LTC1922-1
19
where:
C
OSS
= MOSFET D-S capacitance
l
MAG
= magnetizing inductance
f
SW
= switching frequency
D = duty cycle
L
L
= leakage inductance
For a 48V to 3.3V/5V, 200W converter, the following
values were derived:
f
SW
: 300kHz
L
MAG
: 100µH
L
COM
: 0.9µH
L
OUT
: 2.2µH
Turns Ratio (N) = 2.5
Output Capacitors
Output capacitor selection has a dramatic impact on ripple
voltage, dynamic response to transients and stability.
Capacitor ESR along with output inductor ripple current
will determine the peak-to-peak voltage ripple on the
output. The current doubler configuration is advanta-
geous because it has inherent ripple current reduction.
The dual output inductors deliver current to the output
capacitor 180 degrees out of phase, in effect, partially
canceling each other’s ripple current. This reduction is
maximized at high duty cycle and decreases as the duty
cycle reduces. This means that a current doubler con-
verter requires less output capacitance for the same
performance as a conventional converter. By determining
the minimum duty cycle for the converter, worse-case
V
OUT
ripple can be derived by the formula given below.
V I ESR
V ESR
Lf
DD
ORIPPLE RIPPLE
O
OSW
==
••
(– )(– )
2
112
where:
D = minimum duty cycle
f
SW
= oscillator frequency
L
O
= output inductance
ESR = output capacitor series resistance
The amount of bulk capacitance required is usually system
dependent, but has some relationship to output induc-
tance value, switching frequency, load power and dynamic
load characteristics. Polymer electrolytic capacitors are
the preferred choice for their combination of low ESR,
small size and high reliability. For less demanding applica-
tions, or those not constrained by size, aluminum electro-
lytic capacitors are commonly applied. Most
DC/DC converters in the 100kHz to 300kHz range use 20µF
to 25µF of bulk capacitance per watt of output power.
Converters switching at higher frequencies can usually
use less bulk capacitance. In systems where dynamic
response is critical, additional high frequency capacitors,
such as ceramics, can substantially reduce voltage tran-
sients,
Power converter stability is, to a large extent, determined
by the choice of output capacitor. A zero in the converter’s
transfer function is given by 1/(2π • ESR • C
O
). Aluminum
electrolytic ESR is highly variable with temperature, in-
creasing by about 4× at cold temperatures, making the
ESR zero frequency highly variable. Polymer electrolytic
ESR is essentially flat with temperature. This characteris-
tic simplifies loop compensation and allows for a much
faster responding power supply compared to one with
aluminum electrolytic capacitors. Specific details on loop
compensation are given in the Compensation section of
the data sheet.
Power MOSFETs
The full-bridge power MOSFETs should be selected for
their R
DS(ON)
and BV
DSS
ratings. Select the lowest BV
DSS
rated MOSFET available for a given input voltage range
leaving at least a 20% voltage margin. Conduction losses
are directly proportional to R
DS(ON)
. Since the full-bridge
has two MOSFETs in the power path most of the time,
conduction losses are approximately equal to:
2 • R
DS(ON)
• I
2
, where I = I
O
/2N
Switching losses in the MOSFETs are dominated by the
power required to charge their gates, and turn-on and
turn-off losses. At higher power levels, gate charge power
is seldom a significant contributor to efficiency loss. ZVS
operation virtually eliminates turn-on losses. Turn-off
losses are reduced by the use of an external drain to source
OPERATIO
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LTC1922-1
20
snubber capacitor and/or a very low resistance turn-off
driver. If synchronous rectifier MOSFETs are used on the
secondary, the same general guidelines apply. Keep in
mind, however, that the BV
DSS
rating needed for these can
be greater than V
IN(MAX)
/N, depending on how well the
secondary is snubbed. Without snubbing, the secondary
voltage can ring to levels far beyond what is expected due
to the resonant tank circuit formed between the secondary
leakage inductance and the C
OSS
(output capacitance) of
the synchronous rectifier MOSFETs.
Switching Frequency Selection
Unless constrained by other system requirements, the
power converter’s switching frequency is usually set as
high as possible while staying within the desired efficiency
target. The benefits of higher switching frequencies are
many including smaller size, weight and reduced bulk
capacitance. In the full-bridge phase shift converter, these
principles are generally the same with the added compli-
cation of maintaining zero voltage transitions, and there-
fore, higher efficiency. ZVS is achieved in a finite time
during the switching cycle. During the ZVS time, power is
not delivered to the output; the act of ZVS reduces the
maximum available duty cycle. This reduction is propor-
tional to maximum output power since the parasitic ca-
pacitive element (MOSFETs) that increase ZVS time get
larger as power levels increase. This implies an inverse
relationship between output power level and switching
frequency. Table 1 displays recommended maximum
switching frequency vs power level for a 30V/75V in to
3.3V/5V out converter. Higher switching frequencies can
be used if the input voltage range is limited, the output
voltage is lower and/or lower efficiency can be tolerated.
Table 1.Switching Frequency vs Power Level
<50W 600kHz
<100W 450kHz
<200W 300kHz
<500W 200kHz
<1kW 150kHz
<2kW 100kHz
Closing the Feedback Loop
Closing the feedback loop with the full-bridge converter
involves identifying where the power stage and other
system poles/zeroes are located and then designing a
compensation network around the converters error ampli-
fier to shape the frequency response to insure adequate
phase margin and transient response. Additional modifi-
cations will sometimes be required in order to deal with
parasitic elements within the converter that can alter the
feedback response. The compensation network will vary
depending on the load current range and the type of output
capacitors used. In isolated applications, the compensa-
tion network is generally located on the secondary side of
the power supply, around the error amplifier of the
optocoupler driver, usually an LT1431or equivalent. In
nonisolated systems, the compensation network is lo-
cated around the LTC1922-1’s error amplifier.
