8 D9 DNI ASCNS 100V 1A C12 2700pF 3 R15 13 C36 10UF PGND R10 10 CSI 2 D2 BAV70 1 R4 470 TP34 PGND C21 DNI TP12 Q3 R11 4.7 1 75V 82A Q3 IRF2807S TP60 C5 2700pF 1A R14 13 C3 100nF C13 1 AGND EN OTW C42 10UF + R35 8.06k 25V 2 12V + OUTA OUTB C39 10UF + AGND 13 12 3 R42 2.05k 8 4 1 5 6 13 12 3 R36 2.05k 2 Hi Current Drive U1 ADP3624A Q2 TP11 TP20 OTW R9 4.7 1 75V 82A Q2 IRF2807S OUTB TP10 C19 0.015UF 7 9 12 10 8 11 13 TP61 2 3 3 2 3 3 1 3 6 2 1 1 1 J18 12V + 25V 1W R5 JUMPER R19 DNI 1 3 2 4 R20 DNI C6 1uF J19 10K R49 10K 2 R50 1 1 1 2 R78 1K 10K C18 DNI J16 J17 OTW 10K R57 R77 10K +3.3V R52 2 2 OTW TP45 R70 2.2K +5V 1W TP13 CS2- R16 0 1 3 R17 0.01 Ohm 16V 1W D3 SMZ16 R18 0 2 4 2A TP33 1 2 RED LED TP14 CS2+ D13 +3.3V PLAGIN TP39 C44 100nF 10K R51 SCL SDA Q13 FMMT489 TP5 OUTAUX 2 3 +3.3V R63 2.2K 1UF R48 4.7M C8 U7A OP297 1 C22 100nF R13 0 - + D11 LED 3 12V YELLOW R67 1K R62 2.2K D10 LED GREEN R66 1K +3.3V D12 LED RED R68 470 3 Q1-S TP35 2 SW1 R61 100 1 C49 100 33pF R80 D4 BAV70 2 3 3 1 2 R64 100 J20 C45 33pF C37 33pF 3 25V C15 10UF C34 33pF 1 +3.3V 100V 1A SDA SCL AGND 2 3 4 +3.3V C9 DNI D21 BAV70 1 + R55 0 SLC 100V 390pF C68 DNI D22 BAW56 2 D20 BAW56 D19 BAV70 1 SDA VS3+ TP62 R79 10 12V R25 DNI VS3- VS3+ 2 VS3VS3+ D8 BAV70 2 F1 1A C69 10nF R56 0 TP27 TP44 +5V J11 J12 R59 100K C32 TP26 16V +3.3V 29 26 25 28 TP63 VS3- 100V + C7 1500uF R81 10 Q1-D TP38 C16 1000pF VS3VS3+ VDD MBRS1100T3 R60 + 1 D5 +5V C46 10nF C35 100 33pF C33 33pF 25V C17 22UF 12V TP47 PSON TP29 GATE TP64 2 Q1-G TP15 75V 82A 2 Q4 FMMT489 D14 DNI 1 Q1 IRF2807S DNI R23 10K C43 15K R58 R24 2.2K AD1043 DAUGHTER CARD J1 CONN RECEPT 30POS 25V C67 C64 10uF 10uF VS3- 2 J2 + 16 1 30 NC EGND HIGH VOLTAGE AREA 21 PGND 1 2 19 CS2- 1 2 J3 7 22 VS1 GND ISOLATED VDD1 20 CS2+ 1 3 1 24 GATE VCC PGND 3 C25 DNI 23 VS2 1 3 VIN 3 1 1 3 3 1 1 3 3 1 1 3 3 1 1 3 1 2 1 2 1 2 1 2 1 2 1 2 2 2 GND ISOLATED 2 2 VDD2 7 VDD2 iCOUPLER VDD1 iCOUPLER 3 D15 BAV70 1 1 2 1 2 3 D17 BAV70 1 OUTAUX ACSNS OUTB 13 OUTA 14 SHAREi 2 +5V 27 FLAGIN 6 2 1 PGOOD1 8 PGOOD2 7 2 1 10 3 1 9 SHAREo 1 2 1 1 2 2 1 8 4 1 1 PSON 2 2 2 1 JUMPER 10nF C62 3 3 1 3 2 2 JUMPER 10nF C63 2 2 R54 2.2K +3.3V 1 SDA SCL 1 1 VS3+ J4 J10 J9 COM2 J8 COM1 I SHARE 2 3 4 1 2 3 4 1 VOUT- J5 VOUT+ ADP1043A 100Watt PRD1266 APPENDIX I - SCHEMATIC (MAIN BOARD) 2.2K R53 NOTES: R2 1k R1 27K C10 100pF ACSNS DNI DNI DNI 33pF 33pF DNI R4 10k CS2+ C17 DNI C10 C13 C16 C17 DNI 10k High Side 110k 110k DNI R4 R3 SHARE0 SHAREi SDA SCL RTD FLAGIN PGOOD2 PGOOD1 PSON OUTAUX OUTD OUTC OUTB OUTA CS1 ACSNS SR1 SR2 CS2- CS2+ VS1 VS2 GATE VS3+ VS3- +5V +3.3V Low Side 10k 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 +12V 2 2 PGND C13 100pF C16 DNI CS2- R13 0 R3 10k C2 DNI C1 DNI AGND R6 1k R5 11k VS1 R16 0 R11 1k R10 11k C15 1000pF C4 DNI C3 DNI DGND CS1 R8 1k