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| REFERENCE DESIGN International Rectifier This reference design is capable of delivering up to 120A at an ambient temperature of 45C if the enclosed heatsink is attached and 250LFM of airflow is provided. Performance graphs and waveforms are provided in figures 1 - 9. The figures and table in pages 4 - 7 are provided as a reference design to enable engineers to very quickly and easily design a 4-phase converter. Refer to the data sheet for the controller listed in the bill of materials in order to optimize this design to your specific requirements. A variety of other controllers may also be used, but the design will require layout and control circuit modifications. IRDCIP2002-C * 233 Kansas Street, El Segundo, CA 90245 USA IRDCIP2002-C: 1MHz, 120A, 4-phase Synchronous Buck Converter using iP2002 Overview Demoboard Quick Start Guide Initial Settings: The output is set to 1.3V, but can be adjusted from 0.8V to 3.3V by changing the values of R3 and R32 according to the following formula: R3 = R32 = (24.91k * 0.8) / (VOUT - 0.8) The switching frequency per phase is set to 1MHz with the frequency set resistor R4. This creates an effective output frequency of 4MHz. The graph in figure 11 shows the relationship between R4 and the switching frequency per phase. The frequency may be adjusted by changing R4 as indicated; however, extreme changes from the 1MHz set point may require redesigning the control loop and adjusting the values of input and output capacitors. Refer to the SOA graph in the iP2002 datasheet for maximum operating current at different conditions. Procedure for Connecting and Powering Up Demoboard: 1. Apply input voltage (+12V) across VIN and PGND 2. Apply load across VOUT pads and PGND pads 3. Adjust load to desired level. See recommendations below. iP2002 Recommended Operating Conditions (refer to the iP2002 datasheet for maximum operating conditions) Input voltage: Output voltage: Switching Freq: Output current: 6.5 - 12V 0.8 - 3.3V 1MHz per phase, 4MHz effective output frequency. The reference design is capable of delivering up to 120A at an ambient temperature of 45C if the enclosed heatsink is attached and 250LFM of airflow is provided. With a heatsink and no airflow, the reference board is capable of delivering 110A at 25C ambient. With 250LFM and no heatsink, the reference board is capable of delivering 100A at 25C ambient. 07/22/03 IRDCIP2002-C 35 87% 30 25 VIN = 12V VOUT = 1.3V fSW = 1MHz TA = 25C Efficiency 86% 85% Power Loss (W) 84% 20 83% 15 82% 10 81% 5 80% VIN = 12V VOUT = 1.3V fSW = 1MHz TA = 25C 0 10 20 30 40 50 60 70 80 90 100 110 120 0 0 10 20 30 40 50 60 70 80 90 100 110 120 79% Output Current (A) Output Current (A) Fig. 1: Power Loss vs. Current Fig. 2: Efficiency vs. Current Phase Margin = 59 Cross-Over Freq = 123kHz VIN = 12V VOUT = 1.3V IOUT = 120A fSW = 1MHz TA = 21C Fig. 3: Bode Plot V IN = 12V V OUT = 1.3V I OUT = 120A f SW = 1MHz T A = 25C V IN = 12V VOUT = 1.3V IOUT = 120A fSW = 1MHz T A = 25C Ripple = 132mVp-p Ripple = 12.8mVp-p Fig: 4: Input Voltage Ripple Waveform 2 Fig. 5: Output Voltage Ripple Waveform www.irf.com IRDCIP2002-C 101.2% 101.1% 101.0% 100.9% 100.8% Output Voltage Accuracy 100.7% 100.6% 100.5% 100.4% 100.3% 100.2% 100.1% 100.0% 99.9% 99.8% 0 10 20 30 40 50 60 Output Current (A) 70 80 90 100 110 120 VIN = 12V VOU T = 1.3V IO UT = 120A f SW = 1MHz TA = 25C Fig. 6: Output Voltage Accuracy vs. Current Ch1: VIN 