1
Application Note 1781
Author: Barry Kates
ZL8101_30AEV2Z 30A Demo Board
Description
The ZL8101 is an integrated mixed-signal power conversion
and management IC that combines an efficient step-down
DC/DC converter with key power and thermal management
functions in a single package. The ZL8101 incorporates
current sharing and adaptive efficiency-optimization
algorithms to provide a flexible, efficient power IC building
block.
The ZL8101_30AEV2Z Demo Board is a 6-layer board
demonstrating a 30A synchronous buck converter.
Sequencing, tracking, margining, plus other features can be
evaluated using this board.
A USB to SMBus adapter board can be used to connect the
demo board to a PC. The PMBus command set is accessed by
using the Zilker Labs PowerNavigator™ evaluation software
from a PC running Microsoft Windows.
Key Features
• 30A Synchronous Buck Converter
• Optimized for High Current and High Efficiency
• Configurable through SMBus
• Onboard Enable Switch
• Power-Good Indicator
Target Specifications
•V
IN = 12V
•V
OUT = 1V/30A
•F
SW = 533kHz
• Efficiency: >88% at 20A
• Output Ripple: ±1%
• Dynamic Response: ±3% (33%-83%-33% LOAD STEP,
di/dt = 5A/μs)
• Operating Temperature: +25°C
Ordering Information
PART NUMBER DESCRIPTION
ZL8101_30AEV2Z 30A Single Phase Demo Board
FIGURE 1. ZL8101_30AEV2Z 30A DEMO BOARD SIMPLIFIED SCHEMATIC
PWMH
DRVCTL
SCL
R1
SDA
EN
SYNC
VIN
U2
CSD96370Q5M
C11
COUT
C6R2
VOUT
L1
U1
ZL8101
DGND
SYNC
SCL
SDA
VMON
VTRK
FB+
FB-
ISENB
ISENA
SG
VR
VDD
V25
DDC
EN
PG DRVCTL
PWMH
PAD
VTRK_IN
VDRV
FB+
FB-
I
SENA
I
SENB
DDC
SG
R3
PG
C12
CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures.
1-888-INTERSIL or 1-888-468-3774 |Copyright Intersil Americas Inc. 2012. All Rights Reserved.
Intersil (and design), Zilker Labs (and design), and PowerNavigator are trademarks owned by Intersil Corporation or one of its subsidiaries.
All other trademarks mentioned are the property of their respective owners.
September 6, 2012
AN1781.0
Application Note 1781
2AN1781.0
September 6, 2012
Functional Description
The ZL8101_30AEV2Z 30A Demo Board provides all circuitry
required to demonstrate the features of the ZL8101. The ZL8101
30A has a functionally optimized ZL8101 circuit layout that
allows efficient operation up to the maximum output current.
Power and load connections are provided through plug-in
sockets.
A majority of the features of the ZL8101 such as soft-start delay
and ramp times, supply sequencing, voltage tracking, and
voltage margining are available on this board. For voltage
tracking and sequencing evaluation, the board can be connected
to any other Zilker Labs evaluation boards that supports the
Digital DC (DDC) bus.
Figure1 shows a simplified schematic of the ZL8101_30AEV2Z
30A Demo Board. All power to the board (VIN and I2C bus) must
be removed before changing the jumpers.
The hardware enable function is controlled by a toggle switch on
the ZL8101_30AEV2Z 30A board. The power-good (PG) LED
indicates the state of PG when external power is applied to the
ZL8101_30AEV2Z 30A board. The right angle headers at
opposite ends of the board are for connecting a USB to SMBus
adapter board or for easy chaining of multiple evaluation boards.
Figure 2 shows the ZL8101_30AEV2Z 30A Demo Board
complete circuit. The circuit consists of the ZL8101 IC with its
minimal component count to realize a 30A buck converter. The
board layout has been optimized for thermal performance.
Figure 3 is the board interface circuitry. Figures 5 through 10
show the PCB layout for the board, including the board
fabrication notes.
The bill of materials (BOM) and configuration file are also
included for reference.