R7 11k VS2 8 7 6 5 4 3 2 1 C14 0.1uF VS3+ PGND CS1 ACSNS CS2+ CS2- VS1 AGND VS2 C9 DNI C7 DNI VS3- 2.2k R19 28 31 32 VS3- VS3+ RTD 28 C11 +3.3V U1 ADP1043 RTD 0.1uF C6 26 VCORE SCL SDA PSON FLAGIN PGOOD2 PGOOD1 SHAREO SHAREI 0.1uF R29 2.2k 17 18 19 20 21 22 23 24 R33 DNI +3.3V R24 2.2k R14 1.2k +3.3V SCL SDA PSON FLAGIN PGOOD2 PGOOD1 SHARE0 SHAREi C5 1.0uF 50V R17 0 D1 1N4148 +12V 5 6 8 7 D2 1N4148 GND NR OUT1 OUT2 SDA SCL +5V 4 3 2 1 U2 ADP3303 SD ERR IN1 IN2 +5V 2 1 29 33 PAD DNI R32 49.9k 30 R20 RES OUTA 11 OUTA SR1 9 SR1 29 ADD OUTB 12 OUTB OUTC 13 OUTC SR2 10 SR2 27 VDD OUTD 14 OUTD 25 DGND GATE 16 GATE OUTAUX 15 OUTAUX 1.2k R15 2 1 30 1: R3, R4, R5, R6, R7, R8, R10, R11 ARE 0.1% 25ppm UNLESS OTHERWISE SPECIFIED. 2 J1 4 3 1 2 J7 C8 0.1uF C12 0.47uF R12 1 +3.3V ADP1043A 100Watt PRD1266 APPENDIX II - SCHEMATIC (DAUGHTER CARD) ADP1043A 100Watt APPENDIX III - LAYOUT (MAIN BOARD) PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt APPENDIX IV - LAYOUT (DAUGHTER CARD) PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 APPENDIX V - TRANSFORMER SPECIFICATION PARAMETER MIN TYP MAX UNITS Core and Bobbin NOTES ETD 29 Horizontal, 3F3 or equivalent Primary inductance 77 Leakage inductance 2.31 Magnetizing current Resonant frequency 3 1.58 H Pins 2,3 to pin 4,5 H Pins 2,3 to pin 4,5 with all other windings shorted A 850 KHz Pins 2,3 to pin 4,5 with all other windings open Table 5 - Transformer specifications PARAMETER MIN TYP MAX UNITS Core NOTES 0077720A7, KoolMu, Magnetics Inc. Pearmeability (o) 75 Inductance 6.5 DC resistance 10 H 6 m 11 2, 3 6T, Copper foil, 4 mil, 0.6inch wide 4, 5 3T, Copper foil, 4 mil, 0.6inch wide 10 3T, Copper foil, 4 mil, 0.6inch wide 9 ADP1043A 100Watt TEFLON SLEEVE 4, 5 9 10 10 11 2, 3 PRD1266 ADP1043A 100Watt PRD1266 APPENDIX VI - OUTPUT INDUCTOR SPECIFICATION 4, 2 12T, 16AWG Litz wire 3, 1 ADP1043A 100Watt PRD1266 APPENDIX VII - THERMAL PERFORMANCE All thermal tests were conducted at room temperature with no air flow at 36VDC input voltage and a load of 8A. A pre-soaking time of one hour was before collecting any data with a type K thermocouple for temperature measurement. Component Bulk capacitor (C2, C14) MOSFET (QA) MOSFET (QB) MOSFET (QC) MOSFET (QD) Current sense Transformer (T4) Main transformer (T2) Icoupler (U14, U15) Synchronous Rectifier (SR2) Synchronous Rectifier (SR3) Output Inductor (L1) Output capacitor (C4) ADP1043A OrFET (Q1) RSENSE (R17) Buffer Transistor (Q5 to Q12) Measured temperature at Estimated temperature at 27C 65 C 30 68 40 78 41 79 42 80 40 78 31 69 75 113 50 88 60 98 65 103 57 95 52 90 35 73 52 90 62 100 42 80 ADP1043A 100Watt APPENDIX VIII - STEADY STATE WAVEFORMS PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 APPENDIX IX - EFFICIENCY AND VOLTAGE REGULATION ADP1043A 