Rainbow Electronics MAX8548 User Manual

General Description
The MAX8545/MAX8546/MAX8548 are voltage-mode pulse-width-modulated (PWM), step-down DC-DC con­trollers ideal for a variety of cost-sensitive applications. They drive low-cost N-channel MOSFETs for both the high-side switch and synchronous rectifier, and require no external current-sense resistor. These devices can supply output voltages as low as 0.8V.
DS(ON)
of the low-side MOSFET. The MAX8545 and MAX8548 have a current-limit threshold of 320mV, while the MAX8546 has a current-limit threshold of 165mV. All devices feature foldback-current capability to minimize power dissipation under short-circuit condition. Pulling the COMP/EN pin low with an open-collector or low-capacitance, open­drain device can shut down all devices.
The MAX8545/MAX8546 operate at 300kHz and the MAX8548 operates at 100kHz. The MAX8545/ MAX8546/MAX8548 are compatible with low-cost alu­minum electrolytic capacitors. Input undervoltage lock­out prevents proper operation under power-sag operations to prevent external MOSFETs from overheat­ing. Internal soft-start is included to reduce inrush cur­rent. These devices are offered in space-saving 10-pin µMAX packages.
Applications
Features
2.7V to 28V Input Range
Foldback Short-Circuit Protection
No Additional Bias Supply Needed
0.8V to 0.83 x V
IN
Output
Up to 95% Efficiency
Low-Cost External Components
No Current-Sense Resistor
All N-Channel MOSFET Design
Adaptive Gate Drivers Eliminate Shoot-Through
Lossless Overcurrent and Short-Circuit
Protection
300kHz Switching Frequency
(MAX8545/MAX8546)
100kHz Switching Frequency (MAX8548)
Pin-Compatible with the MAX1967
Thermal Shutdown
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
________________________________________________________________ Maxim Integrated Products 1
Typical Operating Circuit
Ordering Information
Pin Configuration appears at end of data sheet.
19-2795; Rev 0; 7/03
For pricing, delivery, and ordering information, please contact Maxim/Dallas Direct! at 1-888-629-4642, or visit Maxim’s website at www.maxim-ic.com.
Selector Guide
Set-Top Boxes Graphic Card and Video
Supplies Desktops and Desknotes PCI Express Power
Supplies Telecom Power Supplies
Notebook Docking Station Supplies
Cable Modems and Routers
Networking Power Supplies
PART TEMP RANGE PIN-PACKAGE
MAX8545EUB -40°C to +85°C 10 µMAX MAX8546EUB -40°C to +85°C 10 µMAX MAX8548EUB -40°C to +85°C 10 µMAX
PART
MAX8545 300kHz -320mV
MAX8546 300kHz -165mV
MAX8548 100kHz -320mV
SWITCHING
FREQUENCY
CURRENT-LIMIT
THRESHOLD
2.7V TO 28V
OFF
ON
OPTIONAL
INPUT
VLV
CC
IN
COMP/ EN
MAX8545 MAX8546 MAX8548
BSTV
GND
DH
LX
DL
FB
OUTPUT
0.8V TO
0.9 x V
UP TO 6A
IN
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
2 _______________________________________________________________________________________
ABSOLUTE MAXIMUM RATINGS
ELECTRICAL CHARACTERISTICS
(VIN= VL= VCC= 5V, TA= -40°C to +85°C, unless otherwise noted. Typical values are at TA= +25°C.)
Stresses beyond those listed under “Absolute Maximum Ratings” may cause permanent damage to the device. These are stress ratings only, and functional operation of the device at these or any other conditions beyond those indicated in the operational sections of the specifications is not implied. Exposure to absolute maximum rating conditions for extended periods may affect device reliability.
