UC3578

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UC3578 Telecom Buck Converter Mark Dennis Power Supply Control Products
ABSTRACT UC3578 controller with integrated high-side floating gate driver. used buck stepdown converters regulates positive-output voltage. Intended distributed power system, this device allows operation from 14-V 72-V input, which includes prevalent telecom voltages. output duty cycle UC3578 vary between operation over wide input voltage load conditions. This Reference Design describes simple solution buck converter operating from input with N-channel MOSFET switching transistor. Using this switch configuration requires gate potential higher than input source, generally requiring auxiliary supply transformer. UC3578 provides regulated floating gate drive voltage N-channel MOSFET that allows cost-effective design buck stepdown regulators with power levels tens watts. complete converter with schematic, bill materials, performance results presented produce 5-V, 35-W output from 48-V source. Contents Introduction Operation Thermal Considerations High Voltage Applications Comparison Input Supply Methods Summary References
SLUU095
Introduction
This reference guide describes simple solution buck converter operating from input with N-channel MOSFET switching transistor. Using this switch configuration requires gate potential higher than input source, generally requiring auxiliary supply transformer. UC3578 provides regulated floating gate drive voltage N-channel MOSFET that allows cost-effective design buck stepdown regulators with power levels tens watts. complete converter with schematic, bill materials, performance results presented produce 5-V, 35-W output from 48-V source. Distributed power systems have come into widespread communications related industries over last decade. these systems electrical power distribution network been changed from central power supply with cables busses number smaller power processing units which placed throughout host system. usual intent bring power processing closer subsystems where power used. advantages distributed power delineated Distributed Power Systems[1], along with much information distributed power architectures applications. However, cost modules historically been relatively high compared design solutions using discrete components. This Reference Design introduces UC3578 integrated circuit highlights 48-V buck regulator. Utilizing this approach results 35-W converter that fraction cost comparable module. UC3578 used simplify design single switch buck converter incorporating floating high-side driver that allows external N-channel MOSFET switch. bipolar manufacturing process allows operation from prevalent voltage 48-Vdc, with allowable inputs 72-Vdc. Higher output current possible because there preset internal switch current limit used control devices that incorporate onboard switch. These options allow user configure low-cost high-power buck regulator suitable many applications.
UC3578 Telecom Buck Converter
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UC3578 EAOUT EAINV VOUT VOUT
DIODE
UDG-99054
Figure UC3578 Typical Application
Operation
Specifications.
This reference design featuring UC3578 been developed illustrate capabilities UC3578. design targeted telecom converter market following specifications:
(nominal) 38.4 57.6 VOUT Output ripple, IOUT POUT
UC3578 Telecom Buck Converter Reference Design
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Schematic
schematic diagram telecom buck converter meeting these specifications shown Figure components perform power handling tasks. serves filter handle input ripple current. UC3578 provides control circuitry orderly startup, switch protection, regulation, high-side power MOSFET drive. These functions discussed detail following sections, along with selection power components. Alternate components shown schematic used evaluate circuit options described Section 4.2, Resistive Current Sense Applications. further information UC3578 specifications, consult datasheet Literature SLUS341) contact Product Infromation Center.
2.3.1
Circuit Description UC3578 Housekeeping Control Circuits
Undervoltage lockout (UVLO) employed disable device operation until reaches exhibits hysteresis. After UVLO threshold exceeded, soft-start cycle initiated with 45-µA charging current supplied capacitor When soft-start reaches approximately narrow soft-start pulses begin appear output, increasing width until reaches internal oscillator fixed kHz, frequency that proven good compromise between small size efficiency. internal architecture UC3578 configured voltage-mode control. onboard error amplifier voltage amplifier with non-inverting input tied internal reference. Resistors form voltage divider provide feedback information inverting terminal, Control loop compensation components used shape overall closed loop response.
