Application Note 1781 Author: Barry Kates ZL8101_30AEV2Z 30A Demo Board Description Key Features 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. * 30A Synchronous Buck Converter * Optimized for High Current and High Efficiency * Configurable through SMBus * Onboard Enable Switch * Power-Good Indicator Target Specifications 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. * VIN = 12V * VOUT = 1V/30A * FSW = 533kHz 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 PowerNavigatorTM evaluation software from a PC running Microsoft Windows. * Efficiency: >88% at 20A * Output Ripple: 1% * Dynamic Response: 3% (33%-83%-33% LOAD STEP, di/dt = 5A/s) Ordering Information PART NUMBER * Operating Temperature: +25C DESCRIPTION ZL8101_30AEV2Z 30A Single Phase Demo Board VIN VDRV R1 U1 ZL8101 DDC SCL SDA SYNC PG EN VTRK_IN VDD DDC SCL SDA SYNC PG EN VTRK PWMH DRVCTL VR V25 SG C12 L1 PWMH DRVCTL R2 VMON R3 U2 CSD96370Q5M PAD ISENA ISENB FB+ FBDGND VOUT C6 ISENA ISENB FB+ FB- COUT C11 SG FIGURE 1. ZL8101_30AEV2Z 30A DEMO BOARD SIMPLIFIED SCHEMATIC September 6, 2012 AN1781.0 1 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. Application Note 1781 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 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. PMBus Operation 9. Select `No' at prompt to search the Internet for drivers. 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. 10. Follow the steps on the screen to install the drivers from the CD. Install the evaluation software using the CD included in the ZL8101_30AEV2Z 30A Demo Board kit. 12. Using PowerNavigator, set the enable mode to PMBus Enable, press the PMBus Enable button on the PowerNavigator opening screen. 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. 11. Install the PowerNavigator evaluation software by running setup.exe from the PowerNavigator_installer folder on the CD. 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. Use the mouse-over pop-ups for PowerNavigator help. Refer to Zilker Labs application note AN2033 for PMBus details. 2 AN1781.0 September 6, 2012 Board Schematics VIN VIN FB1 1000 Ohm D2 RB521S30 Q1 FMMTL618TA VDRV C1 10uF 25V C15 22uF 16V VDRV 3 R1 100K VTRK_IN VTRK_IN MGN MGN U1 ZL8101 27 6 7 2 32 30 8 14 31 28 12 C4 10uF 10V C3 10uF 10V SG U2 CSD96370Q5M 24 26 5 VDD XTEMP NC DDC SCL SDA SY NC PG EN SALRT VTRK SS MGN VMON 3 171615141312 23 VR FC PWML PWMH DRVCTL NC NC ISENA ISENB FB+ FBSA1 2 4 9 20 22 13 29 17 19 18 15 16 4 PWMH DRVCTL 22 1 SENA SENB 5 20 21 18 19 11 10 9 8 7 6 23 C5 1uF 16V VOUT L1 0.220nH R2 1.18K C6 1uF 10V SG PAD V1 V25 V0 SA0 DGND 21 33 11 25 10 3 1 C10 0.01uF 25V R3 6.65K P3 VOUT C8 100uF 6.3V C9 100uF 6.3V C7 680uF 4V C24 680uF 