ANP012. Contents. Application Note AP2004 Buck Controller
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1 Contents 1. AP004 Specifications 1.1 Features 1. General Description 1. Pin Assignments 1.4 Pin Descriptions 1.5 Block Diagram 1.6 Absolute Maximum Ratings. Hardware.1 Introduction. Typical Application. Schematic.4 Board of Materials.5 Board Layout. Design Procedures.1 Introduction. Operating Specifications. Design Procedures..1 Buck converter..1.1 Selection of the buck inductor (L)..1. Selection of the output capacitor (C out )..1. Selection of power switch (MOSFET)..1.4 Selection of power Rectifier (D)..1.5 Selection of the input capacitor (C in ) This application note contains new product information. Diodes, Inc. reserves the right to modify the product specification without notice. No liability is assumed as a result of the use of this product. No rights under any patent accompany the sale of the product. 1/9
2 1. AP004 Specifications 1.1 Features - Operating Voltage can be up to 7V - Under Voltage Lockout (UVLO) Protection - Short Circuit Protection (SCP) - Soft-Start Circuit - Variable Oscillator Frequency kHz Max - 1.5V Voltage Reference Output - 8-pin PDIP and SOP packages 1. General Description The AP004 integrates Pulse-Width-Modulation (PWM) control circuit into a single chip, mainly designed for power-supply regulator. All the functions include an on-chip 1.5V reference output, an adjustable oscillator, UVLO, SCP, soft-start circuitry, and a push-pull output circuit. Switching frequency is adjustable by trimming the CT. During low V CC situation, the UVLO makes sure that the outputs are off until the internal circuit is operating normally. 1. Pin Assignments ( Top View ) OUT VCC COMP FB GND CT SS SCP PDIP/SOP 1.4 Pin Descriptions Name CT FB SS COMP OUT GND V CC SCP Description Timing Capacitor Voltage Feedback Soft-Start Feedback Loop Compensation PWM Output Ground Supply Voltage Short Circuit Protection /9
3 1.5 Block Diagram VCC SS CT 1.5V Bandgap Reference.5V Internal use Iss UVLO Oscillator MAX.500KH z VCC FB Error Amplifier PWM Amplifier - OUT COMP - 1.5V 0.7V - SCP GND 1.6 Absolute Maximum Ratings Symbol Parameter Rating Unit V CC Supply Voltage 7 V V I Amplifier Input Voltage 0 V V O Collector Output Voltage V CC -1.0V V I SOURCE Source Current 00 ma I SINK Sink Current 00 ma T OP Operating Temperature Range -0 to 85 o C T ST Storage Temperature Range -65 to 150 o C Lead Temperature 1.6 mm (1/16 inch) from Case for 10 T LEAD Seconds 60 o C. Hardware.1 Introduction The demo board supplies a constant DC output voltage of.v, and supplies the output power up to 10W (.V / A). Using a DC input voltage of 1V, full load efficiency varies from 80 percent to 86 percent depending on the input voltage. This type of converter converts an unregulated input voltage to a regulated output voltage that is always lower than the input voltage. The control method used in the board is a fixed frequency, variable on-time pulse-width-modulation (PWM). The feedback method is used voltage-mode control. Other features of the board include Under-Voltage Lockout (UVLO), Short-Circuit Protection (SCP), and Soft-Start. /9
4 . Typical Application The AP004 may operate in either the CCM (Continuous Conduction Mode) or the DCM (Discontinuous Conduction Mode). The following applications are designed for CCM operation. That is, the inductor current is not allowed to fall to zero. To compare the disadvantages and advantages for CCM and DCM, the main disadvantage of CCM is the inherent stability problems (caused by the right-half-plane zero and the double pole in the small-signal control to output voltage transfer function). However, the main disadvantage of DCM is that peak currents of switch and diode are larger than CCM when converting. Using a power switch and output diode with larger current and power dissipation ratings should solve this issue of large peak currents. The designer has to use larger output capacitors, and take more effort on EMI/RFI solution too. The designer could make a choice for each mode. For a light load, DCM is preferred for a buck frame, but for a heavy load, CCM is preferred. Buck (Step Down) The Buck or Step-down converter converts a DC voltage to a lower DC voltage. Figure 1 shows the basic buck topology. When the switch SW is turned on, energy is stored in the inductor L and it has constant voltage V L =V I V o, the inductor current il ramps up at a slope determined by the input voltage. Diode D is off during this period. Once the switch, SW, turns off, diode D starts to conduct and the energy stored in the inductor is released to the load. The current in the inductor ramps down at a slope determined by the difference between the input and output voltages. i S VS i L VL I O SW id L ic V i V D D C R L V O Figure 1. Typical Buck Converter Topology 4/9
