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may 2014 docid025612 rev 1 1/30 AN4415 application note power over ethernet-pd conver ter with 3.3 v, 3 a output, standard ieee 802.3af compliant antonio rotta introduction this document focuses on a demonstration board design for a simple, low cost 3.3 v, 3 a flyback converter based on the pm8800a device. the pm8800a is a hi ghly integrated device embeddi ng an ieee 802.3af compliant ?powered device? (pd) interface together with a pwm controller. it can be successfully used in all lo w power, low cost poe applications. figure 1. steval-tsp006v2 demonstration board photo www.st.com
contents AN4415 2/30 docid025612 rev 1 contents 1 main characteristics and circ uit description . . . . . . . . . . . . . . . . . . . . . 4 2 electrical diagram and bill of material for 3.3 v at 3 a . . . . . . . . . . . . . . 5 3 measurements results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.1 efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3.2 output voltage ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.3 startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 3.4 primary side waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3.5 dynamic load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.6 short-circuit behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 4 loop compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 5 supporting material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 6 pcb layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 7 revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
docid025612 rev 1 3/30 AN4415 list of figures 30 list of figures figure 1. steval-tsp006v2 demons tration board photo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 figure 2. circuit diagram 3.3 v at 3 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 figure 3. overall and dc-dc efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 figure 4. efficiency input stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 figure 5. ripple 3.3 v at 3 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 6. ripple 3.3 v at 1.5 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 7. ripple 3.3 v at 3 a removing l4 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 8. ripple 3.3 v at 1.5 a removing l4 filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 figure 9. startup - full load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 10. startup - full load sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 11. startup - 1.5 a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 12. startup - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 figure 13. steady state 3 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 14. steady state 1.5 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 15. steady state 100 ma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 16. steady state no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 figure 17. dynamic load 3 a - 1.5 a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 18. dynamic load 3 a - 300 ma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 19. dynamic load 2500 ma - 500 ma . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 figure 20. ocp detection - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 21. ocp detection - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 22. ocp steady state - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 23. ocp steady state- no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 figure 24. ocp removed - full load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 figure 25. ocp removed - no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 figure 26. gain loop full load 48 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 figure 27. gain loop half load 48 v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 figure 28. gain loop full load 40 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 