(All voltages referenced to GND unless otherwise noted.) V
IN
to GND ............................................................-0.3V to +30V
V
CC
to GND .............................-0.3V, lower of 6V or (VL + 0.3V)
FB to GND ................................................................-0.3V to +6V
BST to GND ............................................................-0.3V to +36V
VL, DL, COMP to GND ..............................-0.3V to (V
CC
+ 0.3V)
BST to LX..................................................................-0.3V to +6V
DH to LX....................................................-0.3V to (V
BST
+ 0.3V)
VL Short to GND ......................................................................5s
LX to GND ......................................................................0 to 30V
Input Current (any pin) .....................................................±50mA
Continuous Power Dissipation (T
A
= +70°C)
10-Pin µMAX (derate 5.6mW/°C above +70°C) ..........444mW
Operating Temperature Range ...........................-40°C to +85°C
Junction Temperature......................................................+150°C
Storage Temperature Range .............................-65°C to +150°C
Lead Temperature (soldering, 10s) .................................+300°C
VIN Operating Range V
VIN Undervoltage Lockout (UVLO) Trip Level
VIN Operating Supply Current VFB = 0.88V (no switching)
VL Output Voltage
Thermal Shutdown
OSCILLATOR
Frequency f
Minimum Duty Cycle DC
Maximum Duty Cycle DC
SOFT-START
Digital Ramp Period
Soft-Start Levels
PARAMETER SYMBOL CONDITIONS MIN TYP MAX UNITS
VCC = VL, VIN separate from V
IN
VIN = VL = V
Rising and falling edge, hysteresis = 2% 2.35 2.50 2.66 V
OSC
MIN
MAX
5.5V < V 1mA < I
Rising temperature, typical hysteresis = 10°C (Note 1)
MAX8545, MAX8546 250 300 360
MAX8548 80 100 120
DH output, MAX8545, MAX8546 5
MAX8548 10
DH output, MAX8545, MAX8546 83 86
MAX8548 90 95
MAX8545, MAX8546 6.6
MAX8548
MAX8545, MAX8546 V
MAX8548
< 28V, VCC = VL,
IN
LOAD
CC
CC
< 25mA
4.9 28.0
2.7 5.5
0.7
4.7 5 5.3 V
+160 °C
10.2
/ 64
OUT
V
/ 32
OUT
1.2 mA
V
kHz
%
%
ms
V
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
_______________________________________________________________________________________ 3
ELECTRICAL CHARACTERISTICS (continued)
(VIN= VL= VCC= 5V, TA= -40°C to +85°C, unless otherwise noted. Typical values are at TA= +25°C.)
Note 1: Thermal shutdown disables the buck regulator when the die reaches this temperature. Soft-start is reset but the VL regulator
remains on.
ERROR AMPLIFIER
FB Regulation Voltage
FB to COMP/EN Gain
FB to COMP/EN Transconductance
FB Input Bias Current V
COMP/EN Source Current V
Current-Limit Threshold Voltage (Across Low-Side MOSFET)
Foldback Current-Limit Threshold Voltage (Across Low-Side MOSFET) When Output is Short
MOSFET DRIVERS
Break-Before-Make Time
DH On-Resistance in Low State 1.6 4 DH On-Resistance in High State 2.5 5.5 DL On-Resistance in Low State 1.1 2.5 DL On-Resistance in High State 2.5 5.5
BST Leakage Current V
LX Leakage Current V
PARAMETER SYMBOL CONDITIONS MIN TYP MAX UNITS
2.7V < VCC < 5.5V, 0°C to +85°C 0.787 0.800 0.815
2.7V < V
-5µA < I
FB
COMP/EN
LX to GND, MAX8545, MAX8548, V
FB
LX to GND MAX8546, V
LX to GND, VFB = 0V, MAX8545, MAX8548
MAX8546, LX to GND, V
Rising edge, DH going low to DL going high 96
Falling edge, DL going low to DH going high 28
BST
BST
< 5.5V, -40°C to +85°C 0.782 0.800 0.815
CC
4000 V / V
COMP/EN
= 0.88V 1 2 µA
= 0.8V
= 33V, V
= 33V, V
< +5µA 70 108 160 µS
= 0V 15 46 100 µA
-355 -320 -280
= 0.8V -185 -165 -140
FB
-105 -75 -45
= 0 -53 -38 -22
FB
= 28V, VFB = 0.88V 0 50 µA
LX
= 28V, VFB = 0.88V 33 100 µA
LX
V
mV
mV
ns
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
4 _______________________________________________________________________________________
Typical Operating Characteristics
(VIN= VL= VCC= 5V, typical values are at TA = +25°C, unless otherwise noted.)
