where:
DC = Duty cycle. Set to calculated minimum duty
cycle at V
MIN.
PWR
IN
= Input power, at maximum output power
This gives an inductance value (L
PRI
) of approxi-
mately 65µH.
5) The other parameter that defines the transformer is
peak current. This is given by:
The peak secondary current is the peak primary cur-
rent multiplied by the turns ratio, or 0.8A · 8 = 6.4A.
Calculating the minimum duty cycle:
With these numbers, the transformer manufacturer
can choose a core.
6) For this application, the MAX5003 must be pro-
grammed for a maximum duty cycle of 55% at 36V.
The MAX5003 will automatically scale the limit with
the reciprocal of the input voltage as it changes. The
duty-cycle limit for an input voltage of 72V will be
27% (half of 55%). The duty cycle needed to stay out
of continuous conduction at 72V is 37%, so there is a
10% margin. The maximum duty time scales with the
voltage at the undervoltage lockout pin, V
INDIV
. The
voltage at INDIV is set by selecting the power line
undervoltage lockout trip point. The trip point for this
system, running from 36V to 72V, is 32V. Then INDIV
must be connected to the center point of a divider
with a ratio of 32/1.25, connected between the
power line and ground. Then R
MAXTON
is:
R
V
V
kHz
DC V
k
V
V
kHz
kHz
kk
MAXTON
MIN
UVL SW
MAX MIN
=
ƒ
()
=
=
%
%
%
100
75
200
36
32
100
300
55
75
200 55
ΩΩ
DC DC
V
V
V
V
MIN MAX
IN MIN
IN MAX
() ( )
()
()
% =×=43
36
72
I
2 PWR
L
2 6.25W
65 H 300kHz
0.8A
PRI
IN
PRI SW
=
×
ƒ
==
×
×
×µ
MAX5003
High-Voltage PWM
Power-Supply Controller
______________________________________________________________________________________ 13
10µF
0.1µF
51k
1.3k
R
CS
0.1
0.1µF
0.1µF
470nF
62k
V+
INDIV
ES
FREQ
SS
REF
CON
COMP
8
7
6
5
4
3
2
1
9
10
11
12
13
14
15
16
V
DD
V
CC
NDRV
PGND
CS
AGND
MDC217
IRFD620S
L
P
65µH
MAXTON
FB
R2
39k
R1
1M
33µF
0.1µF
100
+5V
1A
-
51
680
240k
6
7
5
2
1
22µF
0.01µF
3900pF
24.9k
24.9k
TL431
4.7µF
22µF
MAX5003
V
IN
0V
XFACOILTRCTX03
CMSD4448
MBRS130L
8
2
5
7
9, 10
11, 12
-48V
-36V TO -72V
Figure 3. Application Example 2: Isolated -48V to +5V Converter
MAX5003
where:
R
MAXTON
= Resistor between the MAXTON pin and
ground
V
MIN
= Minimum power-line voltage
V
UVL
= Power-line trip voltage
DC
MAX
(V
MIN
) = Maximum duty cycle at minimum
power-line voltage
For this application circuit, a 10% margin is reason-
able, so the value used is 50k. This gives a maxi-
mum duty cycle of 50%. The maximum duty cycle
can now be expressed as:
where:
V
CON
= Voltage at the CON pin, input of the PWM
comparator
DC(V
CON
, V
IN
) = Duty cycle, function of V
CON
and
V
IN
0.5V and 2.5V are the values at the beginning and
end of the PWM ramp.
The term ƒ
SW
/ ƒ
NOM
varies from 0.8 to 1.2 to allow
for clock frequency variation. If the clock is running
at 300kHz and the input voltage is fixed, then the
duty cycle is a scaled portion of the maximum duty
cycle, determined by V
CON
.
7) Low-ESR/ESL ceramic capacitors were used in this
application. The output filter is made by two 22µF
ceramic capacitors in parallel. Normally, the ESR of
a capacitor is a dominant factor determining the rip-
ple, but in this case it is the capacitor value.