100Watt PRD1266 ADP1043A 100Watt PRD1266 APPENDIX X - BILL OF MATERIALS (MAIN BOARD) Part Ref C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 C36 C37 C38 C39 C40 C41 C42 C43 C44 C45 C46 C49 C62 C63 C64 C67 C68 C69 C70 C71 C72 D1 D2 D3 D4 Part Description CAP 330UF 100V +/-20% ELECTROLYTIC ALUM CAP CER 100nF 50V 10% X7R CAP 1500UF 16V ELECT FK SMD CAP CER 2700PF 100V +/-10% X7R CAP CER 1UF 25V +/-10% X7R CAP 1500UF 16V ELECT FK SMD CAP CER 1UF 25V +/-10% X7R DNI JUMPER WIRE DNI CAP CER 2700PF 100V +/-10% X7R CAP CERAMIC 10UF 25V +/-20% X5R CAP 330UF 100V +/-20% ELECTROLYTIC ALUM CAP CERAMIC 10UF 25V +/-20% X5R CAP CER 1000pF 100V +/-10% X7R CAP 22UF 25V HA ELECT SMD DNI CAP FILM MKP .015UF 275VAC X2 CAP FILM MKP .015UF 275VAC X2 DNI CAP CER 100pF 50V +/-5% NPO CAP FILM 4.7UF 100V +/-5% METAPOLY CAP CER 100nF 50V 10% X7R DNI DNI CAP CERAMIC 4.7UF 25V +/-10% X5R CAP CERAMIC 1UF 50V +/-10% X7R CAP CERAMIC 1UF 50V +/-10% X7R CAP CERAMIC 4.7UF 25V +/-10% X5R DNI CAP CER 390PF 100V +/-5% NPO CAP CER 33PF 50V +/-5% NPO CAP CER 33PF 50V +/-5% NPO CAP CER 33PF 50V +/-5% NPO CAP CERAMIC 10UF 25V +/-20% X5R CAP CER 33PF 50V +/-5% NPO CAP CER 0.47UF 25V 10% X7R CAP CERAMIC 10UF 25V +/-20% X5R CAP CER 0.47UF 25V 10% X7R CAP CER 0.47UF 25V 10% X7R CAP CERAMIC 10UF 25V +/-20% X5R DNI CAP CER 100PF 50V +/-5% NPO CAP CER 33PF 50V +/-5% NPO CAP CER 10000pF 50V +/-10% X7R CAP CER 33PF 50V +/-5% NPO CAP CER 10000PF 50V 10% X7R CAP CER 10000PF 50V 10% X7R CAP CERAMIC 10UF 25V +/-20% X5R CAP CERAMIC 10UF 25V +/-20% X5R DNI CAP CER 10000PF 50V 10% X7R CAP CER 0.47uF 25V 10% X7R CAP CER 0.47uF 25V 10% X7R CAP CER 0.47uF 25V 10% X7R LED SUPER RED CLEAR 75MA 1.7V SMD DIODE SWITCHING 80V 200mA DIODE ZENER 16V 1W 5% DIODE SWITCHING 80V 200mA Package 18X16.5 0805 10X1.5 1206 0805 10X1.5 0805 Manufacturer Panasonic Murata Panasonic AVX Murata Panasonic Murata Mfg Part No EEV-FK2A331M GRM21BR71H104KA01L EEV-FK1C152Q 12061C272KAT2A GCM21BR71E105KA56L EEV-FK1C152Q GCM21BR71E105KA56L 1206 1210 18X16.5 1210 0805 5X5.8 AVX Panasonic Murata Panasonic AVX Panasonic 12061C272KAT2A ECJ-4YB1E106M GRM21BR71H104KA01L ECJ-4YB1E106M 08051C102KAT2A EEV-HA1E220P MKP X2 MKP X2 Vishay Vishay BFC233820153 BFC233820153 0805 METALPOLY 0805 Murata Panasonic Murata GRM2165C1H101JA01D ECQ-E1475KF GRM21BR71H104KA01L 1210 1210 1210 1210 Panasonic Murata Murata Panasonic ECJ-4YB1E475K GCM21BR71E105KA56L GCM21BR71E105KA56L ECJ-4YB1E475K 0805 0805 0805 0805 1210 0805 0805 1210 0805 0805 1210 Murata Panasonic Panasonic Panasonic Panasonic Panasonic TDK Panasonic TDK TDK Panasonic GRM2165C2A391JA01D ECJ-2VC1H330J ECJ-2VC1H330J ECJ-2VC1H330J ECJ-4YB1E106M ECJ-2VC1H330J C2012X7R1E474K ECJ-4YB1E106M C2012X7R1E474K C2012X7R1E474K ECJ-4YB1E106M 0805 0805 0805 0805 0805 0805 1210 1210 Murata