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1 description ltc 3765/ ltc 3766 360w isolated forward converter with synchronous rectification demonstration circuit 2199 a-a is a 360 w isolated for- ward converter with synchronous rectification featuring the LTC3765/ltc3766 . it produces a regulated 12v, 30a output from an input voltage range of 36v to 60v. this circuit was designed to demonstrate the high levels of performance, efficiency, and small solution size attain - able using these parts in an active-clamp-reset forward converter power supply, suitable for telecom, industrial, and other applications. it has a 4.7in 2 solution footprint area. synchronous rectification helps to attain an effi- l , lt, ltc, ltm, linear technology and the linear logo are registered trademarks of linear technology corporation. all other trademarks are the property of their respective owners. performance summary ciency exceeding 96%. secondary-side control eliminates complex opto-coupler feedback, providing fast transient response with minimum output capacitance. for other output requirements, see the ltc3766 data sheet or contact the lt c sales. design files for this circuit board are available at http://www .linear.com/demo/dc2199a-a specifications are at t a = 25c symbol parameter conditions min typ max units v in input supply range 36 60 v v out output voltage 11.76 12.0 12.24 v i out output current range, continuous 200lfm 0 30 a f sw switching (clock) frequency 200 khz v out(p-p) output ripple v in = 24v, i out = 30a (20mhz bw) 60 mv p-p i reg output regulation line and load (36v in to 60v in , 0a out to 30a out ) 0.02 % p out /p in efficiency (see figure 3) v in =48v, i out = 30a 96 % isolation basic 1500 vdc approximate solution size component area top component height 4.7in 2 0.6 inches dc2199aafa demo manual dc2199a-a
2 operating principles quick start procedure the LTC3765 active clamp forward controller and gate driver is used on the primary and provides start-up, gate drive, and protection functions. once start-up is accom - plished, the ltc3766 high efficiency, secondary - side synchronous forward controller takes over, and provides the LTC3765 with timing information and bias power through a small pulse transformer. when input voltage is applied, the LTC3765 commences soft-start of the output voltage. when the output reaches the run threshold, the ltc3766 comes alive and takes control by sending encoded pwm gate pulses to the LTC3765 through t2. these pulses also provide primary bias power efficiently over a wide input voltage range. the transition from primary to secondary control occurs at some fraction of the nominal output voltage. from then on, operation and design is reduced to that of a simple demonstration circuit 2199 a-a is easy to set up to evalu - ate the performance of the LTC3765/ltc3766. refer to figure 1 for proper measurement equipment setup and follow the procedure below: note: when measuring the output voltage ripple, care must be taken to avoid a long ground lead on the oscilloscope probe. measure the output voltage ripple by touching the probe tip and ground ring directly across the last output capacitor as shown in figure 1. 1. set an input power supply that is capable of 36 v to 60v to 36v. then turn off the supply. 