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc01
LOAD CURRENT (A)
(CIRCUIT OF FIGURE 1; TABLE 1a)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
VIN = 3.3V V
OUT
= 1.2V
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc02
LOAD CURRENT (A)
(CIRCUIT OF FIGURE 1; TABLE 1a)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
VIN = 5V
V
OUT
= 1.8V
V
OUT
= 3.3V
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc03
LOAD CURRENT (A)
(CIRCUIT OF FIGURE 2; TABLE 2a)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
V
OUT
= 1.8V
V
OUT
= 3.3V
VIN = 12V
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc04
LOAD CURRENT (A)
(CIRCUIT OF FIGURE 2; TABLE 2a)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
VIN = 17V
V
OUT
= 3.3V
V
OUT
= 1.8V
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc05
LOAD CURRENT (A)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
V
OUT
= 1.8V
V
OUT
= 1.2V
VIN = 3.3V
(CIRCUIT OF FIGURE 1; TABLE 1b)
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc06
LOAD CURRENT (A)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
V
OUT
= 3.3V
V
OUT
= 2.5V
V
OUT
= 1.8V
V
OUT
= 1.2V
VIN = 5V
(CIRCUIT OF FIGURE 1; TABLE 1b)
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc07
LOAD CURRENT (A)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
V
OUT
= 3.3V
V
OUT
= 2.5V
V
OUT
= 1.8V
V
OUT
= 1.2V
VIN = 12V
(CIRCUIT OF FIGURE 2; TABLE 2b)
EFFICIENCY vs. LOAD CURRENT
MAX8545/46/48 toc08
LOAD CURRENT (A)
EFFICIENCY (%)
10.1
10
20
30
40
50
60
70
80
90
100
0
0.01 10
V
OUT
= 3.3V
V
OUT
= 2.5V
V
OUT
= 1.8V
V
OUT
= 1.2V
VIN = 17V
(CIRCUIT OF FIGURE 2; TABLE 2b)
CHANGE IN OUTPUT VOLTAGE
vs. LOAD CURRENT
MAX8545/46/48 toc09
LOAD CURRENT (A)
OUTPUT VOLTAGE (V)
5432
2.485
2.490
2.495
2.500
2.505
2.510
2.515
2.520
2.480 16
V
OUT
= 2.5V
V
IN
= 12V
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
_______________________________________________________________________________________ 5
Typical Operating Characteristics (continued)
(VIN= VL= VCC= 5V, typical values are at TA = +25°C, unless otherwise noted.)
1.84
1.83
1.82
1.81
1.80
OUTPUT VOLTAGE (V)
1.79
1.78
CHANGE IN OUTPUT VOLTAGE
vs. INPUT VOLTAGE
2.5 INPUT VOLTAGE (V)
FREQUENCY vs. INPUT VOLTAGE
310
306
302
I
= 6V
LOAD
4.54.03.53.0
V
= 2.5V
OUT
NO LOAD MAX8545/ MAX8546
MAX8545/46/48 toc10
MAX8545/46/48 toc12
2.52
2.51
2.50
OUTPUT VOLTAGE (V)
2.49
2.48 10
310
306
302
CHANGE IN OUTPUT VOLTAGE
vs. INPUT VOLTAGE
I
= 6V
LOAD
18 20 22 24161412
INPUT VOLTAGE (V)
FREQUENCY vs. TEMPERATURE
VIN = 12V
= 2.5V
V
OUT
NO LOAD MAX8545/ MAX8546
MAX8545/46/48 toc11
MAX8545/46/48 toc13
298
FREQUENCY (kHz)
294
290
2.70 28.00 INPUT VOLTAGE (V)
22.9417.8812.827.76
LOAD TRANSIENT RESPONSE
VIN = 17V
= 2.5V
V
OUT
0
40µs/div
298
FREQUENCY (kHz)
294
290
-40.00 85.00 TEMPERATURE (°C)
MAX8545 toc14
V
OUT
AC COUPLED 100mV/div
I
OUT
5A/div
60.0035.0010.00-15.00
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
6 _______________________________________________________________________________________
Typical Operating Characteristics (continued)
(VIN= VL= VCC= 5V, typical values are at TA = +25°C, unless otherwise noted.)
