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| february 2013 docid018573 rev 2 1/32 UM1063 user manual evalpm8803-fly: ieee802.3at compliant demonstration kit with synchronous flyback converter by antonio rotta introduction the pm8803 is a highly integrated device embedding an ieee802.3at-2009 compliant powered device (pd) interface together with a pwm controller and support for auxiliary sources. figure 1 is an image of the evalpm8803-fly poe+ demonstration board. the same pcb can be populated with different components to support various configurations and topologies (synchronous flyback with or without active clamp, flyback with diode rectification). this document focuses on a reference design for poe+ based on flyback topology with synchronous rectification, with the pm8803 as the main controller. the schematics and board layout of the poe+ converter are given in section 2 and 3 while the related bill of material is detailed in section 5 . in section 7 efficiency measurements together with main waveforms of the poe interface and flyback converter are shown. figure 1. evalpm8803-fly demonstration kit www.st.com
contents UM1063 2/32 docid018573 rev 2 contents 1 electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 2 demonstration kit schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 3 board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4 i/o connectors and test points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 5 bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6 power-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 7 test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 7.1 efficiency measurement with 3.3 v output . . . . . . . . . . . . . . . . . . . . . . . . 20 7.2 efficiency measurements with 5 v output . . . . . . . . . . . . . . . . . . . . . . . . 21 7.3 waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 7.3.1 startup sequence from poe/poe+ injectors . . . . . . . . . . . . . . . . . . . . . . 23 7.3.2 transition from poe to auxiliary and auxiliary to poe . . . . . . . . . . . . . . 24 7.3.3 primary side mosfet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 7.3.4 secondary side mosfet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7.3.5 line transient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7.3.6 load transient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 7.3.7 output ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 8 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 docid018573 rev 2 3/32 UM1063 list of tables list of tables table 1. specifications for 3.3 v output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 table 2. specifications for 5 v output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 table 3. connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 table 4. leds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 table 5. test points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 table 6. evalpm8803-fwd bom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 table 7. document revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 list of figures UM1063 4/32 docid018573 rev 2 list of figures figure 1. evalpm8803-fly demonstration kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 figure 2. demonstration kit schematic: detail of the poe+ input section including data transformer, diode bridges, protection, and optional cm choke . . . . . . . . . . 6 figure 3. demonstration kit schematic: detail of the poe+ section based on flyback topology with synchronous rectification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 figure 4. assembly view: top layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 figure 5. assembly view: bottom layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 figure 6. top layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 7. inner layer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 figure 8. inner layer 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 figure 9. bottom layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 figure 10. efficiency