Practical Power Application Issues

for Switch-Mode Power Supplies

Fairchild Power Seminar 2006

Agenda

Stability of Synchronous Buck Converters:

How to Design the Compensation Network
What Non-Magnetics Designers Need to
Know About Transformers

Stability of Synchronous Buck Converters:

How to Design the Compensation Network

Fairchild General Purpose Switching

Regulators
Part No.
FAN5182 +
FAN5009
FAN6520A
FAN5069

Vin,op
Vout
Max
(V)
(V)
Description
Io (A)
1 to 3-phase controller
90 10.8 to 13.2
0.8 to 5
w/external drivers
8-pin PWM controller + 30
4.5 to 5.5
0.8V to Vin
drivers
PWM + LDO controller
30
3 to 24
0.8 to 15

PWM/PFM Controller + 15
2 to 24,
0.9 to 5.5
drivers
4.75 to 5.25
Dual PWM/PFM
15 ea.
3 to 24,
0.9 to 5.5
Controller + drivers
4.75 to 5.25
FAN5026
Dual PWM Controller + 15 ea.
3 to 24,
0.9 to 5.5
drivers
4.75 to 5.25
FAN2011/12 Integrated 1.5A
1.5
4.5 to 5.5
0.8V to Vin
synchronous buck
FAN2001/02 Integrated 1A
1
2.5 to 5.5
0.8V to Vin
synchronous buck

Tj,op
(C)
0 to 125

Fsw
Control
(kHz)
Mode
200-1000 I-mode
/phase
-40 to 125
300
V-mode

Compen- Typ Drv

Design
sation
Zout () Packages
Tools
external
1.4 to 3.8 QSOP-20,
SOIC/MLP-8
external
1.0 to 2.5 SOIC-8
AN-6009

-40 to 125

external

1.2 to 1.8 TSSOP-16

AN-6010

internal

1.5 to 8 TSSOP-16,
QSOP-16
1.2 to 12 TSSOP-28,
QSOP-28
1.2 to 12 TSSOP-28

AN-6002

FAN5234

-10 to 150

FAN5236

-10 to 150
-40 to 150
-40 to 150
-40 to 150

200-600 Summing
I-mode
300/600 Avg I-mode
/hysteretic
300
Avg I-mode
/hysteretic
300
Average
I-mode
1300
I-mode
1300 /
PFM

I-mode

internal
internal
internal
internal

95% max
efficiency
96% max
efficiency

3x3 mm
MLP-6
3x3 mm
MLP-6

AN-6002
AN-6002
AN-6011

+5V

MLP

1
VCC
CVCC

FAN6520A

SOIC

4
3
COMP/OCSET

6
RF

CF

TSSOP

CBULK
CHF

Q1

ROCSET

DBOOT
CBOOT

BOOT

HDRV
LOUT

SW
Q2

QSOP

GND
FB

+VOUT
COUT

LDRV

RS
ROFFSET

CI

Synchronous Buck
with Summing Current-Mode Control
Vin
Driver

Osc
PWM Comparator

Vm

Lo

Vout

OUT
+
ESR
Driver

RLOAD
Co

Ri

Current FeedbackTransresistance

C2

C1

R3

R2

C3

R1
Vcomp

OUT
Type 3 Error Amp

Rbias

Vref

Voltage Loop Gain Components

Desired
Voltage

Ve
-

Gc(s)

Vc

Gvd(s)

Ic

Gvc(s)

Gpwm

Vo

Output
Voltage

There are four elements in the output-voltage control loop:

Subtractor element, which generates an error signal by subtracting the
desired voltage from the output voltage
Compensator element Gc(s), added by the designer to stabilize the loop
and improve the loop performance
PWM element Gpwm which defines the relationship between the
compensator output signal and the duty cycle/current-mode control current
(a constant)
Control-to-output transfer function Gvd(s) or Gvc(s)
6

Desired Loop Gain Characteristics

|T|

gain
HighHigh
Gain
at @
frequency
Lowlow
Frequency

-20db/dec

0 dB
Wide bandwidth

Wide Bandwidth

GGain
M

Margin

/T

P M
Phase Margin
-180

Stability Terms
Bandwidth
Related to the speed of transient response

Phase Margin
Related to the damping of the system
Low PM causes oscillatory transient response

Gain Margin
Gain is changed according to the variation of circuit components
Related to robustness against gain variation