2.3.2
Gate Drive Circuit
Gate-drive power provided voltage which charged through when switch off, freewheel diode conducting. Circuitry internal UC3578 regulates Vdc. When applied gate turning source flies close VIN, carrying floating driver with During switch on-time, prevents from discharging into VIN. Resistor serves purposes. First, adds damping circuit formed trace inductance switch gate-to-source capacitance. Second, serves limit current flow into substrate device when node (pin driven below ground when begins conduction. essential that Schottky diode that pulled more than below ground. snubber consisting also placed across reduce high-frequency ringing.
2.3.3
Current Limiting Circuitry
associated circuitry sense input current between drain switch UC3578 current sense input, -0.5-V threshold with respect VCC, chosen develop this signal when current limit threshold reached. Under full load conditions, input current during on-time reaches peak plus one-half ripple current. This normal peak current 0.875 7.875 Headroom least allowed transient conditions current-limit trip point peak current selection burden resistor current transformer calculated:
UC3578 Telecom Buck Converter
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Circuit delays device cause effective (leading edge blanking) period approximately before circuit responds overcurrent condition. This allows suppression leading-edge spikes from rectifier ringing and/or inductive effects sensing circuit. When desired current-limit point reached, UC3578 discharges soft-start capacitor initiates soft-restart cycle minimize fault power. Components have been included form high-frequency filter reduce switching noise that reaches current limit comparator.
2.4.1
Power Circuit Design Power Switch
UC3578 integrated high-side driver allows user benefit from conduction losses lower prices N-channel MOSFET compared P-channel device. telecom buck converter, must block full input voltage every cycle, voltage rating must greater than 57.6 Since ratings MOSFETs generally step from select member IRF520, IRF530, IRF540 family which rated This requires estimation conduction switching losses following guidelines reference [2].
2.4.2
Duty Cycle
order estimate size heatsink required duty cycle must determined. simplified transfer function ideal buck regulator given where duty cycle power switch Reference presents more detailed equation derived from volt-second balance across output inductor during switch times. Comparison between these methods yields values shown Table Table Duty Cycle Comparison
Line 38.4 ideal realistic 13.0% 15.3% Nominal Line 10.4% 12.2% High Line 57.6 8.7% 10.0%
These results show error approximately between calculations.
2.4.3
IRF520, IRF530, IRF540 Comparison
three candidate MOSFETs could handle peak continuous current required buck telecom application. order choose best this example, total power loss calculated following procedures using realistic duty cycles found above. Graphs presented show power loss watts) versus switching frequency low-, nominal-, high-line conditions Figures three cases IRF530 yielded lowest approximate losses best choice telecom converter. IRF540 losses were higher cases because large switching losses. line IRF520 losses grew because increasing conduction losses.
UC3578 Telecom Buck Converter
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There several available heatsinks that have 40°C rise with power dissipation. This decision made depending form factor application availability lack forced air.