2. di rect an airflow of 200 lfm across the unit for sustained operation at full load. 3. with power off, connect the supply to the input terminals +v in and Cv in . a. input voltages lower than 36 v can keep the converter from turning on due to the undervoltage lockout feature of the LTC3765/ltc3766. buck converter. secondary control eliminates delays, tames large-signal overshoot, and reduces output capacitance needed to meet transient response requirements. an optional lc filter stage on the input lowers rms input current. the filter must have output impedance that is less than the converter input impedance to assure stability. this may require a damping impedance, which is provided by r 1. ( see linear technology application note 19 for a discussion of input filter stability.) r1 is coupled through a tiny 2 mm 2 mm inductor l1, and provides damping with arbitrarily low source impedance. for bench testing, an electrolytic capacitor has been added at the input ter - minals to provide suitable ripple current capability. the values selected have a filter resonant frequency that is below the converter switching frequency, thus avoiding high circulating currents in the filter. b. if efficiency measurements are desired, an ammeter capable of measuring 15 adc or a resistor shunt can be put in series with the input supply in order to measure the dc2199a-as input current. c. a voltmeter with a capability of measuring at least 60v can be placed across the input terminals in order to get an accurate input voltage measurement. 4. turn on the power at the input. note: make sure that the input voltage never ex - ceeds 60 v. 5. check for the proper output voltage of 12 v. turn off the power at the input. 6. once the proper output voltages are established, con - nect a variable load capable of sinking 30 a at 12 v to the output terminals +v out and Cv out . set the current for 0a. a. if efficiency measurements are desired, an ammeter or a resistor shunt that is capable of handling 30adc can be put in series with the output load in order to measure the dc2199a-as output current. dc2199aafa demo manual dc2199a-a
3 quick start procedure b. a voltmeter with a capability of measuring at least 12v can be placed across the output terminals in order to get an accurate output voltage measurement. 7. turn on the power at the input. note. if there is no output, temporarily disconnect the load to make sure that the load is not set too high. 8. once the proper output voltage is again established, adjust the load within the operating range and observe the output voltage regulation, ripple voltage, efficiency and other desired parameters. figure 1. proper measurement equipment setup figure 2. efficiency and power dissipation i out (a) 0 efficiency? (%) 98 97 95 96 94 92 93 91 90 power dissipation (w) 18 16 12 14 10 6 8 4 2 10 20 5 15 dc2199aa f02 3025 36v in 48v in 60v in 48v in_pd dc2199aafa demo manual dc2199a-a
4 quick start procedure figure 3. output ripple at 48v in and 30a out (50mv, 10a, 2s/div, 20mhz) figure 4. transient response waveform at 48v in and 15a to 30a to 15a out (10a, 500mv, 200s/div) dc2199aafa demo manual dc2199a-a
5 quick start procedure figure 5. thermal map, front side at 48v in and 30a out (t a = 25c, 200lfm) figure 6. thermal map, back side at 48v in and 30a out (t a = 25c, 200lfm) dc2199aafa demo manual dc2199a-a