Operation
PMBus Operation
The ZL8101 utilizes the PMBus protocol. The PMBus functionality
can be controlled via USB from a PC running the PowerNavigator
evaluation software in a Windows XP, Windows 2000/NT, or
Windows 7 operating system.
Install the evaluation software using the CD included in the
ZL8101_30AEV2Z 30A Demo Board kit.
For board operation, connect the included USB-to-SMBus adapter
board to J2 of the ZL8101_30AEV2Z 30A Demo board. Connect
the desired load and an appropriate power supply to the input
and connect the included USB cable to the PC running the
PowerNavigator evaluation software. Place the ENABLE switch in
“DISABLE” and turn on the power.
The evaluation software allows modification of all ZL8101
PMBus parameters. The ZL8101 device on the board has been
pre-configured as described in the Target Specifications on the
front page, but the user may modify the operating parameters
through the PowerNavigator software or by loading a predefined
scenario from a configuration file.
Use the mouse-over pop-ups for PowerNavigator help. Refer to
Zilker Labs application note AN2033 for PMBus details.
The ENABLE switch can then be moved to “ENABLE” and the
ZL8101_30AEV2Z 30A Demo board can be tested. Alternately,
the PMBus ON-OFF CONFIG and OPERATION commands may be
used.
Quick Start Guide
Stand Alone Operation
1. Set ENABLE switch to “DISABLE”.
2. Apply load to VOUT+/VOUT- .
3. Connect the USB to SMBus adapter board to J2 of the board.
4. Ensure that jumper shorting headers J1, J6, and J7 are
installed.
5. Connect supplied USB cable from computer to USB to SMBus
adapter board.
6. Connect power supply to VIN+/VIN- (supply turned off).
7. Turn power supply on.
8. Set ENABLE switch to “ENABLE”.
9. Monitor the ZL8101_30AEV2Z 30A demo board operation
using an oscilloscope.
USB (PMBus) Operation
1. Set ENABLE switch to “DISABLE”.
2. Apply load to VOUT+/VOUT- .
3. Connect power supply to VIN+/VIN- (supply turned off).
4. Turn power supply on.
5. Insert the Zilker Labs Eval Kit CD.
6. Connect USB to SMBus adapter board to J2 of
ZL8101_30AEV2Z 30A Demo Board.
7. Connect supplied USB cable from computer to USB to SMBus
adapter board.
8. Upon first-time connection, the Found New Hardware Wizard
will appear.
9. Select ‘No’ at prompt to search the Internet for drivers.
10. Follow the steps on the screen to install the drivers from the
CD.
11. Install the PowerNavigator evaluation software by running
setup.exe from the PowerNavigator_installer folder on the CD.
12. Using PowerNavigator, set the enable mode to PMBus Enable,
press the PMBus Enable button on the PowerNavigator
opening screen.
13. Monitor and configure the ZL8101_30AEV2Z 30A Demo
Board using PMBus commands in the evaluation software.
14. Test the ZL8101_30AEV2Z 30A Demo Board operation using
an oscilloscope and the evaluation software.
Typical room temp efficiency curves are shown in Figure 11.
Typical transient and operational waveforms are shown in
Figures 12 through 15.