4V FB+ FB- C11 10uF 10V XX5 Address set to 0x24 Vout set to 3.3V P4 SG FIGURE 2. ZL8101_30AEV2Z 30A DEMO BOARD COMPLETE CIRCUIT Application Note 1781 DDC SCL SDA SY NC PG EN DDC SCL SDA SYNC PG EN C2 4.7uF 25V AN1781.0 September 6, 2012 Board Schematics (Continued) R7 4.75k SCL SALRT SDA VAUX DDC VTRK VDRV SDA SCL VI2C SALRT SDA R9 FROM PREQUEL4.75k J2 2 1 4 3 6 5 8 7 10 9 R10 4.75k U5 REG1117A J7 1 DDC R11 R12 VTRK_IN DDC 49.9 MSTR_EN SY NC PG_0 49.9 2 3 N I R D V SCL VI2C SALRT R8 4.75k VTRK_IN DDC HEADER 4 TO SEQUEL J3 2 1 4 3 6 5 8 7 10 9 VOUT 1 2 + VDRV - G-ADJ 1 C25 10uF 25V SY NC VDRV J1 2 VOUT 4 VOUT VIN R28 909 R29 2.74K MSTR_SYNC R6 4.75k C12 100uF 6.3V C16 22uF 16V P1 VOUT VIN PG PG 3 4 6 1 D4 ESDA6V1-4BC6 3 4 6 J5 2 1 2 3 VIN D5 ESDA6V1-4BC6 5 2 5 1 EN EN C13 330u 16V C14 330u 16V P2 JACK_BARREL 2 3 4 R13 100K VAUX D1 GRN Enable_1 R4 10.0K R5 392 3 2 1 Disable Monitor Enable SW1 PG Q2 2N7002/SOT U3 REG1117A J6 2 R14 49.9 1 3 R15 10.0K MSTR_EN R16 49.9 JP1 C23 1uF 25V VAUX D9 BAT54 VI2C R18 115 C18 10uF 25V FIGURE 3. ZL8101_30AEV2Z 30A DEMO BOARD - INTERFACE CIRCUITRY D8 BAT54 VAUX G-ADJ 1 HW_EN R17 49.9 C21 0.1uF 10V D7 BAT54 2 VOUT 4 VOUT VIN R19 187 C22 10uF 25V C19 0.1u 10V C20 10u 25V Application Note 1781 + VIN - VIN SOCKET 1 AN1781.0 September 6, 2012 Application Note 1781 12 13 16 14 1 11 17 10 18 9 2 20 21 8 19 22 15 7 3 4 5 6 FIGURE 4. ZL8101_30AEV2Z 30A DEMO BOARD GUIDE The top view of the ZL8101_30AEV2Z 30A Demo Board is shown in Figure 4, and the most important parts of the board are covered in Table 1 5 AN1781.0 September 6, 2012 Application Note 1781 TABLE 1. COMMENTS ABOUT DIFFERENT PARTS IN THE ZL8101_30AEV2Z 30A DEMO BOARD ITEM QUANTITY REFERENCE VALUE TOLERANCE RATING 1 1 C1 10% 25V 2 1 C2 3 3 C3, C4, C11 4.7F 10% 25V X7R 10F 10% 10V X7R 4 1 C5 1F 10% 16V X7R 5 1 C6 1F 10% 10V 6 2 C7, C24 680F 20% 4V 7 3 C8, C9, C12 100F 6.3V X5R Taiyo Yuden JMK325BJ107MY-T Digikey 587-1388-2-ND 8 1 C10 0.01F 10% 25V X7R Kemet C0402C103K3RACTU Digikey 399-1278-2-ND 9 2 C13, C14 330 20% 16V AL POLY United Chemi-Con APXA160ARA331MJC0G Digikey 565-3081-2-ND 10 2 C15, C16 22F 20% 16V X5R Murata GRM31CR61C226ME15L Digikey 490-4739-2-ND 11 3 C18, C22, C25 10F 10% 25V X5R Panasonic - ECG ECJ-3YB1E106K Digikey PCC2414TR-ND 12 1 C19 0.1 10% 10V X7R Kemet C0603C104K8RACTU Digikey 399-1095-2-ND 13 1 C20 10 10% 25V X5R Panasonic - ECG ECJ-3YB1E106K Digikey PCC2414TR-ND 14 1 C21 0.1F 10% 10V X7R Kemet C0603C104K8RACTU Digikey 399-1095-2-ND 15 1 C23 1F 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 ON SEMI RB521S30 Digikey RB521S30CT-ND 18 2 D4, D5 ST Micro ESDA6V1-4BC6 Digikey 497-4643-2-ND 19 3 D7, D8, D9 BAT54 30V On Semi BAT54XV2T1OS Digikey