figure 29. gain loop full load 60 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 figure 30. electrical diagram (general) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 figure 31. pcb layer: top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 32. pcb layer: layer 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 33. pcb layer: layer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 34. pcb layer: bottom view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 figure 35. pcb layer: components on top side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 8 figure 36. pcb layer: components on bottom side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
main characteristics and circuit description AN4415 4/30 docid025612 rev 1 1 main characteristics and circuit description the main characteristics (reference and electric al specifications) of the converter are listed in table 2 . this document details the characteristics an d performances of the pm8800a demonstration kit steval-tsp006v2 which has been designed to cover a broad range of power over ethernet (poe) applications. the pm8800a is a highly integrated device embedding an ieee 802.3af compliant powered device (pd) interface togeth er with a pwm controller and s upport for auxiliary sources. even though the pm8800a can be configured to work in both isolated and non-isolated topologies, single or double output; this app lication note focuses on a low cost isolated flyback converter topology with diode rectificat ion, 3.3 v output voltage with an up to 3 a output current capability. auxiliary sources can be connec ted to the board on 2 input co nnectors. one input (aux ii) allows prevalence of the auxiliary sources wit h respect to the poe, while the other input (aux i) allows the usage of a wall adaptor with voltage lower than th e internal poe uvlo threshold and still benefits from the in herent inrush and dc current limit. the above mentioned configurations are all supported by the pm8800a demonstration kit as options on the same pcb. table 3: bill of material 3.3 v at 3 a provides the list of components to be mounted to obtain a 3.3 v at 3 a demonstration board. table 1. reference reference code device pm8800a demonstration board steval-tsp006v2 table 2. electrical specification parameter specifications input voltage supplies vin [vdc ] from 40 to 60 v at 13 w output voltage vout [vdc ] 3.3 vdc 5% at 3 a peak-to-peak output ripple 30 mv (100 mv without l4 output filter) efficiency dc-dc full-load > 83% efficiency overall peak > 80% transient response ? v outpk to 50% load step < 400 mv ? v in load line case < 0.5% gloop bandwidth 4 khz gloop phase margin at 0 db 64 deg. gloop db margin at 0 deg. -11 db
docid025612 rev 1 5/30 AN4415 electrical diagram and bill of material for 3.3 v at 3 a 30 2 electrical diagram and bill of material for 3.3 v at 3 a figure 2. circuit diagram 3.3 v at 3 a $*1' 571 5 10 $*1' & q) 9 ' %$7 - 62' 5&/$66 ' %$ 7 - 62' $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ $8;,b,5/ '&&/ ' %$ 7 - 62' 5 . 4 6761) 62 & x) 9 5 . ' %$7- 62' &6 ' 677+5$ 60$ 5 . 5 5 5 n & x) 9 *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' *' 5 5 5 n & x) & s) 5 5 5 5 5 5 . *1' & 10 5 10 5 . 5 n - 5 n 5 n 5 . & q) & s) & x) 5 5 & s) 5 n 5 5 / x+ 0(0/ 5 5 & x) & x) 57 57 5 5 & x) [ 9 966 ' %=;& 627 5 rkp & q) 9 5 n & x) 7 32(3/ & q) 9 9&& & x) [ 9 *1' - ' 60$-$ 5 n ' *uhhq/(' & x) 9 ' ')6 ' ')6 5 n ' *uhhq/(' &203 - $*1' 8 30$ +7 6623 57 66 $8;,, 9,1 &6 &203 9)% $*1' 5&/$66 $8;,b,5/ '&&/ *1' *' 9&& q3*' ([3dg 966 $*1' & x) 9 9,1 $8;,, 9)% ' 30(*(3 62' 5 5 73 %/$&. 571 73 %/$&. 73 %/$&. 73 %/$&. 5 5 966 73 %/$&. 966 32(b) 32(b) & x) 9 & x) 9 & x) 9 73 %/$&. & x) 9 & x) 9 7kh$*1'lvdghglfdwhgsodqhrivljqdojurxqgwkdw zlooehfrqqhfwhgwrwkh*1'srzhujurxqgsodqhforvhwrslq ri30 :khuhqrwlqglfdwhgwkherg\lvdqgwrohudqfh 127(irufdsdflwruv :khuhqrwlqglfdwhgwkherg\lvdqgwkhyrowdjhlv9 & x) 9 *1' *1' 4 )'1 627 287 287 287 5 5 5 q3*' 287387 &kdvvlv 7 +1/7/$7/) - 5-'dwd-dfn & q) .9 *1' 5 5 5 5 &kdvvlv &kdvvlv ' 677+5$ 60$ & q) 9 5 5 &kdvvlv & q) .9 5 5 &kdvvlv 5 5 - 5- gdwddqgsrzhumdfn & q) 9 &kdvvlv & q) 9 & q) 9 5 5 & q) 9 & q) 9 8 76$,/7 627 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg 73 5hg & x) 9 5 . / x+ '2+0/ & q) 9 & q) 9 8 )dlufklog)2'$ *1' 5 5 & q) 9 5 5 $0y