measurements at 48 v input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 figure 11. dc-dc only efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 figure 12. overall efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 13. efficiency measurements at 48 v input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 figure 14. dc-dc only efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 15. overall efficiency measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 figure 16. startup from an ieee 802.3af injector with 2 a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 figure 17. startup from an ieee 802.3at injector with 4 a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 figure 18. switching between poe and auxiliary source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 figure 19. primary side power mosfet waveforms at 0 a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 figure 20. primary side power mosfet waveforms at 4 a load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 figure 21. details of primary side power mosfet waveforms at 4 a load . . . . . . . . . . . . . . . . . . . . . 26 figure 22. secondary side power mosfet waveforms at 0 a load . . . . . . . . . . . . . . . . . . . . . . . . . . 26 figure 23. secondary side power mosfet waveforms at 4 a load . . . . . . . . . . . . . . . . . . . . . . . . . . 27 figure 24. effect of a 12 v line transient on the converter at 4 a load. . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 25. effect of a 12 v line transient on the converter at 0 a load. . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 26. response of the converter to a 2 a - 4 a load transient . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 figure 27. response of the converter to a 0 a - 4 a load transient . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 figure 28. output ripple measurement at 4 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 figure 29. output ripple measurement at 4 a with infinite persistence . . . . . . . . . . . . . . . . . . . . . . . . 30 docid018573 rev 2 5/32 UM1063 electrical specifications 1 electrical specifications table 1. specifications for 3.3 v output parameter description min. typ. max. unit input voltage range applied at j3 connector 0 57 v operative input voltage 42 57 v uvlo vin rising edge 36 v vin falling edge 30 v auxiliary input voltage range 35 60 v output voltage (vout) vin= 42 v to 57 v, iout 0 to imax 3.25 3.35 3.45 v output current (iout) vin= 42 v to 57 v 0 6 a peak-to-peak output ripple 48 vin, iout=imax 20 30 mvpp inrush current limit 140 ma dc current limit 640 ma 3.3 v efficiency dc-dc only vin=48 v, iout=imax 90 % 3.3 v overall efficiency vin=48 v, iout=imax 87 % switching frequency 200 khz table 2. specifications for 5 v output parameter description min. typ. max. unit input voltage range applied at j3 connector 0 57 v operative input voltage 42 57 v uvlo vin rising edge 36 v vin falling edge 30 v auxiliary input voltage range 35 60 v output voltage (vout) vin= 42 v to 57 v, iout 0 to imax 4.95 5.1 5.25 v output current (iout) vin= 42 v to 57 v 0 4 a peak-to-peak output ripple 48vin, iout=imax 20 30 mvpp inrush current limit 140 ma dc current limit 640 ma 5 v efficiency dc-dc only vin=48 v, iout=imax 92 % 5 v overall efficiency vin=48 v, iout=imax 89 % switching frequency 200 khz demonstration kit schematic UM1063 6/32 docid018573 rev 2 2 demonstration kit schematic figure 2. demonstration kit schematic: detail of the poe+ input section including data transformer, diode bridges, protection, and optional cm choke ! - v 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 3 3 6 & % / 0 & % / 0 & % / 0 0 / % & 6 3 3 6 / 5 4 3 0 # h a s s i s # h a s s i s # h a s s i s # h a s s i s # h a s s i s # h a s s i s 2 4 . 2 4 . ! 5 8 ! u x i l i a r y i n p u t f r o n t a l o r ! 