V
OUT
1V/div
V
IN
5V/div
INDUCTOR CURRENT 5A/div
1ms/div
START-UP WAVEFORM
MAX8545 toc15
I
LOAD
= 3A
V
OUT
1V/div
V
IN
5V/div
INDUCTOR CURRENT 2A/div
2ms/div
SHUTDOWN WAVEFORM
MAX8545 toc16
I
LOAD
= 3A
V
OUT
2V/div
V
IN
5V/div
I
IN
10A/div
I
OUT
5A/div
SHORT-CIRCUIT WAVEFORM
MAX8545 toc18
V
OUT
2V/div
V
IN
20V/div
I
IN
2A/div
INDUCTOR CURRENT 5A/div
1ms/div
0
0
0
0
SHORT-CIRCUIT WAVEFORM
MAX8545 toc17
GAIN AND PHASE vs. FREQUENCY
MAX8545/46/48 toc19
FREQUENCY (kHz)
GAIN (dB)
PHASE (DEGREES)
101
-120
-100
-80
-60
-40
-20
0
20
40
60
-140
0.1 100
180
150
120
90
60
30
VIN = 17V, V
OUT
= 2.5V
I
LOAD
= 6A
GAIN
PHASE
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
_______________________________________________________________________________________ 7
Pin Description
Functional Diagram
PIN NAME FUNCTION
1 COMP/EN
Compensation Input. Pull COMP/EN low with an open-collector or open-drain device to turn off the output.
2 FB Feedback Input. Connect a resistive-divider network to set V
3V
4V
CC
IN
5VL
Internal Chip Supply. Connect VCC to VL through a 10 resistor. Bypass VCC to GND with at least a 0.1µF ceramic capacitor.
Power Supply for LDO Regulator for VIN > 5.5V, and Chip Supply for VIN < 5.5V. Bypass VIN with at least a 1µF ceramic capacitor to GND.
Output of Internal 5V LDO. Connect VL to V
for VIN < 5.5V. Bypass VL with at least a 1µF ceramic
IN
capacitor to GND.
. FB threshold is 0.8V.
OUT
6 DL Low-Side External MOSFET Gate-Driver Output. DL swings from VL to GND.
7 GND Ground and Negative Current-Sense Input
8 LX Inductor Switching Node. LX is used for both current limit and the return supply of the DH driver.
9 DH High-Side External MOSFET Gate-Driver Output. DH swings from BST to LX.
10 BST Positive Supply of DH Driver. Connect a 0.1µF ceramic capacitor between BST and LX.
V
VL
COMP/EN
FB
V
IN
CC
5V LINEAR
REGULATOR
RAMP
GENERATOR
INTERNAL
CHIP SUPPLY
800mV
SOFT-START
REF
100kHz/ 300kHz*
CLOCK
GENERATOR
*SEE SELECTOR GUIDE
1V
ERROR
AMPLIFIER
PWM COMP
TEMPERATURE
SHUTDOWN
CONTROL
LOGIC
MAX8545 MAX8546 MAX8548
CURRENT-LIMIT
COMPARATOR
BST
DH
LX
DL
GND
FOLD-
FB
BACK
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
8 _______________________________________________________________________________________
Detailed Description
The MAX8545/MAX8546/MAX8548 are BiCMOS switch­mode power-supply controllers designed to implement simple, buck-topology regulators in cost-sensitive applications. The main power-switching circuit consists of two N-channel MOSFETs, an inductor, and input/out­put filter capacitors. An all N-channel synchronous-rec­tified design provides high efficiency at reduced cost. These devices have an internal 5V linear regulator that steps down the input voltage to supply the IC and the gate drivers. The low-side-switch gate driver is directly powered from the 5V regulator (VL), while the high­side-switch gate driver is indirectly powered from VL plus an external diode-capacitor boost circuit.
Current-Limit and
Short-Circuit Protection
The MAX8545/MAX8546/MAX8548 employ a valley cur­rent-sensing algorithm that uses the R
DS(ON)
of the low­side N-channel MOSFET to sense the current. This eliminates the need for an external sense resistor usually placed in series with the output. The voltage measured across the low-side MOSFETs R
DS(ON)
is compared to a fixed -320mV reference for the MAX8545/MAX8548 and a fixed -165mV reference for the MAX8546. The cur­rent limit is given by the equations below:
Aside from current limiting, these devices feature fold­back short-circuit protection. This feature is designed to reduce the current limit by 80% as the output voltage drops to 0V.
MOSFET Gate Drivers
The DH and DL drivers are optimized for driving N­channel MOSFETs with low gate charge. An adaptive dead-time circuit monitors the DL output and prevents the high-side MOSFET from turning on until the low-side MOSFET is fully off. There must be a low-resistance, low-inductance connection from the DL driver to the MOSFET gate for the adaptive dead-time circuit to work properly. Otherwise, the sense circuitry in the MAX8545/ MAX8546/MAX8548 may detect the MOSFET gate as off while there is actually charge left on the gate. Use very short, wide traces measuring no less than 50 to 100 mils
wide if the MOSFET is 1 inch away from the MAX8545/ MAX8546/MAX8548. The same type of adaptive dead­time circuit monitors the DH off edge. The same recom­mendations apply for the gate connection of the high-side MOSFET.