POWER LOSS SWITCHING FREQUENCY LINE
IRF540 Power IRF530 Switching Frequency Power IRF520 IRF520 IRF530 IRF540
POWER LOSS SWITCHING FREQUENCY NOMINAL LINE
Switching Frequency
Figure
POWER LOSS SWITCHING FREQUENCY HIGH LINE
Power IRF530 IRF520 IRF540
Figure
Switching Frequency
Figure
UC3578 Telecom Buck Converter
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2.4.4
Diode
Schottky diode used carry freewheeling current, should have voltage rating larger than maximum input voltage with safety margin. power dissipation approximately W[2]. Since range 57.6 this application 100-V Schottky diode specified, MBR10100[5]. same heatsink specified Q1is also used
Output Inductor Selection
output filter buck regulator optimized around many parameters. These include transient response, output ripple voltage, physical size, temperature rise, other factors including availability cost parts. This design been undertaken with goal obtaining good electrical performance using commercially available parts. Setting ripple current circuit full load current results ripple current 1.75 Using basic inductor equation:
which, when rearranged find inductance substituting appropriate values, yields minimum inductor value: (38.2 1.75 ON(max)
1.44
Several vendors list inductors this range which capable handling order have inductance over full load, load inductance considerably higher. Many available choices based cost powdered iron that have soft saturation characteristic current varied from minimum maximum. this case inductor value decreases load current increases. designer must ensure that full-load inductor value known predict ripple voltage output. winding resistance inductor generally noted, order power loss calculated. Part #CTX50-5-52, rated selected this example. series resistance 0.021 inductance least 32.5
2.5.1
Choosing Output Capacitor
output capacitor choice strongly affect regulator size cost. battery charger Application Note, Implementing Multi-State Charge Algorithm with UC3909 Switchmode Lead-Acid Battery Charger Controller[2], output capacitor selected ability handle inductor ripple current provide filtering absence battery. Output ripple voltage transient capability were major concern because battery swamps effect output filter capacitor. buck regulators that drive sensitive electronic loads, ripple voltage transient capability become major factors choosing output capacitors, along with ripple current capability. ensure margin specification compliance, output voltage ripple calculations made using 37.5 limit, which 50-mV requirement. Equation from Magnetics Definitions Equations[6] allows calculation ripple current flowing through output capacitor.
UC3578 Telecom Buck Converter
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1.75 0.505 3.46
capacitors were ideal parasitic resistance inductance, equation would define capacitance needed carry specified amount ripple current with stated voltage ripple fixed frequency: 1.75 58.3 0.0375
real applications, capacitor plays major role determining output ripple voltage. this example, calculate maximum allowed stay within ripple voltage specification using ripple current calculated with inductance 32.5 0.0375 output capacitor chosen must have following attributes:
voltage rating greater than ripple current capability over 0.505A minimum value 58.3 below temperatures interest
options available designer follows:
Bulk capacitance: more capacitors from three applicable classes (Aluminum Electrolytic, Tantalum, Organic Semiconductor) meet minimum capacitance maximum requirements. capacitors handle inductor ripple current then secondary filter meet output voltage ripple requirements.
Table shows electrical parameters normalized costs various capacitor technologies that candidates output filter this 100-kHz buck converter. cost figures were taken quantity 1000 pieces through normal distribution channels. total cost factor based number capacitors needed parallel reach goal this example, Total Cost Factor assigned 2200-µF aluminum electrolytic capacitors. ripple current over capacitor types mentioned, specific ratings given. evident that these choices reveal severe tradeoffs between cost size buck converter. Option incorporating secondary ripple filter, investigated this presentation. Table Capacitor Technology Comparison
MANUFACTURER Panasonic Sanyo PART NUMBER Series ECA-OJFQ222[7] Series 6SA330M[8] Series TPSE337M006R0100[9] TYPE Tantalum VOLTAGE VALUE 2200 0.042 0.025 0.100 TOTAL COST FACTOR 1.00 1.45 8.70
UC3578 Telecom Buck Converter
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Another factor worthy mention pertains transient loads that power supply subjected application. Solutions that utilize smaller capacitance values have larger transient deviations because these load changes must propagate through L1-C6 output filter. larger capacitor would have more stored energy supply load while inductor current climbs larger value load current. telecom buck converter incorporates aluminum electrolytic output capacitors minimize costs while providing large value reservoir capacity handle load transients. comparison, design also configured stabilized with capacitor demonstrate smallest practical size solution.
2.6.1
Control Loop Stability Considerations Aluminum Electrolytics
UC3578 circuit design, filter components have been chosen follows: Output capacitors C6A,C6B: Output inductor total 4400 approximately 0.021 32.5 rating
These values allow designer calculate output corner frequency 4400 32.5
capacitor ESR, Figure output filter capacitors contribute power circuit zero frequency
RESR VOUT
COUT
Figure Output Filter with RESR Bode Plot.
gain falls with slope after filter resonance, this converted slope frequency where capacitor equals capacitive impedance, This slope continues through desired unity gain crossover frequency, FCO, kHz. UC3578 error amplifier should tailored have flat gain this region maintain slope stable operation (see Closing Feedback Loop[10]), this achieved shown Figure using amplifier (see Practical Techniques Analyzing, Measuring, Stabilizing Feedback Control Loops Switching Regulators Converters[11]) with zero-pole pair.
