QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
DESCRIPTION
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
LTC3725/LTC3706
Demonstration circuit 888A-B is a high power isolated synchronous forward converter featuring the
LTC3725 and LTC3706. When powered from a 3672V input, a single DC888A-B provides an isolated
5V at 40A in a quarter-brick footprint. If higher output current is required, multiple DC888A boards may
be stacked together using on-board connectors for a
complete PolyPhase current sharing solution. The
converter operates at 250kHz and achieves efficiency
up to 93.5% with synchronous output rectifiers.
pler feedback, providing fast transient response with
a minimum amount of output capacitance. Additional
DC888A versions include DC888A-A (3.3V at 50A)
and DC888A-C (12V at 20A). The simple architecture
can be easily modified to meet different input and
output voltage requirements.
Design files for this circuit board are available.
Call the LTC factory.
, LTC and LT are registered trademarks of Linear Technology Corporation.
Secondary-side control eliminates complex optocou-
Table 1. Performance Summary (TA = 25°C)
PARAMETER CONDITION VALUE
Minimum Input Voltage 36V
Maximum Input Voltage 72V
Output Voltage V
Maximum Output Current 200LFM 40A
Typical Output Ripple V
Output Regulation Over All Input Voltages and Output Currents ±1% (Reference)
VIN = 36V to 72V, I
OUT
VIN = 48V, I
OUT
= 0A to 40A 5V
OUT
= 40A, 250kHz < 60mV
OUT
P–P
Load Transient Response
Nominal Switching Frequency 250kHz
Efficiency VIN = 36V, I
Isolation BASIC 1500VDC
Size Component Area x Top x Bottom Component Height 2.3” x 1.45” x 0.4” x 0.075”
Peak Deviation with 20A to 40A Load Step (10A/us) ±250mV
Settling Time •50us
= 28A 93.5% Typical
OUT
OPERATING PRINCIPLES – SINGLE PHASE
The LTC3706 secondary side controller is used on the
secondary and the LTC3725 smart driver with selfstarting capability is used on the primary. When an
input voltage is applied, the LTC3725 (U1 in Figure
15), which is powered through R29 and Q28, begins
a controlled soft-start of the output voltage by switching MOSFETs Q9 and Q11. As the output voltage begins to rise, the LTC3706 secondary controller is
quickly powered up via D24, Q29, C67, and Q27. The
LTC3706 then assumes control of the output voltage
by sending encoded PWM gate pulses to the
LTC3725 primary driver via signal transformer, T2.
The LTC3725 then operates as a simple driver receiving both input signals and bias power through T2.
The transition from primary to secondary control occurs seamlessly at a fraction of the output voltage.
From that point on, operation and design simplifies to
that of a simple buck converter. The LTC3706 regu-
1
Page 2
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
lates by observing the output voltage directly resulting in superior output voltage regulation and transient
response.
OPERATING PRINCIPLES – POLYPHASE
The LTC3725 and LTC3706 allow the user to develop
modular power supply “building blocks” that can be
added as power/current requirements increase. Connecting two DC888A power supplies in a PolyPhase
configuration has several advantages. By distributing
power across multiple high power/current supplies,
heat is also distributed, reducing individual component temperatures. Each parallel module develops
equal output currents so that electrical and thermal
stresses are shared, increasing reliability. Multi-phase
operation and Shared input and output filtering result
in fewer/smaller input/output capacitors and inductors for a given voltage/current ripple or transient response.
In PolyPhase systems, one power supply is configured as a “master” and one as a “slave”. The master
communicates switching frequency via the PT+ pin to
FS/SYNC pin of the slave (Figures 19 and 20). The
relative clock phase of each stage is determined by
the slave. The master’s voltage error amplifier’s output (ITH pin) controls the output current of all the
phases via the ITH pin voltage which is distributed to
each slave’s unity-gain differential amplifier.
Several of the signals that are shared between the
master and the slave are of a bidirectional nature. A
fault on either phase can be communicated to the opposite phase via the primary side SS/FLT pin interconnection or the secondary side RUN/SS interconnection. Sharing Vcc on the secondary side ensures
the master, which initially develops this bias voltage,
and slave power up simultaneously. Each phase then
contributes to the shared Vcc bus. Finally, the input
voltage (Vin) and output voltage (Vout) busses are
interconnected to allow for load sharing.
OPTIONALPOLYPHASE SETUP
Only minor modifications and minimal interconnections are needed to implement PolyPhase with the
DC888. See component changes list (Figure 18) and
schematics (Figures 21 and 22) for the required electrical changes to master and slave units. After the
modifications are done, the boards are then stacked
one on top of another (Figure 23). J1 and P1 headers
interconnect small signals and E1, E2, E3, and E4
stand offs provide interconnection for the power signals.