Application Note 1781
3AN1781.0
September 6, 2012
Board Schematics
FIGURE 2. ZL8101_30AEV2Z 30A DEMO BOARD COMPLETE CIRCUIT
SCL
R1
100K
EN
SYNC
SDA
FB1
1000 Ohm
VIN
MGN
U2
CSD96370Q5M
4
1
5
3
2
6
7
8
9
10
11
121314151617 18
19
23
22
20
21
C11
10uF
10V
C7
680uF
4V
C8
100uF
6.3V
C6
1uF
10V
R2
1.18K
P3
P4
XX5
C4
10uF
10V
SG
C15
22uF
16V
L1
0.220nH
U1
ZL8101
DGND
1
SYNC
2
SA0
3
SA1 4
SCL
6
SDA
7
SALRT
8
FC 9
V0
10
V1
11
VMON
12
VTRK
14
FB+ 15
FB- 16
NC 17
ISENB 18
ISENA 19
PWML 20
SG
21
VR
23
VDD
24
V25
25
XTEMP
26
DDC
27
MGN
28
EN
30
SS
31
PG
32
NC
5
DRVCTL 13
PWMH 22
NC 29
PAD
33
FB+
VTRK_IN C9
100uF
6.3V
VOUT
VIN
Q1
FMMTL618TA
MGN
D2
RB521S30
SCL
VDRV
VDRV
DDC
SDA
FB-
SYNC
PG
Address set to 0x24
Vou t set to 3.3V
EN
C3
10uF
10V
C5
1uF
16V
VTRK_IN C24
680uF
4V
C2
4.7uF
25V
PWMH
SENA
VOUT
SENB
C1
10uF
25V
DRVCTL
DDC
C10
0.01uF
25V
SG
PG
R3
6.65K
Application Note 1781
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September 6, 2012
FIGURE 3. ZL8101_30AEV2Z 30A DEMO BOARD – INTERFACE CIRCUITRY
Board Schematics (Continued)
PG
R4
10.0K
C25
10uF
25V R29
2.74K
VDR
︳
IN
R28
909
J7 21
U5
REG1117A
G-ADJ
1
2
VOUT
3VIN 4
VOUT
VDRV
R6
4.75k
VI2C
DDC
PG
SCL
SDA VTRKSALRT
SALRT R11 49.9
R10
4.75k
C19
0.1u
10V
C22
10uF
25V
D7
BAT54 D8
BAT54
D9
BAT54
C20
10u
25V
R19
187
C18
10uF
25V
R18
115
VAUX
PG_0
R13
100K
VI2C
EN
JP1
21
34
SYNC
D4
ESDA6V1-4BC6
31
2
4
5
6
DDC
PG
DDC
J2
HEADER
2
4
6
8
10
1
3
5
7
9
TO SEQUEL
FROM PREQU EL
SYNC
J3
SOCKET
2
4
6
8
10
1
3
5
7
9
R12 49.9
VOUT
R14
49.9
C23
1uF
25V
SW1
1
2
3
R15
10.0K
Disable
Monitor
Enable
C21
0.1uF
10V
MSTR_SYNC
D5
ESDA6V1-4BC6
31
2
4
5
6
VDRV
VAUX
P1
+
VDRV
-
J1 21
VIN
C14
330u
16V
C13
330u
16V
C16
22uF
16V
J5
JACK_BARREL
1
2
3
+
VIN
-
VIN
P2
VIN
J6
2 1
R16
49.9
Enable_1
HW_EN
R17
49.9
VTRK_IN
VTRK_IN
U3
REG1117A
G-ADJ
1
2
VOUT
3VIN 4
VOUT
MSTR_EN
SCL
VOUT
R9
4.75k
VAUX
R7
4.75k
R8
4.75k
DDC
C12
100uF
6.3V
SDA
SALRT
SCL
SDA
VI2C
VAUX
D1
GRN
Q2
2N7002/SOT
R5
392 MSTR_EN
EN
Application Note 1781
6AN1781.0
September 6, 2012
TABLE 1. COMMENTS ABOUT DIFFERENT PARTS IN THE ZL8101_30AEV2Z 30A DEMO BOARD
ITEM QUANTITY REFERENCE VALUE TOLERANCE RATING TYPE MANUFACTURER PART NUMBER DISTRIBUTOR DIST. PN
1 1 C1 10µF ±10% 25V X7R Taiyo Yuden TMK316B7106KL-TD Digikey 587-2399-2-ND
2 1 C2 4.7µF ±10% 25V X7R AVX 0805YC475KAT2A Digikey 478-5722-1-ND
3 3 C3, C4, C11 10µF ±10% 10V X7R Murata GRM21BR71A106KE51L Digikey 490-3905-2-ND