Panasonic Murata Panasonic Murata Murata Panasonic Panasonic GRM2165C1H101JA01D ECJ-2VC1H330J GRM216R71H103KA01D ECJ-2VC1H330J GRM216R71H103KA01D GRM216R71H103KA01D ECJ-4YB1E106M ECJ-4YB1E106M 0805 0805 0805 0805 1206 SOT-23 MSB-403 SOT-23 TDK TDK TDK Chicago miniature lighting Infenion Diodes Inc Infenion C2012X7R1E474K C2012X7R1E474K C2012X7R1E474K CMD15-21SRC/TR8 BAV70E6327 SMAZ16-13-F BAV70E6327 ADP1043A 100Watt Part Ref D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 F1 J1 J2 J3 J4 J5 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 L1 L3 QA QB QC QD Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 Q13 RT1 R3 R4 R5 R9 R10 R11 R13 R14 R15 R16 Part Description DIODE SCHOTTKY 100V 1A DIODE SCHOTTKY 100V 2A DIODE SCHOTTKY 100V 2A DIODE SWITCHING 80V 200mA DNI LED GREEN CLEAR 75MA 2.1V SMD LED YELLOW CLEAR 75mA 2.0V SMD LED SUPER RED CLEAR 75mA 1.7V SMD LED SUPER RED CLEAR 75mA 1.7V SMD DNI DIODE SWITCHING 80V 200mA DIODE SWITCHING 80V 200mA DIODE SWITCHING 80V 200mA DIODE SWITCHING 80V 200mA DIODE SWITCHING 80V 200mA DIODE SWITCHING 70V 200mA DIODE SWITCHING 80V 200mA DIODE SWITCHING 80V 200mA FUSE FAST-ACT 1.00A 250V UL TR5 CONN RECEPT 30POS .100 VERT DUAL CONN JACK BANANA UNINS PANEL MOU CONN JACK BANANA UNINS PANEL MOU CONN JACK BANANA UNINS PANEL MOU CONN JACK BANANA UNINS PANEL MOU CONN HDR 4POS SGL PCB 30GOLD CONN HEADER 4POS SGL PCB 30GOLD CONN JACK BANANA UNINS PANEL MOU CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR CONN HEADER BRKWAY .100 02POS STR INDUCTOR 10UH JUMPER WIRE MOSFET N-CH 100V 44A MOSFET N-CH 100V 44A MOSFET N-CH 100V 44A MOSFET N-CH 100V 44A MOSFET N-CH 75V 62A MOSFET N-CH 75V 62A MOSFET N-CH 75V 80A TRANS HIGH POWER NPN 30V 1A TRANS HIGH POWER NPN 30V 1A TRANS HP PNP 30V 1A TRANS HIGH POWER NPN 30V 1A TRANS HP PNP 30V 1A TRANS HIGH POWER NPN 30V 1A TRANS HP PNP 30V 1A TRANS HIGH POWER NPN 30V 1A TRANS HP PNP 30V 1A TRANS HIGH POWER NPN 30V 1A THERMISTOR 100K OHM NTC 0805 RES 24.9K OHM 1/3W 1% SMD RES 470 OHM 1/8W 1% SMD JUMPER WIRE RES 4.70 OHM 1/8W 1% SMD RES 10 OHM 1/8W 1% SMD RES 4.70 OHM 1/8W 1% SMD RES 0.0 OHM 1/8W 5% SMD RES 13.0 OHM 1W 1% SMD RES 13.0 OHM 1W 1% SMD RES 0.0 OHM 1/8W 5% SMD PRD1266 Package SMB-403 SMB-403 SMB-403 SOT-23 Manufacturer On Semi Vishay Vishay Infenion Mfg Part No MBRS1100T3G SS2H10-E3/52T SS2H10-E3/52T BAV70E6327 1206 1206 1206 1206 Chicago miniature lighting Chicago miniature lighting Chicago miniature lighting Chicago miniature lighting CMD15-21VGC/TR8 CMD15-21VYC/TR8 CMD15-21SRC/TR8 CMD15-21SRC/TR8 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 TR5 F-Socket-Dual Infenion Infenion Infenion Infenion Infenion Infenion Infenion Infenion Littlefuse Tyco Electronics Emerson Emerson Emerson Emerson FCI FCI Emerson Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Tyco