6 parts list item qty reference part description manufacturer/ part number required circuit components 1 2 c1, c22 cap., alum., elect., 33f, 80v, cap-10x 12.5 panasonic, eehza1k330p 2 5 c2, c3, c4, c5, c6 cap., x7r, 4.7f, 100v, 10%, 1210 murata, grm32er72a475ke14 3 4 c7, c31, c33, c68 cap., poscap, 150f, 16v, 20%, 7343 panasonic, 16tqc150myf 4 1 c10 cap., x7r, 2.2nf, 630v, 5%, 1206 murata, grm31a7u2j222jw31 5 1 c11 cap., x7r, 0.015f, 25v, 10%, 0603 avx , 06033c153 kat 2a 6 2 c24, c71 cap., x7r, 1.0f, 16v, 10%, 0805 murata, grm21br71c105ka01 7 1 c30 cap., x7r, 2200pf, 250v, 10%, 1812 murata, ga343qr7gd222kw01l 8 1 c34 cap., x5r, 22f, 16v, 20%, 1206/1210 murata, grm32er71c226mea8l 9 1 c51 cap., c0g, 470pf, 630v, 5%, 1206 murata, grm31a5c2j471jw01 10 1 c66 cap., x7r, 0.047f, 200v, x7r, 10% 1206 murata, grm31cr72d473kw03 11 1 c69 cap., x7r, 1.5nf, 630v, 5%, 1206 murata, grm31a7u2j152jw31 12 2 c70, c76 cap., x7r, 3.3nf, 25v, 10%, 0603 avx , 06033c332 kat 2a 13 2 c72, c102 cap., x7r, 0.1f, 25v, 10%, 0805 avx , 08053c104 kat 2a 14 4 c55, c73, c80, c119 cap., x7r, 1nf, 25v, 10%, 0603 murata, grm188r71e102ka01 15 1 c75 cap., npo, 100pf, 25v, 5%, 0603 avx , 06033a101 jat 2a 16 1 c77 cap., x7r, 4.7f, 25v, 10%, 1206 av x , 12063c475 kat 2a 17 1 c78 cap., npo, 0.033f, 25v, 5%, 0805 tdk, c2012c0g1e333j 18 1 c79 cap., x7r, 4.7nf, 25v, 10%, 0603 murata, grm188r71e472ka01 19 1 c101 cap., npo, 220pf, 25v, 5%, 0603 avx , 06033a221 jat 2a 20 1 c106 cap., cog, 150pf, 250v, 5%, 0603 tdk, c1608c0g2e151j080aa 21 1 c112 cap., x7r, 0.22f, 250v, 10%, 1206/1210 tdk c3225x7r2e224k 22 1 c113 cap., x7r, 0.033f, 25v, 10%, 0603 avx , 06033c333 kat 2a 23 1 c118 cap., npo, 1500pf, 5%, 0603 avx , 06033a152 jat 2a 24 2 d1, d34 diode ultra fast 1a, 200v, smp vishay, es1pd-m3 / 84a 25 3 d27, d29, d30 diode schottky 60v, 0.5a, sot23 diodes inc, zhcs506ta 26 1 d40 diode, 1n4148ws, sod323 vishay, 1n4148ws-e3-08 27 1 l1 inductor, 1.0h, 20% coilcraft, xpl2010-102ml 28 1 l2 inductor, 2.0h, 20% vishay, ihlp4040dzer2r0m11 29 1 l3 inductor, 3.3h, 10% coilcraft, ser2915l-332kl 30 2 q8, q9 mosfet n-ch 150v, powerpak-so-8 infineon, bsc190n15ns3 g 31 4 q12, q13, q14, q15 mosfet n-ch 80v, powerpak-so-8 infineon, bsc028n06ns3 32 1 q27 trans., npn 40v, 1a, sot-89 diode inc., fcx491ata 33 1 q28 mosfet, n-ch, super, sot-6 fairchild, fdc2512-nl 34 1 q29 mosfet, p-ch, irf6217, powerpak- so-8 ir , irf6217trpbf 35 1 r1 res., chip, 0.33, 1/4w, 5%, 2512 panasonic, erj-1trqjr33u 36 1 r4 res., chip, 8.2k, 1w, 5%, 2512 panasonic, erj-1 tyj 822u 37 1 r18 res., chip, 102k, 1/8w, 1%, 0805 vishay, crcw0805102kfkea 38 1 r22 res., chip, 3.74k, 1/16w, 1%, 0603 vishay, crcw06033k74fkea 39 2 r23, r24 res., chip, 8.2, 1/4w, 5%, 1206 vishay, crcw12068r20jkea 40 1 r29 res., chip, 100k, 1/8w, 5%, 0805 vishay, crcw0805100kjnea 41 1 r41 res., chip, 11.5k, 1/16w, 1%, 0603 vishay, crcw060311k5fkea dc2199aafa demo manual dc2199a-a
7 parts list item qty reference part description manufacturer/ part number 42 1 r42 res., chip, 1k, 1/16w, 1%, 0603 vishay, crcw06031k00fkea 43 1 r46 res., chip, 604, 1/16w, 1%, 0603 vishay, crcw0603604rfkea 44 2 r51, r52 res., chip, 3.0, 1/4w, 5%, 1206 panasonic, erj-8geyj3r0v 45 1 r53 res., chip, 6.8, 1/2w, 1%, 1206 panasonic, erj-8rqf6r8v 46 1 r68 res., chip, 2.15k, 1/16w, 1%, 0603 vishay, crcw06032k15fkea 47 1 r69 res., chip, 46.4k, 1/16w, 1%, 0603 vishay, crcw060346k4fkea 48 1 r75 res., chip, 215, 1/8w, 1%, 0805 vishay, crcw0805215rfkea 49 1 r76 res., chip, 4.22, 1/8w, 1%, 0805 vishay, crcw08054r22fkea 50 1 r84 res., chip, 1.21k, 1/8w, 1%, 0805 vishay, crcw08051k21fkea 51 4 r101, r148, r149, r151 res., chip, 100, 1/16w, 1%, 0603 vishay, crcw0603100rfkea 52 1 r109 res., chip, 10k, 1/16w, 1%, 0603 vishay, crcw060310k0fkea 53 1 r110 res., chip, 1.20, 1/2w, 1%, 1206 susumu, rl1632s-1r20-f 54 1 r114 res., chip, 28.7k, 1/16w, 1%, 0603 vishay, crcw060328k7fkea 55 1 r117 res., chip, 12.7k, 1/16w, 1%, 0603 vishay, crcw060312k7fkea 56 1 r118 res., chip, 681k, 1/16w, 1%, 0603 vishay, crcw0603681kfkea 57 