BAT54XV2T1OSTR-ND 20 1 FB1 1000 150mA 21 1 JP1 4 PIN 22 3 J1, J6, J7 2 POS 23 1 J2 24 1 25 1 26 1 L1 0.220nH 70 27 2 P1, P2 JACK_DUAL_BANANA 15A 28 2 P3, P4 JACK_BANANA_1 29 1 Q1 FMMTL618TA 20V NPN Diodes Inc 30 1 Q2 2N7002/SOT 60V 115mA N-CH 10F ESDA6V1-4BC6 TYPE X7R MANUFACTURER DISTRIBUTOR DIST. PN TMK316B7106KL-TD Digikey 587-2399-2-ND AVX 0805YC475KAT2A Digikey 478-5722-1-ND Murata GRM21BR71A106KE51L Digikey 490-3905-2-ND Kemet C0603C105K4RACTU Digikey C0603C105K4RACTU-ND X7R Taiyo Yuden LMK107B7105KA-T Digikey 587-1242-2-ND AL POLY Kemet T530Y687M004ATE005 Digikey 399-4750-1-ND Schottky 6.1V, 80W Schottky Taiyo Yuden BK1005HM102-T Digikey 587-1835-2-ND Tyco 3-644456-4 Digikey A31114-ND VERT Samtec TSW-102-07-L-S Digikey SAM1031-02-ND HEADER RA Samtec TSW-105-08-T-D-RA Digikey SAM1049-05-ND J3 SOCKET RA Samtec SSQ-105-02-T-D-RA Digikey SAM1224-05-ND J5 JACK_BARREL RA Kobiconn 163-5004-E Mouser 163-5004-E 1.5A @ 18VDC Ferrite Taiyo Yuden PART NUMBER Inductor ITG SL3732_R22KHF ITG SL3732_R22KHF Emerson 108-0740-001 Digikey J147-ND Digikey J147-ND FMMTL618TA Digikey FMMTL618CT-ND 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 6 AN1781.0 September 6, 2012 Application Note 1781 TABLE 1. COMMENTS ABOUT DIFFERENT PARTS IN THE ZL8101_30AEV2Z 30A DEMO BOARD (Continued) ITEM QUANTITY REFERENCE TOLERANCE RATING TYPE 42 1 R19 187 VALUE 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 54 1 U2 CSD96370Q5M 55 2 U3, U5 REG1117A 7 25V MANUFACTURER PART NUMBER DISTRIBUTOR DIST. PN Intersil ZL8101 Intersil ZL8101 Texas Instruments CSD96370Q5M Digikey 296-28235-2-ND Texas Instruments REG1117A Digikey REG1117A-ND AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers FIGURE 5. PCB - TOP LAYER 8 AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers (Continued) FIGURE 6. PCB - INNER LAYER 1 (VIEWED FROM TOP) 9 AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers (Continued) FIGURE 7. PCB - INNER LAYER 2 (VIEWED FROM TOP) 10 AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers (Continued) FIGURE 8. PCB - INNER LAYER 3 (VIEWED FROM TOP) 11 AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers (Continued) FIGURE 9. PCB - INNER LAYER 4 (VIEWED FROM TOP) 12 AN1781.0 September 6, 2012 Application Note 1781 Board Layout - 6 Layers (Continued) FIGURE 10. PCB - BOTTOM LAYER (VIEWED FROM TOP) 13 AN1781.0 September 6, 2012 Application Note 1781 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 MFR_MODEL MFR_REVISION MFR_LOCATION MFR_DATE MFR_SERIAL VOUT_COMMAND FREQUENCY_SWITCH POWER_GOOD_DELAY IOUT_SCALE IOUT_CAL_OFFSET TON_DELAY TON_RISE TOFF_DELAY TOFF_FALL VOUT_OV_FAULT_RESPONSE VOUT_UV_FAULT_RESPONSE OVUV_CONFIG IOUT_OC_FAULT_LIMIT IOUT_AVG_OC_FAULT_LIMIT