Calculating
the ripple will be a fraction of this depending on the
duty cycle. For a 50% duty cycle, the ripple due to
the capacitance is approximately 45mV.
8)The PWM gain can be calculated from:
Note that while the above formula incorporates the
product of the maximum duty cycle and V
IN
, it is
independent of V
IN
. For 1A output (R
L
= 5), the
PWM gain is +3.0V/V. For a 10% load (R
L
= 50),
the gain is multiplied by the square root of 10 and
becomes +10V/V. The pole of the system due to the
output filter is 1 / 2πRC, where R is the load resis-
tance and C the filter capacitor. Choosing a capaci-
tor and calculating the pole frequency by:
it is 723Hz at full load. At 10% load it will be 72Hz,
since the load resistor is then 50 instead of 5. The
total loop gain is equal to the PWM gain times the
gain in the combination of the voltage divider and
the error amplifier. The worst case for phase margin
is at full load. For a phase margin of 60 degrees, this
midband gain (G) must be set to be less than:
where:
ƒ
U
= Unity-gain frequency of error amplifier
PM = Phase margin angle
The DC accuracy of the regulator is a function of the
DC gain. For 1% accuracy, a DC gain of 20 is required.
Since the maximum midband gain for a stable
response is 16, an integrator with a flat midband gain
given by a zero is used. The midband gain is less than
16, to preserve stability, and the DC gain is much larger
than 20, to achieve high DC accuracy.
Optimization on the bench showed that a midband gain
of 5 gave fast transient response and settling with no
ringing. The zero was pushed as high in frequency as
possible without losing stability. The zero must be a
factor of two or so below the system unity-gain frequen-
cy (crossover frequency) at minimum load. With the
G
PM A
MHz
Hz
UErrorAmp
PWM P
tan( ) .
<
ƒ
×׃
=
××
1
1 7 3 723
ƒ=
××
=
×
×
P
LL
RC F
1
2
1
2544ππµ
A
dV
dV
R
2L
V
2.0V
R
2L
PWM
OUT
CON
L
PRI SW
MIN
L
PRI SW
==
×׃
=
×׃
.
%
(
DC
V
V
MAX VM
I
36
20
50 3
I
C
A
kHz F
mV
OUT
SW
ƒ×
=
×
=
1
300 44
76
µ
DC(V ,V ) =
V - 0.5V
2.0V
50%
DC(V ,V )
V - 0.5V
2.0V
25%
DC(2.5V,V ) 50%
DC(2.5V,V ) 25%
DC(0.5V,V ) 0
DC(0.5V,V ) 0
CON MIN
CON
CON MAX
CON
MIN
MAX
MIN
MAX
=
=
=
=
=
DC(V )
V - 0.5V
2.0V
V
V
DC
V - 0.5V
2.0V
36V
V
50%
CON,VIN
CON MIN
IN NOM
MAX(VMIN)
CON
IN
SW
NOM
=
ƒ
ƒ
×
ƒ
ƒ
SW
High-Voltage PWM
Power-Supply Controller
14 ______________________________________________________________________________________
zero at 2kHz, the crossover frequency is 4kHz and the
phase margin is 50°.
Given the above considerations, R
A
, R
B
, R
F
, and C
F
can be chosen (Figure 2). The sum of R
A
and R
B
is
chosen for low current drain. In the example, R
A
plus
R
B
is 58k and draws 80µA. The following ratio sets
the output voltage:
R
B
/ (R
A
+ R
B
) = V
SET
/ V
OUT
Since V
SET
= 1.5V and V
OUT
= 5V, R
A
is set to 41.2k
and R
B
to 17.4k.
