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| (R) SP6122 Low Voltage, Micro 8, PFET, Buck Controller Ideal for 1A to 5A, Small Footprint, DC-DC Power Converters Optimized for Single Supply, 3V-5.5V Applications High Efficiency, Greater than 90% Possible 8 PDRV VCC 1 20ns/1nF PFET Output Driver SP6122 FFLAG 2 7 GND 8 Pin MSOP Fast Transient Response VOUT 3 6 ISET Open Drain Fault Output Pin ENABLE 4 5 ISENSE Internal Soft Start Circuit Accurate 1.5% Reference Programmable Output Voltage or Fixed 1.5V Output Now Available in Lead Free Packaging Loss-less Adjustable Current Limit with High side RDS(ON) Sensing Hiccup or Lock-up Fault Modes Low 5A Sleep Mode Quiescent Current APPLICATIONS Low 300A Protected Mode Quiescent Current Video Cards Ultra Low, 150A Unprotected Mode Quiescent High Power Portable Current Microcontrollers High Light Load Efficiency I/O & Logic Offered in Tiny 8 pin MSOP Package Industrial Control Distributed Power Low Voltage Power DESCRIPTION The SP6122 is a PWM/PFM minimum on-time controller designed to work from a single 3V5.5V input supply. It is engineered specifically for size and minimum component count, simplifying the transition from a linear regulator to a switcher solution. However, unlike other "micro" parts, the SP6122 has an array of value added features such as optional hiccup mode, over current protection, TTL enable, "jitter and frequency stabilization" and a fault flag pull-down pin. Combined with reference and driver specifications usually found on more expensive integrated circuits, the SP6122 delivers great performance and value in an 8 pin MSOP package. TYPICAL APPLICATION CIRCUIT R1 C1 4.7F VCC VIN C2 100F PDRV (R) 3.0V to 7.0V 5 RSET 1k Q1 PDS6375 FFLAG FFLAG VOUT GND SP6122 ISET ISENSE ENABLE ENABLE L1 2.2H STPS2L25U DFLY 1A to 5A VOUT COUT 470F Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 1 ABSOLUTE MAXIMUM RATINGS These are stress ratings only and functional operation of the device at these ratings or any other above those indicated in the operation sections of the specifications below is not implied. Exposure to absolute maximum rating conditions for extended periods of time may affect reliability. VCC .............................................................................................................. 7V All other pins ...................................... -0.3V to VCC+0.3V Peak Output Current < 10s PDRV ......................................................................... 2A Storage Temperature .............................. -65C to 150C Power Dissipation Lead Temperature (Soldering, 10 sec) ................. 300C ESD Rating ...................................................... 2kV HBM ELECTRICAL CHARACTERISTICS Unless otherwise specified: 0C < TAMB < 70C, 3.0V < VCC < 5.5V, CPDRV = 1nF, VENABLE = VCC, VFFLAG = VCC, ISET = ISENSE = VCC, GND = 0.0V PARAMETER QUIESCENT CURRENT VCC Supply Current, OVC Enabled VCC Supply Current, OVC Disabled VCC Supply Current, OVC Disabled, Ultra Low IQ VCC Supply Current, Sleep Mode REFERENCE Output Voltage, Initial Accuracy Output Voltage, Over Line, Load and Temperature Reference Comparator Hysteresis VOUT Input Current MIN TYP MAX UNITS CONDITIONS - 300 250 150 5 450 360 225 15 A A A A No Switching, ISET = ISENSE = VCC No Switching, ISET = ISENSE = 0 No Switching, ISET = 0, ISENSE=VCC Enable=0 VR*0.985 VR*0.980 - VR VR 5 23 VR*1.015 VR*1.020 - V V mV A VR = Factory Set Voltage, see Note VR = Factory Set Voltage, see Note Internal Hysteresis at Feedback Terminal VOUT = VR; SP6122ACU-1.5 ONLY OSCILLATOR Oscillator Frequency Minimum Pulse Width during Startup (Blanking Time) Soft Start Soft Start Ramp Time 3.5 ms VOUT = VR - 30mV, Measure time from ENABLE = 1V to PDRV Low Measure VSoft Start when PDRV goes Low. (internal) 210 150 300 270 390 380 kHz ns Soft Start Voltage when PDRV Switches - 250 - mV Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 2 ELECTRICAL CHARACTERISTICS Unless otherwise specified: 0C < TAMB < 70C, 3.0V < VCC < 5.5V, CPDRV = 1nF, VENABLE = VCC, VFFLAG = VCC, ISET = ISENSE = VCC, GND = 0V PARAMETER MIN TYP MAX UNITS CONDITIONS RDS OVER CURRENT COMPARATOR Over Current Comparator Threshold Voltage Threshold Voltage Temperature Coefficient ISET Sink Current ISET Current Temperature Coefficient ISENSE Input Bias Current ISET, ISENSE Common Mode Input Range Over Current Peak Detection Time Constant ENABLE INPUT & FFLAG OUTPUT ENABLE Threshold ENABLE Pin Source Current FFLAG Sink Current GATE DRIVER PDRV Rise Time PDRV Fall Time 20 20 75 75 ns ns 0.5V to 4.5V 4.5V to 0.5V 0.90 0.8 3.0 1.21 5.0 7.5 1.45 10.0 15.0 V A mA V(FFLAG) = 1V 130 15 2.0 150 3800 20 4300 10 180 25 100 VCC mV ppm/C A ppm/C nA V s Current into ISET 25C only V(ISET) - V(ISENSE) 25C only NOTE: Available Output Voltages: 1.5V Fixed, 1.25V Adj. Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 3 PIN DESCRIPTION PIN # 1 2 3 4 PIN NAME VCC FFLAG VOUT ENABLE DESCRIPTION Main Supply Pin: A RC filter as shown in the application circuit is recommended. The decoupling capacitor needs to be close to the pin. Fault Flag Pull-down Pin: Sinks current during a fault condition. Can be hooked up to ENABLE to initiate Hiccup Timing. Regulated Output Voltage: This voltage is divided internally and compared to a 1.5%, 1.25V reference at the PFM comparator. Enable Input: Floating this pin or pulling above 1.45V enables the part. Pulling this pin to less than 0.9V will disable the part. A minimum 100pF capacitor is required between this pin and Ground to ensure proper startup. If FFLAG is hooked to ENABLE, the capacitor on ENABLE will control hiccup timing. Negative Input to the Over Current Amplifier/Comparator: This input is subtracted from the ISET input and gained by a factor of 3.3. The output of this amplifier is compared with a 0.5V threshold, yielding a 150mV threshold. This threshold has a 3800 ppm/C temperature coefficient. If the subtraction exceeds 150mV, charge is pumped into a capacitor until the capacitor hits VCC/2. At this time, the over current fault is activated. If ISET = 0V and ISENSE = VCC, the part enters an unprotected, 150A quiescent current mode. Positive Input to the Over Current Amplifier: 20A flows into the ISET pin if it is pulled through a resistor to VIN. This current has a 4300ppm/C temperature coefficient and can be used via external resistor to raise the overcurrent trip point from 150mV to some higher value. If ISET = 0V and ISENSE = 0V, the part enters an unprotected, 250A quiescent current mode. Power and Analog Ground: Hook directly to output ground. Drive for PFET High Side Switch: 1nF/20ns Output Driver. 5 ISENSE 6 ISET 7 8 GND PDRV Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 4 BLOCK DIAGRAM Soft Start SS + Reset Dominant R SS Latch S QB PFET OFF ENABLE 4 1.25V Reference + 1V Reset Dominant POR R QB Run Latch S Q Soft Start Clock VOUT * K1 TON Min On Time Clock RESET Dominant S QB Loop Latch R Q PFET OFF 7 GND Blank Start On Time 1 VCC Reference Comparator Driver Logic PFET Driver 8 PDRV VOUT 3 X K1 + ISET 6 20A (4300 ppm/C) PDRV Over Current (Gated S&H) 200ns Blanking One Shot + X 3.3 ISENSE 5 + POR Reset Dominant S Q FAULT R POR 2 FFLAG 500mV (3800 ppm/C) ISET ISENSE ISET < 1V Low IQ Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 5 OPERATION General Overview The SP6122 is a minimum on-time, PFM/PWM controller for low cost DC/DC step down converters. The main control loop consists of a REFERENCE COMPARATOR, an ON-TIME CLOCK, a LOOP LATCH and a BLANKING ONESHOT. The REFERENCE comparator has 10mV of internal hysteresis and a 1.25V internal reference. Both hysteresis and reference voltage are multiplied upward by the internal feedback resistor divider, K1 (K1 = 1 for the adjustable version). This value is set by the factory and determines the output voltage of the converter. This divider is also used in the ontime algorithm for the controller. If the output voltage drops below K1*1.25V, then the DRIVER LOGIC tells the PFET switch to be "on" for a certain minimum time. The on-time is set by the Soft Start CLOCK frequency and is factory programmed to run at 300kHz. When the part is enabled, through VCC or the ENABLE pin, the DRIVER LOGIC is configured to first look at the fixed frequency Soft Start loop. The output voltage is then controlled by a 0.5V/ms internal ramp. When the output voltage reaches K1*1.25V, the Soft Start loop is switched off and the main loop takes over. Fault management is controlled either through power-on-reset (POR) or RDS(ON) sense over current protection. Should an over current condition occur, the SP6122 will completely "lock-up" and turn the PFET switch off. The only way to recover will be to either cycle the ENABLE pin or VCC. A Fault flag output (FFLAG) has been included to either signal the upstream circuitry or to engage a hiccup mode that will restart the SP6122. Tying FFLAG to ENABLE allows the controller to restart without assistance. Lastly, the SP6122 includes a powerful 4 PFET driver stage designed to drive a PFET associated with high speed converter designs in the 1 A - 5 A range. Date: 10/02/04 Enable Low quiescent mode or "Sleep Mode" is initiated by pulling the ENABLE pin below 650mV. The ENABLE pin has an internal 4A pull-up current and does not require any external interface for normal operation. If the ENABLE pin is driven from a voltage source, the voltage must be above 1.45V in order to guarantee proper "awake" operation. Assuming that VCC is above about 2.9V, the SP6122 transitions from "Sleep Mode" to "Awake Mode" in about 20s - 30s and from "Awake Mode" to "Sleep Mode" in a few microseconds. SP6122 quiescent current in sleep mode is 5A typical. During Sleep Mode, the PFET switch is turned off, the internal SS voltage is held low and the FFLAG pin is high impedance. Low Current Operation If over current fault protection is not needed, the SP6122 offers two options to lower its quiescent current. By grounding both ISET and ISENSE pins, the circuitry responsible for over current detection is turned off. This option results in a saving of about 50A in quiescent current. Option two requires that ISET is grounded and ISENSE is greater than 1.3V. This option put the SP6122 in a low performance mode that cuts the operating frequency roughly in half and slows down critical comparators in the main loop. Option two can result in additional saving of 100A bringing the total quiescent current to only 150A (typ). Power On Reset (POR) The POR command is given every time the bandgap reference is started. The internal 1.25 V reference is compared against a 1V NFET threshold. When the reference is below the threshold, FAULT and RUN latches are reset, the internal SS voltage is discharged and the PFET switch is "off". The SP6122 is allowed to begin a soft start cycle when the SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 6 Power On Reset (POR): continued internal 1.25V is greater than the 1 V threshold. Note this is a "loose" threshold and should not be used to guarantee under voltage