5V/div Ch1: VIN 2V/div Ch2: VO UT 0.2V/div VIN = 12V VOU T = 1.3V IOUT = 40A fSW = 1MHz TA = 25C VIN = 12V VOU T = 1.3V IOUT = 120A f SW = 1MHz TA = 25C Ch2: VOUT 0.5V/div Fig. 7: Power Up Waveform Fig. 8: Power Down Waveform Ch2: VOUT 0.5V/div Short circuit at start-up V IN = 12V V OUT = 1.3V f SW = 1MHz T A = 25C Hiccups until short circuit is removed Ch4: IOUT 100A/div Fig 9: Short Circiut Condition Waveform www.irf.com 3 IRDCIP2002-C Adjusting the Over-Current Limit R5, R7, R8 & R9 are the resistors used to adjust the over-current trip point. The trip point is a function of the controller and corresponds to the per phase output current indicated on the x-axis of Fig. 10. For example, selecting 2.7k resistors will set the trip point of each phase to 49.5A. (Note: Fig. 10 is based on iP2002 TBLK = 125C. The trip point will be higher than expected if the reference board is cool and is being used for short circuit testing.) 2.8 2.7 2.6 2.5 2.4 RISEN (k) 2.3 2.2 2.1 2.0 1.9 1.8 1.7 32 34 36 38 40 42 44 46 48 50 Over-Current Trip Point (per Phase) Fig. 10: RISEN vs. Current (per Phase) 100 90 80 70 60 R4 (k ) 50 40 30 20 10 300 400 500 600 700 800 900 1000 Output Frequency (kHz) (per Phase) Fig. 11: R4 vs. Frequency (per Phase) 4 www.irf.com IRDCIP2002-C Fig. 12: Component Placement Top Layer 127mm 1.5mm 5mm 17mm 20mm 3mm Heatsink Notes: 1) Always use the supplied Bergquist Gap PadTM A2000 thermal interface material with heatsink. 2) Torque 4 x #2-56 machine screws to 15 1 in-oz. 3) The heatsink is optimized for 250 LFM with unconfined airflow. Performance will improve with more airflow or confined airflow. 4) Airflow direction should be parallel to fins for maximum performance. Fig. 13: Heatsink Specificationss www.irf.com 5 5 4 3 FB COMP DROOP 10uF Adj/Gnd 1 6 R1 20k 1% R35 +5V R6 20 499 1% VOUTS IP2002-1 PWM1.sch TP13 Vin VIN1 VIN VINS R2 15pF 560pF C26 C25 SGND1 C1 C3 PWM1 10uF PGND 10uF 10uF open 330uF 330uF 330uF VDD1 TP18 C33 C39 TP19 C40 C41 24.9k 1% 220pF C4 C5 40.2k 1% 10k 1% R3 R19 TP17 PGNDS R36 +5V open +5V VCC 1 ENABLE1 10k 1% R21 ENABLE1 2.74k 1% VSW1 R5 VSW1 VSW1 0.3uH TP6 L1 VOUT C2 10uF open R22 C15 100uF 100uF open TP10 VOUT ISEN1 PGND1 14 C16 C42 TP11 VOUT PRDY1 PWM1 0 PRDY1 TP12 VOUT R31 13 R10 24.9k 1% IRDCIP2002-C 6 VSEN R32 ISEN2 VDD2 VIN2 SGND2 PWM2 0 10uF 10uF 10uF open C47 11 Vin +5V 40.2k 1% open IP2002-2 PWM2.sch TP14 PGND TP15 C6 C7 C8 C30 PGND D1 12 PWM2 R11 R16 10k 1% PRDY3 CMPD3003A TP16 PGND 3 +5V TP5 R23 R7 VSW2 10k 1% 0.22uF C35 ISEN3 10 ENABLE2 ENABLE2 +5V VSW2 VSW2 2.74k 1% PRDY2 1 PGOOD TP7 2 2 PGOOD 0.22uF open C36 R24 open R30 9 TP21 L2 0.3uH VOUTS VOUT S 7 PWM3 FS/EN R12 R29 +5V PRDY2 PRDY2 PGND2 open 0 C17 100uF C18 100uF C43 open C34 0.1uF C46 10uF PRDY1 PWM4 16 R4 PGNDS 3 20k 1% 0.22uF 0 C37 R13 PRDY4 1 TP22 PGNDS 2 0.22uF C38 ISEN4 VDD3 VIN3 SGND3 15 +5V D2 CMPD3003A 8 GND IP2002-3 PWM3.sch Vin U1 C9 10uF ISL6558CB C10 10uF C11 10uF C31 open PWM3 +5V R17 10k 1% 10k 1% R25 ENABLE3 ENABLE3 2.74k 1% R8 TP8 VSW3 U6 open R26 VSW3 +5V VSW3 L3 0.3uH LM1117DTX-5.0 Vin PRDY3 PRDY3 Vout 4 C19 100uF C20 100uF C44 open 3 Input Fig. 14: Reference Design Schematic PGND3 C27 C28 10uF Output 2 +5V VDD4 SGND4 IP2002-4 PWM4.sch VIN4 Vin C12 PWM4 +5V 10uF C13 10uF C14 10uF C32 open R18 10k 1% 10k 1% R27 ENABLE4 ENABLE4 2.74k 1% R9 VSW4 TP9 VSW4 R28 open VSW4 L4 0.3uH C21 100uF C22 100uF C45 open www.irf.com PRDY4 PRDY4 PGND4 IP2002_4 phase demo board IRDCIP2002-C Quantity 1 14 8 2 1 1 31 