1 r121 res., chip, 133k, 1/16w, 1%, 0603 vishay, crcw0603133kfkea 58 1 r123 res., chip, 118k, 1/16w, 1%, 0603 vishay, crcw0603118kfkea 59 1 r125 res., chip, 17.4k, 1/16w, 1%, 0603 vishay, crcw060317k4fkea 60 1 r136 res., chip, 0.005, 1w, 1%, 1225 susumu, krl6432d-m-r005-f-t5 61 1 r139 res., chip, 26.7k, 1/16w, 1%, 0603 vishay, crcw060326k7fkea 62 1 r140 res., chip, 274, 1/8w, 1%, 0805 panasonic, erj-6enf2740 v 63 1 r 150 res., chip, 14.3k, 1/16w, 1%, 0603 visha y, crcw060314k3fkea 64 1 t1 transformer champs tech., lt c -pq26-0402 65 1 t2 transformer, 1.25:1 pulse, pa 3493nl 66 1 t3 transformer, 1:100, ct02-100 ice components , ct02-100 = 1:100 67 1 u1 i.c. LTC3765emse, msop-16pin linear tech., LTC3765emse#pbf 68 1 u2 i.c. ltc3766egn, ssop-gn28 linear tech., ltc3766egn#pbf additional demo board circuit components 1 0 c12, c13, c14, c16, c20 cap., opt , 0603 opt 2 0 c8, c9, c18, c19, c103, c111 cap., opt , 0603 opt 3 0 c15, c21, c114 cap., opt , 0805 opt 4 0 c17, c116 cap., opt , 1206 opt 5 0 c23, c25, c26 cap., opt , cap-svpf-e12 opt 6 2 c74, c105 cap, 0, jumper 0603 vishay, crcw06030000z0ea 7 0 d2 diode tbd sod323 opt 8 0 d4, d35 diode opt , sod323 opt 9 0 d28, d37, d38 diode opt , sot23 opt 10 0 l4 inductor, opt , do1606t opt 11 0 q1, q2 mosfet, opt , sot23-6 opt 12 0 q4 mosfet, opt , d- pak opt 13 0 q11, q23, q24 mosfet, opt , powerpak-so-8 opt 14 0 r5 res., opt , 2512/2010 opt dc2199aafa demo manual dc2199a-a
8 item qty reference part description manufacturer/ part number 15 13 r6, r7, r8, r9, r49, r103, r111, r112, r113, r122, r124, r137, r146 res., chip, 0, 0603 vishay, crcw06030000z0ea 16 0 r10, r13, r14, r15 res., opt , 2512 opt 17 0 r17, r108, r116, r127 res., opt , 1206 opt 18 0 r25, r26, r27, r28, r30, r31, r32, r33, r34, r35, r43, r106, r107, r119, r120, r126, r138, r147 res., opt , 0603 opt 19 1 r77 res., chip, 0, 1/8w, 0805 vishay, crcw08050000z0ea 20 1 r102 res., chip, 0, 1225 tepro,rn5326 21 1 r115 res., chip, 0, 1/4w, 1206 vishay, crcw12060000z0ea 22 0 r152 res., opt , 0805 opt 23 0 u3 i.c. opt , so16 opt hardware: for demo board only 1 4 e1, e2, e3, e4 testpoint, turret, .094" mill-max, 2501-2-00-80-00-00-07-0 2 3 e5, e6, e7 testpoint, turret, .061" mill-max, 2308-2-00-80-00-00-07-0 3 0 j1 header, opt , 27pin, 0.079cc opt , molex, 87331-1420 4 2 j3, j4 stud, test pin pem, kfh-032-10 5 4 j3, j4(2 each) nut, brass, #10-32 any #10-32 6 2 j3, j4 washer, star #10 brass nickel any, #10ext bz tn 7 2 j3, j4 ring, lug ring # 10 keystone, 8205 8 0 tp1-tp6 pad -smd pad -smd 9 4 (stand-off) stand-off, nylon 0.25" keystone, 8831 (snap on) 10 1 fab , printed circuit board demo circuit 2199a parts list dc2199aafa demo manual dc2199a-a
9 simplified schematic (without unneeded components) schematic diagram 5 5 4 4 3 3 2 2 1 1 d d c c b b a a +vout 36v-60vin -vout 1210 1812 0805 0805 0805 1210 0805 0805 1210 0805 12vout / 30a cog 7343 1.25t 1t 1/4w = 1206, 1w = 2512. unless otherwise specified: all resistors are in ohms 0603. all capacitors are in microfarads 0603. all capacitors are 25v. 1/16w = 0402, 1/10w = 0603, 1/8w = 0805, note: 4.7uf 100v murata, grm32er72a475ke14 (x7r 1210) 4.7uf 25v avx, 12063c475kat2a (x7r 1206) 22uf 16v murata, grm32er71c226mea8l (1210 x5r) 2.2nf 250v murata ga343qr7gd222kw01l (x7r 1812) 150uf 16v panasonic, 16tqc150myf 33uf 80v panasonic, eehza1k330p (10x12.5mm) l2 vishay ihlp4040dzer2r0m11 l3 coilcraft ser2915l-332kl 0.005 ohm susumu krl6432d-m-r005-f-t5 (1225) r110 susumu, rl1632s-1r20-f (1206) t1 champs, ltc-pq26-0402 t2 pulse, pa3493nl 0805 0805 0805 0805 1206 1206 0805 