QUICK START PROCEDURE
Demonstration Circuit 888A-B is easy to set up to
evaluate the performance of the LTC3725 and
LTC3706. Refer to Figure 1 for proper equipment
setup. Follow the procedure below:
The DC888 was designed primarily to demonstrate
the chipset’s single phase operation and therefore be
further optimized for PolyPhase applications. A small
resistor can be placed between the R76/D27 junction
and C70/U2-16 junction to reduce already small PWM
jitter associated with separate master and slave
ground planes. Another optimization can result from
combining each individual phase’s input/output filter
components into one shared input/output filter.
NOTE:
When measuring the input or output voltage
ripple, care must be taken to avoid a long ground lead
on the scope probe. Measure the output (or input)
voltage ripple by touching the probe tip and probe
2
Page 3
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
ground directly across the +Vout and –Vout (or +Vin
and –Vin) terminals. See 0 for proper scope probe
technique.
1.
The optional input LC filter stage (C2/L5) lowers ac
input rms current. A power supply’s complete input filter must have output impedance that is less
than the converter input impedance to assure stability. This may require a damping impedance. (See
Linear Technology Application Note AN19 for a
discussion of input filter stability.) A source with a
50mOhm or higher ESR at the filter resonant frequency is one way of providing damping for the filter elements provided on the DC888A. For bench
testing, adding an 82uF electrolytic capacitor such
as a Sanyo 100MV82AX to the input terminals will
provide suitable damping and ripple current capability. The values selected have a filter resonant
frequency that is below the converter switching
frequency, thus avoiding high circulating currents
in the filter.
2.
Set an input power supply to a voltage of 36V.
Make sure that it is capable of 36V to 72V at a current supplying capability of at least 8A per number
of phases being tested. Then, turn off the supply.
3.
With power off, connect the supply to the input
terminals +Vin and –Vin.
a.
Input voltages lower than 36V can keep the converter from turning on due to the undervoltage
lockout feature of the LTC3725.
b.
If efficiency measurements are desired, an ammeter capable of measuring at least 8Adc per
phase can be put in series with the input supply
in order to measure the DC888A-B’s input current.
c.
A voltmeter with a capability of measuring • 72V
can be placed across the input to get an accurate
input voltage measurement.
4.
Turn on the power at the input.
NOTE:
Make sure that the input voltage •72V.
5.
Check for the proper output voltage of 5V.
6.
Turn off the power at the input.
7.
Once the proper output voltages are established,
connect a variable load capable of sinking 40A per
phase at 5V to the output terminals +Vout and –
Vout. Set current to 0A.
a.
If efficiency measurements are desired, an ammeter or a resistor current shunt that is capable
of handling at least 40Adc per phase can be put
in series with the output load in order to measure the DC888A-B’s output current.
b.
A voltmeter with a capability of measuring at
least 5V can be placed across the output terminals in order to get an accurate output voltage
measurement.
8.
Turn on the power at the input.
NOTE:
If there is no output, disconnect the load to
verify that the load is not set too high.
9.
Once the proper output voltage is established, adjust the load within the operating range and observe the output voltage regulation, ripple voltage,
efficiency and other desired parameters.
3
Page 4
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
VIN
GND
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 1. Proper Measurement Equipment Setup
Figure 2. Measuring Input or Output Ripple
4
Page 5
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
MEASURED DATA
Figures 3 through 14 are measured data for a typical DC888A-B. Figures 15 through 23 consist of schematics, bill of
materials, and a picture.