UC3578 Telecom Buck Converter
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REF=2V
Figure Error Amplifier with Zero-Pole Pair
This amplifier configuration been fully analyzed Practical Techniques Analyzing, Measuring, Stabilizing Feedback Control Loops Switching Regulators Converters[11] yield pole origin that sets initial slope, zero C2), pole C3). zero turns gain slope from before unity gain crossover frequency reached, pole turns slope from roll gain high frequencies. summary circuit component selections given Table
2.6.2
OSCON Capacitors
circuit also built using OSCON output capacitor. Output capacitor: Output inductor: 0.025W 32.5
This yielded output corner frequency (10)
OSCON capacitor circuit zero 19.3 beyond crossover frequency 12.5 kHz, output filter characteristic exhibits slope throughout this region, shown Figure
RESR SMALL
Figure Output Filter with Negligible RESR
UC3578 Telecom Buck Converter
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this situation error amplifier must provide slope during crossover region convert overall loop slope This requires amplifier with pole-zero pairs with schematic characteristic shown Figure
REF=2V
Figure Error Amplifier with Pole-Zero Pairs
Table Control Loop Configuration Comparing Aluminum Electrolytic Capacitors OSCON Capacitors
CONFIGURATION COMPONENT ALUMINUM ELECTROLYTIC CAPACITORS 1.81 1.54 2000 (used used used 8.25 OSCON CAPACITOR 19.3 12.5 Origin 19.3 69.8 46.4
Filter cutoff, zero, Modulator gain Sampling gain Crossover frequency chosen, Error amplifier gain Error amplifier zero frequency Error amplifier zero frequency Error amplifier zero frequency Error amplifier pole Error amplifier pole Error amplifier pole
UC3578 Telecom Buck Converter
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2.6.3
Output Capacitor Summary
UC3578 could implemented with various output capacitor technologies. aluminum provide lowest cost solution with good transient response large bulk capacitance. OSCON family provides smallest solution with acceptable transient response higher cost. Both versions implemented stabilized evaluation board; left designer determine best configuration particular application.
Thermal Considerations High-Voltage Applications
UC3578 voltage regulator able operate from input voltage range Vdc. However, thermal considerations play limiting role application UC3578 device supply voltage increased. package rating information allows calculation junction temperature rise various power dissipation levels. example, 16-pin SOIC power lead frame thermal resistance 58°C/W square inch board with one-ounce copper. maximum allowable power 70°C calculates (150 1.38 (11)
16-pin plastic batwing package, allowable power 70°C. 150°C, power dissipation allowed, 70°C differences between packages shown Figure Operation permitted only left line representing particular package; right, maximum junction temperature exceeded. Reliability enhanced operating point moved farther left from line. application using package, input supply voltage limited approximately because power dissipation (approximately device package. becomes obvious that using UC3578 48-Vdc input application find dissipate excess bias power external control device. Methods accomplish this presented this application note.
Bias Current Components
this point appropriate discuss three components bias currents feeding circuit; namely IVCC, IVGG, IGATE. IVCC quiescent current drawn power entire chip except floating gate driver VGG. Current IVGG supplies driver section quiescent current through external diode. current needed drive external MOSFET, IGATE, supplied through external diode regulator. power related IVCC IVGG dissipated internally UC3578, however, this case IGATE. only power loss internal device IGATE comes from conduction totem pole driver section while MOSFET gate being charged discharged. IGATE varies with choice power MOSFET used buck switch. IRF530 selected minimize heatsink size needed circuit layout. total gate charge, which must supplied drive this device, 26nC (see HEXFET Power MOSFET Designer's Manual[4]). This requires current GATE (12)
VBIAS this represents power loss 36-mW, only small portion this dissipated integrated circuit. This loss small comparison that IVCC IVGG included calculations junction temperature device.