lock out with respect to VCC. Care should be take to ensure that VCC does not "get stuck" on the way to its regulated value. Soft Start Soft start is required on step-down controllers to prevent excess inrush current through the power train during start-up. On the SP6122, this is managed through turning the PFET switch on with a fixed frequency clock and then turning the switch off when divided down version of the output voltage exceeds the internal SS voltage ramp. The internal SS voltage ramp rises with a 0.5 V/ ms slew rate and the internal feedback voltage follows this rate of change. The presence of the output capacitor creates extra current draw during startup. Since dVOUT/dt creates an average sustained current in the output capacitor, this current must be considered while calculating peak inrush current and over current thresholds. An expression to determine the excess inrush current due to the dVOUT/dt of the output capacitor is: VOUT , ICOUT = COUT*0.5 V/ms * VR where VR is the internal reference voltage. Lock Up & Hiccup Modes As previously stated, if the SP6122 detects an over current condition and initiates a fault, the power supply remains "locked up". That is, the FFLAG pin immediately pulls low (if loaded) and the PFET switch turns off. This condition is permanent unless the either the VCC or ENABLE is cycled. However if FFLAG is tied to ENABLE, the SP6122 will restart without assistance (Hiccup Mode). Furthermore, the restart time can be controlled by the addition of a small capacitor on the ENABLE pin to ground. The restart time is equal to the amount of time it takes for the 5A ENABLE pin current to charge the external capacitor to an NFET threshold (roughly 1V). The waveforms that describe the Hiccup Mode operation are shown below. 150mV SS Voltage dVSS/dt = 0.5Vms 0.25V 0V Comparator Reference Voltage 1.25V VISET - VISENSE 0V V(VCC) 0V FFLAG Voltage 0V V(VCC) ILOAD Inductor Current 0A V(VIN) ENABLE Voltage 1.0V 0V V(VCC) 0V TIME dVENABLE/dt = 4A/CENABLE SWN Voltage PDRV Voltage 0V TIME Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 7 Over Current Protection Over current protection on the SP6122 is implemented through detection of an excess voltage condition across the PFET switch during conduction. This is typically referred to as high side RDS(ON) detection. The over current comparator charges a sampling capacitor each time V(ISET) - V(ISENSE) exceeds 150mV (typ) and the PDRV voltage is low. The discharge current/charge current ratio on the sampling capacitor is about 2%. Therefore, provided that the over current condition persists, the capacitor voltage will be pumped up during each time PDRV switches low and this voltage will trigger an over current condition upon reaching a CMOS inverter threshold. There are many advantages to this approach. First, the filtering action of the gated S/H scheme protects against false triggering during a transient load condition or supply line noise. In addition, the total amount of time to trigger the fault depends on the on-time of the PFET switch. Ten, 1s pulses are equivalent to twenty, 500ns pulses or one, 1s pulse, however, depending on the period, each scenario takes a different amount of total time to trigger a fault. Therefore, the fault becomes an indicator of average power in the PFET switch. Also, because the CMOS trip threshold is dependent on VCC, the over current scheme is protected against false triggering due to changes in line voltage. Although the 150mV threshold is fixed, the overall RDS(ON) detection voltage can be increased by placing a resistor from ISET to VCC. A 20A sink current programs the additional voltage. The 150 mV threshold and 20A ISET current have 3800 ppm/C and 4300 ppm/C temperature coefficients, respectively. These TC's are designed into the SP6122 in an effort to match the thermal characteristics of the PFET switch. It assumed that the SP6122 will be used in compact designs where there is a high amount of thermal coupling between the PFET and the controller. Light Load Operation One of the advantages of the SP6122 minimum on-time control scheme is the loop's ability to seamlessly and efficiently transition from heavy loads to light loads. In most other control schemes, the controller is notified about a light load condition and then must abruptly change control schemes in order to maintain efficiency. The SP6122 simply reduces the frequency when the average load current is less than the average inductor ripple current. As a result, switching loss decreases as the load current decreases and overall efficiency is maintained. Output Driver The driver stage consists of a high side, 4 ohm PFET driver. The following waveforms illustrate basic behavior of the driver. Gate Driver Test Conditions 5V 90 % FALL TIME 10 % RISE TIME 10 % 90 % PDRV V(VCC) PDRV Voltage 0V V(VCC) = VIN SWN Voltage 0V - V(VDIODE) TIME Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 8 APPLICATION INFORMATION As an SP6122 application example, we will use the circuit from the SP6122 Evaluation Board Manual. This evaluation board uses the Sipex SP6122ACU, 1.25V adjustable PFET controller to realize a 3.3V to 1.9V step down converter. The board is optimized for 1A - 4A operation and has an RDS(ON) over current trip threshold of about 7A. The body of the applications section contains: * * * * * Data for the Evaluation Board Guidelines for Component Selection Features and Protection Layout Guidelines Introduction to the "Buck Cad Calculator" Spreadsheet +3.3V VIN + C1 4.7F Ceramic 1V CC PDRV 8 (R) CIN 47F Ceramic Q1 PMOS PDS6375 FFLAG J1 1 2 FFLAG 3V OUT 4 ENABLE GND 7 SP6122 ISET 6 ISENSE 5 RS 1.00k 2.2H L1 DS STPS2L25U VOUT +1.9V VOUT 2 ENABLE 3 CEN 4.7nF GND R1 + COUT 6.5k 470F R2 12.5k Figure 1. SP6122 Evaluation Board Application Schematic Data For Evaluation Board The SP6122 is engineered for size and minimum pin count, yet has a very accurate 2.0% reference over line, load and temperature. Figure 2 data shows a typical SP6122 Evaluation Board Efficiency plot, with efficiencies to 88% and output currents to 4A. Load Regulation plot in Figure 3 shows an essentially flat response of only 3mV change for up to 4A load. Figure 4 Line Regulation illustrates a 1.90V output that varies only 4mV or 0.2% for an input voltage change from 3.0V to 5.5V. While data on individual power supply boards may vary, the capability of the SP6122 of achieving high accuracy over load and line shown here is quite impressive and desirable for accurate power supply design. 89 88 87 86 85 84 83 0 1 2 3 4 5 Efficiency (%) ILOAD (A) Figure 2. SP6122 Efficiency with VIN = 3.3V, VOUT = 1.9V. Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 9 Data For Evaluation Board: continued 1.902 1.905 1.904 1.903 1.901 1.900 VOUT (V) 1.899 1.898 VOUT (V) 1. 9 0 2 1.901 1.900 1.899 1.897 0 1 2 3 4 5 3 4 5 6 ILOAD (A) ILOAD (A) Figure 3. SP6122 Load Regulation with Input Voltage = 3.3V. Figure 4. SP6122 Line Regulation with ILOAD = 2A. Guidelines for Component Selection GENERAL The SP6122 is a minimum on-time PFM controller. This means there is no error amp controlling the loop. Although an internal algorithm adjusts the on-time approximate the performance of a fixed frequency controller, the loop control is generated by looking at OUTPUT RIPPLE. The peak to peak value of this output ripple must be no less than 2% of the DC output voltage in order to maintain reasonable fixed frequency operation. In addition, as with all PFM controllers, board layout is critical and careful attention must be paid to minimize paths that can generate noise. Fortunately, the SP6122 is designed for simplicity and minimal external components, making it easy to design small, quiet power converters up to 12W. INDUCTOR SELECTION cost, set the inductor ripple current between 20% to 40% of the maximum output current. The inductor operating point and switching frequency determine the inductor value as seen in the following expression: L = (VOUT + VDIODE)*(VIN - VOUT)/ ((VIN + VDIODE)*( FS KR IOUT(max))) Where FS = switching frequency (see Soft Start Frequency Specification) KR = ratio of the ac inductor ripple current to the maximum output current VDIODE = forward Schottky diode voltage For an application with 1.9V out, 4A maximum IOUT, 3.3V input supply, 400 mV typical forward diode voltage, 300kHz frequency and a 30% inductor ripple current, a 2.2H inductor was selected (see Table 1 SP6122 Component Selection). The peak to peak inductor ripple current is: IPP = (VOUT + VDIODE)*(VIN - VOUT)/ ((VIN + VDIODE)*( FS L)) For that same 2.2H inductor application, the IPP = 1.32A. The inductor must be selected to not saturate the core at the peak inductor current: IPEAK = IOUT(max) + IPP/2 (c) Copyright 2004 Sipex Corporation In a SP6122 application, the main factors for choosing an inductor are likely to be cost, size, saturation current and efficiency. If you use low inductor values, you get the smallest size, but you may cause larger ripple currents and poor efficiency and require more output capacitance to smooth the output ripple. Increasing the inductor value will decrease the output voltage ripple but degrade the transient response. For a good compromise between size, losses and Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller 10 Guidelines for Component Selection: continued Again, for that same 2.2H application, IPEAK = 4.6A. Therefore, a 2.2H inductor with at least a 5A rating would be desired. The type of core material to use must also be determined. For low cost, powdered iron cores can be used, and they have a gradual saturation characteristic, but they can cause ac core loss when the inductor value is low and ripple current is high. Ferrite cores, on the other hand, have an abrupt saturation characteristic and the inductor value drops sharply when the peak design current is exceeded. But, ferrites are preferred for high switching frequencies because they have low core losses as long as the saturation current is avoided. Table 1 lists examples of both shielded and unshielded ferrite core inductors for applications appropriate for SP6122 applications from 2A to 5A output current. The inductors listed are both shielded and unshielded, the customer can decide what is needed for their application. For the SP6122 Evaluation Board, the unshielded ferrite inductor 2.2H Coilcraft DO3316P-222 was selected for its cost/performance features. INDUCTORS - SURFACE MOUNT Note: Components highlighted in bold are those used on the SP6122 Evaluation Board. Inductance (H) Manufacturer/ Part No. Series R () Isat (A) INDUCTOR SPECIFICATION Size LxWxH (mm) Inductor Type Manufacturer Website 1.5 2.2 3.3 1.5 2.5 3.8 1.5 2.2 3.3 Coilcraft DO3316P-152 Coilcraft DO3316P-222 Coilcraft DO3316P-332 Sumida CDRH104R-1R5 Sumida CDRH104R-2R5 Sumida CDRH104R-3R8 Murata LQN6C1R5M04 Murata LQN6C2R2M04 Murata LQN6C3R3M04 0.010 0.012 0.015 0.006 0.008 0.010 0.019 0.024 0.029 8.0 7.0 6.4 10.0 7.5 6.0 3.7 3.2 2.7 12.9x9.4x5.0 12.9x9.4x5.0 12.9x9.4x5.0 10x10x3.8 10x10x3.8 10x10x3.8 