electrical diagram and bill of ma terial for 3.3 v at 3 a AN4415 6/30 docid025612 rev 1 . table 3. bill of material 3.3 v at 3 a item ref. description value pcb footprint supplier voltage 1 c1 ceramic capacitor 1 nf c0805 several 100 v 2 c2 ceramic capacitor 0.1 ? f c0805 several 100 v 3 c5 ceramic capacitor 10 nf c0603 several 100 v 4 c7 ceramic capacitor 1 nf c0603 several 100 v 5 c10 ceramic capacitor 1 nf c0805 several 100 v 6 c11 ceramic capacitor 0.1 ? f c0805 several 100 v 7 c12 elect. capacitor 22 ? f c-pol8-10 panasonic eeefk2a220p 100 v 8 c13 ceramic capacitor 1 nf c0805 several 100 v 9 c14 ceramic capacitor 0.1 ? f c0603 several 50 v 10 c15 ceramic capacitor 0.1 ? f c0805 several 100 v 11 c16 ceramic capacitor 10 nf c0603 several 100 v 12 c17 ceramic capacitor 1 ? f c1206 several 100 v 13 c18 ceramic capacitor 1 nf c0603 several 100 v 14 c19 ceramic capacitor 1 nf c0603 several 100 v 15 c20 ceramic capacitor 1 ? f c1206 several 100 v 16 c21 ceramic capacitor 470 pf c0603 several 50 v 17 c22 ceramic capacitor 0.1 ? f c0603 several 50 v 18 c23 ceramic capacitor 0.1 ? f c0603 several 50 v 19 c24 ceramic capacitor 1 nf c0805 several 200 v 20 c26 ceramic capacitor 1 nf c0805 several 200 v 21 c27 ceramic capacitor n. m. c0805 several 50 v 22 c28 ceramic capacitor 1 ? f c0603 tdk c1608x5r1e105k 25 v 23 c29 ceramic capacitor 1 nf c0805 several 200 v 24 c30 ceramic capacitor 2.2 nf c1812 tdk 4532x7r3d222k 2 kv 25 c31 ceramic capacitor 1 nf c0805 several 200 v 26 c33 ceramic capacitor 0.1 ? f c0603 several 50 v 27 c35 ceramic capacitor 2.2 nf c1812 tdk 4532x7r3d222k 2 kv 28 c37 ceramic capacitor 560 pf c0805 several 50 v 29 c38 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 30 c41 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 31 c42 ceramic capacitor 1 ? f c0603 several 16 v
docid025612 rev 1 7/30 AN4415 electrical diagram and bill of material for 3.3 v at 3 a 30 32 c47 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 33 c48 ceramic capacitor 1 ? f c0603 tdk c1608x5r1e105k 25 v 34 c51 ceramic capacitor 22 nf c0603 several 50 v 35 c53 elect. capacitor 330 ? f c-pol8-6_3 panasonic eeefk1c331p 16 v 36 c54 ceramic capacitor 100 pf c0603 several 50 v 37 c56 ceramic capacitor 0.1 ? f c0603 several 50 v 38 d3 diode bridge df01s df01s diodes 39 d5 zener diode bzx84c10 sot23 several 40 d10 diode bridge df01s df01s diodes 41 d14 diode stth2r02a sma stmicroelectronics ? 42 d15 diode stth2r02a sma stmicroelectronics 43 d18 tvs diode smaj58a sma stmicroelectronics 44 d19 led diode green led led-tlge1100b toshiba 45 d21 diode bat46j sod323 stmicroelectronics 46 d23 diode bat46j sod323 stmicroelectronics 47 d28 schottky diode pmeg3050ep sod128 nxp 48 d29 diode bat46j sod323 stmicroelectronics 49 d30 diode bat46j sod323 stmicroelectronics 50 d36 led diode green led led-tlge1100b toshiba 51 j1 connector rj45 data and power jack rj45-8pin several 52 j2 connector rj45 data jack rj45-8pin several 53 j3 connector con3 p-jack-rapc722 switchcraft 54 j4 connector con3 p-jack-rapc722 switchcraft 55 j6 connector mor-10x10.5-p5-2pin mor-2poli-508 several 56 l1 inductor 5.6 ? h me3220-562ml coilcraft 57 l4 inductor 0.33 ? h lps4012-331l coilcraft 58 q1 mosfet sts4nf100 so8 stmicroelectronics 59 q2 mosfet fdn86246 sot23 fairchild 60 r1 resistor 15 k ? r0805 several 61 r2 resistor 47 k ? r0805 several 62 r3 resistor 47 k ? r0805 several 63 r4 resistor 470 k ? r0805 several 64 r5 resistor 15 k ? r0805 several table 3. bill of material 3.3 v at 3 a (continued) item ref. description value pcb footprint supplier voltage