UC3578 Telecom Buck Converter
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Maximum specifications IVCC IVGG given Power Management Products Data Book Literature SLUD003) IVCC(max) IVGG(max) 10.5 varies with temperature given Figure 48-Vdc circuit, goal regulate increases. This reduces power dissipated UC3578 levels which allow operation with reasonable maximum junction temperature.
ALLOWABLE POWER DISSIPATION
TEMPERATURE
SUPPLY CURRENT TEMPERATURE
Supply Current
BATWING PACKAGE
Power
PACKAGE
Ambient Temperature
-100
Ambient Temperature
Figure
Figure
Comparison Input Supply Methods
methods considered limit voltage available supply bias power UC3578.
Series dropping resistor voltage regulator
series resistor utilized lowest cost applications works best when supply voltage variation relatively small. resistor must sized allow maximum required current minimum input voltage. this case IN(min) GATE 38.4 10.5 (13)
Note that IGATE included because associated voltage must dropped resistor even though very little this power dissipated device. input increased VIN(max) 57.6 drop across RLIM remains essentially constant because increase seen with higher offset decrease higher junction temperature.
UC3578 Telecom Buck Converter
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R(LIM)
27.1
22.2
(14)
IN(max)
R(LIM)
57.6 22.2 35.4
(15)
UC3578 power dissipation 35.4 24.5 0.87 (16)
high calculate UC3578 temperature rise 0.87 43.5 (17)
This significant improvement over datasheet example which limited
Input Voltage Regulator
voltage regulator Figure consists 16-V zener diode connected from base ground, bias voltage emitter regulated diode drop below zener, approximately selected bring into conduction also provide base current power MOSFET could also used increasing zener diode value offset drop gate-to-source threshold voltage. current regulator chosen this application because level supplied chip would vary changes with temperature, possibly necessitating addition second zener clamp fixed level. Under these conditions with power dissipated device 24.5 0.37 (18)
With this power dissipation, junction temperature rise 0.37 18.5 (19)
This allows room increase maximum ambient temperature full industrial range raise allowable range upward 72-Vdc(max), long junction temperature allowable power dissipation monitored. Keep mind that bias voltage regulator should sized handle power 57.6
UC3578 Telecom Buck Converter
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Resistive Current Sense Applications
Alternate circuits that UC3578 lower input voltages and/or reduced ambient temperatures often able current-sense resistor place current transformer. this case, filter formed more critical provide clean waveform because there current transformer with associated filtering action reduce noise produced during switching operation. circuit resistive current-sense application, configure circuit follows: Remove Components CT1, Populate Components
selected produce when input current limiting reached current limit activation level. value jumper current-sense signal into filter components also low-value jumper provide bias directly device from VIN.
Other Considerations
UC3578 capable operating duty-cycle approximately Below this level, controller begins skip pulses maintain output desired value. Figure gives approximate versus calculated using ideal duty-cycle equation. This used give worst-case estimate because been shown that realistic duty cycle runs little longer than ideal duty-cycle because effect parasitic circuit components.