5.0x5.7x4.7 5.0x5.7x4.7 5.0x5.7x4.7 Unshielded Ferrite Core Unshielded Ferrite Core Unshielded Ferrite Core Shielded Ferrite Core Shielded Ferrite Core Shielded Ferrite Core Unshielded Ferrite Core Unshielded Ferrite Core Unshielded Ferrite Core www.coilcraft.com www.coilcraft.com www.coilcraft.com www.sumida.com www.sumida.com www.sumida.com www.murata.com www.murata.com www.murata.com CAPACITORS - SURFACE MOUNT & THROUGH HOLE Note: Components highlighted in bold are those used on the SP6122 Evaluation Board. Capacitance (F) Manufacturer/ Part No. ESR (max) CAPACITOR SPECIFICATION Ripple Current Size LxWxH Voltage (A) @ 25C (mm) (V) Capacitor Type Manufacturer Website 470 47 4.7 100 SANYO 6TPB470M TDK C4532X5R0J476M TDK C3216X5R1C475M SANYO 16SA100M 0.035 0.005 0.020 0.030 3.0 4.0 4.0 2.7 7343H 1812 1206 8Dx10L 10.0 SMT Tant. www.sanyovideo.com 6.3 SMT X5R Cer. www.tdk.com 10.0 SMT X5R Cer. www.tdk.com 16.0Thru-hole OS-CON www.sanyovideo.com PMOS SWITCH - SURFACE MOUNT Note: Components highlighted in bold are those used on the SP6122 Evaluation Board. RDS(ON) Manufacturer/Part No. @ 3.3V Gate Charge nc @ 3.3V PMOS SPECIFICATION Crss Id (max) (pF) (A) Package Type Manufacturer Website Fairchild PDS6375 Siliconix SI4463DY Intersil ITF86172SK8T 0.022 0.015 0.023 15 34 17 300 800 400 8 10 8 SO-8 SO-8 SO-8 www.fairchildsemi.com www.siliconix.com www.intersil.com SCHOTTKY DIODE - SURFACE MOUNT Note: Components highlighted in bold are those used on the SP6122 Evaluation Board. DIODE SPECIFICATION Manufacturer/Part No. VF @ IF (V) IF(AV) (A) Size LxWxH (mm) Reverse V (V) Package Type Manufacturer Website STMicro STPS2L25U On-Semi MBRD835L 0.50 0.50 4.0 8.0 5.5x3.9x2.5 9.4x6.7x2.3 25 35 SMB DPAK www.st.com www.onsemi.com Table 1: SP6122 Component Selection Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 11 Guidelines for Component Selection: continued The copper loss in the inductor can be calculated from the equation: PL(Cu) = IL(RMS)2 RWINDINGIOUT(max)2 RWINDING For the 2.2H example with 0.012 ESR in the winding, 4A load and 1.9V output, the copper loss in the inductor is 190mW. OUTPUT CAPACITOR SELECTION waveform. For a 1.9V output voltage, the required ripple is a reasonable 38 mV. The designer must chose all other trade-offs wisely to maintain this ripple 0.02 * VOUT < IPP * RESR and ILOAD * RESR < VTOL where: VOUT = DC output voltage RESR = ESR of the output capacitor DILOAD = change in current due to load step DVTOL = tolerable deviation due to load transient IPP = peak to peak inductor ripple current Output ripple is due primarily to the output ripple current and the output capacitor ESR value as seen in the following equation: VOUT IPP RESR For our SP6122 evaluation board example with ESR = 35m and IPP = 1.32A, VOUT = 46mV. Note that a 4A step creates a 140mV deviation. If this is unacceptable, ESR and IPP must be reconsidered in order to improve step response and maintain output ripple. Recommended capacitors that can be used effectively in SP6122 applications are: lowESR aluminum electrolytic capacitors, OSCON capacitors that provide a very high performance/size ratio for electrolytic capacitors and low-ESR tantalum capacitors. AVX TPS series and Kemet T510 surface mount capacitors are popular tantalum capacitors that work well in SP6122 applications. POSCAP from Sanyo is a solid electrolytic chip capacitor that has low ESR and high capacitance. For the same ESR value, POSCAP has lower profile compared with a tantalum capacitor. The output capacitor is typically selected based on its ability to maintain the output within specified tolerance limits during load transients. During an output load transient, the output capacitor must supply all the additional current demanded by the load until the SP6122 adjusts the inductor current to the new value. Therefore the capacitance must be large enough so that the output voltage is held up while the inductor current ramps up or down to the value corresponding to the new load current. For power converters delivering greater than 1A at less than 1MHz switching frequency, the output capacitor is typically greater than 100F. Typically, tantalum and OSCON capacitors are used to get high output capacitance in a small space. These capacitors have a high Equivalent Series Resistance (ESR) when compared to ceramic capacitors and this ESR is both a curse and a blessing. Unfortunately, the ESR (Equivalent Series Resistance) in the output capacitor causes a step in the output voltage equal to the ESR value multiplied by the change in load current. As a result, in a power supply using a tantalum, aluminum electrolytics or OSCON output capacitor, the value of output capacitance (or number of output capacitors) is typically chosen to minimize the output variation due to the load step imposed on this ESR. However, the SP6122 takes advantage of the natural presence of this ESR to control the loop. Because the inductor ripple current also flows through this ESR, and output ripple voltage is created and the waveform is resembles a miniature current-mode timing Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 12 Guidelines for Component Selection: continued INPUT CAPACITOR SELECTION The input capacitor should be selected for ripple current rating, capacitance and voltage rating. The input capacitor must meet the ripple current requirement imposed by the switching current. In continuous conduction mode, the source current of the high-side MOSFET is approximately a square wave of duty cycle VOUT/VIN. Most