In current mode control, the dominant system pole is
determined by the load resistance (V
O
/I
O
) and the output
capacitor 1/(2π • R
O
• C
O
). The output capacitors ESR
1/(2π • ESR • C
O
) introduces a zero. Excellent DC line and
load regulation can be obtained if there is high loop gain at
DC. This requires an integrator type of compensator
around the error amplifier. A procedure is provided for
deriving the required compensation components. More
complex types of compensation networks can be used to
obtain higher bandwidth if necessary.
Step 1. Calculate location of minimum and maximum
output pole:
F
P1(MIN)
= 1/(2π • R
O(MAX)
• C
O
)
F
P1(MAX)
= 1/(2π • R
O(MIN)
• C
O
)
Step 2. Calculate ESR zero location:
F
Z1
= 1/(2π • R
ESR
• C
O
)
Step 3. Calculate the feedback divider gain:
R
B
/(R
B
+ R
T
) or V
REF
/V
OUT
If Polymer electrolytic output capacitors are used, the ESR
zero can be employed in the overall loop compensation
and optimum bandwidth can be achieved. If aluminum
electrolytics are used, the loop will need to be rolled off
prior to the ESR zero frequency, making the loop response
OPERATIO
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LTC1922-1
21
slower. A linearized SPICE macromodel of the control loop
is very helpful tool to quickly evaluate the frequency
response of various compensation networks.
Polymer Electrolytic (see Figure 12) 1/(2πC
C
R
I
) sets a
low
frequency pole. 1/(2πC
C
R
F
) sets the low frequency
zero. The zero frequency should coincide with the worst-
case lowest output pole frequency. The pole frequency
and mid frequency gain (R
F
/R
I
) should be set such so that
the loop crosses over zero dB with a –1 slope at a
frequency lower than (f
SW
/8). Use a bode plot to graphi-
cally display the frequency response. An optional higher
frequency pole set by CP2 and R
f
is used to attenuate
switching frequency noise.
Aluminum Electrolytic (see Figure 12) the goal of this
compensator will be to cross over the output minimum
pole frequency. Set a low frequency pole with C
C
and R
IN
at a frequency that will cross over the loop at the output
pole minimum F, place the zero formed by C
C
and R
f
at the
output pole F.
Synchronous Rectification
The LTC1922-1 produces the precise timing signals nec-
essary to control current doubler secondary side synchro-
nous MOSFETs on OUTE and OUTF. Synchronous rectifi-
ers are used in place of Schottky or Silicon diodes on the
secondary side of the power supply. As MOSFET R
DS(ON)
levels continue to drop, significant efficiency improve-
ments can be realized with synchronous rectification,
provided that the MOSFET switch timing is optimized. An
additional benefit realized with synchronous rectifiers is
bipolar output current capability. These characteristics
improve transient response, particularly overshoot, and
improve ZVS ability at light loads.
Figure 12. Compensation for Polymer Electrolytic
Current Doubler
The current doubler secondary employs two output induc-
tors that equally share the output load current. The trans-
former secondary is not center-tapped. This configuration
provides 2× higher output current capability compared to
similarly sized single output inductor modules, hence the
name. Each output inductor is twice the inductance value
as the equivalent single inductor configuration and the
transformer turns ratio is 1/2 that of a single inductor
secondary. The drive to the inductors is 180 degrees out
of phase which provides partial ripple current cancellation
in the output capacitor(s). Reduced capacitor ripple cur-
rent lowers output voltage ripple and enhances the
capacitors’s reliability. The amount of ripple cancellation
is related to duty cycle (see Figure 13). Although the
current doubler requires an additional inductor, the induc-
tor core volume is proportional to LI
2
, thus the size penalty
is small. The transformer construction is simplified with-
out a center-tap winding and the turns ratio is reduced by
1/2 compared to a conventional full wave rectifier configu-
ration.
Figure 13. Ripple Current Cancellation vs Duty Cycle
Synchronous rectification of the current doubler second-
ary requires two ground referenced N-channel MOSFETs.
The timing of the LTC1922-1 drive signals is shown in the
Timing Diagram. Synchronous rectifier turn-on is inter-
nally delayed by the LTC1922-1 after OUT (C or D)
turn-off—just after the end of a power cycle. Synchronous
rectifier turn-off occurs coincident with OUT (A or B)
turn-off. This gives a passive transition time margin before
+
2.5V
R
f
R
L
R
D
ESR
REF
R
I
C
C
C
O
C
P2
V
OUT
COLL
COMP
OPTO
V
OUT
LT1431 OR EQUIVALENT
PRECISION ERROR
AMP AND REFERENCE
OPTIONAL
1922 F12
1
0
0 0.25 0.5
DUTY CYCLE
NORMALIZED
OUTPUT RIPPLE
CURRENT
ATTENUATION
1922 • F13
NOTE: INDUCTOR(S) DUTY CYCLE
IS LIMITED TO 50% WITH CURRENT
DOUBLER PHASE SHIFT CONTROL.
OPERATIO
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LTC1922IN-1#PBF

Mfr. #:
Manufacturer:
Analog Devices / Linear Technology
Description:
Switching Voltage Regulators Sync PhModulated Full-Bridge Cntr
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