4 1 C5 1µF ±10% 16V X7R Kemet C0603C105K4RACTU Digikey C0603C105K4RACTU-ND
5 1 C6 1µF 10% 10V X7R Taiyo Yuden LMK107B7105KA-T Digikey 587-1242-2-ND
6 2 C7, C24 680µF 20% 4V AL POLY Kemet T530Y687M004ATE005 Digikey 399-4750-1-ND
7 3 C8, C9, C12 100µF 6.3V X5R Taiyo Yuden JMK325BJ107MY-T Digikey 587-1388-2-ND
8 1 C10 0.01µF ±10% 25V X7R Kemet C0402C103K3RACTU Digikey 399-1278-2-ND
9 2 C13, C14 330µ 20% 16V AL POLY United Chemi-Con APXA160ARA331MJC0G Digikey 565-3081-2-ND
10 2 C15, C16 22µF 20% 16V X5R Murata GRM31CR61C226ME15L Digikey 490-4739-2-ND
11 3 C18, C22,
C25
10µF 10% 25V X5R Panasonic - ECG ECJ-3YB1E106K Digikey PCC2414TR-ND
12 1 C19 0.1µ 10% 10V X7R Kemet C0603C104K8RACTU Digikey 399-1095-2-ND
13 1 C20 10µ 10% 25V X5R Panasonic - ECG ECJ-3YB1E106K Digikey PCC2414TR-ND
14 1 C21 0.1µF 10% 10V X7R Kemet C0603C104K8RACTU Digikey 399-1095-2-ND
15 1 C23 1µF 10% 25V X5R Taiyo Yuden TMK107BJ105KA-T Digikey 587-1248-2-ND
16 1 D1 GRN 2V Chicago Minature CMD17-21VGC Mouser 606-CMD17-21VGC
17 1 D2 RB521S30 30V Schottky ON SEMI RB521S30 Digikey RB521S30CT-ND
18 2 D4, D5 ESDA6V1-4BC6 6.1V, 80W ST Micro ESDA6V1-4BC6 Digikey 497-4643-2-ND
19 3 D7, D8, D9 BAT54 30V Schottky On Semi BAT54XV2T1OS Digikey BAT54XV2T1OSTR-ND
20 1 FB1 1000 Ω150mA Ferrite Taiyo Yuden BK1005HM102-T Digikey 587-1835-2-ND
21 1 JP1 4 PIN Tyco 3-644456-4 Digikey A31114-ND
22 3 J1, J6, J7 2 POS VERT Samtec TSW-102-07-L-S Digikey SAM1031-02-ND
23 1 J2 HEADER RA Samtec TSW-105-08-T-D-RA Digikey SAM1049-05-ND
24 1 J3 SOCKET RA Samtec SSQ-105-02-T-D-RA Digikey SAM1224-05-ND
25 1 J5 JACK_BARREL 1.5A @ 18VDC RA Kobiconn 163-5004-E Mouser 163-5004-E
26 1 L1 0.220nH 70 Inductor ITG SL3732_R22KHF ITG SL3732_R22KHF
27 2 P1, P2 JACK_DUAL_BANANA 15A Emerson 108-0740-001 Digikey J147-ND
28 2 P3, P4 JACK_BANANA_1 Digikey J147-ND
29 1 Q1 FMMTL618TA 20V NPN Diodes Inc FMMTL618TA Digikey FMMTL618CT-ND
30 1 Q2 2N7002/SOT 60V 115mA N-CH ON SEMI 2N7002LT1 Digikey 2N7002LT1OSTR-ND
31 1 R1 100k 1% 1/16W Vishay/Dale CRCW0402100KFKED Digikey 541-100KLTR-ND
32 1 R2 1.18k 1% Resistor Panasonic - ECG ERJ-3EKF1181V Digikey P1.18KHTR-ND
33 1 R3 6.65k 1% 1/16W Panasonic - ECG ERJ-2RKF6651X Digikey P6.65KLTR-ND
34 1 R4 10.0k 1% 1/16W Yageo RC0402FR-0710KL Digikey 311-10.0KLRTR-ND
35 1 R5 392 1% THK FILM Panasonic - ECG ERJ-3EKF3920V Digikey P392HTR-ND
36 5 R6, R7, R8,
R9, R10