5 8 / p t i o n 3 t a n d a r d $ i o d e " r i d g e . o t - o u n t e d / p t i o n 3 t a n d a r d $ i o d e " r i d g e . o t - o u n t e d / p t i o n ! c t i v e " r i d g e . o t - o u n t e d / p t i o n ! c t i v e " r i d g e . o t - o u n t e d / p t i o n ) n p u t # o m m o n - o d e & i l t e r . o t - o u n t e d / p t i o n $ i f f e r e n t p o s i t i o n f o r 4 6 3 a n d # - c h o k e " y p a s s c a p a c i t o r s . o t - o u n t e d # . - # . - # n & 6 # n & 6 2 2 2 2 2 . - 2 . - $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! 4 0 4 0 2 . - 2 . - 2 . - 2 . - 2 2 2 2 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! # n & + 6 # n & + 6 # . - + 6 # . - + 6 2 + 2 + # n & 6 # n & 6 $ 3 4 4 ( 3 3 - # $ 3 4 4 ( 3 3 - # # n & 6 # n & 6 $ . - 3 - ! $ . - 3 - ! # . - 6 # . - 6 # n & 6 # n & 6 2 2 2 2 # u & 6 # u & 6 2 2 2 2 # n & 6 # n & 6 # n & 6 # n & 6 # . - 6 # . - 6 2 2 2 2 4 0 4 0 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! 2 . - 2 . - * 3 0 * 3 0 2 & e r r i t e " e a d o h m ! 2 & e r r i t e " e a d o h m ! # n & 6 # n & 6 2 2 2 2 2 2 2 2 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! 4 0 4 0 * $ ! 4 ! / 5 4 0 5 4 * $ ! 4 ! / 5 4 0 5 4 # u & 6 # u & 6 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! 2 2 2 2 2 2 2 2 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! * $ ! 4 ! 0 / 7 % 2 ) . 0 5 4 * $ ! 4 ! 0 / 7 % 2 ) . 0 5 4 2 . - 2 . - # n & 6 # n & 6 # n & 6 # n & 6 2 . - 2 . - # . - 6 # . - 6 2 2 2 2 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! # n & 6 # n & 6 # n & 6 # n & 6 2 2 2 2 4 % 4 ( , $ 4 % 4 ( , $ 2 . - 2 . - 2 & e r r i t e " e a d o h m ! 2 & e r r i t e " e a d o h m ! $ 3 - ! * ! 3 - ! $ 3 - ! * ! 3 - ! 4 0 4 0 $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! 4 % 4 ( , $ 4 % 4 ( , $ 4 0 4 0 # n & 6 # n & 6 4 0 4 0 4 . - 7 u r t h 3 4 . - 7 u r t h 3 docid018573 rev 2 7/32 UM1063 demonstration kit schematic figure 3. demonstration kit schematic: detail of the poe+ section based on flyback topology with synchronous rectification ! - v 6 3 3 0 / % & , / + 6 / 5 4 ! 5 8 0 2 % 3 % . 4 3 0 2 4 . ! 2 4 . ! 2 4 . 2 4 . ! 2 4 . 2 4 . 2 4 . 2 4 . 2 4 . ! 2 4 . 4 i t l e r e b m u . t n e m u c o $ e z i 3 e t a $ ! 4 i t l e r e b m u . t n e m u c o $ e z i 3 e t a $ ! 4 i t l e r e b m u . t n e m u c o $ e z i 3 e t a $ ! 0 o w e r c i r c u i t / u t p u t & i l t e r & e e d b a c k c i r c u i t 6 ! 5 8 ) n p u t & i l t e r 0 - c i r c u i t . / 4 % f o r 2 e s i s t o r s 7 h e r e n o t i n d i c a t e d t h e b o d y i s a n d t o l e r a n c e . / 4 % f o r # a p a c i t o r s 7 h e r e n o t i n d i c a t e d t h e b o d y i s a n d t h e v o l t a g e i s 6 . / 4 % 4 h e ! 2 4 . i s a d e d i c a t e d p l a n e o f s i g n a l g r o u n d t h a t w i l l b e c o n n e c t e d t o t h e 2 4 . p o w e r g r o u n d p l a n e c l o s e t o p i n a n d o f 0 - / p t i o n ! c t i v e # l a m p # i r c u i t . o t # o n n e c t e d . / 4 % f o r * u m p e r s * - a n d * - - o v e t h e s h o r t o n b o t h j u m p e r s a t t h e s a m e t i m e s h o r t b e t w e e n p i n a n d w h e n u s e d ! 5 8 i n p u t s h o r t b e t w e e n p i n a n d w h e n u s e d ! 5 8 i n p u t / p t i o n a l t e r n a t i v e p o w e r t r a n s f o r m e r s f o r e s e e n o n t h e p c b 0 / % 0 s e r i e s i n % 0 0 / % & s e r i e s i n % & $ . o t - o u n t e d / p t i o n $ i o d e 2 e c t i f i c a t i o n w i t h $ 0 a k b o d y . o t - o u n t e d 6 o u t / p t i o n $ i s c r e t e , i n e a r 2 e g u l a t o r o n 6 # . o t - o u n t e d / p t i o n ! l t e r n a t i v e s y n c h m o s f e t d r i v i n g c i r c u i t . o t # o n n e c t e d 2 + 2 + 2 2 2 2 4 0 4 0 2 + 2 + 4 0 4 0 2 2 2 2 # . - + 6 # . - + 6 2 2 2 2 # n & # n & 2 . - 2 . - # u & 6 x # u & 6 x 4 # / ) , # 2 ! & 4 $ ! ! , 4 # / ) , # 2 ! & 4 $ ! ! , $ . - 3 - ! $ . - 3 - ! # u & 6 # u & 6 # u 6 # u 6 4 # o i l c r a f t ( ! ! , 4 # o i l c r a f t ( ! ! , # u 6 # u 6 2 2 2 2 $ ! 5 8 $ ! 5 8 5 & a i r c h i l d & / $ ! 3 5 & a i r c h i l d & / $ ! 3 # n & + 6 # n & + 6 2 2 2 2 2 2 2 2 2 2 2 o h m 2 o h m # u & 6 # u & 6 2 + 2 + # u & 6 # u & 6 $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ $ 3 4 0 3 ( ! 3 - ! $ 3 4 0 3 ( ! 3 - ! # n & # n & # . - # . - 2 + 2 + 2 k 2 k 2 2 2 + 2 + 2 + 2 + 2 2 2 2 2 . - 2 . - 4 0 4 0 4 0 ! 