Figure 3. Efficiency
Figure 4. Output Voltage Ripple (48Vin, 40A, Single Phase)
5
Page 6
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 5. Load Transient Response (48Vin, 20A to 40A to 20A at 10A/us, Single Phase)
Figure 6. Loop Response (48Vin, 4A & 40A, Single Phase)
6
Page 7
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 7. Turn-on (48Vin, 40A, Single Phase)
Figure 8. Turn-on (48Vin, 80A, PolyPhase)
7
Page 8
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 9. Transient Sharing of Inductor Current (48Vin, 30A to 60A, PolyPhase)
Figure 10. Transient Sharing of Inductor Current (48Vin, 60A to 30A, PolyPhase)
8
Page 9
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 11. Temp Data (48Vin, 40A, 200LFM airflow – top)
Figure 12. Temp Data (48Vin, 40A, 200LFM airflow – bottom)
9
Page 10
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Figure 13. Temp Data (48Vin, 36A, 0LFM airflow – top)
Figure 14. Temp Data (48Vin, 36A, 0LFM airflow – bottom)
10
Page 11
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
+Vout
5Vo@40A
C31, C33, C68
6.3V
PSLV0J227M12
+
+VOUT
L6
-VOUT
1/4W
1/4W
R23
R24
6.8
6.8
C51
2.2n
100V
A
T1
1
PA0954(4:4:1:1)
22n
C34
PA1382.650
Vaux
Q13
Q12
Q23
R75
510
Q14
Q15
B
Si7336ADP
72
41138105
6
Q11
Q9
Si7450DP
Q8
-VOUT
T3
CT02-100
34
R76
1k
1 2
R84
D27
IS+
BAS21
-Vout
R41
4.42K
C77
2.2uF
220u
-VOUT
25V
C67
10uF
Vsg
Si7336ADP
SW
Q24
C69
2.2n
100V
C66
200V
1.5n
R48
R3
100
8.06
VCC
Q27
SG
IS+
-VOUT
VCC
D26
CMPSH1-4
Q25
FMMT718
15m
R53
R52
6.8
1/4W
-VOUT
6.8
R51
1/4W
1.5W
R58
C27
100pF
R29
100K
Q28
FDC2512
11
-VOUT
4
24
FCX491A
18
19
1
16
C70
3.3n
IS-
15
20
FG
2
12
C71
8
T2
5
C72
0.1uF
5.1K
4
IS
10
7
3
8
6
10
VS-
VS+
MODE
VCC
NDRV
VIN
SG
IS+
U2
LTC3706EGN
SW
PT+
PT-
22
21
1uF
1
634
C100
150pF
C101
R101
100
470pF
FB/IN+
GATE
U1
NDRV
LTC3725EMSE
ULVO
VCC
2
1
R46
604
Vsg
Q32
FMMT619
FMMT718
FB
VSOUT
9
3.3n
C79
9.1K
R68
C75
ITH
PHASE
FS/SYNC
REGSD
SLP
PGOOD
RUN/SS
PGND
GND
5
FS/IN-
GND
PGND
VSLMT
SSFL T
C24
100p
7
5
R69
13
17
14
3
8
23
12
R63
C29
110K
R66
100K
C78
10nF
SW
100K
11
6
9
Q29
10nF
1uF
VCC
Q31
MMBT2907A
150
R81
R82
-VOUT
-VOUT
C30
C83
10pF
Q30
2N7002
D29
Si2303BDS
750
R78
BAS21
C85
0.1uF
R79
68K
R80
100K
C84
0.1uF
Q26
-VOUT
R56
100
150
C86
68pF
SG
250V
2.2nF
-VOUT
Vaux
+VOUT
L1
100uH
D2
CMPSH1-4
C3-C5
3 X 2.2uF
100V
L5
0.68uH
C2
2.2uF
100V
+Vin
-Vin
36V-72Vin
C55
1nF
D24
CMPSH1-4
R18
365K
NOTE:
C2-C5 2.2uF,100V Murata GRM32ER72A225K
L5 VISHAY IHLP2525CZERR68M01
T2 Pulse PA1954NL
R22
15.0K
D1
CMPSH1-4
C
1
T4
4
A
D
3
6
DA2318-ALC
B
Figure 15. Single Phase Schematic
11
Page 12
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
SSS
SYNC
-ITH
+ITH
7
8
7
J1-7
+VPKS
-VPKS
J1-5
P1-5
J1-6
6
5
TO CONFIGURE
FOR POLYPHASE
*
+Vout
E3
C68
+
+
E7
C31
+
+VOUT
C33
+
C34
2
*
L6
41
5
Vaux
*
Q12
Q13
-VOUT
1/4W
1/4W
R24
R23
*
*
R75
*
Q14
Q15
C51
100V
*
B
A
72
*
T1
41138105
1
*
Q11
Q8
Q9
Si7450DP
-VOUT
T3
CT02-100
34
1 2
L5
+Vin
R84
*
D27
IS+
BAS21
C5
2.2uF
100V
C4
2.2uF
100V
C3
2.2uF
100V
0.68uH
C2
2.2uF
100V
E1
36V-72Vin
-Vout
E4
*
-
*
-VOUT
*
*
*
C67
25V
Vsg
4
4
4
5
1
5
1
5
1
Q23
23
678
23
678
23
678
SW
510
4
4
4
Q24
5
1
5
1
5
1
23
678
23
678
23
678
C69
100V
*
C66
6
200V
*
2 3
6 7 8
2 3
6 7 8
2 3
6 7 8
5
1
5
1
5
1
4
4
4
R3
0
100
R49
R76
*
-VIN
E2
-Vin
6
5
E8
FMMT718
R48
*
P1-6
R59
R60
OPT
OPT
VCC
*
R41
OPT
C74
6
10
11
FB
VS-
VS+
MODE
4
VCC
24
FCX491A
1
18
Q27
23
19
SG
1
SG
16
IS+
C70
-VOUT
*
IS-
15
VCC
CMPSH1-4
D26
Q25
*
R52
*
R51
1.5W
C27
100pF
20
FG
2
12
R53
1/4W
1/4W
C71
8
-VOUT
T2
5
C100
C72
0.1uF
5.1K
R58
4
IS
10
7
R29
100K
3
8
3
Q28
FDC2512
41
2
5
6
R18
1
1
J1-1
-VIN
TO CONFIGURE
FOR POLYPHASE
VSOUT
VCC
NDRV
ITH
PHASE
VIN
FS/SYNC
REGSD
IS+
U2
LTC3706EGN
SLP
PGOOD
RUN/SS
SW
PGND
GND
PT+
PT-
22
21
1uF
1
634
opt.