electrical diagram and bill of ma terial for 3.3 v at 3 a AN4415 8/30 docid025612 rev 1 65 r8 resistor 10 k ? r0603 several 66 r10 resistor 10 k ? r0603 several 67 r11 resistor 52.3 ?? -1% r0805 several 68 r13 resistor 22.1 k ?? -1% r0603 several 69 r14 resistor 10 ? r0603 several 70 r15 resistor 0 ? r0805 several 71 r16 resistor 0 ? r0805 several 72 r17 resistor 124 k ? -1% r0603 several 73 r19 resistor 510 ? r0603 several 74 r20 resistor 4.7 k ? r0603 several 75 r23 resistor 0 ? r0805 several 76 r24 resistor 75 ? r0805 several 77 r25 resistor 56 ? r0805 several 78 r27 resistor 75 ? r0805 several 79 r29 resistor 75 ? r0805 several 80 r30 resistor n. m. r1206 several 81 r31 resistor 75 ? r0805 several 82 r32 resistor 10 ? r0603 several 83 r33 resistor 10 k ? r0603 several 84 r35 sense resistor 0.33 ?? -1% r1206 vishay - rcwe1206r330fke 85 r36 resistor 560 ? r0603 several 86 r37 resistor 0 ? r0603 several 87 r40 resistor 4.7 ? r1206 several 88 r43 resistor 0 ? r0805 several 89 r44 resistor 0 ? r1206 several 90 r45 resistor 47 k ? r0603 several 91 r48 resistor 390 ? r0603 several 92 r50 resistor 10 ? r0603 several 93 r51 resistor n. m. r0603 several 94 r52 resistor 3.3 k ?? -1% r0603 several 95 r54 resistor 2.2 k ? r0603 several 96 r55 resistor 21 k ? - 1% r0603 several 97 r56 resistor 12.4 k ? - 1% r0603 several 98 tp1 test point red th-5013 keystone table 3. bill of material 3.3 v at 3 a (continued) item ref. description value pcb footprint supplier voltage
docid025612 rev 1 9/30 AN4415 electrical diagram and bill of material for 3.3 v at 3 a 30 99 tp2 test point black th-5013 keystone 100 tp3 test point red th-5013 keystone 101 tp4 test point black th-5013 keystone 102 tp6 test point red th-5013 keystone 103 tp7 test point black th-5013 keystone 104 tp8 test point red th-5013 keystone 105 tp9 test point black th-5013 keystone 106 tp10 test point red th-5013 keystone 107 tp11 test point red th-5013 keystone 108 tp12 test point black th-5013 keystone 109 tp13 test point red th-5013 keystone 110 tp14 test point red th-5013 keystone 111 tp16 test point red th-5013 keystone 112 tp17 test point red th-5013 keystone 113 tp19 test point black th-5013 keystone 114 t1 data transfo. h2019nl / tla-6t127lf pulse-h2019 pulse 115 t3 power transfo. poe13p-33l poe13p coilcraft 116 u1 controller ic pm8800a htssop16 stmicroelectronics 117 u2 optocoupler fairchild fod817a fod817 fairchild 118 u5 voltage reference ts431ailt sot23-5l stmicroelectronics table 3. bill of material 3.3 v at 3 a (continued) item ref. description value pcb footprint supplier voltage
measurements results AN4415 10/30 docid025612 rev 1 3 measurements results 3.1 efficiency figure 3. overall and dc-dc efficiency figure 3 shows overall and dc-dc efficiencies for the converter. overall efficiency includes all loss from the rj45 to the 3.3 v output voltage rail. dc-dc efficiency is a figure of a merit of the converter standalone and typically does not include the losses associated to the poe interface section, that are: the rj45 con nector, data transformer, bridges, power consumption of the i/f section of the pm8800a device. (ii >@ ,rxw >p$@ 67(9$/ 7639 hiilflhqf\ 2yhudoo hiilflhqf\ '&'& hiilflhqf\ $0
docid025612 rev 1 11/30 AN4415 measurements results 30 figure 4. efficiency input stage figure 4 shows the efficiency comparison implemen ting three different settings of bridge rectification on the board. no relevant differ ences have been highlighted using a standard diode bridge (1 a or 0.5 a). the best efficien cy has been captured using a bridge with four discrete 1 a schottky diodes, reaching even a gain of about 1%. (iilflhqf\>@ ,qsxwfxuuhqw >p$@ (iilflhqf\ lqsxw vwdjh (ii ,) zlwk eulgjh $ (ii ,) zlwk eulgjh $ (ii ,) zlwk [6fkrwwn\ $ $0