5 8 4 0 ! 5 8 # . - 6 # . - 6 2 + 2 + # . - # . - 2 2 2 2 2 + 2 + 2 2 2 2 4 0 4 0 # n & # n & 4 0 4 0 $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ 2 + 2 + 2 2 2 2 $ , / + $ , / + , u ( - 3 3 - , , u ( - 3 3 - , # . - # . - $ 3 4 4 ( 3 3 - # $ 3 4 4 ( 3 3 - # 2 o h m 2 o h m # u & 6 # u & 6 * * 1 3 i $ 9 3 / 1 3 i $ 9 3 / $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ * - * u m p e r d o p p i o * - * u m p e r d o p p i o 2 2 2 2 2 + 2 + 1 - - " 4 , 4 3 / 4 1 - - " 4 , 4 3 / 4 2 + 2 + 4 0 , o k 4 0 , o k 2 + 2 + # u & 6 # u & 6 , u ( $ / - , , u ( $ / - , # u 6 # u 6 # n & # n & 2 4 " $ 2 4 " $ # p & # p & 5 4 3 ! ) , 4 3 / 4 5 4 3 ! ) , 4 3 / 4 4 0 4 0 2 2 2 2 2 + 2 + # p & # p & 5 & a i r c h i l d & / $ ! 3 5 & a i r c h i l d & / $ ! 3 # u 6 # u 6 * - * u m p e r d o p p i o * - * u m p e r d o p p i o # n & # n & # n & # n & 4 0 4 0 2 + 2 + 2 k 2 k # u & 6 # u & 6 6 $ $ $ % 4 3 0 # , 3 ' ! 4 2 4 . # 3 ! 2 4 . $ # # , 3 ! $ 4 4 0 2 4 . ' ! 4 6 # % x 0 a d 6 3 3 6 " # 4 , & 2 3 6 $ $ 5 0 - ( 4 3 3 / 0 5 0 - ( 4 3 3 / 0 # u 6 # u 6 2 + 2 + # u 6 # u 6 2 . - 2 . - $ ' 2 % % . , % $ $ ' 2 % % . , % $ 4 0 4 0 4 0 4 0 4 0 4 0 2 + 2 + 2 + 2 + * 3 ! * 3 ! 1 3 4 3 . , , ( 3 / 0 7 2 0 ! + 3 / 1 3 4 3 . , , ( 3 / 0 7 2 0 ! + 3 / 2 . - 2 . - # u & 6 # u & 6 $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ 4 0 4 0 # n & # n & 2 k 2 k 2 k 2 k # . - # . - 4 0 4 0 # n & # n & # . - # . - # u & x 6 # u & x 6 2 + 2 + # n & # n & $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ # u & 6 # u & 6 2 2 2 2 2 + 2 + 5 & a i r c h i l d & / $ ! 3 5 & a i r c h i l d & / $ ! 3 4 0 4 0 4 0 4 0 2 k 2 k $ . - 3 / $ $ . - 3 / $ 2 2 2 2 4 0 4 0 # n & # n & $ " ! 4 * 3 / $ $ " ! 4 * 3 / $ 2 2 2 2 board layout UM1063 8/32 docid018573 rev 2 3 board layout board size: 10 x 16 cm. layer copper thickness: 70 micron. figure 4. assembly view: top layer figure 5. assembly view: bottom layer ! - v ! - v docid018573 rev 2 9/32 UM1063 board layout figure 6. top layer figure 7. inner layer 1 ! - v ! - v board layout UM1063 10/32 docid018573 rev 2 figure 8. inner layer 2 figure 9. bottom layer ! - v ! - v docid018573 rev 2 11/32 UM1063 i/o connectors and test points 4 i/o connectors and test points this section provides a description of input/output connectors ( table 3 ), led indicators and commands ( table 4 ), as well as the available test points ( table 5 ). table 3. connectors connector label description j3 data and power input power and ethernet data input port j4 data output ethernet data output port j2 sp wall adapter input. use this input jack to connect auxiliary source without priority in respect to poe. j1 sa wall adapter input. use this input jack to connect auxiliary source with priority in respect to poe. j5 - output voltage connector jm1 - move the short on both jumpers at the same time: short between pin 1 and 2 when sa auxiliary source is used on j1 connector; short between pin 2 and 3 when sp auxiliary source is used on j2 connector jm2 - move the short on both jumpers at the same time: short between pin 1 and 2 when sa auxiliary source is used on j1 connector; short between pin 2 and 3 when sp auxiliary source is used on j2 connector table 4. leds led label description d20 aux on when an auxiliary source is applied to the board; proper selection of the auxiliary source connection is done with jumpers jm1 and jm2 d44 l1_ok on when t2p is asserted. this is achieved when a 2-finger event is detected. if, after a successful poe+ layer-1 classification, an auxiliary voltage is connected, the t2p signal is de-asserted and the l1_ok led is turned off. d26 green led on when output voltage is present. table 5. test points test point color description tp1 red data transformer bias voltage tp2 red positive of auxiliary source aux 1 on j2 tp3 black ground of auxiliary source aux 1 on j2 i/o connectors and test points UM1063 12/32 docid018573 rev 2 tp4 red input voltage vdd tp5 red secondary winding output tp6 red output voltage at j5 tp7 red positive of auxiliary source aux 2 on j1 tp8 black ground of auxiliary