4.75k 1% 1/16W Panasonic - ECG ERJ-2RKF4751X Digikey P4.75KLTR-ND
37 4 R11, R12,
R16, R17
49.9 1% 100mW THK FILM Panasonic - ECG ERJ-3EKF49R9V Digikey P49.9HTR-ND
38 1 R13 100k 1% 63mW THK FILM Panasonic - ECG ERJ-2RKF1003X Digikey P100KLTR-ND
39 1 R14 49.9 1% 63mW THK FILM Vishay/Dale CRCW040249R9FKED Digikey 541-49.9LTR-ND
40 1 R15 10.0k 1% 63mW THK FILM Panasonic - ECG ERJ-2RKF1002X Digikey P10.0KLTR-ND
41 1 R18 115 1% 100mW THK FILM Panasonic - ECG ERJ-3EKF1150V Digikey P115HTR-ND
Application Note 1781
7AN1781.0
September 6, 2012
42 1 R19 187 1% 100mW THK FILM Panasonic - ECG ERJ-3EKF1870V Digikey P187HTR-ND
43 1 R28 909 1% 100mW THK FILM Panasonic - ECG ERJ-3EKF9090V Digikey P909HTR-ND
44 1 R29 2.74k 1% 100mW THK FILM Panasonic - ECG ERJ-3EKF2741V Digikey P3.32KHTR-ND
45 1 SW1 SW_SPDT PCB VERT NKK G13AP-RO Mouser 633-G13AP-RO
53 1 U1 ZL8101 Intersil ZL8101 Intersil ZL8101
54 1 U2 CSD96370Q5M 25V Texas
Instruments
CSD96370Q5M Digikey 296-28235-2-ND
55 2 U3, U5 REG1117A Texas
Instruments
REG1117A Digikey REG1117A-ND
TABLE 1. COMMENTS ABOUT DIFFERENT PARTS IN THE ZL8101_30AEV2Z 30A DEMO BOARD (Continued)
ITEM QUANTITY REFERENCE VALUE TOLERANCE RATING TYPE MANUFACTURER PART NUMBER DISTRIBUTOR DIST. PN
Application Note 1781
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September 6, 2012
Board Layout – 6 Layers
FIGURE 5. PCB - TOP LAYER
Application Note 1781
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September 6, 2012
FIGURE 6. PCB - INNER LAYER 1 (VIEWED FROM TOP)
Board Layout – 6 Layers (Continued)
Application Note 1781
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September 6, 2012
FIGURE 7. PCB - INNER LAYER 2 (VIEWED FROM TOP)
Board Layout – 6 Layers (Continued)
Application Note 1781
11 AN1781.0
September 6, 2012
FIGURE 8. PCB - INNER LAYER 3 (VIEWED FROM TOP)
Board Layout – 6 Layers (Continued)
Application Note 1781
12 AN1781.0
September 6, 2012
FIGURE 9. PCB - INNER LAYER 4 (VIEWED FROM TOP)
Board Layout – 6 Layers (Continued)
Application Note 1781
13 AN1781.0
September 6, 2012
FIGURE 10. PCB - BOTTOM LAYER (VIEWED FROM TOP)
Board Layout – 6 Layers (Continued)
Application Note 1781
14 AN1781.0
September 6, 2012
Default Configuration Text
The following text is loaded into the ZL8101 device on the board as default settings. Each PMBus command is loaded via the
PowerNavigator software. The # symbol is used for a comment line.