Electronics Precision Inc. BAV70E6327 BAV70E6327 BAV70E6327 BAV70E6327 BAV70E6327 BAV70E6327 BAV70E6327 BAV70E6327 37311000410 1-534206-5 108-0740-001 108-0740-001 108-0740-001 108-0740-001 69167-104HLF 69167-104HLF 108-0740-001 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 4-102973-0-01 019-6329-00R DPAK DPAK DPAK DPAK D2PACK D2PACK D2PACK SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 SOT-23 RNTC-0805 1210 0805 Fairchild Semi Fairchild Semi Fairchild Semi Fairchild Semi International Rectifier International Rectifier International Rectifier Zetex Zetex Zetex Zetex Zetex Zetex Zetex Zetex Zetex Zetex Murata Vishay Any FDD3672 FDD3672 FDD3672 FDD3672 IRF2807STRLPBF IRF2807STRLPBF IRF2807STRLPBF FMMT489TA FMMT489TA FMMT589TA FMMT489TA FMMT589TA FMMT489TA FMMT589TA FMMT489TA FMMT589TA FMMT489TA NCP21WF104J03RA CRCW121024K9FKEA 0805 0805 0805 0805 2512 2512 0805 Any Any Any Any Any Any Any Header Male Header Male Header Header Header Header Header Header Header Header Header Header ADP1043A 100Watt Part Ref R17 R18 R19 R20 R23 R24 R25 R32 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 R56 R57 R58 R59 R60 R61 R62 R63 R64 R66 R67 R68 R70 R71 R72 R73 R74 R75 R76 R77 R78 R79 R80 R81 SW1 TP1-64 T2 T4 U1 U7A U14 U15 Part Description RES CURRENT SENSE 0.01 OHM 1W 0.5% SMD RES 0.0 OHM 1/8W 5% SMD DNI DNI RES 10.0K OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD DNI RES 10.0 OHM 1/8W 1% SMD RES 1.0 OHM 1/8W 1% SMD RES 8.06K OHM 1/8W 1% SMD RES 2.05K OHM 1/8W 1% SMD RES 1.0 OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 8.06K OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 2.05K OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 1.0 OHM 1/8W 1% SMD RES 1.00K OHM 1/8W 1% SMD RES 4.7M OHM 1/8W 5% SMD RES 10.0K OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD RES 0.0 OHM 1/2W 5% SMD RES 0.0 OHM 1/8W 5% SMD RES 10.0K OHM 1/8W 1% SMD RES 15.0K OHM 1/8W 1% SMD RES 100K OHM 1/8W 1% SMD RES 100 OHM 1/8W 1% SMD RES 100 OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD RES 100 OHM 1/8W 1% SMD RES 1.00K OHM 1/8W 1% SMD RES 1.00K OHM 1/8W 1% SMD RES 470 OHM 1/8W 1% SMD RES 2.20K OHM 1/8W 1% SMD RES 0.0 OHM 1/2W 5% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 10.0K OHM 1/8W 1% SMD RES 1.00K OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD RES 100 OHM 1/8W 1% SMD RES 10.0 OHM 1/8W 1% SMD SW SLIDE SPDT 30V 0.2A PC MNT TEST POINT PC MULTIPURPOSE RED Transformer SMT CURRENT SENSE TRANSFORMERS 500kHz 15A IC MOSFET DRVR DUAL HS 4A DNI ISOLATED 2CH HALF-BRIDGE DRIVER ISOLATED 2CH HALF-BRIDGE DRIVER PRD1266 Package 2512 0805 Manufacturer Any Any 0805 0805 Any Any 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 2010 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 