source aux 2 on j1 tp9 red input of the primary side winding tp10 red secondary winding output tp11 red vss - i/f ground voltage tp12 black output voltage ground at j5 tp13 red gate drive of the secondary side mosfet tp14 red vc supply voltage tp15 red gate drive of the primary side mosfet (connected to gat1) tp16 red drain of the primary side mosfet tp17 red gate drive of the active clamp mosfet (connected to gat2) tp18 red current sense input tp19 black rtn - dc-dc ground voltage tp20 red l1 status indicator - referred to output voltage ground tp21 red aux present indicator - referred to output voltage ground tp22 red poe voltage after the input diode bridges tp23 black ground of the poe voltage after the input diode bridges tp24 black chassis ground of the rj45 connectors table 5. test points (continued) test point color description UM1063 bill of material docid018573 rev 2 13/32 5 bill of material ta ble 6 shows the bill of material for the poe+ section based on the pm8803 configured in flyback topology with synchronous rectification using a gatedriver transformer. with minimal bom changes it is possible to switch from 3.3 v to 5 v output voltage. table 6. evalpm8803-fwd bom 3.3 v 5 v reference description value tol. voltage body vendor 1 1 evalpm8803 fly rev1 board pcb 88 c1,c2,c3,c4,c11c36, c44,c45 ceramic capacitor 100 nf 50 v 603 std 5 5 c5,c6,c7,c8,c30 ceramic capacitor 10 nf 10% 100 v 603 tdk nm nm c9,c22 ceramic capacitor nm 1812 nm 66 c10,c39,c41,c48c53, c59 ceramic capacitor 1 f 20% 16 v 603 std 1 1 c12 ceramic capacitor 2.2 nf 2 kv 1812 tdk nm nm c13,c20 ceramic capacitor nm 100 v 603 nm 3 3 c14,c16,c21 ceramic capacitor 1 nf 10% 100 v 603 tdk nm nm c15,c17,c24,c60 ceramic capacitor nm 100 v 805 nm 2 2 c18,c32 ceramic capacitor 0.1 f 10% 100 v 805 tdk 2 2 c19,c38 ceramic capacitor 22 nf 50 v 603 std nm nm c42,c46,c57,c66c69 ceramic capacitor nm 603 nm 1 1 c26 aluminium capacitor 33 f 20% 100 v 10x10.2 std 66 c27,c33,c35,c37c67, c68 ceramic capacitor 10 f 20% 6.3 v 805 std 2 2 c28,c29 ceramic capacitor 1 f 20% 100 v 1206 tdk 1 1 c31 ceramic capacitor 1 nf 10% 100 v 805 std 1 1 c34 aluminium capacitor 330 f 6.3 v 8x10.5 suncon bill of material UM1063 14/32 docid018573 rev 2 nm nm c40 ceramic capacitor nm 805 nm nm nm c43 aluminium capacitor nm 4x6 nm nm nm c47 ceramic capacitor nm 603 nm 1 1 c49 ceramic capacitor 10 nf 50 v 603 std 1 1 c50 ceramic capacitor 100 nf 50 v 603 std nm nm c51 ceramic capacitor nm 1206 nm option ac 1 1 c54 ceramic capacitor 470 pf 50 v 603 std 1 1 c55 ceramic capacitor 100 pf 50 v 603 std 1 1 c56 ceramic capacitor 22 nf 50 v 603 std 1 1 c61 ceramic capacitor 2.2 nf 2 kv 1812 tdk 1 1 d1, d21 std diode stth302s 200 v smc st nm nm d2,d3,d5,d6,d15d16, d18,d19 zener diode (bzx84c10) sot23 nm 1 1 d32 zener diode bzx84c10 sot23 std 88 d4,d7,d8,d9,d12d13, d14, d17 schottky diode stps2h100a 100 v sma st nm nm d10 tvs diode nm sma nm 1 1 d11 tvs diode smaj58a sma st 1 1 d20 led diode aux 2.2 v plcc-2 std nm nm d22 schottky diode (stps15l45cb) dpak nm 1 1 d23 schottky diode stps1h100a 100 v sma st nm nm d24,d25 bridge rectifier nm sdip nm 1 1 d26 led diode green led 2.2 v plcc-2 std nm nm d27 zener diode nm sot23 nm 66 d28,d34,d36,d37d39, d41 schottky diode bat46j 100 v sod323 st table 6. evalpm8803-fwd bom (continued) 3.3 v 5 v reference description value tol. voltage body vendor UM1063 bill of material docid018573 rev 2 15/32 2 2 d38, d41 schottky diode bat46j 100 v sod323 st option ac nm nm d31,d35 schottky diode nm sod323 nm nm nm d42 schottky diode nm sma nm 1 1 d44 led diode l1 ok 2.2 v plcc-2 std 2 2 jm1,jm2 connector jumper 3 pins male pitch 2.54 mm std 2 2 jumper jumper jumper 2 pins female pitch 2.54 mm std 2 2 j1,j2 power jack sa, sp std 1 1 j3 rj45 connector data and power input std 1 1 j4 rj45 connector data output std 1 1 j5 terminal block 2-way mor-10x10.5-p5-2pin std 1 1 l5 smt inductor 10 h mss7341-103ml coilcraft 1 1 l6 smt inductor 0.33 h do1813-331ml coilcraft nm nm l7 smt inductor nm nm nm q1,q2,q3,q4 mosfet, p-ch (irf6216pbf) so8 nm nm nm q5,q6,q7,q8 mosfet, n-ch (sts4nf100) so8 nm 1 1 q12 