1210 1/2w nd vcp fg fg +vout +vout vin is+ -vin is+ -vout uv vin rs- -vin nd -vout +vout pgndp sgndp sgndp sgnd pgnd sgnd sgnd sgnd pgnd pss sgnd sgndp sgndp size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 friday, october 31, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn28 dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 friday, october 31, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn28 dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 friday, october 31, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn28 dc2199a with direct flux limit revision history description date approved eco rev david b. production 2 8-18-14 __ revision history description date approved eco rev david b. production 2 8-18-14 __ revision history description date approved eco rev david b. production 2 8-18-14 __ q15 bsc028n06ns3 q15 bsc028n06ns3 q12 bsc028n06ns3 q12 bsc028n06ns3 r151 100 r151 100 fcx491a q27 fcx491a q27 1 3 2 c119 1nf c119 1nf c34 22uf 16v c34 22uf 16v c10 2.2nf 630v 1206 c10 2.2nf 630v 1206 q24 opt q24 opt c102 0.1uf c102 0.1uf ltc3766egn28 u2 ltc3766egn28 u2 ith 7 fg 2 sw 23 fb 6 gnd 14 is+ 18 is- 17 sg 1 vcc 28 pt+ 26 pt- 25 regsd 16 fs/sync 15 ss 9 mode 4 pgnd 27 vin 22 ndrv 21 ipk 10 phase 5 vs+ 12 vs- 13 vsout 11 run 8 fgd/swb 20 vsec 3 sgd 19 vaux 24 t2 trans-pa3493nl t2 trans-pa3493nl 3 1 6 4 r148 100 r148 100 r101 100 r101 100 r69 46.4k r69 46.4k q14 bsc028n06ns3 q14 bsc028n06ns3 q11 opt q11 opt c73 1nf c73 1nf d34 es1pd d34 es1pd c69 1.5nf 630v c69 1.5nf 630v t3 ct02-100 t3 ct02-100 1 2 3 4 c72 0.1uf c72 0.1uf +vin +vin r117 12.7k r117 12.7k c3,4,5,6 4x4.7uf 100v c3,4,5,6 4x4.7uf 100v d27 zhcs506 d27 zhcs506 1 3 r68 2.15k r68 2.15k c76 3.3nf c76 3.3nf q29 irf6217 q29 irf6217 -vin -vin r139 26.7k r139 26.7k + c1,22 2x33uf 80v + c1,22 2x33uf 80v c55 1nf c55 1nf q13 bsc028n06ns3 q13 bsc028n06ns3 c66 47nf 200v 1206 c66 47nf 200v 1206 q8 bsc190n15ns3 q8 bsc190n15ns3 c75 100pf c75 100pf t1 ltcp26-0402 t1 ltcp26-0402 12 6 9 2 14 8 10 13 3 5 r42 1k r42 1k q23 opt q23 opt r114 28.7k r114 28.7k r29 100k r29 100k c80 1nf c80 1nf r149 100 r149 100 r23,24 2x8.2 1206 r23,24 2x8.2 1206 r18 102k r18 102k r4 8.2k 2512 r4 8.2k 2512 r41 11.5k r41 11.5k r121 133k r121 133k d30 zhcs506 d30 zhcs506 1 3 r123 118k r123 118k c71 1uf 16v c71 1uf 16v r84 1.21k r84 1.21k r51,52 2x3.0 1206 r51,52 2x3.0 1206 r118 681k r118 681k l2 2.0uh l2 2.0uh d1 es1pd d1 es1pd 1 2 c11 15nf c11 15nf r46 604 r46 604 c30 2.2nf 250v c30 2.2nf 250v LTC3765emse u1 LTC3765emse u1 ndrv 14 vcc 3 pg 2 in+ 15 in- 16 run 12 ag 4 delay 6 is- 7 gnd 17 is+ 8 fs/uv 10 ssflt 13 pgnd 1 gnd2 9 rcore 11 ismag 5 c101 220pf c101 220pf c77 4.7uf c77 4.7uf r76 4.22 r76 4.22 r1 0.33 2512 r1 0.33 2512 r110 1.20 1206 r110 1.20 1206 r125 17.4k r125 17.4k c79 4.7nf c79 4.7nf q28 fdc2512 q28 fdc2512 + c7,31,33,68 4x150uf 16v + c7,31,33,68 4x150uf 16v c51 470pf 630v 1206 c51 470pf 630v 1206 c78 33nf c78 33nf c113 33nf c113 33nf c106 150pf 250v c106 150pf 250v l1 1.0uh l1 1.0uh r75 215 r75 215 r136 0.005 1225/2512 r136 0.005 1225/2512 c112 0.22uf 200v c112 0.22uf 200v c70 3.3nf c70 3.3nf d29 zhcs506 d29 zhcs506 1 3 r140 274 1/8w r140 274 1/8w c118 1.5nf c118 1.5nf r22 3.74k r22 3.74k l3 3.3uh l3 3.3uh r109 10k r109 10k r53 6.8 1206 r53 6.8 1206 q9 bsc190n15ns3 q9 bsc190n15ns3 c24 1uf 16v c24 1uf 16v c2 4.7uf 100v c2 4.7uf 100v r150 14.3k r150 14.3k dc2199aafa demo manual dc2199a-a