2010 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 SLIDE-SW TP-063 ETD29 PE-68280 8-SOIC 8-SOIC SOIC-W-16 SOIC-W-16 Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Keystone Electronics Keystone Electronics Precision Inc Pulse Analog Devices Analog Devices Analog Devices Analog Devices Mfg Part No 5010 5010 019-6330-00R PE-68280 ADP3624 OP297FSZ ADUM5230 ADUM5230 ADP1043A 100Watt PRD1266 APPENDIX XI - BILL OF MATERIALS (DAUGHTER CARD) Part Ref C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 Part Description DNI DNI DNI DNI CAPACITOR CERAMIC 1.0UF 50V 10% X7R CAPACITOR CERAMIC 0.1UF 10% 50V X7R DNI CAPACITOR CERAMIC 0.1UF 10% 50V X7R DNI DNI CAPACITOR CERAMIC 0.1UF 10% 50V X7R CAPACITOR CERAMIC 0.47UF 5% 17V X7R DNI CAPACITOR CERAMIC 0.01UF 10% 100V X7R CAPACITOR CERAMIC 1000pF 10% 100V X7R J1 J7 R1 R2 R3 R4 R5 R6 R7 R8 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R24 R29 R32 R33 U1 U2 CONNETOR HEADER FEMALE 30PS .1" DL TIN CONNECTOR HEADER 4POS SGL PCB 30 GOLD RESISTOR 27.0K OHM 1/8W 1% SMD RESISTOR 1.00K OHM 1/8W 1% SMD RESISTOR 10.0K OHM 1/10W .1% +/-25ppm SMD RESISTOR 10.0K OHM 1/10W .1% +/-25ppm SMD RESISTOR 11.0K OHM 1/10W .1% +/-25ppm SMD RESISTOR 1.00K OHM 1/10W .1% +/-25ppm SMD RESISTOR 11.0K OHM 1/10W .1% +/-25ppm SMD RESISTOR 1.00K OHM 1/10W .1% +/-25ppm SMD RESISTOR 11.0K OHM 1/10W .1% +/-25ppm SMD RESISTOR 1.00K OHM 1/10W .1% +/-25ppm SMD RESISTOR 0.0 OHM 1/8W 5% SMD RESISTOR 0.0 OHM 1/8W 5% SMD RESISTOR 1.00K OHM 1/8W 1% SMD RESISTOR 1.00K OHM 1/8W 1% SMD RESISTOR 0.0 OHM 1/8W 5% SMD RESISTOR 0.0 OHM 1/8W 5% SMD DNI RESISTOR 10.0K OHM 1/8W 1% SMD RESISTOR 49.9K OHM 1/8W 1% SMD RESISTOR 2.20K OHM 1/8W 1% SMD RESISTOR 2.20K OHM 1/8W 1% SMD DNI DNI I.C. Secondary Side Power Supply Controller I.C. LDO LINEAR REGULATOR 200MA 3.3V Package Manufacturer Murata Mfg Part No GRM32RR71H105KA01L 1210 0805 Murata AVX GRM32RR71H105KA01L 08055C104KAT2A 0805 AVX 08055C104KAT2A 0805 0805 AVX AVX 08055C104KAT2A 0805YC474JAT2A 0805 0603 Fmal Socket Header-4POS 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 0805 AVX Murata Sullins Connector Solutions FCI Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any Any 0805 0805 0805 0805 Any Any Any Any LFCSP-32 SOIC-8 ADP1043A ADP3303 08051C103KAT2A GRM188R72A102KA01D PPTC152LFBN-RC 69167-104HLF Analog Devices Analog Devices ADP1043A 100Watt PRD1266 APPENDIX XII - REGISTER FILE (ADP1043AFB100_I_0710.43R) Reg(0h) = 0h - Fault Register 1 Reg(2Ah) = 1Ah - Share Bus Setting Reg(1h) = 0h - Fault Register 2 Reg(2Bh) = 4h - Temperature Trim Reg(2h) = 0h - Fault Register 3 Reg(2Ch) = E2h - PSON/Soft Start Setting Reg(3h) = 0h - Fault Register 4 Reg(2Dh) = 58h - Pin Polarity Setting Reg(4h) = 10h - Latched Fault Register 1 Reg(2Eh) = B4h - Modulation Limit