Open Loop System Gain

10

M0 (dB)

-20 dB / decade

0
1.E+03

1.E+04

-5

f p1
Gain (dB)

-10

1.E+05

1
M

i
2 Co RL M0
-40 dB / decade

-15

fp2

-20

1
M
v
2 Lo / RL M i
-20 dB / decade

-25

-30

fz =

-35

1
2 Co ESR

-40
Frequency (Hz)

M ( s ) = M0
9

1 + s Co ESR
Lo M0

R + ESR M0
M

+ Co RL 0 + ESR + s 2 Lo Co L

1+s
RL
Mv
Mi

RL M v

Compensator Types
The key task of the feedback amplifiers compensation function is to
boost the loop gain and phase to raise the crossover frequency (for
better transient response) while maintaining adequate stability
margins. The compensator type is determined by the amount of
phase boost needed at the crossover frequency:
Type 1: Single pole - no phase boost
Type 2: Two poles, 1 zero - up to 90 degrees
Type 3: Three poles, 2 zeros - up to 180 degrees

10

C2

Type 2 Compensator

R2

C1

R1

Vout

OUT

Rbias

60

Vref

Vcomp

135

Type 2 Error Amp

-20 dB / decade
40

fzero =

R2
R1

1
2 R2 C1

f pole =

1
2 R2

90

C1 C2
C1 + C2

20

45

Gain (dB)

funity _ gain
0
1.E+02

1
=
2 R1 ( C1 + C2 )
1.E+03

-20 dB / decade

1.E+04

-20

1.E+05

0
1.E+07

1.E+06

Gain
Phase

-45

Phase boost
(up to 90 in theory,
75 in practice)

-40

11

Phase (degrees)

20 log

-90

-60

-135
Frequency (Hz)

C2

Type 3 Compensator

C3

R3

R2

R1

Vout

Rbias

OUT
Vref

60

f pole1 =

1
2 C3 R3

= f pole 2 =

Gain (dB)

20 log

0
1.E+02

-20

R2
R1

funity _ gain

1.E+03

1.E+04

1.E+05

Phase boost
(up to 180 in theory,
160 in practice)

90

1
2 R2

1
=
2 R1 ( C1 + C2 )

-40

1.E+06

C1 C2
C1 + C2

45

0
1.E+07

Gain
Phase

-45

-90

-60

12

Vcomp

Type 3 Error Amp

1
1
= fzero 2 =
2 C1 R2
2 C3 (R1 + R3 )

40

20

135

fzero1 =

C1

-135
Frequency (Hz)

Venable K-Factor Calculation

A method to calculate the compensation circuit values from the amount
of phase boost needed at the crossover frequency(1)
Uses Venables K-factor:

K = tan 2 boost + 45
4

For a Type 3 compensator, this places both poles at the same frequency
and both zeros at the same frequency, which maximizes the gain below
crossover and minimizes it above crossover. (We will modify this later)
(1) Venable, H. Dean, "The K Factor: A New Mathematical Tool for Stability Analysis and Synthesis;'

Proceedings of Powercon 10, March 1983. (Also Optimum Feedback Amplifier Design from
http://www.venable.biz/.)
13

Final Loop Gain with Type 3

Compensator
100

80

Error Amp
DC Gain

60

Gain (dB)

20

0
1.E+02

BW K

BW
K

40

Gain-bandwidth
product
Converter
bandwidth (BW)

1.E+03

1.E+04

1.E+05

1.E+06

1.E+07

Open-Loop Error Amp

Type 3 Compensator
Overall Converter
Modulator + Filter

-20

-40

-60

Pole due to load &

output capacitance
Pole due to
inductor

Zero due to ESR &

output capacitance

-80

-100
Frequency (Hz)

14

Tool Suite for Switching Regulators

Excel-Based Components Calculator
Output Filter L and C
Input filter capacitor ripple current
Various external R's and C's to set:
ISENSE , ILIMIT , Soft Start, etc.