of this current is supplied by the input bypass capacitors. The RMS value of input capacitor current is determined at the maximum output current and under the assumption that the peak to peak inductor ripple current is low, it is given by: ICIN(RMS) = IOUT(MAX) D(1-D) The worse case occurs when the duty cycle D is 50% and gives an RMS current value equal to IOUT/2. Select input capacitors with adequate ripple current rating to ensure reliable operation. The power dissipated in the input capacitor is: PCIN = ICIN2 (RMS) RESR(CIN) This can become a significant part of power losses in a converter and hurt the overall energy transfer efficiency. The input voltage ripple primarily depends on the input capacitor ESR and capacitance. Ignoring the inductor ripple current, the input voltage ripple can be determined by: VIN = IOUT (MAX) RESR(CIN) + IOUT(MAX)VOUT(VIN - VOUT)/( FS CIN VIN2) The capacitor type suitable for the output capacitors can also be used for the input capacitors. However, exercise extra caution when tantalum capacitors are considered. Tantalum capacitors are known for catastrophic failure when exposed to surge current, and input capacitors are prone to such surge current when power supplies are connected `live' to low impedance power sources. Certain tantalum capacitors, such as AVX TPS series, are surge tested. For generic tantalum capacitors, use 2:1 voltDate: 10/02/04 age derating to protect the input capacitors from surge fall-out. For accurate control it is important to keep ripple voltages on Vin to a minimum. Vin powers the SP6122 and its internal reference used to maintain output regulation, so proper input bypassing is critical to reduce reference noise. With a reference comparator internal hysteresis of 5mV, and a 1.25V reference voltage, noise on the VCC of the ICC should be kept to about 20mV or less to reduce reference noise effect on output regulation. The use of very low ESR capacitors is recommended for Vin bypassing, through the use of parallel combinations of tantalum capacitors or even better using some of the new large valued multi-layer ceramic capacitors. ESR values as low as 0.005 can be obtained with a 47F ceramic (see table 1 capacitor selection) and these ceramic capacitors will reduce the power loss in the input capacitance greatly by their reduced ESR values. For the SP6122 example using the 47F ceramic input capacitor, the PCIN = 20mW, which is very efficient, and the input ripple voltage at the VIN post (not the VCC pin of the IC) is about 90mV. MOSFET SELECTION A SP6122 design uses a PMOS switch on the high side, without the need for a high side charge pump, simplifying the application circuit. The losses associated with the PMOS can be divided into conduction and switching losses. Conduction losses are related to the on resistance of the PMOS, and increase with the load current. Switching losses occur on each on/off transition when the PMOS experiences both high current and voltage. The switching losses are difficult to quantify due to all the variables affecting turnon/turnoff time. However, the following equation provides an approximation on the switching losses associated with the PMOS driven by SP6122. (c) Copyright 2004 Sipex Corporation SP6122 Low Voltage, Micro 8, PFET, Buck Controller 13 Guidelines for Component Selection: continued PSH(MAX) 1/2 IOUT(MAX)VIN(MAX)(tRISE + tFALL)FS where tRISE (SP6122) for 8A PMOS is typically 20ns and tFALL (SP6122) for 8A PMOS is typically 40ns. Switching losses need to be taken into account for high switching frequency, since they are directly proportional to switching frequency. The conduction losses associated with the PMOS is determined by: PCH(MAX) = IOUT (MAX) 2 RDS(ON) D Where RDS(ON) = drain to source on resistance. The total power losses of the PMOS are the sum of switching and conduction losses. For input voltages of 3.3V and 5V, conduction losses often dominate switching losses. Therefore, lowering the RDS(ON) of the PMOS always improves efficiency even though it gives rise to higher switching losses due to increased CRSS. For the SP6122 design example, the Fairchild PMOS PDS6375 was selected for its low RDS(ON) and good switching characteristics including low gate charge at the 3.3V input. Using table 1 values for RDS(ON) and tRISE and tFALL for the SP6122, we calculate; PSH(MAX) = 119mW and PCH(MAX) = 203mW. RDS(ON) varies greatly with the gate driver voltage. The MOSFET vendors often specify RDS(ON) on multiple gate to source voltages (VGS), as well as provide typical curve of RDS(ON) versus VGS. For 5V input, use the RDS(ON) specified at 4.5V VGS. At the time of this publication, vendors, such as Fairchild, Siliconix and International Rectifier, have started to specify RDS(ON) at VGS less than 3V. This has provided necessary data for designs in which these MOSFETs are driven with 3.3V and made it possible to use SP6122 in 3.3V only applications. Thermal calculation must be conducted to ensure the MOSFET can handle the maximum load current. The junction temperature of the MOSFET, determined as follows, must stay below the maximum rating. TJ(MAX) = TA (MAX) + PMOSFET(MAX) RJA where TA (MAX) = maximum ambient temperature PMOSFET(MAX) = maximum power dissipation of the MOSFET, including both switching and conduction losses RJA = junction to ambient thermal resistance. RJA of the device depends greatly on the board layout, as well as device package. Significant thermal improvement can be achieved in the maximum power dissipation through the proper design of copper mounting pads on the circuit board. For example, in a SO-8 package, placing two 0.04 square inches copper pad directly under the package, without occupying additional board space, can increase the maximum power from approximately 1 to 1.2W. For the PMOS PDS6375, assuming TA (MAX) = 20C, PMOSFET(MAX) = PSH(MAX) + PCH(MAX) = 321mW, and assuming per PDS6375 data sheet, RJA = 50C/W if using 0.5 in2 pad of 2oz Cu, TJ(MAX) = 36C which is only a 16C rise from ambient. SCHOTTKY DIODE SELECTION The schottky diode is selected for low forward voltage, current capability and fast switching speed. The average power dissipation of the schottky diode is determined by PDIODE = VF IOUT (1- D) Where VF is the forward voltage of the Schottky diode at IOUT. Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 14 Guidelines for Component Selection: continued For the SP6122 example, the schottky STPS2L25U has VF = 0.5V for IOUT of 4A, the power loss in the schottky PDIODE = 848mW. Note that this power dissipation is 2.5 times greater than the MOSFET. If we assume the same thermal conductivity as the MOSFET (according to the data sheets, this is close) we should get a 40C rise due to the Schottky diode alone. It is apparent that due to the proximity of all the components involved that the board temperature is higher than ambient and this temperature rise must be considered when attempting to protect the power converter. Features and Protection PROGRAMMING THE SP6122 OUTPUT VOLTAGE The 1.5V version of SP6122 has built in voltage divider that presets the output voltage. Simply connect the VOUT pin to the power supply output for 1.5V regulation. Due to the internal voltage divider, the version of SP6122 sinks 23A current at the VOUT pin. Consider this error term if a resistor voltage divider is used. SOFT START The SP6122 has a built-in soft start feature that automatically limits the inrush currents to reasonable levels for most power supplies. For our 1.9V example, the inrush current on start up is: IINRUSH = 470F * 0.5V/ms * 1.9V/1.25V = 357mA This extra current must be factored in when calculating over current margins. LOCK-UP AND HICCUP MODES For Applications requiring output other than 1.5V, the 1.25V adjustable version is recommended. The output voltage can be programmed through a simple voltage divider shown in Figure 5. The set point for the output voltage can be determined by VOUT = 1.25 (R1 + R2) R2 Select R1 and R2 in the range from 1k to 100k. VOUT (R) R1 Basically, when the SP6122 sees an over current fault, the part can react in two ways. If the FFLAG is not tied to ENABLE, the part will put the driver into a low impedance state to the high rail during a fault. The ENABLE pin must be manually cycled to remove the fault. This mode is useful when power supply sequencing and system fault management is complex. If the FFLAG pin is tied to ENABLE, then a `hiccup' time can be designed by adding a capacitor from ENABLE to ground. The 4A ENABLE pin charge current acts as a timer. The driver will be put into a low impedance state to the high rail for a certain amount of time. TOFF = CENABLE* 1.21V/5A SP6122 Vb Pin 3 RIN1 R2 Va - + Error Amplifier + - 1.25V For CENABLE = 4.7nF, this time equals 1.3ms. This represents a `cool off' time required for the power supply to cycle and see if the fault has been removed. This mode is useful for short term faults or in single supply systems. Figure 5: Schematic: Output Voltage Divider Resistors Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 15 Features and Protection: continued RDS(ON) OVER CURRENT PROTECTION Fault conditions are detected via an over voltage condition across the PMOS switch during conduction. This is commonly known as RDS(ON) sensing. RDS(ON) sensing is inaccurate but efficient and is used where an indicator of over current behavior is required for protection. Two advanced features are incorporated in the SP6122 RDS(ON) sensing scheme. The sensing environment is very noisy. Typical schemes require some external filtering in order to avoid spurious faults due to noise or load transients, often compromising the protection and performance at low duty ratios. The SP6122 incorporates a 10s internal sample and hold filter after the main sense comparator. In this fashion, small pulse widths can be detected while maintaining adequate filtering against false glitches. In addition, temperature compensation is added such that the over current detection threshold at any temperature can be calculated with reasonable accuracy at room temperature. For our evaluation board example: ITRIP = (150mV + ISETRSET)/RDS(ON)= (150mV + 20A*1k)/25m = 6.8A This is the about the same trip threshold at room, hot or cold because a temperature coefficient has been added to both the 150mV and the 20A set currents. This temperature coefficient tracks the 25m RDS(ON) of the external FET. Due to the small size of these power supplies, thermal coupling exists between the PFET and the SP6122, making this thermal compensation reasonable, but not perfect. Notice there is about a 50% pad between the maximum usable current (5A) and the over current trip threshold (7A) in order to accommodate PFET and overall system variation. Layout Guidelines PCB layout plays a critical role in proper function of the converters and EMI control. In switch mode power supplies, loops carrying high di/dt give rise to EMI and ground bounce. The goal of layout optimization is to identify these loops and minimize them. It is also crucial on how to connect the controller ground such that its operation is not affected by noise. The following guidelines should be followed to ensure proper operation. 