10 schematic diagram full schematic, page 1 5 5 4 4 3 3 2 2 1 1 d d c c b b a a +vout 36v-60vin -sense +sense -vout 1210 1210 1210 1210 1812 7343 7343 0805 0805 0805 0805 1210 0805 0805 1210 0805 12vout / 30a cog 7343 1206 1.25t 1t 1/4w = 1206, 1w = 2512. unless otherwise specified: all resistors are in ohms 0603. all capacitors are in microfarads 0603. all capacitors are 25v. 1/16w = 0402, 1/10w = 0603, 1/8w = 0805, note: 4.7uf 100v murata, grm32er72a475ke14 (x7r 1210) 4.7uf 25v avx, 12063c475kat2a (x7r 1206) 22uf 16v murata, grm32er71c226mea8l (1210 x5r) 2.2nf 250v murata ga343qr7gd222kw01l (x7r 1812) 150uf 16v panasonic, 16tqc150myf 33uf 80v panasonic, eehza1k330p (10x12.5mm) l2 vishay ihlp4040dzer2r0m11 l3 coilcraft ser2915l-332kl 0.005 ohm susumu krl6432d-m-r005-f-t5 (1225) r110 susumu, rl1632s-1r20-f (1206) t1 champs, ltc-pq26-0402 t2 pulse, pa3493nl 1206 0805 0805 0805 0805 1206 1206 1206 7343 0805 ith- 1210 run 1/2w ag ag1 nd vs+ vs- vcp vcc fg fg +vout +vout vin run is+ -vin is+ -vout uv vpk vin as rs- -vin run nd rs+ rs- vaux rs+ rs- swb vcc sw -vout as -vout +vout vcc va pgnd pgndp sgndp sgndp sgnd pgnd sgnd pgnd sgnd sgnd pgnd fg pt- pss sss sync ith sgnd sgndp sgndp vcc clamp ag ag1 size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 12 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit revision history description date approved eco rev david b. production 2 10-29-14 __ revision history description date approved eco rev david b. production 2 10-29-14 __ revision history description date approved eco rev david b. production 2 10-29-14 __ r137 0 r137 0 q12 bsc028n06ns3 q12 bsc028n06ns3 4 5 2 3 6 7 8 1 r52 3.0 1206 r52 3.0 1206 c5 100v 4.7uf c5 100v 4.7uf r122 0 r122 0 r111 0 r111 0 c10 2.2nf 630v 1206 c10 2.2nf 630v 1206 r146 0 r146 0 c34 22uf 16v c34 22uf 16v r106 opt r106 opt c119 1nf c119 1nf fcx491a q27 fcx491a q27 1 3 2 r151 100 r151 100 + c31 150uf 16v + c31 150uf 16v q15 bsc028n06ns3 q15 bsc028n06ns3 4 5 2 3 6 7 8 1 r138 opt r138 opt r147 opt r147 opt r69 46.4k r69 46.4k r101 100 r101 100 r148 100 r148 100 t2 trans-pa3493nl t2 trans-pa3493nl 3 1 6 4 ltc3766egn u2 ltc3766egn u2 ith 7 fg 2 sw 23 fb 6 gnd 14 is+ 18 is- 17 sg 1 vcc 28 pt+ 26 pt- 25 regsd 16 fs/sync 15 ss 9 mode 4 pgnd 27 vin 22 ndrv 21 ipk 10 phase 5 vs+ 12 vs- 13 vsout 11 run 8 fgd/swb 20 vsec 3 sgd 19 vaux 24 + c23 opt + c23 opt c102 0.1uf c102 0.1uf q24 opt q24 opt 4 5 2 3 6 7 8 1 c105 0 c105 0 t3 ct02-100 t3 ct02-100 1 2 3 4 c69 1.5nf 630v c69 1.5nf 630v q11 opt q11 opt 4 5 2 3 6 7 8 1 q14 bsc028n06ns3 q14 bsc028n06ns3 4 5 2 3 6 7 8 1 d34 es1pd d34 es1pd j3 j3 c73 1nf c73 1nf e4 - e4 - c76 3.3nf c76 3.3nf r107 opt r107 opt q31 opt q31 opt 1 3 2 r68 2.15k r68 2.15k d27 zhcs506 d27 zhcs506 1 3 e6 e6 r115 0 1/4w r115 0 1/4w r127 opt 1/4w r127 opt 1/4w r124 0 r124 0 c3 4.7uf 100v c3 4.7uf 100v c74 0 c74 0 r117 12.7k r117 12.7k d40 1n4148ws d40 1n4148ws 1 2 e1 +vin e1 +vin c72 0.1uf c72 0.1uf c55 1nf c55 1nf + c1 33uf 80v + c1 33uf 80v r8 0 r8 0 q29 irf6217 q29 irf6217 4 1 5 2 3 6 7 8 r139 26.7k r139 26.7k c6 4.7uf 100v c6 4.7uf 100v e2 -vin e2 -vin j4 j4 r77 0 r77 0 r103 0 r103 0 q13 bsc028n06ns3 q13 bsc028n06ns3 4 5 2 3 6 7 8 1 + c22 33uf 80v + c22 33uf 80v + c26 + c26 c9 opt c9 opt r49 0 r49 0 c66 47nf 200v 1206 c66 47nf 200v 1206 r42 1k r42 1k r7 0 0603 r7 0 0603 q8 bsc190n15ns3 q8 bsc190n15ns3 4 5 2 3 6 7 8 1 t1 ltcp26-0402 t1 ltcp26-0402 12 6 9 2 14 8 10 13 3 5 c75 100pf c75 100pf r6 0 0603 r6 0 0603 q23 opt q23 opt 4 5 2 3 6 7 8 1 r119 opt r119 opt r41 11.5k r41 11.5k c111 opt c111 opt r4 8.2k 2512 r4 8.2k 2512 r18 102k r18 102k r24 8.2 1206 r24 8.2 1206 r149 100 r149 100 c80 1nf c80 1nf r29 100k r29 100k r108 opt r108 opt r114 28.7k r114 28.7k q3 opt q3 