Compensation components (where applicable)

Bode plot

PSPICE model
Tests loop stability and transient response from the values chosen as a
result of the calculations from the Excel spreadsheet above.
Runs in student PSPICE version (free distribution from Cadence)
Continuous time model : Excellent correlation with both switching
model and lab results
Runs fast. Allowing iterative compensation design

MOSFET Selection / Efficiency simulation: AN-6005

15

Spreadsheet Design Procedure

Overview
Step Tab
1 OutputFilter
2

Main Sheet

Compensation
Compensation

InputFilter
Bode
BodePlot
Plot

Input
System requirements:
VIN, VOUT, IOUT(MAX)

Output
Output filter L and C

RDS(ON) of MOSFETs,
Start-up ramp, etc
From Main Sheet and
OutputFilter
From OutputFilter.

External R's and C's

Compensation components

Calculates RMS ripple

requirement for input filter cap.
Examine small signal stability on this tab

Color Code:
User Inputs
Calculated values that can be overwritten
Limit condition
Calculated system performance

16

Compensation Worksheet
Parameter:
RL (load resistance) = VOUT / IMAX
Loop Bandwidth
Compensator Type

Value
Units
0.075
ohm
38
KHz.
Synthesized
User
Values
Values
373
390
93
100
1,524
1,500
4.990
4.990
25.47
25.47
1.243
1.243
5.703
5.703
76
75

C1 =
C2 =
C3 =
R1 =
R2 =
R3 =
RBIAS
Phase Margin

Comments
Use this value for
Default is FSW/8.
Bode plot uses
synthesized
pF
pF
pF
K Do not modify he
K
K
K Do not modify he

These component-value
calculations are based on
Venables K-Factor method,
modified to guarantee minimum
phase margins of 60 at crossover
& 45 at lower frequencies.
Values may be overwritten and
results examined on the Bode
plot.

Components calculated by this

sheet (figure 24 in FAN5069 data
sheet)

17

dB or degrees

Loop Gain Bode Plot

170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0
-10
-20
-30

User Phase Margin is 75

Synthesized Phase Margin is 76

Phase Margin

User Bandwidth is 33.1 KHz.

Synthesized Bandwidth is 36.3 KHz.

Magnitude: Synthesized components

Magnitude: User Components
Phase margin: Synthesized Components
Phase Margin: User Components
1

10

100

1,000

10,000

100,000

1,000,000

f(Hz)

18

PSPICE Model Schematic

In

Time_Av g_SW
A

Rdc

SW

F1
F

{L_ESR}

L1

R4

Out

1u

{L}

Vtest
10mV
D

Rx
{CX_ESR}

SENSE

CX
{CX}

COMP
Rramp
RAMP
{Rramp}

FAN5069

PGN D

Vin
{Vin}

C1
{C1}

U1

C3
{C3}

C2
{C2}

R2
{R2}

CZ
{CZ}

R3
{R3}

Output Filter and System

PARAMETERS:

Rbias
{Rbias}

Vin = 13
f sw = 300kHz
Rds_on_hs = 4m
Rds_on_ls = 3m

External Components
PARAMETERS:

RLoad = 1

RRAMP = 237k

L = 0.8u
L_ESR = 2m

C1 = 390p
C2 = 100p
C3 = 1500p

CX = 10u
CX_ESR = 5m

R1 = 4990
R2 = 25.47k
R3 = 1243
RBIAS = 5.703k

CZ = 1120u
CZ_ESR = 8m

Application Circuit
Notes:
(1) Reset RLoad to desired value when switching
between AC sweep and transient simulation.
(2) For more accurate AC sweep, descend into U1
and set Esampling XFORM to 1+s/(wn*Qz)+(s/wn)**2.
(3) For transient analysis, set XFORM to 1.

R1
{R1}

FB

FB

I1 = 0.1A
I2 = 6A
TD = 3ms
PW = 500us
PER = 10ms

Rz
{CZ_ESR}

SW

DCX_CCM

Istep

RLoad
{RLoad}

Expressions for Probe

to generate Bode plot:
DB(V(Out)/V(SENSE))
P(V(Out)/V(SENSE))

19

PSPICE Load-Transient Response

10A

Inductor current
5A

Load Current

SEL>>
0A
I(L1)

I(R4)

1.55V

Output voltage
1.50V

1.45V
2.4ms
V(Out)

2.6ms

2.8ms

3.0ms

3.2ms

3.4ms

3.6ms

3.8ms

4.0ms

Time

20

10

Transformers:
What Non-Magnetic Designers
Need to Know

21

How Do I Get a Transformer?