DUTY CYCLE OUTPUT VOLTAGE
0.35 0.30 0.25 Duty Cycle
VOUT
0.20 VOUT 0.15 0.10 VOUT VOUT
0.05 Supply Voltage
Figure
UC3578 Telecom Buck Converter
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Evaluation Board Performance
evaluation board built tested using parts list given. Typical efficiencies given Table operating conditions listed. Table Typical UC3578 Evaluation Board Efficiencies
SUPPLY VOLTAGE (VIN) SUPPLY CURRENT (IIN) 0.61 0.45 0.91 0.35 0.69 0.97 OUTPUT VOLTAGE (VOUT) 4.92 4.92 4.91 4.91 4.91 4.91 OUTPUT CURRENT (IOUT) INPUT POWER (WIN) 15.25 15.75 31.85 16.80 33.12 46.56 OUTPUT POWER (WOUT) 12.30 12.30 24.55 12.28 24.55 34.37 EFFICIENCY
load transient from applied evaluation board compare output capacitor configurations discussed stability section. Figure shows transient response with 2200-µF aluminum electrolytic capacitors installed. maximum undershoot Figure single 330-µF OSCON capacitor fitted place aluminum electrolytic capacitors. Noting that scales have changed, maximum undershoot near importance performance, cost, size tradeoffs must evaluated make most appropriate output capacitor selection.
TRANSIENT RESPONSE WITH 2200 ALUMINUM ELECTROLYTIC CAPACITORS TRANSIENT RESPONSE WITH SINGLE OSCON CAPACITOR
Figure
Figure
UC3578 Telecom Buck Converter
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Summary
UC3578 Buck Stepdown Voltage Regulator provides power supply designer with integrated circuit controller that incorporates floating high-side driver capable operating input voltages 72-Vdc. This Reference Design explains power losses associated with using this high-voltage device, suggests circuit configurations relieve thermal load. addition, circuit adapted evaluate resistive current sense versions making simple component changes.
UC3578 Telecom Buck Converter
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Table Evaluation Board List Materials
REFERENCE DESIGNATOR C1A, C6A,C6B C7,C10,C12 TB1, DESCRIPTION aluminum capacitor 2200 ceramic capacitor ceramic capacitor aluminum capacitor ceramic capacitor 2200 aluminum capacitor ceramic capacitor 0.01 ceramic capacitor ceramic capacitor ceramic capacitor text Current transistor, 100:1 switching diode zener diode, Schottky diode switching diode heatsink heatsink heatsink 10A, inductor 1/4W, resistor 1/4W, resistor 1/4W, resistor 1/4W, resistor 1/4W, resistor 1/4W resistor text 1/4W, resistor resistor 8.25 1/4W, resistor 5.62 1/4W, resistor text text text 0.16 N-channel, MOSFET transistor Buck stepdown voltage regulator Terminal block, position, spacing Texas Instruments IRF530 TIP47 UC3578N Thermalloy Thermalloy Aavid Coiltronics Magnetek Triad CST306-2A 1N4148 1N4745A MBR10100 1N4148 7020B-MT 7020B-MT 579302B00000 50-5-52 Panasonic ECA-OJFQ222 MANUFACTURER Panasonic PART NUMBER ECA-1JFQ221
UC3578 Telecom Buck Converter
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References
Mammano, Distributed Power Systems, Unitrode Power Supply Design Seminar SEM-900, Topic 1993. Laszlo Balogh, Implementing Multi-State Charge Algorithm with UC3909 Switchmode Lead-Acid Battery Charger Controller, Application Note Literature SLUA098) Larry Spaziani, UC3886 Controller Uses Average Current Mode Control Meet Transient Regulation Performance High Processors, Application Note Literature SLUA127) HEXFET Power MOSFET Designer's Manual, International Rectifier, 1993 Rectifier Device Data, Motorola, Q1/95 Unitrode SEM-700, Magnetics Definitions Equations, p.M2-3, M7-8 Digikey Catalog 975Q, Oct.-Dec. 1997, p244 Sanyo OS-CON Technical Book, Ver. Tantalum Capacitors Catalog Dixon, Closing Feedback Loop, Unitrode Power Supply Design Seminar Manual SEM-700, 1990. Dean Venable Stephen Foster, Practical Techniques Analyzing, Measuring, Stabilizing Feedback Control Loops Switching Regulators Converters, Proceedings Powercon Power Concepts, 1980. more complete information, descriptions specifications UC3578 Telecom Buck Converter, please refer UC3578 datasheet Literature SLUS341)
UC3578 Telecom Buck Converter
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