opt 3 1 2 r113 0 r113 0 c103 opt c103 opt r23 8.2 1206 r23 8.2 1206 r118 681k r118 681k r51 3.0 1206 r51 3.0 1206 r84 1.21k r84 1.21k c71 1uf 16v c71 1uf 16v r123 118k r123 118k + c68 150uf 16v + c68 150uf 16v d30 zhcs506 d30 zhcs506 1 3 r121 133k r121 133k c30 2.2nf 250v c30 2.2nf 250v r126 opt r126 opt r46 604 r46 604 c11 15nf c11 15nf d1 es1pd d1 es1pd 1 2 l2 2.0uh l2 2.0uh r109 10k r109 10k c8 opt c8 opt r3 opt r3 opt c77 4.7uf c77 4.7uf r116 opt 1206 r116 opt 1206 d28 opt d28 opt 1 3 c101 220pf c101 220pf LTC3765emse u1 LTC3765emse u1 ndrv 14 vcc 3 pg 2 in+ 15 in- 16 run 12 ag 4 delay 6 is- 7 gnd 17 is+ 8 fs/uv 10 ssflt 13 pgnd 1 gnd2 9 rcore 11 ismag 5 r112 0 r112 0 c79 4.7nf c79 4.7nf r125 17.4k r125 17.4k r110 1.20 1206 r110 1.20 1206 r1 0.33 2512 r1 0.33 2512 r76 4.22 r76 4.22 r75 215 r75 215 + c25 + c25 e3 + e3 + l1 1.0uh l1 1.0uh r43 opt r43 opt c106 150pf 200v c106 150pf 200v c113 33nf c113 33nf q28 fdc2512 q28 fdc2512 3 4 1 2 5 6 c78 33nf c78 33nf c51 470pf 630v 1206 c51 470pf 630v 1206 + c7 150uf 16v + c7 150uf 16v r5 opt 2512 r5 opt 2512 r102 0 1225 r102 0 1225 r140 274 1/8w r140 274 1/8w d29 zhcs506 d29 zhcs506 1 3 c70 3.3nf c70 3.3nf c112 0.22uf 200v c112 0.22uf 200v c4 100v 4.7uf c4 100v 4.7uf r136 0.005 1225/2512 r136 0.005 1225/2512 r10 opt 2512 r10 opt 2512 r2 opt r2 opt r53 6.8 1206 r53 6.8 1206 e5 e5 l3 3.3uh l3 3.3uh r22 3.74k r22 3.74k r120 opt r120 opt c118 1.5nf c118 1.5nf r150 14.3k r150 14.3k q9 bsc190n15ns3 q9 bsc190n15ns3 4 5 2 3 6 7 8 1 r9 0 r9 0 e7 e7 c2 4.7uf 100v c2 4.7uf 100v + c33 150uf 16v + c33 150uf 16v c24 1uf 16v c24 1uf 16v dc2199aafa demo manual dc2199a-a
11 information furnished by linear technology corporation is believed to be accurate and reliable. however, no responsibility is assumed for its use. linear technology corporation makes no representa- tion that the interconnection of its circuits as described herein will not infringe on existing patent rights. schematic diagram full schematic, page 2 5 5 4 4 3 3 2 2 1 1 d d c c b b a a optional circuits active snubber vcc from t1 ac driver peak charge vcc ith- hd2x7-molex ag ag1 vccp sw fg vcc rs- vaux va pgnd pgnd va sw +vout vpk va sgnd pt- pss sss ith sync vs+ vs- pgndp pgndp pgndp rs- sgndp clamp ag ag1 size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 22 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 22 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit size date: ic no. rev. sheet of title: approvals pcb des. app eng. technology fax: (408)434-0507 milpitas, ca 95035 phone: (408)432-1900 1630 mccarthy blvd. ltc confidential-for customer use only customer notice linear technology has made a best effort to design a circuit that meets customer-supplied specifications; however, it remains the customer's responsibility to verify proper and reliable operation in the actual application. component substitution and printed circuit board layout may significantly affect circuit performance or reliability. contact linear technology applications engineering for assistance. this circuit is proprietary to linear technology and schematic supplied for use with linear technology parts. scale = none www.linear.com 2 wednesday, october 29, 2014 22 active clamp forward converter lt david b. n/a LTC3765emse / ltc3766egn dc2199a with direct flux limit j1 opt j1 opt 5 5 8 8 1 1 2 2 3 3 4 4 7 7 6 6 14 14 13 13 12 12 11 11 10 10 9 9 pt- pt- q4 fqd4p25 q4 fqd4p25 d2 opt d2 opt 1 2 r33 opt r33 opt c17 15nf 200v 1206 c17 15nf 200v 1206 r26 opt r26 opt sync sync r28 opt r28 opt r13 6.8 2512 r13 6.8 2512 vs- vs- c116 