C82
150pF
C101
100
R101
470pF
opt.
C81
5
FS/IN-
FB/IN+
GATE
NDRV
VCC
P1-1
GND
PGND
U1
VSLMT
LTC3725EMSE
ULVO
SSFLT
2
1
365K
2
2
J1-2
P1-2
SSP
P1-7
C77
2.2uF
OPT
R62
604
R46
9
R64
OPT
*
R68
7
5
0
R70
R67
opt.
R69
VCC
13
17
R66
100K
14
3
C78
8
23
12
R63
100K
11
6
9
C29
10nF
C24
1uF
1nF
C55
R22
15.0K
9
9
8
J1-9
J1-8
R71
OPT
*
C79
C75
110K
10nF
-VOUT
D30
SW
C83
10pF
D29
BAS21
31
Q29
T4 connection for A-B & A-C
10
P1-9
P1-8
R73
OPT
R72
R74
OPT
*
*
*
36V
D31
23
1
Q30
2N7002
*
R78
32
1
Si2303BDS
R79
68K
R80
100K
C84
0.1uF
D24
CMPSH1-4
C
D
3
1
T4
6
4
B
A
-VOUT
11
10
11
J1-11
J1-10
OPT
-VOUT
C85
0.1uF
P1-11
P1-10
J1-4
J1-3
4
3
-VOUT
P1-3
P1-4
3
4
Vsg
Q32
FMMT718
Q26
VCC
FMMT619
-VOUT
*
R102
Q31
MMBT2907A
150
R81
Vaux
L1
D1
C
T4
T4 connection for A-A
A
100
R56
150
R82
C86
68pF
SG
-VOUT
C30
250V
2.2nF
-VIN
C2-C5 2.2uF,100V Murata GRM32ER72A225K
NOTE:
L5 VISHAY IHLP2525CZERR68M01
+VOUT
*
R108
100uH
D2
CMPSH1-4
4
1
*
R107
CMPSH1-4
D
6
3
DA2318-ALC
B
T1
PA0950(6:6:1:1)
PA0955(6:6:2:1)
PA0954(4:4:1:1)
03.3V@50A
0
opt.
R108
0
opt.
opt.DC888A-A
R107
opt.
240
opt.
330
R84C51,C69
2.2K
1.0K
39012V@20A
750
620
R78
R76
8.06
9.53
7.50
R68R102
6.2K
9.1K
9.1K
R48
0.015
0.010
0.015
R41
11.5K
2.74K
4.42K
10
6.8
5.1
R23,R24,R51,R52
opt.
Q23,Q24
Si7336ADP
Si7336ADP
Q12-Q15
HAT2244WP
opt.
Q8
Si7450DP
Si7450DP
L6
PA1494.242470pF
PA1382.650
PA1382.650
opt.
opt.
D31
MMBZ5258B
opt.
opt.
D30
BAS21
C79
4.7nFDC888A-C
4.7nF
3.3nF
C75
47pF
T2 Pulse PA1954NL
-VOUT
100pF
C70
3.3nF
3.3nF
10nF
C67
10uF
4.7uF
10uF
1.0nF
4.7nF
2.2nF
C66
680pF
1.5nF
1.5nF
C34
22uF
10uF
22uF
opt
C33
220uF, 4V
220uF, 6.3V
C31,C68
68uF, 16V
Vout/Iout
VER SION TABLE
5.0V@40A
*
VERSION
DC888A-B
Figure 16. Full Single Phase Schematic
12
Page 13
QUICK START GUIDE FOR DEMONSTRATION CIRCUIT 888A-B
36V-72VIN, ISOLATED SYNCHRONOUS FORWARD
Qty Reference Part Description Manufacturer / Part #