5 . Schematic Q1 1 8 S D 7 6 G PMOS J1 1 CON Vin C1 1000uF C 0.1u Scp ss C6 C7 0nF 50nF ct C8 0p U1 VCC OUT 1 5 SCP FB SS CT COMP GND 8 AP004 out comp R1 short C Short R 56K Switch D1 5A L1 uh R 5.6K R4.K C9 NA C5 0.1uF Vout C4 1000uF J 1 CON Figure. Demo board schematic.4 Board of Materials Part Reference Value Description Manufactu Part Q'ty rers Number U1 AP004 PWM Buck Controller Anachip AP004S 1 Q1 0V, 8.8A PMOS Fairchild SI445DY 1 D1 5A, 40V Schottky Diode B540A 1 R1 0Ω ±5% Resister L1 uh, A Inductor AXIS Power 1 R 56KΩ ±1% Resister R 5.6KΩ ±1% Resister R4.KΩ ±1% Resister C1 1000uF, 5V Aluminum electrolytic OST OST RLX 1 series C, C5 0.1uF, ±10% Ceramic, 50V, 0805 X7R C Short 1 C4 1000uF, 16V Aluminum electrolytic OST OST RLX 1 series C6 0nF, ±10% Ceramic, 50V, 0805 X7R 1 C7 50nF, ±10% Ceramic, 50V, 0805 X7R 1 C8 0pF, ±10% Ceramic, 50V, 0805 X7R 1 C9 NA Option J1, J Pitch = 5.08mm, pin Terminal Block 5/9
6 .5 Board Layout Figure. Silkscreen Layer Figure 4. Top Layer 6/9
7 . Design Procedure Figure 5. Bottom Layer.1 Introduction The AP004 integrated circuit is a PWM controller, it operates over a wide input voltage range. This section will describe the AP004 to design procedure. The operation and the design of the Buck converter will also be discussed in detail.. Operating Specifications Specifications Min. Typ. Max. Units Input Voltage Range V Output Voltage Range. V Output Power Range W Output Current Range 0 A Operating Frequency khz Output Ripple 50 mv Efficiency % Table 1. Operating Specifications. Design Procedures This section describes the steps to design continuous-mode Buck converter, and explains how to construct basic power conversion circuits including the design of the control chip functions and the basic loop. A switching frequency of 15 khz was chosen. 7/9
8 ..1 Buck converter Example calculations accompany the design equations. Since this is a fixed output converter, all example calculations apply to the converter with output voltage of.v and input voltage set to 1 V, unless specified otherwise. The first quantity to be determined is the duty cycle value. Duty cycle = V IN V V o D ( I O RDS ( ON ) ) V D = T T ON S, 0 D 1 V D R DS (ON ) Assuming the commutating diode forward voltage = 0.5 V, and the P-MOS = 0mΩ When V = 1V, I = 0.~A, and the duty cycle is equal to 0.. IN O..1.1 Selection of the buck inductor (L) A buck converter uses a single-stage LC filter. Choose an inductor to maintain continuous-mode operation down to 10 percent (I o(min) ) of the rated output load: The inductor value L is: ΔI L = x 10% x I o = x 0.1 x = 0.6A [ V ( I R ) V ] D [ 1 ( ).] IN O L ΔI So we can choose μh. DS ( ON ) L f..1. Selection of the output capacitor (C out ) S O = = μh Assuming that all of the inductor ripple current flows through the capacitor and the effective series resistance (ESR) is zero, the capacitance needed is: C out ΔI L 0.6 = = 7μF 8 x fs x ΔV o 8 x (15 x 10 ) x 0.05 Assuming the capacitance is very large, the ESR needed to limit the ripple to 50 mv is: ESR ΔV o 0.05 = ΔI o 0.6 = 0.08Ω The output filter capacitor should be rated at least ten times the calculated capacitance and 0 50 percent lower than the calculated ESR. This design used a 1000μF/16V OS-Con capacitor in parallel with a ceramic to reduce ESR. 8/9
9 ..1. Selection of the power switch (MOSFET) Based on the preliminary estimate, the R DS(on) of MOSFET is 0mΩ. The SI445DY is a -0V p-channel MOSFET with R DS(on) = 5mΩ. Power dissipation (conduction switching losses) can be estimated as: P MOSFET = I o x R ds(on) x D max [0.5 x V in x I o x (t r t f ) x f s ] Assuming total switching time (t r t f ) is 0 ns, a 55 C maximum ambient temperature, and thermal impedance R θja = 50 C/W, thus: 9 P MOSFET = ( x x 0.05 x 0.) [0.5 x 1 x x (0 x 10 ) x (15 x 10 ) = W T J = T A (R θja x P MOSFET ) = 55 (50 x ) = C..1.4 Selection of the Rectifier (D) The catch rectifier conducts during the time interval when the MOSFET is off. The B540A(DIODES) is a 5A, 40V Schottky Rectifier in a SOP-8 package. The power dissipation is: P D = I o x V d x (1 D min ) = x 0.5 x (1 0.) = 1.0W Assuming a 55 C maximum ambient temperature, and thermal impedance R θja = 15 C/W, thus: T J = T A (R θja x P D ) = 55 (15 x 1.0) = 70. C..1.5 Selection of the input capacitor (C in ) The RMS current rating of the input capacitor can be calculated from the following formula. The capacitor manufacturer s datasheet must be checked to assure that this current rating is not exceeded. I in(rms) = [D x (I o(max) I o(min) ) x (I o(max) - I o(min) ) (ΔI L )/] = [0. x ( 0.) x ( 0.) 0.6/] = 1.7A This capacitor should be located close to the IC using short leads and the voltage rating should be approximately times the Maximum Input Voltage. The input capacitor value is 1000uF/5V. 9/9
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