opt 1206 c116 opt 1206 d37 opt d37 opt 1 3 c16 56pf c16 56pf c114 opt 0805 c114 opt 0805 r11 1.00k r11 1.00k c13 10pf c13 10pf c12 47pf c12 47pf c21 opt 0805 c21 opt 0805 sss sss r30 opt r30 opt pss pss l4 opt l4 opt r12 4.99k r12 4.99k c18 opt c18 opt r14 6.8 2512 r14 6.8 2512 r32 opt r32 opt r27 opt r27 opt r17 100k 1206 r17 100k 1206 d35 opt d35 opt 1 2 ith ith d38 opt d38 opt 1 3 c19 opt c19 opt c15 0.1uf 0805 c15 0.1uf 0805 r19 1.5k r19 1.5k ith- ith- r25 opt r25 opt vs+ vs+ r31 opt r31 opt c20 0.1uf c20 0.1uf r152 opt 0805 r152 opt 0805 d4 opt d4 opt 1 2 r34 opt r34 opt c14 0.1uf c14 0.1uf r15 6.8 2512 r15 6.8 2512 sgndp sgndp q1 zxgd3002e6 q1 zxgd3002e6 2 3 1 6 4 5 r35 opt r35 opt q2 opt q2 opt 2 3 1 6 4 5 hef4528bt u3 so16 hef4528bt u3 so16 res 3 vss2 15 vdd 16 a1 4 vss1 8 vss 1 b1 5 crx 2 q1 7 dc2199aafa demo manual dc2199a-a
12 linear technology corporation 1630 mccarthy blvd., milpitas, ca 95035-7417 (408) 432-1900 fax : (408) 434-0507 www.linear.com linear technology corporation 2014 lt 1114 rev a ? printed in usa demonstration board important notice linear technology corporation ( lt c ) provides the enclosed product(s) under the following as is conditions: this demonstration board ( demo board) kit being sold or provided by linear technology is intended for use for engineering development or evaluation purposes only and is not provided by lt c for commercial use. as such, the demo board herein may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety measures typically found in finished commercial goods. as a prototype, this product does not fall within the scope of the european union directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations. if this evaluation kit does not meet the specifications recited in the demo board manual the kit may be returned within 30 days from the date of delivery for a full refund. the foregoing warranty is the exclusive warranty made by the seller to buyer and is in lieu of all other warranties, expressed, implied, or statutory, including any warranty of merchantability or fitness for any particular purpose. except to the extent of this indemnity, neither p arty shall be liable to the other for any indirect, special, incidental, or consequential damages. the user assumes all responsibility and liability for proper and safe handling of the goods. further, the user releases lt c from all claims arising from the handling or use of the goods. due to the open construction of the product, it is the users responsibility to take any and all appropriate precautions with regard to electrostatic discharge. also be aware that the products herein may not be regulatory compliant or agency certified (fcc, ul, ce, etc.). no license is granted under any patent right or other intellectual property whatsoever. lt c assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind. lt c currently services a variety of customers for products around the world, and therefore this transaction is not exclusive. please read the demo board manual prior to handling the product . persons handling this product must have electronics training and observe good laboratory practice standards. common sense is encouraged. this notice contains important safety information about temperatures and voltages. for further safety concerns, please contact a lt c applica- tion engineer. mailing address: linear technology 1630 mccarthy blvd. milpitas, ca 95035 copyright ? 2004, linear technology corporation dc2199aafa demo manual dc2199a-a

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