mosfet, n-ch sts14n3llh5 30 v so8 st 1 1 q14 transistor, npn mmbt3904lt1 40 v sot23 std 1 1 q16 transistor, pnp mmbt3906lt1 40 v sot23 std 1 1 q17 mosfet, n-ch si4848dy 150 v so8 vishay 1 1 q20 mosfet, p-ch si2325ds 150 v sot23 option ac nm nm q21 mosfet, p-ch irf6216pbf 150 v so8 nm 4 4 r1,r2,r5,r7 chip resistor 0 603 std nm nm r3,r4,r6,r8,r16 chip resistor nm 805 nm 4 4 r10,r11,r12,r13 chip resistor 75 603 std nm nm r14,r125 chip resistor nm 1206 nm table 6. evalpm8803-fwd bom (continued) 3.3 v 5 v reference description value tol. voltage body vendor bill of material UM1063 16/32 docid018573 rev 2 1 1 r15 chip resistor 0 805 std 2 2 r17,r43 ferrite bead mpz012101a 100 , 4 a 805 tdk 1 1 r18 chip resistor 100 k 1206 std nm nm r19,r20,r22,r25r39, r40,r41,r42 chip resistor nm 603 nm 4 4 r26,r37,r49,r54 chip resistor 0 0805 std 2 2 r27,r58 chip resistor 124 k 1% 603 std nm nm r28,r29,r30,r31r33, r34,r35,r36r70,r71, r100, r120,r121 chip resistor nm 603 nm 2 2 r32,r51 chip resistor 100 k 805 std 3 3 r38,r65,r117 chip resistor 4.75 k 1% 603 std 3 3 r44,r52,r119 chip resistor 1 k 603 std 2 2 r45,r99 chip resistor 47 k 603 std 1 1 r53 chip resistor 10 805 std 66 r60,r64,r68, r84,r87,r98 chip resistor 0 603 std 2 2 r62,r80 chip resistor 10 603 std nm nm r66,r81,r97 chip resistor nm 603 nm 2 2 r67,r106 chip resistor 10 k 603 std 1 1 r72 chip resistor 124 k 1% 603 std 1 1 r73 trimmer resistor 100 k vishay 2 2 r83,r107 chip resistor 100 k 603 std 1 1 r89 chip resistor 2.7 k 603 std 1 1 r90 chip resistor 3.31 k 1% 603 std table 6. evalpm8803-fwd bom (continued) 3.3 v 5 v reference description value tol. voltage body vendor UM1063 bill of material docid018573 rev 2 17/32 1 1 r91 chip resistor 10 603 std 1 1 r92 chip resistor 22 603 std 1 1 r93 chip resistor 680 603 std 1 1 r94 chip resistor 21 k 1% 603 std 1 1 r95 chip resistor 24.9 k 1% 603 std 1 1 r96 chip resistor 0 603 std nm nm r101 chip resistor nm 603 nm 1 1 r102 chip resistor 35.6 1% 805 std 1 1 r103 chip resistor 510 603 std 1 nm r104 chip resistor 3.31 k 1% 603 std nm 1 r104 chip resistor 4.75 k 1% 603 std 2 2 r108,r109 chip resistor 0.30 1% 1206 std low value 1 1 r111 chip resistor 12.4 k 1% 603 std nm 1 r112 chip resistor 15 k 1% 603 std 17 17 tp1,tp2,tp4,tp5tp6, tp7,tp9, tp10,tp13,tp14,tp15, tp16,tp17,tp18,tp20, tp21,tp22 test points red std 77 tp3,tp8,tp11, tp12,tp19,tp23,tp24 test points black std 2 2 t1,t2 poe+ magnetics eth1-230ld coilcraft nm nm t3 cm choke nm nm nm 1 t5 power transformer ha3691-al coilcraft 1 nm t5 power transformer ja4173-al coilcraft nm nm t6 power transformer (poe300f series) nm table 6. evalpm8803-fwd bom (continued) 3.3 v 5 v reference description value tol. voltage body vendor bill of material UM1063 18/32 docid018573 rev 2 nm nm t7 power transformer (poe13p series) nm 11t8 gate driver transformer da2319-al coilcraft 1 1 u1 poe+ controller pm8803 htssop20 st 3 3 u2,u3,u7 smt optocoupler fairchild fod817as 4pdip fairchild 1 1 u4 shunt regulator ts431ailt sot23-5 st nm nm u5 shunt regulator (ts2431ailt) sot23 nm table 6. evalpm8803-fwd bom (continued) 3.3 v 5 v reference description value tol. voltage body vendor docid018573 rev 2 19/32 UM1063 power-up sequence 6 power-up sequence it is recommended to apply power at poe input first, slowly increasing the voltage to verify the absence of abnormal input current levels. from about 2 v to about 12 v input, the demonstration kit performs the detection signature. at 10 v input the current drawn is about 400 a. in the range of 14 v to 23 v, the demonstration kit performs a class-4 classification, and the current drawn is about 40 ma. after those two steps are verified, the voltage can be increased to 48 v typical. the poe converter starts operations at about 36 v input. three green leds indicate proper operation of the poe and dc-dc section of the pm8803 demonstration kit: ? d44 is the t2p led and is on when the pm8803 has successfully recognized a type 2 pse or a 802.3at compliant injector; using a bench power supply to power up the pm8803 demonstration board, this led is off. ? d26 indicates the presence of the output