measurements results AN4415 12/30 docid025612 rev 1 3.2 output voltage ripple above measurement are referred to the output voltage ripple (around 30 mv in full load condition). a ripple voltage comparison has been done replacing a 0.33 ? h inductor on the l4 position with a resistor r47 = 0 ? . the output voltage ripple, as shown in figure 7 , is around 100 mv in full load condition. figure 5. ripple 3.3 v at 3 a f igure 6. ripple 3.3 v at 1.5 a ch2: output voltage ch3: output current ch2: output voltage ch3: output current figure 7. ripple 3.3 v at 3 a removing l4 filter figure 8. ripple 3.3 v at 1.5 a removing l4 filter ch2: output voltage ch3: output current ch2: output voltage ch3: output current
docid025612 rev 1 13/30 AN4415 measurements results 30 3.3 startup figure 9. startup - full load figure 10. startup - full load sequencing ch1: input voltage ch2: output voltage ch3: output current ch1: vss - gnd ch2: output voltage ch3: input current ch4: vcc figure 11. startup - 1.5 a figure 12. startup - no load ch1: input voltage ch2: output voltage ch3: output current ch1: input voltage ch2: output voltage ch3: output current
measurements results AN4415 14/30 docid025612 rev 1 3.4 primary side waveforms figure 13. steady state 3 a figure 14. steady state 1.5 a ch1: primary mosfet drain ch2: primary mosfet gate ch3: output current ch4: vcc ch1: primary mosfet drain ch2: primary mosfet gate ch3: output current ch4: vcc figure 15. steady state 100 ma figure 16. steady state no load ch1: primary mosfet drain ch2: primary mosfet gate ch3: output current ch4: vcc ch1: primary mosfet drain ch2: primary mosfet gate ch3: output current ch4: vcc
docid025612 rev 1 15/30 AN4415 measurements results 30 3.5 dynamic load figure 17. dynamic load 3 a - 1.5 a figure 18. dynamic load 3 a - 300 ma figure 19. dynamic load 2500 ma - 500 ma ch1: output voltage ch3: output current ch1: output voltage ch3: output current
measurements results AN4415 16/30 docid025612 rev 1 3.6 short-circuit behavior figure 20. ocp detection - full load figure 21. ocp detection - no load ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs figure 22. ocp steady state - full load figure 23. ocp steady state- no load ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs
docid025612 rev 1 17/30 AN4415 measurements results 30 figure 24. ocp removed - full load figure 25. ocp removed - no load ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs ch1: primary mosfet drain ch2: soft-start ch3: output current ch4: vcs
loop compensation AN4415 18/30 docid025612 rev 1 4 loop compensation figure 26. gain loop full load 48 v figure 27. gain loop half load 48 v
docid025612 rev 1 19/30 AN4415 loop compensation 30 figure 28. gain loop full load 40 v figure 29. gain loop full load 60 v
loop compensation AN4415 20/30 docid025612 rev 1 table 4. gain loop measurement 12 vout 48 v, 3 a 40 v, 3 a 60 v, 3 a 48 v, 1.5 a bw [khz] 4.25 3.91 4.52 4.53 phase margin [deg.] at 0 db 64 62 65 66 gain margin [db] at 0 deg. -11 -11 -11 -11
docid025612 rev 1 21/30 AN4415 supporting material 30 5 supporting material figure 30. electrical diagram (general) $*1' 62 7 / 5 10 ' 10 60$ 9 57 1 4 10 '3 dfn 4 10 627 4 10 3bvrxufh 3bgudlq 3bjdwh 5 10 $*1' & q) 9 ' 10 60$ 9 ' %$ 7 - 62' 5&/$66 ' %$ 7 - 62' b,5/ b,5/ b,5/ b,5/ b,5/ b,5/ b,5/ b,5/ b,5/ b,5/ $8;,b,5/ b,5/ b,5/ b,5/ b,5/ b, 73 5hg10 $8;, , 5 10 $qrgh $qrgh .dwkrgh '&&/ 5 . 4 6761) .dwkrgh &6 ' 677+5$ 60$ ' 10 60$ 9 ' 10 5 . 5 5 5 . & x) 9 & 10 5 10 *' 5 5 5 n & x) 5 5 5 5 . ' *uhhq/('10 6\ q f , q s x w *1' 5 rkp10 5 . 5 n - 8 6kdus3&+'10 5 n & 10 9 5 . & q) 5 . 5 10 & s) ' 10 60% & x) 5 5 ' 10 3rzhu)/$7[ $ . $ ' 10 3rzhu)/$7[ & s) 5 . 5 5 / x+ 0(0/ 5 5 & x) ' 10 60$ 9 & x) 57 57 5 10 5 5 & x) [ 9 966 & 10 ' %=;& 627 5 rkp & q) 9 5 . & x) 7 &2,/&5$)732(3/ & q) 9 9&& & x) [ 9 / x+10 /36/ :khuhqrwlqglfdwhgwkherg\lvdqgwrohudqfh 127(iru fdsdflwruv :khuhqrwlqglfdwhgwkherg\lvdqgwkhyrowdjhlv9 *1' - 5 5 & s) ' 60$- $ 5 . ' *uhhq/(' & x) 9 / x+ '2+0/ ' ')6 ' ')6 '& 2 87 387 7kh$*1'lvdghglfdwhgsodqhrivljqdojurxqgwkdw zlooehfrqqhfwhgwrwkh*1'srzhujurxqgsodqhforvhwrslq ri30 5 . ' *uhhq/( ' &203 - 5 510 $o w h u q d w l y h g l r g h sdfn djhv ' 10 60$ 9 $*1' 8 30$ +76623 57 66 $8;,, 9,1 &6 &203 9)% $*1' 5&/$66 $8;,b,5/ '&&/ *1' *' 9&& q3*' ([3dg 966 $*1' & x) 9 66 9,1 $8;,, 9)% ' 30(*(3 62' 7 &2,/&5$)7 32(310 & 10 9 3bvrxufh 3bjdwh 5 5 5 10 5 10 ' 10 60$ 9 73 %/$&. 