The midband gain is the ratio of R
F
/R
A
. R
B
does not
affect the gain because it is connected to a virtual
ground. For a midband gain of 5, the feedback resistor
equals 200k. To set the zero at 2kHz, the capacitor
value is:
C
F
= 1 / (2π x R
F
x f
z
) = 400pF
Layout Recommendations
All connections carrying pulsed currents must be very
short, be as wide as possible, and have a ground plane
behind them whenever possible. The inductance of
these connections must be kept to an absolute mini-
mum due to the high di/dt of the currents in high-
frequency switching power converters. In the develop-
ment or prototyping process, multipurpose boards, wire
wrap, and similar constructive practices are not suit-
able for these type of circuits; attempts to use them will
fail. Instead, use milled PC boards with a ground plane,
or equivalent techniques
Current loops must be analyzed in any layout pro-
posed, and the internal area kept to a minimum to
reduce radiated EMI. The use of automatic routers is
discouraged for PC board layout generation in the
board area where the high-frequency switching con-
verters are located. Designers should carefully review
the layout. In particular, pay attention to the ground
connections. Ground planes must be kept as intact as
possible. The ground for the power-line filter capacitor
and the ground return of the power switch or current-
sensing resistor must be close. All ground connections
must resemble a star system as much as practical.
“Short” and “close” are dimensions on the order of
0.25in to 0.5in (0.5cm to about 1cm).
Setting the Output Voltage
The output voltage of the converter, if using the internal
error amplifier, can easily be set by the value of the FB
pin set voltage. This value is 1.5V. A resistive divider
must be calculated from the output line to ground, with
a dividing ratio such that when the output is at the
desired value, the center-point voltage will be 1.5V. The
Thevenin equivalent of the resistors must be low
enough so the error amplifier bias current will not intro-
duce a division error. The two resistors must have simi-
lar temperature coefficients (tempcos), so the dividing
ratio will be constant with temperature.
Component Selection
CS Resistor
The CS resistor is connected in series with the source
of the N-channel MOSFET and ground, sensing the
switch current. Its value can be calculated from the fol-
lowing equation:
where η = efficiency and 0.5 < KT
OL
< 0.75.
K
TOL
includes the tolerance of the sensing resistor, the
dispersion of the MAX5003 CS trip point, and the
uncertainties in the calculation of the primary maximum
current.
The sensing resistor must be of the adequate power
dissipation and low tempco. It must also be noninduc-
tive and physically short. Use standard surface-mount
CS resistors. A 100 resistor is recommended between
the CS resistor and the CS pin. If the current surge at
the beginning of the conduction period is large and dis-
rupts the MAX5003
s operation, add a capacitor
between the CS pin and PGND, to form an RC filter.
Power Switch
The MAX5003 will typically drive an N-channel MOSFET
power switch. The maximum drain voltage, maximum
R
DS(ON)
, and total gate switching charge are the para-
meters involved in choosing the FET. The maximum
gate switching charge is the most important factor
defining the MAX5003 internal power consumption,
since the product of the switching frequency and the
total gate charge is the IC current consumption.
R
DS(ON)
is the parameter that determines the total con-
duction power losses in the switch, and the choice
depends on the expected efficiency and the cooling
and mounting method. The maximum drain voltage
requirements can be different depending on the topolo-
gy used. In the flyback configuration, the maximum
voltage is the maximum supply voltage plus the reflect-
ed secondary voltage, any ringing at the end of the
conduction period, and the spike caused by the leak-
age inductance. In the case of the forward converter,
the reset time of the core will set the maximum voltage
R
mV
I
mV
PWR
L
K
CS
LIM PRI
OUT MAX
PRI SW
TOL
()
()
==
׃ ×
×
100 100
2
η
MAX5003
High-Voltage PWM
Power-Supply Controller
______________________________________________________________________________________ 15

MAX5003ESE+T

Mfr. #:
Manufacturer:
Maxim Integrated
Description:
Switching Controllers PWM Power-Supply Controller
Lifecycle:
New from this manufacturer.
Delivery:
DHL FedEx Ups TNT EMS
Payment:
T/T Paypal Visa MoneyGram Western Union