voltage. ? d20 is the aux led and indicates the presence of an auxiliary voltage applied to the converter; proper selection of the auxiliary voltage is done with jumper jm1 and jm2: put a short between pin 1 and 2 when sa auxiliary source on j1 connector is used; put the short between pin 2 and 3 when sp auxiliary source on j2 connector is used. note: set the r73 trimmer at a value around 10 k adjust this value for best converter performances in terms of efficiency over its actual load range. note: in the case of sa external auxiliary source tests, it is strongly recommended to change the position of the 100 nf, 100 v from c18, at the input filter, where it is soldered to c60, across the internal hot-swap mosfet. this change of position, that has no impact on the standard compliance, permits an optimal behavior of the pm8803 device during the change of ground reference consequent to the power jack insertion/removal. test results UM1063 20/32 docid018573 rev 2 7 test results 7.1 efficiency measurement with 3.3 v output figure 10. efficiency measurements at 48 v input figure 11. dc-dc only efficiency measurements ! - v ( i i l f l h q f \ > @ , r x w > $ @ 9 r x w h i i l f l h q f \ # 9 r y h u d o o ' & ' & ! - v ( i i l f l h q f \ > @ , r x w > $ @ 9 r x w ' & ' & r q o \ h i i l f l h q f \ ' & ' & 9 ' & ' & 9 ' & ' & 9 docid018573 rev 2 21/32 UM1063 test results figure 12. overall efficiency measurements 7.2 efficiency measurements with 5 v output figure 13. efficiency measurements at 48 v input ! - v ( i i l f l h q f \ > @ , r x w > $ @ 9 r x w r y h u d o o h i i l f l h q f \ r y h u d o o 9 r y h u d o o 9 r y h u d o o 9 ! - v ( i i l f l h q f \ > @ , r x w > $ @ 9 r x w h i i l f l h q f \ # 9 r y h u d o o ' & ' & test results UM1063 22/32 docid018573 rev 2 figure 14. dc-dc only efficiency measurements figure 15. overall efficiency measurements ! - v ( i i l f l h q f \ > @ , r x w > $ @ 9 r x w ' & ' & r q o \ h i i l f l h q f \ ' & ' & 9 ' & ' & 9 ' & ' & 9 ! - v ( i i l f l h p f \ > @ , r x w > $ @ 9 r x w r y h u d o o h i i l f l h q f \ r y h u d o o 9 r y h u d o o 9 r y h u d o o 9 docid018573 rev 2 23/32 UM1063 test results 7.3 waveforms the following images were taken on a 5 v output demonstration board. similar waveforms are also applicable for the 3.3 v output version. 7.3.1 startup sequence from poe/poe+ injectors figure 16. startup from an ieee 802.3af injector with 2 a load note the inrush current limited at about 140 ma and the t2p signal not asserted. figure 17. startup from an ieee 802.3at injector with 4 a load test results UM1063 24/32 docid018573 rev 2 note, in this case, the presence of the 2-finger during the classification phase and thet2p signal now asserted (t2p is valid low). 7.3.2 transition from poe to auxiliary and auxiliary to poe figure 18 shows the behavior of the pm8803 when commuting sources. the image depicts the transition from poe to an auxiliary source whose voltage is ~10 v lower then poe. it can be seen that when the auxiliary voltage is applied (sa pin goes above its threshold) the current drawn from the poe drops to a few milliamps. smooth transition occurs as can be seen from the output voltage (blue line). figure 18. switching between poe and auxiliary source docid018573 rev 2 25/32 UM1063 test results 7.3.3 primary side mosfet figure 19. primary side power mosfet waveforms at 0 a load figure 20. primary side power mosfet waveforms at 4 a load test results UM1063 26/32 docid018573 rev 2 figure 21. details of primary side power mosfet waveforms at 4 a load 7.3.4 secondary side mosfet figure 22. secondary side power mosfet wavefor ms at 0 a load docid018573 rev 2 27/32 UM1063 test results figure 23. secondary side power mosfet wavefor ms at 4 a load test results UM1063 28/32 docid018573 rev 2 7.3.5 line transient figure 24 depicts the effect of a line transient on the poe converter. a 12 v step on a 42 v input poe line (green trace) is shown. the hot-swap mosfet (yellow trace) withstands the transient while the input current (pink trace) is limited during the input capacitor