1. A ground plane is recommended for minimizing noises, copper losses and maximizing heat dissipation. 2. Connect the ground of the feedback divider to the GND pin of the IC. Then connect this pin as close as possible to the ground of the output capacitor. 3. The Vcc bypass capacitor should be right next to the Vcc and GND pins. 4. The traces connecting to the feedback resistors and current sense components should be short and far away from the switch node and switching components. 5. Minimize the trace length/maximize the trace width between the PDRV pin and the gate of the PMOS. 6. Minimize the loop composed of input capacitors, PMOS and Schottky diode, as this loop carries high di/dt current. Also increase the trace width to reduce copper losses. 7. Maximize the trace width of the loop connecting the inductor, output capacitors, and Schottky diode. 8. For an layout example of an SP6122 power supply (3.3Vin and 1.9Vout at 4A) see the SP6122 Evaluation Board Manual. Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 16 SP6122 Design Calculator Example: Evaluation Board with 3.3VIN, 1.9VOUT Table 2, SP6122 Design Calculator, illustrates the calculations and formulas contained in the Sipex Non-Synchronous Buck Cad Calculator spreadsheet, (available in the applications section of the Sipex website at www.sipex.com). The example shown is the same SP6122 Evaluation Board used previously with VIN = 3.3V, VOUT = 1.9V at 4A. As you can see, the SP6122 efficiency at 4A output is calculated to be 84.3%. Compare this with the Typical Performance Characteristics curve of 84.5%, which is very close considering the tolerances of various components, and you see how useful this easy design calculator is to evaluate your SP6122 designs. SP6122 Non-Synchronous Buck Design Calculator STEADY STATE CALCULATION Enter Values VIN = Input Voltage (V) VOUT = Output Voltage (V) Fs = Switching Frequency (kHz) IOUT = Load Current (A) L = Inductance (H) ESRin = Input Capacitor ESR (m) CIN = Input Capacitance (F) ESROUT = Output Capacitor ESR () Calculation Results 3.3 D = Duty Cycle 1.9 Iripple = Ripple Current (A) 300 4 Ipeak = Peak Inductor Current (A) Output Ripple (mV) 0.58 1.22 4.61 42.75 2.56 96.99 1.98 Formula = VOUT/VIN = (VIN-VOUT)*VOUT/(Fs*1000*L*0.000001*VIN) = IOUT+Iripple/2 = Iripple*ESRout = IOUT*D/0.9 = IOUT*ESRin+Iin*(1-D)/(Fs*CIN*0.000001) = IOUT*SQRT(D*(1-D)) 2.2 Iin = Max Input Current (A) 5 47 35 Max Input Ripple (mV) Iin_rms = Input Cap RMS Current (A) EFFICIENCY CALCULATION Enter Values RGH = GH Impedance () PMOS TRISE = SP6122 typ. PMOS rise time (ns) 20 Psch = Schottky Conducting Loss (mw) 848.48 = Vf*IOUT*(1-D)*1000 4 Calculation Results Pic = IC Power (switching) (mW) 31.35 Formula = Icc*VIN+Chs*VIN*Fs*0.001 TFALL = SP6122 typ. PMOS rise time (ns) 40 Chs = PMOS Gate Charge @ VIN (nc) Rhs = RDS(ON) @ VIN (m) 15 22 Pch = PMOS Conducting Loss (mW) Psh = PMOS Switching Loss (mW) Phs = Total PMOS Loss (mW) Vf = Schottky Forward Voltage ICC = Supply Current (no switch) (mA) ESR_L = Inductor ESR (m) 0.5 Pl = Inductor loss (mW) 5 12 PcIN = Input Capacitor Loss(mW) Pltot = Total Power Losses (mW) Efficiency (%) 202.67 118.80 321.47 192.00 19.54 1412.84 84.32 = IOUT*IOUT*D*Rhs = 1/2*IOUT*VIN*(TRISE+TFALL)*Fs*0.001 = Pch + Psh = IOUT*IOUT*ESR_L = ESRIN*Iin_rms*Iin_rms = Pic+Pls+Phs+Pl+Psch = VOUT*IOUT/(VOUT*IOUT - Pltot/1000)*100 Table 2: Design Calculator Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 17 PACKAGE: 8 PIN MSOP D e1 O1 E/2 R1 R Gauge Plane O E E1 L2 Seating Plane 1 2 O1 L L1 e Pin #1 indentifier must be indicated within this shaded area (D/2 * E1/2) 8-PIN MSOP JEDEC MO-187 (AA) Variation A A1 A2 b c D E E1 e e1 L L1 L2 N R R1 O O1 Dimensions in (mm) MIN 0 0.75 0.22 0.08 NOM MAX 0.85 3.00 BSC 4.90 BSC 3.00 BSC 0.65 BSC 1.95 BSC 0.40 0.60 0.95 REF 0.25 BSC 0.07 0.07 0 0 8 8 15 0.80 1.10 0.15 0.95 0.38 0.23 B B A2 b A1 WITH PLATING A (b) c Section B-B BASE METAL 1 8-PIN MSOP Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 18 ORDERING INFORMATION Part Number Operating Temperature Range Package Type SP6122ACU .............................................. 0C to 70C ............................................. 8 Pin MSOP SP6122ACU/TR ........................................ 0C to 70C ............................................ 8 Pin MSOP SP6122ACU-1.5 ....................................... 0C to 70C ............................................. 8 Pin MSOP SP6122ACU-1.5/TR .................................. 0C to 70C ............................................ 8 Pin MSOP Available in lead free packaging. To order add "-L" suffix to part number. Example: SP6122ACU-1.5/TR = standard; SP6122ACU-L-1.5/TR = lead free /TR = Tape and Reel Pack quantity is 2,500 for MSOP. Corporation ANALOG EXCELLENCE Sipex CorporationHeadquarters 233 South Hillview Drive Milpitas, CA 95035 TEL: (408) 934-7500 FAX: (408) 935-7600 Sipex Corporation reserves the right to make changes to any products described herein. Sipex does not assume any liability arising out of the application or use of any product or circuit described herein; neither does it convey any license under its patent rights nor the rights of others. Date: 10/02/04 SP6122 Low Voltage, Micro 8, PFET, Buck Controller (c) Copyright 2004 Sipex Corporation 19 |
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