571 73 %/$&. 73 %/$&. 73 %/ $&. 5 5 sdfndjhv srvvleohrswlrqv :xuwk6ru3xovh3(1/ 966 73 %/$&. 966 32(b) 32(b) & x) 9 ' 10 60$ 92/7$ *(! & x) 9 & x) 9 & x)10 / x+10 /36/ 73 %/$&.10 73 %/$&. & x)10 [ 9 / x+10 '2+0/ 571 571 571 '& 2 87 387 5 .10 & x) 9 - 5 510 5 10 5 10 8 76$,/7 627 & x) 9 & x)10 9 & x) 9 & x)10 9 *1' 5 10 *1' 5 10 & x)10 9 7 3xovh3(1/10 & x)10 9 7 &2,/&5$)7+$$/10 & s)10 5 10 287 287 287 ' 10 3rzhu)/$7[ ' 10 62' & x)10 9 4 )'1 627 7 :xuwk610 73 5hg & x)10 9 ' +'10 4 10 62 5 5 5 ' 10 60$ iruhv hhqp xowlsohirrwsulqwlqrughuwrdoorfdwh [dqg[pperglhv & x)10 9 q3*' &kdvvlv 7 +7/$7/) & q) .9 - 5-gdwd mdfn *1' 5 10 5 5 5 5 &kdvvlv &kdvvlv ' +'10 ' %$7-10 62' ' 677+5$ 60$ & q) 9 5 5 &kdvvlv & q) .9 5 5 &kdvvlv 5 5 - 5- gdwddqgsrzhumdfn & q) 9 &kdvvlv & q) 9 srvvleohrswlrqv vwgglrgheulgjh$ vwgglrgheulgjh$ glvfuhwh6fkrwwn\glrgh$sodfhglrghvlq60$sdfndjh dooriwkhp duhorfdwhgrqerwwrp v lgh & q) 9 5 5 & q) 9 & q) 9 & s)10 ' 10 60$ 9 ' %$ 7 - 62' 4 10 627 73 5hg & q)10 73 5hg ' %$7- 62' 73 5hg & x) 9 73 5hg 73 5hg 5 . 73 5hg10 73 5hg 73 5hg 73 5hg 73 5hg10 73 5hg & x) 9 8 76$,/710 627 5 . ' 10 60$ 9 & 10 9 & 10 9 & q) 9 *1' & q) 9 8 )dluf klog )2'$ *1' 5 5 & q) 9 5 5 5 10 $09
supporting material AN4415 22/30 docid025612 rev 1 table 5. bill of material (general) item ref. description value pcb footprint supplier voltage 1 c1 ceramic capacitor 1 nf c0805 several 100 v 2 c2 ceramic capacitor 0.1 ? f c0805 several 100 v 3 c3 ceramic capacitor n. m. c0805 several 100 v 4 c4 ceramic capacitor n. m. c0805 several 100 v 5 c5 ceramic capacitor 10 nf c0603 several 100 v 6 c6 ceramic capacitor 100 pf - n. m. c0603 several 50 v 7 c7 ceramic capacitor 1 nf c0603 several 100 v 8 c8 ceramic capacitor n. m. c0603 several 100 v 9 c9 ceramic capacitor n. m. c0603 several 100 v 10 c10 ceramic capacitor 1 nf c0805 several 100 v 11 c11 ceramic capacitor 0.1 ? f c0805 several 100 v 12 c12 electrol. capacitor 22 ? f c-pol8-10 panasonic eeefk2a220p 100 v 13 c13 ceramic capacitor 1 nf c0805 several 100 v 14 c14 ceramic capacitor 0.1 ? f c0603 several 50 v 15 c15 ceramic capacitor 0.1 ? f c0805 several 100 v 16 c16 ceramic capacitor 10 nf c0603 several 100 v 17 c17 ceramic capacitor 1 ? f c1206 several 100 v 18 c18 ceramic capacitor 1 nf c0603 several 100 v 19 c19 ceramic capacitor 1 nf c0603 several 100 v 20 c20 ceramic capacitor 1 ? f c1206 several 100 v 21 c21 ceramic capacitor 470 pf c0603 several 50 v 22 c22 ceramic capacitor 0.1 ? f c0603 several 50 v 23 c23 ceramic capacitor 0.1 ? f c0603 several 50 v 24 c24 ceramic capacitor 1 nf c0805 several 200 v 25 c26 ceramic capacitor 1 nf c0805 several 200 v 26 c27 ceramic capacitor n. m. c0805 several 50 v 27 c28 ceramic capacitor 1 ? f c0603 tdk c1608x5r1e105k 16 v 28 c29 ceramic capacitor 1 nf c0805 several 200 v 29 c30 ceramic capacitor 2.2nf c1812 tdk 4532x7rd222k 2kv 30 c31 ceramic capacitor 1 nf c0805 several 200 v 31 c32 ceramic capacitor n. m. c0603 several 50 v 32 c33 ceramic capacitor 0.1 ? f c0603 several 50 v 33 c34 ceramic capacitor 560 pf n. m. c0805 several 50 v
docid025612 rev 1 23/30 AN4415 supporting material 30 34 c35 ceramic capacitor 2.2 nf c1812 tdk 4532x7rd222k 2kv 35 c37 ceramic capacitor 560 pf c0805 several 50 v 36 c38 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 37 c39 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 38 c40 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 39 c41 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 40 c42 ceramic capacitor 1 ? f c0603 several 16 v 41 c43 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 42 c44 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 43 c45 ceramic capacitor 10 nf - n. m. c0603 several 50 v 44 c46 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 45 c47 ceramic capacitor 22 ? f c1206 tdk c3216x5r1e226m 16 v 46 c48 ceramic capacitor 1 ? f c0603 tdk c1608x5r1e105k 