charge; the converter continues to work and the output voltage (blue trace) remains in regulation. figure 24. effect of a 12 v line transient on the converter at 4 a load figure 25. effect of a 12 v line transient on the converter at 0 a load docid018573 rev 2 29/32 UM1063 test results 7.3.6 load transient figure 26. response of the converter to a 2 a - 4 a load transient figure 27. response of the converter to a 0 a - 4 a load transient test results UM1063 30/32 docid018573 rev 2 7.3.7 output ripple figure 28. output ripple measurement at 4 a figure 29. output ripple measurement at 4 a with infinite persistence docid018573 rev 2 31/32 UM1063 revision history 8 revision history table 7. document revision history date revision changes 23-mar-2011 1 initial release. 18-feb-2013 2 document title has been changed. UM1063 32/32 docid018573 rev 2 please read carefully: information in this document is provided solely in connection with st products. stmicroelectronics nv and its subsidiaries (?st ?) reserve the right to make changes, corrections, modifications or improvements, to this document, and the products and services described he rein at any time, without notice. all st products are sold pursuant to st?s terms and conditions of sale. purchasers are solely responsible for the choice, selection and use of the st products and services described herein, and st as sumes no liability whatsoever relating to the choice, selection or use of the st products and services described herein. no license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. i f any part of this document refers to any third party products or services it shall not be deemed a license grant by st for the use of such third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoev er of such third party products or services or any intellectual property contained therein. unless otherwise set forth in st?s terms and conditions of sale st disclaims any express or implied warranty with respect to the use and/or sale of st products including without limitation implied warranties of merchantability, fitness for a particular purpose (and their equivalents under the laws of any jurisdiction), or infringement of any patent, copyright or other intellectual property right. st products are not authorized for use in weapons. nor are st products designed or authorized for use in: (a) safety critical applications such as life supporting, active implanted devices or systems with product functional safety requirements; (b) aeronautic applications; (c) automotive applications or environments, and/or (d) aerospace applications or environments. where st products are not designed for such use, the purchaser shall use products at purchaser?s sole risk, even if st has been informed in writing of such usage, unless a product is expressly designated by st as being intended for ?automotive, automotive safety or medical? industry domains according to st product design specifications. products formally escc, qml or jan qualified are deemed suitable for use in aerospace by the corresponding governmental agency. resale of st products with provisions different from the statements and/or technical features set forth in this document shall immediately void any warranty granted by st for the st product or service described herein and shall not create or extend in any manner whatsoev er, any liability of st. st and the st logo are trademarks or register ed trademarks of st in various countries. information in this document supersedes and replaces all information previously supplied. the st logo is a registered trademark of stmicroelectronics. all other names are the property of their respective owners. ? 2013 stmicroelectronics - all rights reserved stmicroelectronics group of companies australia - belgium - brazil - canada - china - czech republic - finland - france - germany - hong kong - india - israel - ital y - japan - malaysia - malta - morocco - philippines - singapore - spain - sweden - switzerland - united kingdom - united states of america www.st.com |
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