The internal pulldown transistor that drives DL low is robust, with a 1.1(typ) on-resistance. This helps pre­vent DL from being pulled up due to capacitive cou­pling from the drain to the gate of the low-side synchronous-rectifier MOSFET during the fast rise time of the LX node.
Soft-Start
The MAX8545/MAX8546/MAX8548 feature an internally set soft-start function that limits inrush current. It accom­plishes this by ramping the internal reference input to the controllers transconductance error amplifier from 0 to the 0.8V reference voltage. The ramp time is 1024 oscil­lator cycles for the MAX8548 and 2048 oscillator cycles for the MAX8545/MAX8546. At the nominal 100kHz and 300kHz switching rate, the soft-start ramp is approxi­mately 10.2ms and 6.8ms, respectively.
High-Side Gate-Drive Supply (BST)
A flying-capacitor boost circuit generates gate-drive volt­age for the high-side N-channel MOSFET. The flying capacitor is connected between the BST and LX nodes.
On startup, the synchronous rectifier (low-side MOSFET) forces LX to ground and charges the boost capacitor to VL. On the second half-cycle, the MAX8545/MAX8546/ MAX8548 turn on the high-side MOSFET by closing an internal switch between BST and DH. This provides the necessary gate-to-source voltage to drive the high-side MOSFET gate above its source at the input voltage.
Internal 5V Linear Regulator
All MAX8545/MAX8546/MAX8548 functions are internally powered from an on-chip, low-dropout 5V regulator (VL). These devices have a maximum input voltage (VIN) of 28V. Connect VCCto VLthrough a 10resistor and bypass VCCto GND with a 0.1µF ceramic capacitor. The VIN-to-VL dropout voltage is typically 140mV, so when V
IN
is less than 5.5V, VL is typically VIN- 140mV.
The internal linear regulator can source a minimum of 25mA and a maximum of approximately 40mA to supply power to the IC low-side and high-side MOSFET drivers.
Duty-Cycle Limitations for
Low V
OUT/VIN
Ratios
The MAX8545/MAX8546/MAX8548s output voltage is adjustable down to 0.8V. However, the minimum duty cycle can limit the ability to supply low-voltage outputs
I
LIMIT
=
320
R
DS ON
mV
(/)
MAX MAX
()
8545 8548
mV
=
165
R
DS ON
8546
()
MAX
()
I
LIMIT
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
_______________________________________________________________________________________ 9
from high-voltage inputs. With high input voltages, the required duty factor is approximately:
where R
DS(ON)
x I
LOAD
is the voltage drop across the synchronous rectifier. Therefore, the maximum input voltage (V
IN(DFMAX)
) that can supply a given output
voltage is:
If the circuit cannot attain the required duty cycle dic­tated by the input and output voltages, the output volt­age still remains in regulation. However, there may be intermittent or continuous half-frequency operation as the controller attempts to lower the average duty cycle by deleting pulses. This can increase output voltage ripple and inductor current ripple, which increases noise and reduces efficiency. Furthermore, circuit sta­bility is not guaranteed.
Applications Information
Design Procedures
1) Input Voltage Range. The maximum value
(V
IN(MAX)
) must accommodate the worst-case high
input voltage. The minimum value (V
IN(MIN)
) must account for the lowest input voltage after drops due to connectors, fuses, and switches are considered. In general, lower input voltages provide the best efficiency.
2) Maximum Load Current. There are two current values to consider. Peak load current (I
LOAD(MAX)
) determines the instantaneous component stresses and filtering requirements and is key in determining output capacitor requirements. I
LOAD(MAX)
also determines the required inductor saturation rating. Continuous load current (I
LOAD
) determines the thermal stresses, input capacitor, and MOSFETs, as well as the RMS ratings of other heat-contribut­ing components such as the inductor.
3) Inductor Value. This choice provides tradeoffs between size, transient response, and efficiency. Higher inductance value results in lower inductor ripple current, lower peak current, lower switching losses, and, therefore, higher efficiency at the cost of slower transient response and larger size. Lower inductance values result in large ripple currents, smaller size, and poor efficiency, while also provid­ing faster transient response.