IOUT_UC_FAULT_LIMIT IOUT_AVG_UC_FAULT_LIMIT MFR_IOUT_OC_FAULT_RESPONSE MFR_IOUT_UC_FAULT_RESPONSE MFR_VMON_OV_FAULT_LIMIT VMON_OV_FAULT_RESPONSE MFR_VMON_UV_FAULT_LIMIT VMON_UV_FAULT_RESPONSE VIN_OV_WARN_LIMIT VIN_OV_FAULT_LIMIT VIN_OV_FAULT_RESPONSE VIN_UV_WARN_LIMIT VIN_UV_FAULT_LIMIT VIN_UV_FAULT_RESPONSE OT_WARN_LIMIT OT_FAULT_LIMIT OT_FAULT_RESPONSE UT_WARN_LIMIT UT_FAULT_LIMIT 14 Zilker_Labs 30A REV_A Austin 8/2012 1p0V_35A 1.0 533 5 0.30 -2.0 5 5 5 5 0x80 0x80 0x80 50 45 -40 -40 0x80 0x80 7.0 0x80 4.5 0x80 14.3 14.5 0x80 4.2 4.0 0x80 110.0 125 0x80 -20 -40 AN1781.0 September 6, 2012 Application Note 1781 UT_FAULT_RESPONSE DEADTIME DEADTIME_CONFIG DEADTIME_MAX MAX_DUTY TRACK_CONFIG INTERLEAVE #SEQUENCE MFR_CONFIG NLR_CONFIG TEMPCO_CONFIG MISC_CONFIG ISHARE_CONFIG AUTO_COMP_CONFIG PID_TAPS USER_CONFIG DDC_GROUP #DDC_CONFIG INDUCTOR ON_OFF_CONFIG STORE_DEFAULT_ALL RESTORE_DEFAULT_ALL 0x00 0x0C0C 0x8686 0x0C0C 94 0x00 0x0000 0x0000 0x6A10 0x00000000 0x28 0x2000 0x0000 0x79 A=6504.62, B=-11568.50, C=5078.00 0x0011 0x00000000 0x0000 0.22 0x1A 15 AN1781.0 September 6, 2012 Application Note 1781 Measured Data The following data was acquired using a ZL8101_30AEV2Z 30A Demo Board. EFFICIENCY 96 VOUT = 2.5V EFFICIENCY (%) 91 VOUT = 3.3V VOUT = 1.8V VOUT = 1.2V 86 VOUT = 1V 81 76 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 OUTPUT CURRENT (A) FIGURE 11. EFFICIENCY FOR DIFFERENT OUTPUT VOLTAGES, VIN = 12V, F SW = 533kHz TURNON RAMP VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A TRISE = 5ms, MIN DUTY = DISABLED AUTOCOMP = OFF 5ms MINIMUM DUTY CYCLE ARTIFACT ~100mV FIGURE 12. RAMP UP 16 AN1781.0 September 6, 2012 Application Note 1781 TURN OFF RAMP VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A TFALL= 5ms, MIN DUTY = DISABLED AUTOCOMP = OFF VOUT 5ms FIGURE 13. RAMP DOWN TRANSIENT RESPONSE VIN = 12V, VOUT = 1V, FSW = 533kHz, I = 10A AUTOCOMP = ON, TAPS A = 8728.25 B = 14684.25, C = 5966.00 55mVP-P VOUT, MEASURED ACROSS C7 DYNAMIC LOAD CURRENT di/dt = 5A/s IMIN = 15A, IMAX = 25A FIGURE 14. DYNAMIC RESPONSE, 10A TO 25A (AND VICE VERSA) LOAD STEP 17 AN1781.0 September 6, 2012 Application Note 1781 STATIC RIPPLE MEASURED ACROSS C24 VIN = 12V, VOUT = 1V, FSW = 533kHz, IOUT = 15A VOUT = 10mVP-P SWITCH NODE USED AS SYNC SIGNAL FIGURE 15. OUTPUT VOLTAGE RIPPLE WHEN VO = 1V, IO = 25A, V IN = 12V, F sw= 800kHZ References [1] ZL8101 Data Sheet, Zilker Labs, Inc., 2012. [2] AN2033 - PMBusTM Command Set, Zilker Labs, Inc., 2009. 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 18 AN1781.0 September 6, 2012 Mouser Electronics Authorized Distributor Click to View Pricing, Inventory, Delivery & Lifecycle Information: Intersil: ZL8101-30AEV2Z