Reg(5h) = 0h - Latched Fault Register 2 Reg(2Fh) = 1Bh - OTP Threshold Reg(6h) = 1h - Latched Fault Register 3 Reg(30h) = 5Eh - OrFET Reg(7h) = 1h - Latched Fault Register 4 Reg(31h) = A5h - VS3 Voltage Setting Reg(8h) = 3h - Fault Configuration Register 1 Reg(32h) = 51h - VS1 Overvoltage Limit Reg(9h) = 3Ah - Fault Configuration Register 2 Reg(33h) = 11h - VS3 Overvoltage Limit Reg(Ah) = 37h - Fault Configuration Register 3 Reg(34h) = 42h - VS1 Undervoltage Limit Reg(Bh) = 73h - Fault Configuration Register 4 Reg(35h) = FFh - Line Impedance Limit Reg(Ch) = ACh - Fault Configuration Register 5 Reg(36h) = 7h - Load Line Impedance Reg(Dh) = 8Ah - Fault Configuration Register 6 Reg(37h) = FFh - Reserved Reg(Eh) = 65h - Flag Configuration Reg(38h) = 83h - VS1 Trim Reg(Fh) = ADh - Soft-Start Flag Blank Reg(39h) = 1h - VS2 Trim Reg(10h) = 0h - First Flag ID Reg(3Ah) = 81h - VS3 Trim Reg(11h) = FFh - Reserved Reg(3Bh) = 1h - Light Load Disable Setting Reg(12h) = EEAh - VS1 Value Reg(3Ch) = 5h - Silicon Revision ID Reg(13h) = 356Ch - CS1 Value Reg(3Dh) = 41h - Manufacturer ID Reg(14h) = 31C0h - CS1 x VS1 Value Reg(3Eh) = 43h - Device ID Reg(15h) = A7D0h - VS1 Voltage Value Reg(3Fh) = 11h - OUTAUX Switching Frequency Setting Reg(16h) = A68Ch - VS2 Voltage Value Reg(40h) = 11h - PWM Switching Frequency Setting Reg(17h) = A504h - VS3 Voltage Value Reg(41h) = 40h - PWM 1 Positive Edge Timing Reg(18h) = B408h - CS2 Value Reg(42h) = 80h - PWM 1 Positive Edge Setting Reg(19h) = 7404h - CS2 x VS3 Value Reg(43h) = 5Fh - PWM 1 Negative Edge Timing Reg(1Ah) = 3720h - RTD Temperature Value Reg(44h) = 98h - PWM 1 Negative Edge Setting Reg(1Bh) = FFh - Reserved Reg(45h) = 2h - PWM 2 Positive Edge Timing Reg(1Ch) = FFh - Reserved Reg(46h) = 80h - PWM 2 Positive Edge Setting Reg(1Dh) = 0h - Share Bus Value Reg(47h) = 21h - PWM 2 Negative Edge Timing Reg(1Eh) = B0h - Modulation Value Reg(48h) = 88h - PWM 2 Negative Edge Setting Reg(1Fh) = 2h - Line Impedance Value Reg(49h) = 2h - PWM 3 Positive Edge Timing Reg(20h) = FFh - Reserved Reg(4Ah) = 80h - PWM 3 Positive Edge Setting Reg(21h) = 4Ah - CS1 Gain Trim Reg(4Bh) = 21h - PWM 3 Negative Edge Timing Reg(22h) = A8h - CS1 OCP Limit Reg(4Ch) = 88h - PWM 3 Negative Edge Setting Reg(23h) = 67h - CS2 Gain Trim Reg(4Dh) = 40h - PWM 4 Positive Edge Timing Reg(24h) = 8h - CS2 Offset Trim Reg(4Eh) = 80h - PWM 4 Positive Edge Setting Reg(25h) = 2Ah - CS2 Digital Trim Reg(4Fh) = 5Fh - PWM 4 Negative Edge Timing Reg(26h) = E1h - CS2 OCP Limit Reg(50h) = 98h - PWM 4 Negative Edge Setting Reg(27h) = E7h - CS1 and CS2 OCP Setting Reg(51h) = 23h - SR 1 Positive Edge Timing Reg(28h) = 1h - VS Balance Gain Setting Reg(52h) = 8Ah - SR 1 Positive Edge Setting Reg(29h) = 2h - Share Bus Bandwidth Reg(53h) = 0h - SR 1 Negative Edge