1 4 3 2 4 4 2 4 8 2 2 1 4 1 8 4 8 1 4 1 Designator C1 C10, C11, C12, C13, C14, C27, C3, C4, C46, C5, C6, C7, C8, C9 C15, C16, C17, C18, C19, C20, C21, C22 C2, C28 C25 C26 C30, C31, C32, C33, C42, C43, C44, C45, C47, R22, R24, R26, R28, R29, R30, R36, SHORT, SHORT1, C34 C35, C36, C37, C38 C39, C40, C41 D1, D2 HN1, HN2, HN3, HN4 L1, L2, L3, L4 R1, R4 R10, R11, R12, R13 R16, R17, R18, R19, R21, R23, R25, R27 R2, R31 R3, R32 R35 R5, R7, R8, R9 R6 SC1, SC2, SC3, SC4, SC5, SC6, SC7, SC8 ST1, ST2, ST3, ST4 TC1, TC2, TC3, TC4, TC5, TC6, TC7, TC8 U1 U2, U3, U4, U5 U6 Type 1 capacitor capacitor capacitor capacitor capacitor capacitor open capacitor capacitor capacitor diode hardware inductor resistor resistor resistor resistor resistor resistor resistor resistor hardware hardware hardware ISL6558 iP2002 LM1117 Type 2 NPO X5R X5R X5R NPO NPO X7R X5R polymer general purpose hexnut ferrite thick film thick film thick film thick film thick film thick film thick film thick film hexnut stand off machine screw PWM controller BGA unit LDO linear regulator Value 1 560pF 10.0uF 100uF 10.0uF 15.0pF 220pF 0.100uF 0.22uF 330uF 200V 4-40 0.30uH 20.0K 0 10.0K 24.9K 40.2K 20 2.74K 499 10-24 4-40 10-24 4.5 - 5.5V 5 - 12V 5.0V Value 2 50V 16V 6.3V 6.3V 50V 50V 50V 6.3V 16V 600mA 36A 1/8W 1/8W 1/10W 1/8W 1/8W 1/8W 1/8W 1/8W 2 3/4 0.8 - 5V 30A 800mA Tolerance 5% 10% 20% 10% 5% 5% 10% 10% 20% 20% 1% <50m 1% 1% 1% 1% 1% 1% Package 0805 1206 1210 1206 0805 0805 0805 0603 SMD sot23 SMT 0805 0805 0603 0805 0805 0805 0805 0805 alumininum 16 Ld SOIC 11mm x 11mm TO-252 Manufac 1 ROHM Murata TDK TDK ROHM Phicomp ROHM TDK Panasonic Central semiconductor Building Fasteners Panasonic KOA ROHM KOA KOA KOA KOA KOA KOA McMaster Carr Keystone McMaster Carr Intersil International Rectifier National Semiconductor Table 1: Reference Design Bill of Materials Refer to the following application notes for detailed guidelines and suggestions when implementing iPOWIR Technology products: AN-1028: Recommended Design, Integration and Rework Guidelines for International Rectifier's iPOWIR Technology BGA Packages This paper discusses the assembly considerations that need to be taken when mounting iPOWIR BGA's on printed circuit boards. This includes soldering, pick and place, reflow, inspection, cleaning and reworking recommendations. AN-1029: Optimizing a PCB Layout for an iPOWIR Technology Design This paper describes how to optimize the PCB layout design for both thermal and electrical performance. This includes placement, routing, and via interconnect suggestions. AN-1030: Applying iPOWIR Products in Your Thermal Environment This paper explains how to use the Power Loss and SOA curves in the data sheet to validate if the operating conditions and thermal environment are within the Safe Operating Area of the iPOWIR product. AN-1047: Graphical solution for two branch heatsinking Safe Operating Area Detailed explanation of the dual axis SOA graph and how it is derived. Use of this design for any application should be fully verified by the customer. International Rectifier cannot guarantee suitability for your applications, and is not liable for any result of usage for such applications including, without limitation, personal or property damage or violation of third party intellectual property rights. IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, USA Tel: (310) 252-7105 TAC Fax: (310) 252-7903 www.irf.com 7 |
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