Setting the Output Voltage
An output voltage between 0.8V and (0.83 x VIN) can be configured by connecting FB to a resistive divider between the output and GND (see Figures 1 and 2). Select resistor R4 in the 1kto 10krange. R3 is then given by:
where VFB= +0.8V.
Inductor Selection
Determine an appropriate inductor value with the fol­lowing equation:
where LIR is the ratio of inductor ripple current to aver­age continuous maximum load current. Choosing LIR between 20% to 40% results in a good compromise between efficiency and economy. Choose a low-core­loss inductor with the lowest possible DC resistance. Ferrite-core-type inductors are often the best choice for performance; however, the MAX8548s low switching frequency also allows the use of powdered iron core inductors in ultra-low-cost applications where efficiency is not critical. With any core material, the core must be large enough not to saturate at the peak inductor cur­rent (I
PEAK
).
Setting the Current Limit
The MAX8545/MAX8546/MAX8548 provide valley cur­rent limit by sensing the voltage across the external low-side MOSFET. The minimum current-limit threshold voltage is -280mV for the MAX8545/MAX8548 and
-140mV for the MAX8546. The MOSFET on-resistance required to allow a given peak inductor current is:
where I
VALLEY
= I
LOAD(MAX)
x (1 - LIR / 2), and
R
DS(ON)MAX
is the maximum on-resistance of the low­side MOSFET at the maximum operating junction temperature.
)
V
IN DFMAX
VR I
()
OUT DS ON LOAD
1
≤+×
DC
()
V
IN
VR I
()
MIN
()
OUT DS ON LOAD() ()
RR
V
34
OUT
V
FB
1=−
 
LV
OUT
V f LIR I
IN OSC LOAD MAX
R
DS ON MAX
R
DS ON MAX
II
=+
PEAK LOAD MAX LOAD MAX
.
028
()
()
I
VALLEY
.
014
I
VALLEY
VV
()
IN OUT
×××
LIR
() ()
2
×
()
I
V
( /
for the MAX MAX
V
( )
for the MAX
8545 8548
8546
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
10 ______________________________________________________________________________________
Figure 1. Typical Application Circuit (2.7V to 5V) Input (see Tables 1a, 1b)
Figure 2. Typical Application Circuit (10V to 24V) Input (see Tables 2a, 2b)
+2.7V TO
+5.5V INPUT
C3 C2C4
R1
C9
IN
CC
MAX8545*
MAX8546
MAX8548*
COMP/ EN
D2 R2
C10 C11
*FOLLOW THE DATA SHEET DESIGN PROCEDURE TO SELECT THE EXTERNAL COMPONENTS FOR THE MAX8545/MAX8548.
C1
VLV
BSTV
DH
LX
DL
GND
FB
D1
Q1
C5
R3
R4
L1
C6
C7 C8
OUT
1.8V/3A OR 6A
+10V TO
D2 R2
*FOLLOW THE DATA SHEET DESIGN PROCEDURE TO SELECT THE EXTERNAL COMPONENTS FOR THE MAX8545/MAX8548.
+24V INPUT
C12
C10 C11
R1
C9
CC
V
IN
MAX8545*
MAX8546
MAX8548*
COMP/ EN
C1
VLV
BST
DH
LX
DL
GND
FB
D1
C5
R4
C3 C2C4
Q1
L1
C6
C7 C8
R3
OUT
2.5V/3A OR 6A
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
______________________________________________________________________________________ 11
A limitation of sensing current across a MOSFETs on­resistance is that the current-limit threshold is not accu­rate since MOSFET R
DS(ON)
specifications are not precise. This type of current limit provides a coarse level of fault protection. It is especially suited when the input source is already current-limited or otherwise protected.
Power MOSFET Selection
The MAX8545/MAX8546/MAX8548 drive two external, logic-level, N-channel MOSFETs as the circuit switch­ing elements. The key selection parameters are:
1) On-resistance (R
DS(ON)
): the lower, the better.
2) Maximum drain-to-source voltage (V
DSS
) should be at least 10% higher than the input supply rail at the high-side MOSFETs drain.
3) Gate charges (Qg, Qgd, Qgs): the lower, the better.
Choose the MOSFETs with rated R
DS(ON)
at VGS= 4.5V for an input voltage greater than 5V, and at VGS= 2.5V for an input voltage less than 5.5V. For a good compro­mise between efficiency and cost, choose the high-side MOSFET (N1) that has conduction losses equal to the switching losses at nominal input voltage and maximum output current. For N2, make sure it does not spuriously turn on due to a dV/dt caused by N1 turning on as this would result in shoot-through current degrading the efficiency. MOSFETs with a lower Qgd/ Qgsratio have higher immunity to dV/dt.