The Options
Go to a transformer suppliers catalog (or website)
only if the application is simple & common

Design & wind the prototype yourself

requires some magnetics expertise

Request a prototype from a transformer supplier

what to tell them

22

11

A Catalog Transformer

23

[Source: CoEv Magnetics]

A Catalog Transformer (contd)

24

[Source: CoEv Magnetics]

12

A Completed Design (from Fairchild)

(1) Transformer Schematic Diagram
T1
EER28L

12

11

10

Na
Np/2
4

N13V
N6.7V
N1.2V

N2.5V
Np/2

(2) Winding Specification

Np/2

Pin (S F)

Wire (mm)

Turns

Winding Method

21

33

Solenoid winding

87

0.40 x 1
0.32 x 4

Solenoid winding

N2.5V

98

0.32 x 2

Solenoid winding

N6.7V

11 10

0.40 x 4

Solenoid winding

12 11

0.40 x 2

Solenoid winding

N1.2V

N13V
Np/2

32

0.40 x 1

32

Solenoid winding

Na

56

0.32 x 1

10

Solenoid winding

Core : EER28L (Ae=81.4mm2)

Bobbin : EER28L
(3) Electrical Characteristics
Pin

Spec.

Remark

Inductance

13

1.20 mH

70kHz, 1V

Leakage

1-3

8 uH (?)

Short all other pins

25

Design & Wind the Prototype

Yourself: The Steps
Design the power supply turn ratios, magnetizing inductance (at
the primary winding), rms winding currents
Choose a core
Material (Mn-Zn ferrite), shape, size

Design the windings the hard part

Wind the prototype
Set the gap
Test in the circuit adjust the design until it works well
Deliver the design to a magnetics supplier for high-volume production
(& check that their prototype works in the circuit!!)
26

13

27

Some Terminology
[Units: SI & cgs]

Magnetic characteristic of the:

Core

Material
Magnetic
flux density
[T,G]

Magnetic
flux
[Wb, Mx]

H
Magnetic field
intensity
[A-t/m, Oe]
Slope: = Permeability
= r 0

Circuit Element

= BAm

Flux
linkages
[Wb-t, Mx-t]

= mmf
= Hlm = Ni

i = /N
Current
[A]

Magnetomotive
force [A-t, Gb]

P = Permeance

= N

L = Inductance

= 1/ (Reluctance)
= N2P = N2AL
= Am/lm = AL (Inductance factor)

These curves are all related by geometric constants & the number of turns!
28

14

B-H Curves for Some Magnetic

Materials
= 10 x Tesla

Wider at higher
frequency
Shorter at high
temperature
(especially ferrite)

29

[Source: CoEv Magnetics]

Core Utilization

Single-Ended
AC operation with DC offset

Flyback big transformer

Forward smaller transformer

30

Double-ended
AC-only Operation

Push-pull, Half- or Full-bridge

smallest transformer

[Source: CoEv Magnetics]

15

Some Common Core Shapes

B

F GE

F E
M

F E

EP

ER
C

F E
M

EFD

C E F H

F E
M

K
D

PLANAR E

POT
C

F GE

31

PQ

B A

RM

TOROID

[Source: CoEv Magnetics]

Some Common Core Shapes

32

[Source: CoEv Magnetics]

16

Power Output vs. Frequency & Topology

10000

Power Output
vs
Frequency & Topology
ETD44

1000

ETD39

Theoretical Max Output Pwr - Watts

ETD29
EE30
EFD30
EFD25

100

EFD20
EP17
EE13
EP13
EFD15

10

CEP10
EF12.6
EP10
CEP7

EP7
ER11/5
ER9.5
EE8.8
EE5

0.1
100 250 500 750
1
100 250 500 750
1
100 250 500 750
1
100 250 500 750
1
100 250 500 750
1
KHz KHz KHz KHz MHz KHz KHz KHz KHz MHz KHz KHz KHz KHz MHz KHz KHz KHz KHz MHz KHz KHz KHz KHz MHz
Full or Half Bridge

33

Push-Pull

Forward Converter

Flyback - Single Output

Flyback - Multiple Output

[Source: CoEv Magnetics]

Core Material Pages

34

[Source: TDK]

17

Core Material Pages (contd)

35

[Source: TDK]

Core Shape Page

36

18

Design the Windings

Choose primary turns for a reasonable gap (~0.2 to 1.5 mm)
Choose wire:

Shape: round, ribbon, twisted, Litz

Size: 0.32 (mm, = AWG#28), 0.25 x 4, etc.
Material: polyurethane/nylon (Nyleze), polyimide (Kapton, TEX-E)
Thermal class: 105C, 130C, 180C,
Build: single, heavy (double), triple, quad

Determine the configuration or stack-up

Determine safety agency requirements:
Use yellow polyester film tape; space terminations properly

37

Techniques to Reduce Stray

Effects
Leakage Inductance:
Lowest for adjacent, thin windings (tighter coupling)

Eddy current losses (skin & proximity effects):

Split the primary
Limit conductor thickness to approx. 2 skin depths
At 100 kHz & 80C, maximum wire diameter is just 0.46 mm!

f sw 0 Cu

(100 kHz )( 4 10 7 Wb/m - A - t)(4.8 10 7 S/m)

= 0 .23 mm

Stray capacitance noise coupling:

Use shield(s)
38

19

The Gap
lm
Gapping of the magnetic core along
the flux path causes a shearing over
of the effective B-H loop (really the loop), which lowers the effective
permeability and allows unsaturated
operation at higher bias operating
levels.

lg

L = N2 A Lg , A Lg =

1
l
1
+ g
A L 0 A g
=

B-H Loop before gapping

39

1
l
lm
+ g
m A m 0 A g

B-H Loop after gapping

[Source: CoEv Magnetics]

Design for a Reasonable Gap

If possible, use standard gap from core manufacturer
Target between 0.2 & 1.5 mm
Use spacer (fish) paper for prototyping
Set final gap by measuring inductance
For production, center leg is typically ground shorter

40

Fringing Flux
[Source: CoEv Magnetics]

20

Regulatory Jargon
Safety agencies: VDE, UL, TUV, etc.
Grade of Insulation System:
Functional, Basic, Supplementary, Reinforced

Pollution Degree 1 (sealed), 2 (UL1950), 3 (conductive)

Material Class I, II, IIIa, IIIb
Based on CTI (Current Tracking Index) level

41

Bobbin Winder

(Adams-Maxwell 1201-3AX)

May also want a solder pot, transformer electrical tester

42

21

Requesting a Prototype
What a Supplier Needs to Know
Who designed the power supply?
What are the electrical requirements?
What is the switching/operating FREQUENCY? (Fo)
What is the VA (Tx) or CURRENT rating (Inductor)?
What is the TOPOLOGY? (Flyback, Push-Pull, Buck/Boost, Forward Converter,
etc.)
What are the INPUT VOLTAGES & CURRENTS?
What are the OUTPUT VOLTAGES & CURRENTS (also known as output VA)?
Which Pulse Width Modulator (PWM) IC?
What Agency Approval requirements (UL1459, IEC950, etc.)?

Any SIZE constraints/footprint already determined?

EAU - Expected Annual Usage
Target PRICE & COMPETITION

43

[Source: CoEv Magnetics]

Suppliers Design Worksheet

44

[Source: CoEv Magnetics]

22

What a Magnetics Supplier Prefers

to Keep Private
Turns
Give ratios instead

Winding design
Wire sizes
Stack-up

Core & bobbin supplier &

part numbers

45

The Bottom Line

Without a magnetics specialist, you can do it yourself
(but it can be tricky)
Each approach has advantages:
Do-it-yourself
Faster prototyping & debug
You know & control the design

Outside expert
Easy to find & use (ask your distributor)
Usually can do a better job: smaller, cheaper, more
manufacturable, passes safety agencies

46

23

Related Links
The pdf version of the Power Seminar presentations are available on the our external
website. To access or download the pdfs, please visit
www.fairchildsemi.com/power/pwrsem2006.html
For product datasheets, please visit www.fairchildsemi.com
For application notes, please visit www.fairchildsemi.com/apnotes
For application block diagrams, please visit www.fairchildsemi.com/markets
For design tools, please visit the design center at www.fairchildsemi.com
For PSPICE models, please visit
http://www.fairchildsemi.com/models/PSPICE/Discrete/index.html
For SMPS design tool, please visit
http://www.fairchildsemi.com/whats_new/offline_smps_toolkit.html
Some of this content is presented with permission from CoEv Magnetics, a division of
Tyco Electronics, www.tycopowercomponents.com/magnetics.asp

47

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