16 v 47 c49 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 48 c50 ceramic capacitor 22 ? f - n. m. c1206 tdk c3216x5r1e226m 16 v 49 c51 ceramic capacitor 22 nf c0603 several 50 v 50 c52 electrol. capacitor 330 ? f - n. m. c-pol8-6_3 panasonic eeefk1c331p 16 v 51 c53 electrol. capacitor 330 ? f c-pol8-6_3 panasonic eeefk1c331p 16 v 52 c54 ceramic capacitor 100 pf c0603 several 50 v6 v 53 c55 ceramic capacitor 0.1 ? f - n. m. c0603 several 50 v 54 c56 ceramic capacitor 0.1 ? f c0603 several 50 v 55 d1 diode n. m. sma several 56 d2 diode n. m. sma several 57 d3 diode bridge df01s df01s diodes 58 d4 diode bridge hd01 - n. m. hd01 diodes 59 d5 zener diode bzx84c10 sot23 several table 5. bill of material (general) (continued) item ref. description value pcb footprint supplier voltage
supporting material AN4415 24/30 docid025612 rev 1 60 d6 diode n. m. sma several 61 d7 diode n. m. sma several 62 d8 diode n. m. sma several 63 d9 diode n. m. sma several 64 d10 diode bridge df01s df01s diodes 65 d11 diode bridge hd01 - n. m. hd01 diodes 66 d12 diode n. m. sma several 67 d13 diode n. m. sma several 68 d14 diode stth2r02a sma stmicroelectronics 69 d15 diode stth2r02a sma stmicroelectronics 70 d16 diode n. m. sma several 71 d17 diode bat46j-n. m. sod323 stmicroelectronics 72 d18 tvs diode smaj58a sma stmicroelectronics 73 d19 led diode green led led-tlge1100b toshiba 74 d20 diode n. m. sma several 75 d21 diode bat46j sod323 stmicroelectronics 76 d22 diode n. m. sma several 77 d23 diode bat46j sod323 stmicroelectronics 78 d24 diode n. m. pflat_3_3x3_3- 2pin 79 d25 diode n. m. sod128 80 d28 schottky diode pmeg3050ep sod128 nxp 81 d29 diode bat46j sod323 stmicroelectronics 82 d30 diode bat46j sod323 stmicroelectronics 83 d31 diode n. m. pflat_6x5- 3leads 84 d33 diode n. m. smb 85 d34 diode n. m. pflat_3_3x3_3- 2pin 86 d35 led diode green led-n. m. led-tlge1100b toshiba 87 d36 led diode green led led-tlge1100b toshiba 88 j1 connector rj45 data and power jack rj45-8pin several 89 j2 connector rj45 data jack rj45-8pin several 90 j3 connector con3 p-jack-rapc722 switchcraft 91 j4 connector con3 p-jack-rapc722 switchcraft table 5. bill of material (general) (continued) item ref. description value pcb footprint supplier voltage
docid025612 rev 1 25/30 AN4415 supporting material 30 92 j5 connector mor-10x10.5-p5-2pin- n. m. mor-2poli-508 several 93 j6 connector mor-10x10.5-p5-2pin mor-2poli-508 several 94 l1 inductor 5.6 ? h me3220 coilcraft 95 l2 inductor 0.33 ? h - n. m. do1813h-331ml coilcraft 96 l3 inductor 0.33 ? h - n. m. lps4012-331l coilcraft 97 l4 inductor 0.33 ? h do1813h-331ml coilcraft 98 l5 inductor 0.33 ? h - n. m. lps4012-331l coilcraft 99 q1 mosfet sts4nf100 so8 stmicroelectronics 100 q2 mosfet fdn86246 sot23 fairchild 101 q3 transistor n. m. sot23 several 102 q4 mosfet n. m. sot23-6l 103 q5 mosfet n. m. so8 104 q6 mosfet n. m. dpak 105 q7 mosfet n. m. sot-223 106 r1 resistor 15 k ? r0805 several 107 r2 resistor 47 k ? r0805 several 108 r3 resistor 47 k ? r0805 several 109 r4 resistor 470 k ? r0805 several 110 r5 resistor 15 k ? r0805 several 111 r6 resistor n. m. r1206 several 112 r7 resistor n. m. r1206 several 113 r8 resistor 10 k ? r0603 several 114 r9 resistor n. m. r0603 several 115 r10 resistor 10 k ? r0603 several 116 r11 resistor 52.3 ?? - 1% r0805 several 117 r12 resistor n. m. r0603 several 118 r13 resistor 22.1 ?? - 1% r0603 several 119 r14 resistor 10 ? r0603 several 120 r15 resistor 0 ? r0805 several 121 r16 resistor 0 ? r0805 several 122 r17 resistor 124 k ?? - 1% r0603 several 123 r18 resistor n. m. r0603 several 124 r19 resistor 510 ? r0603 several 125 r20 resistor 4.7 k ? r0603 several table 5. bill of material (general) (continued) item ref. description value pcb footprint supplier voltage