Timing ADP1043A 100Watt PRD1266 Reg(54h) = 3h - SR 1 Negative Edge Setting Reg(80h) = 35h - Reg(55h) = 61h - SR 2 Positive Edge Timing Reg(81h) = 35h - Reg(56h) = 88h - SR 2 Positive Edge Setting Reg(82h) = 35h - Reg(57h) = 3Dh - SR 2 Negative Edge Timing Reg(58h) = 50h - SR 2 Negative Edge Setting Reg(59h) = 0h - PWM AUX Positive Edge Timing Reg(5Ah) = 0h - PWM AUX Positive Edge Setting Reg(5Bh) = 8h - PWM AUX Negative Edge Timing Reg(5Ch) = 90h - PWM AUX Negative Edge Setting Reg(5Dh) = 80h - PWM and SR Pin Disable Setting Reg(5Eh) = 0h - Password Lock Reg(5Fh) = 3h - Soft-Start Digital Filter LF Gain Setting Reg(60h) = 91h - Normal Mode Digital Filter LF Gain Setting Reg(61h) = 83h - Normal Mode Digital Filter Zero Setting Reg(62h) = 14h - Normal Mode Digital Filter Pole Setting Reg(63h) = 5Dh - Normal Mode Digital Filter HF Gain Setting Reg(64h) = 1Ah - Light Load Digital Filter LF Gain Setting Reg(65h) = 76h - Light Load Digital Filter Zero Setting Reg(66h) = Eh - Light Load Digital Filter Pole Setting Reg(67h) = 13h - Light Load Digital Filter HF Gain Setting Reg(68h) = 0h - Dead Time Threshold Reg(69h) = 88h - Dead Time 1 Reg(6Ah) = 88h - Dead Time 2 Reg(6Bh) = 88h - Dead Time 3 Reg(6Ch) = 88h - Dead Time 4 Reg(6Dh) = 88h - Dead Time 5 Reg(6Eh) = 88h - Dead Time 6 Reg(6Fh) = 88h - Dead Time 7 Reg(70h) = 8h Reg(71h) = 36h Reg(72h) = 54h Reg(73h) = 1Fh Reg(74h) = 0h Reg(75h) = FFh Reg(76h) = FFh Reg(77h) = 0h Reg(78h) = 0h Reg(79h) = 1Fh Reg(7Ah) = 4h Reg(7Bh) = FFh - Factory Default Settings Reg(7Ch) = 1h - EEPROM X Address Reg(7Dh) = 35h - EEPROM Y Address Reg(7Eh) = 35h - EEPROM Register Reg(7Fh) = FFh - ADP1043A 100Watt PRD1266 APPENDIX XIII - BOARD FILE (ADP1043AFB100_I_0710.43B) INPUT VOLTAGE = 48 V N1 = 6 N2 = 3 R (CS2) = 11 MOHM I (LOAD) = 8 A R1 = 11 KOHM R2 = 1 KOHM C3 = 1 UF C4 = 1 UF N1 (CS1) = 1 N2 (CS1) = 100 R (CS1) = 10 OHM ESR (L1) = 6 MOHM L1 = 6.5 UH C1 = 1500 UF ESR (C1) = 50 MOHM ESR (L2) = 40 MOHM L2 = 0 UH C2 = 1500 UF ESR (C2) = 50 MOHM R (NORMAL-MODE) (LOAD) = 1.5 OHM R (LIGHT-LOAD-MODE) (LOAD) = 44 OHM CAP ACROSS R1 & R2 = 0 "(1 = YES: 0 = NO)" TOPOLOGY = 0 (0 = FULL BRIDGE: 1 = HALF BRIDGE: 2 = TWO SWITCH FORWARD: 3 = INTERLEAVED TWO SWITCH FORWARD: 4 = ACTIVE CLAMP FORWARD: 5 = RESONANT MODE: 6 = CUSTOM) SWITCHES / DIODES = 0 (0 = SWITCHES: 1 = DIODES) HIGH SIDE / LOW SIDE SENSE (CS2) = 0 (1 = HIGH-SIDE: 0 = LOW-SIDE SENSE) SECOND LC STAGE = 1 (1 = YES: 0 = NO) CS1 INPUT TYPE = 1 (1 = AC: 0 = DC) R3 = 0 KOHM R4 = 0 KOHM PWM MAIN = 0 (0 = OUTA: 1 = OUTB: 2 = OUTC: 3 = OUTD: 4 = SR1: 5 = SR2: 6 = OUTAUX) C5 = 0 UF C6 = 0 UF ADP1043A 100Watt PRD1266 APPENDIX XIV - CS1 AND CS2 MEASUREMENT VS GUI READING ADP1043A 100Watt NOTES (c)2009 Analog Devices, Inc. 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