MOSFET Power Dissipation
For proper thermal-management design, the power dis­sipation must be calculated at the desired maximum operating junction temperature, maximum output cur­rent, and worst-case input voltage (for the low-side MOSFET (N2) the worst case is at V
IN(MAX)
, for the high­side MOSFET (N1) the worst case can be either at V
IN(MIN)
or V
IN(MAX)
). N1 and N2 have different loss components due to the circuit operation. N2 operates as a zero-voltage switch; therefore, the major losses are: the channel conduction loss (P
N2CC
), the body-diode
conduction loss (P
N2DC
), and the gate-drive loss
(P
N2DR
).
Use R
DS(ON)
at T
J(MAX)
.
where V
F
is the body-diode forward voltage drop, tdtis the dead time between N1 and N2 switching transitions (which is 30ns), and fSis the switching frequency.
Because of zero-voltage switch operation, the N2 gate­drive losses are due to charging and discharging the input capacitor, C
ISS
. These losses are distributed between the average DL gate drivers pullup and pull­down resistors and the internal gate resistance. The RDLis typically 1.8, and the internal gate resistance (R
GATE
) of the MOSFET is typically 2. The drive
power dissipated in N2 is given by:
N1 operates as a duty-cycle control switch and has the following major losses: the channel conduction loss (P
N1CC
), the voltage and current overlapping switching
loss (P
N1SW
), and the drive loss (P
N1DR
). N1 does not have a body-diode conduction loss because the diode never conducts current.
Use R
DS(ON)
at T
J(MAX)
.
where I
GATE
is the average DH high driver output-cur-
rent capability determined by:
where RDHis the high-side MOSFET drivers average on-resistance (2.05typ) and R
GATE
is the internal gate resistance of the MOSFET (2typ).
where VGS~ VL.
In addition to the losses above, allow about 20% more for additional losses due to MOSFET output capaci­tance and N2 body-diode reverse recovery charge dis­sipated in N1. Refer to the MOSFET data sheet for thermal resistance specifications to calculate the PC board area needed. This information is essential to maintain the desired maximum operating junction tem­perature with the above calculated power dissipation.
To reduce EMI caused by switching noise, add a 0.1µF ceramic capacitor from the high-side MOSFET drain to the low-side MOSFET source or add resistors in series
P
NCC
1=−
 
PIVtf
N DC LOAD F dt S2
V
OUT
××
V
IN
2 × × ×
2
IR
LOAD
DS ON2
()
PCVf
N DR ISS GS S
2
2
()
××
R
GATE
RR
+
GATE DL
P
NCC
PVI f
=
 
××
N SW IN LOAD S
1
V
OUT
V
IN
×
()
 
2
IR
LOAD DS ON1
×
QQ
GS GD
I
GATE
()
+
I
GATE ON
()
1
2
VL
+
RR
DH GATE
PQVf
=×××
NDR GS GS S
1
R
GATE
+
RR
DH GATE
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
12 ______________________________________________________________________________________
with DH and DL to slow down the switching transitions. However, adding series resistors increases the power dissipation of the MOSFET, so ensure temperature rat­ings of the MOSFET are not exceeded.
Input-Capacitor Selection
The input capacitors (C2 and C3 in Figure 1) reduce noise injection and current peaks drawn from the input supply. The input capacitor must meet the ripple-cur­rent requirement (I
RMS
) imposed by the switching cur-
rents. The RMS input ripple current is given by:
For optimal circuit reliability, choose a capacitor that has less than 10°C temperature rise at the RMS current. I
RMS
is maximum when the input voltage equals 2 x
V
OUT
, where I
RMS
= 1/2 I
LOAD
.
Output Capacitor Selection
The key parameters for the output capacitor are the actual capacitance value, the equivalent series resis­tance (ESR), the equivalent series inductance (ESL), and the voltage-rating requirements. All these parame­ters affect the overall stability, output ripple voltage, and transient response.
The output ripple has three components: variations in the charge stored in the output capacitor, the voltage drop across the ESR, and the voltage drop across the ESL.
V
RIPPLE
= V
RIPPLE(ESR)
+ V
RIPPLE(C)
+ V
RIPPLE(ESL)
The output voltage ripple as a consequence of the ESR and output capacitance is:
where I
P-P
is the peak-to-peak inductor current (see the
Inductor Selection section).