# Zilker Labs 8101 6/7/2012
# ZL Configuration File Revision A
# Schematic revision level
# BOM revision level
# Change log:
RESTORE_FACTORY
STORE_USER_ALL
STORE_DEFAULT_ALL
MFR_ID Zilker_Labs
MFR_MODEL 30A
MFR_REVISION REV_A
MFR_LOCATION Austin
MFR_DATE 8/2012
MFR_SERIAL 1p0V_35A
VOUT_COMMAND 1.0
FREQUENCY_SWITCH 533
POWER_GOOD_DELAY 5
IOUT_SCALE 0.30
IOUT_CAL_OFFSET -2.0
TON_DELAY 5
TON_RISE 5
TOFF_DELAY 5
TOFF_FALL 5
VOUT_OV_FAULT_RESPONSE 0x80
VOUT_UV_FAULT_RESPONSE 0x80
OVUV_CONFIG 0x80
IOUT_OC_FAULT_LIMIT 50
IOUT_AVG_OC_FAULT_LIMIT 45
IOUT_UC_FAULT_LIMIT -40
IOUT_AVG_UC_FAULT_LIMIT -40
MFR_IOUT_OC_FAULT_RESPONSE 0x80
MFR_IOUT_UC_FAULT_RESPONSE 0x80
MFR_VMON_OV_FAULT_LIMIT 7.0
VMON_OV_FAULT_RESPONSE 0x80
MFR_VMON_UV_FAULT_LIMIT 4.5
VMON_UV_FAULT_RESPONSE 0x80
VIN_OV_WARN_LIMIT 14.3
VIN_OV_FAULT_LIMIT 14.5
VIN_OV_FAULT_RESPONSE 0x80
VIN_UV_WARN_LIMIT 4.2
VIN_UV_FAULT_LIMIT 4.0
VIN_UV_FAULT_RESPONSE 0x80
OT_WARN_LIMIT 110.0
OT_FAULT_LIMIT 125
OT_FAULT_RESPONSE 0x80
UT_WARN_LIMIT -20
UT_FAULT_LIMIT -40
Application Note 1781
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September 6, 2012
UT_FAULT_RESPONSE 0x00
DEADTIME 0x0C0C
DEADTIME_CONFIG 0x8686
DEADTIME_MAX 0x0C0C
MAX_DUTY 94
TRACK_CONFIG 0x00
INTERLEAVE 0x0000
#SEQUENCE 0x0000
MFR_CONFIG 0x6A10
NLR_CONFIG 0x00000000
TEMPCO_CONFIG 0x28
MISC_CONFIG 0x2000
ISHARE_CONFIG 0x0000
AUTO_COMP_CONFIG 0x79
PID_TAPS A=6504.62, B=-11568.50, C=5078.00
USER_CONFIG 0x0011
DDC_GROUP 0x00000000
#DDC_CONFIG 0x0000
INDUCTOR 0.22
ON_OFF_CONFIG 0x1A
STORE_DEFAULT_ALL
RESTORE_DEFAULT_ALL
Application Note 1781
16 AN1781.0
September 6, 2012
Measured Data The following data was acquired using a ZL8101_30AEV2Z 30A Demo Board.
EFFICIENCY
76
81
86
91
96
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
EFFICIENCY (%)
OUTPUT CURRENT (A)
VOUT = 1V
VOUT = 1.2V
VOUT = 1.8V
VOUT = 2.5V VOUT = 3.3V
FIGURE 11. EFFICIENCY FOR DIFFERENT OUTPUT VOLTAGES, VIN = 12V, FSW = 533kHz
FIGURE 12. RAMP UP
TURNON RAMP
VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A
TRISE = 5ms, MIN DUTY = DISABLED
AUTOCOMP = OFF
5ms
MINIMUM DUTY CYCLE ARTIFACT
~100mV
Application Note 1781
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September 6, 2012
FIGURE 13. RAMP DOWN
TURN OFF RAMP
VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A
TFALL= 5ms, MIN DUTY = DISABLED
AUTOCOMP = OFF
VOUT
5ms
FIGURE 14. DYNAMIC RESPONSE, 10A TO 25A (AND VICE VERSA) LOAD STEP
TRANSIENT RESPONSE
VIN = 12V, VOUT = 1V, FSW = 533kHz, ΔI = 10A
AUTOCOMP = ON, TAPS A = 8728.25
B = 14684.25, C = 5966.00
DYNAMIC LOAD CURRENT
di/dt = 5A/µs
IMIN = 15A, IMAX = 25A
VOUT, MEASURED ACROSS C7
55mVP-P
Application Note 1781
18
Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is
cautioned to verify that the Application Note or Technical Brief is current before proceeding.
For information regarding Intersil Corporation and its products, see www.intersil.com
AN1781.0
September 6, 2012
References
[1] ZL8101 Data Sheet, Zilker Labs, Inc., 2012.
[2] AN2033 – PMBus™ Command Set, Zilker Labs, Inc., 2009.
FIGURE 15. OUTPUT VOLTAGE RIPPLE WHEN VO = 1V, IO = 25A, VIN = 12V, Fsw= 800kHZ
STATIC RIPPLE MEASURED ACROSS C24
VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A
VOUT = 10mVP-P
SWITCH NODE USED AS
SYNC SIGNAL