supporting material AN4415 26/30 docid025612 rev 1 126 r21 resistor n. m. r0603 several 127 r22 resistor n. m. r0603 several 128 r23 resistor 0 ? r0805 several 129 r24 resistor 75 ? r0805 several 130 r25 resistor 56 ? r0805 several 131 r26 resistor n. m. r1206 several 132 r27 resistor 75 ? r0805 several 133 r29 resistor 75 ? r0805 several 134 r30 resistor n. m. r1206 several 135 r31 resistor 75 ? r0805 several 136 r32 resistor 10 ? r0603 several 137 r33 resistor 10 ? r0603 several 138 r34 sense resistor 0.33 ?? - 1% - n. m. r1206 vishay - rcwe1206r330fke 139 r35 sense resistor 0.33 ? 1% r1206 vishay - rcwe1206r330fke 140 r36 resistor 560 ? r0603 several 141 r37 resistor 0 ? r0603 several 142 r38 resistor n. m. r1206 several 143 r40 resistor 4.7 ? r1206 several 144 r41 resistor n. m. r1206 several 145 r42 resistor n. m. r1206 several 146 r43 resistor 0 ? r0805 several 147 r44 resistor 0 ? r1206 several 148 r45 resistor 47 k ? r0603 several 149 r46 resistor 0 ?? - n. m. r1206 several 150 r47 resistor 0 ?? - n. m. r1206 several 151 r48 resistor 390 ? r0603 several 152 r49 resistor n. m. r0603 several 153 r50 resistor 10.0 ? r0603 several 154 r51 resistor n. m. r0603 several 155 r52 resistor 3.3 k ?? - 1% r0603 several 156 r53 resistor 10 k ?? - n. m. r0603 several 157 r54 resistor 2.2 k ? r0603 several 158 r55 resistor 21 k ?? - 1% r0603 several table 5. bill of material (general) (continued) item ref. description value pcb footprint supplier voltage
docid025612 rev 1 27/30 AN4415 supporting material 30 159 r56 resistor 12.4 k ?? - 1% r0603 several 160 r57 resistor n. m.- 1% r0603 several 161 tp1 test point red th-5013 keystone 162 tp2 test point black th-5013 keystone 163 tp3 test point red th-5013 keystone 164 tp4 test point black th-5013 keystone 165 tp5 test point red - n. m. th-5013 keystone 166 tp6 test point red th-5013 keystone 167 tp7 test point black th-5013 keystone 168 tp8 test point red th-5013 keystone 169 tp9 test point black th-5013 keystone 170 tp10 test point red th-5013 keystone 171 tp11 test point red th-5013 keystone 172 tp12 test point black th-5013 keystone 173 tp13 test point red th-5013 keystone 174 tp14 test point red th-5013 keystone 175 tp15 test point red - n. m. th-5013 keystone 176 tp16 test point red th-5013 keystone 177 tp17 test point red th-5013 keystone 178 tp18 test point black - n. m. th-5013 keystone 179 tp19 test point black th-5013 keystone 180 tp20 test point red - n. m. th-5013 keystone 181 t1 data transfo. h2019 / tla-6t127lf pulse-h2019 pulse 182 t2 cm choke wrth 744226s - n. m. 744226s wrth 183 t3 power transfo. coilcraft poe13p-33l poe13p coilcraft 184 t4 power transfo. coilcraft poe70p- 33l-nm poe70p coilcraft 185 t5 power transfo. coilcraft ha3893-al - n. m. ha3893-al- coilcraft coilcraft 186 t6 cm choke pulse pe65855nl - n. m. pe-65855nl- pulse pulse 187 u1 controller ic pm8800a htssop16 stmicroelectronics 188 u2 optocoupler fairchild fod817a fod817 fairchild 189 u3 optocoupler sharp pc3h7d - n. m. pc3h7 sharp 190 u4 voltage reference ts2431ailt-n. m. sot23 stmicroelectronics 191 u5 voltage reference ts431ailt sot23-5l stmicroelectronics table 5. bill of material (general) (continued) item ref. description value pcb footprint supplier voltage
pcb layers AN4415 28/30 docid025612 rev 1 6 pcb layers figure 31. pcb layer: top view figure 32. pcb layer: layer 2 figure 33. pcb layer: layer 3 figure 34. pcb layer: bottom view figure 35. pcb layer: components on top side figure 36. pcb layer: co mponents on bottom side
docid025612 rev 1 29/30 AN4415 revision history 30 7 revision history table 6. document revision history date revision changes 30-may-2014 1 initial release.
AN4415 30/30 docid025612 rev 1 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 parti cular 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 designed or authorized for use in: (a) safety critical applications such as life supporting, active implanted devices or systems wi th 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 registered 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. ? 2014 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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