While these equations are suitable for initial capacitor selection to meet the ripple requirement, final values may also depend on the relationship between the LC double-pole frequency and the capacitor ESR-zero fre­quency. Generally, the ESR zero is higher than the LC double pole; however, it is preferable to keep the ESR
zero close to the LC double pole when possible to negate the sharp phase shift of the typically high-Q double LC pole (see the Compensation Design sec­tion). Aluminum electrolytic or POS capacitors are rec­ommended. Higher output current requires multiple capacitors to meet the output ripple voltage.
The MAX8545/MAX8546/MAX8548s response to a load transient depends on the selected output capacitor. After a load transient, the output instantly changes by (ESR x I
LOAD
) + (ESL x dI/dt). Before the controller can respond, the output deviates further depending on the inductor and output capacitor values. After a short period of time (see the Typical Operating Characteristics), the controller responds by regulating the output voltage back to its nominal state. The controller response time depends on the closed-loop bandwidth. Higher band­width results in faster response time, preventing the out­put voltage from further deviation. Do not exceed the capacitor’s voltage or ripple-current ratings.
Boost Diode and Capacitor Selection
A low-current Schottky diode, such as the CMPSH-3 from Central Semiconductor, works well for most appli­cations. Do not use large power diodes since higher junction capacitance can charge up BST to LX voltage that could exceed the device rating of 6V. The boost capacitor should be in the range of 0.1µF to 0.47µF, depending on the specific input and output voltages and the external components and PC board layout. The boost capacitance needs to be as large as possible to prevent it from charging to excessive voltage, but small enough to adequately charge during the minimum low­side MOSFET conduction time, which happens at the maximum operating duty cycle (this occurs at the mini­mum input voltage). In addition, ensure the boost capacitor does not discharge to below the minimum gate-to-source voltage required to keep the high-side MOSFET fully enhanced for lowest on-resistance. This minimum gate-to-source voltage V
GS(MIN)
is deter-
mined by:
where Qg is the total gate charge of the high-side MOSFET and C
BOOST
is the boost capacitor value.
Compensation Design
The MAX8545/MAX8546/MAX8548 use a voltage-mode control scheme that regulates the output voltage. This is done by comparing the error amplifiers output (COMP) to a fixed internal ramp. The inductor and output capacitor create a double pole at the resonant frequency, which
VVV
×−
()
II
RMS LOAD
OUT IN OUT
V
IN
V I ESR
RIPPLE ESR P P
V
RIPPLE C
V
RIPPLE ESL
=
I
PP
()
()
()
VV
IN OUTSWOUT
 
I
=
fLVV
PP
××
8
Cf
OUT SW
×
V ESL
IN
=
+
L ESL
×
IN
 
Q
VV
GS MIN L
=−
()
C
BOOST
G
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
______________________________________________________________________________________ 13
has a gain drop of 40dB per decade, and a phase shift of 180°. The error amplifier must compensate for this gain drop and phase shift to achieve a stable high­bandwidth, closed-loop system.
The basic regulator loop consists of a power modulator (Figure 3), an output feedback divider, and an error amplifier. The power modulator has DC gain set by VIN/V
RAMP
, with a double pole set by the inductor and output capacitor, and a single zero set by the output capacitor (C
OUT
) and its equivalent series resistance (ESR). Below are equations that define the power mod­ulator:
The DC gain of the power modulator is:
where V
RAMP
= 1V.
The pole frequency due to the inductor and output capacitor is:
The zero frequency due to the output capacitors ESR is:
The output capacitor is usually comprised of several same capacitors connected in parallel. With n capaci­tors in parallel, the output capacitance is:
C
OUT
= n X C
EACH
The total ESR is:
The ESR zero (f
ZESR
) for a parallel combination of
capacitors is the same as for an individual capacitor.
The feedback divider has a gain of GFB= VFB/V
OUT
,
where VFBis 0.8V.
The transconductance error amplifier has DC gain G
EA(dc)
of 72dB. A dominant pole (f
DPEA
) is set by the compensation capacitor (CC), the amplifier output resistance (RO) equals 37M, and the compensation resistor (RC):
The compensation resistor and the compensation capacitor set a zero:
The total closed-loop gain must equal unity at the crossover frequency. The crossover frequency should be higher than f
ZESR
, so that the -1 slope is used to cross over at unity gain. Also, the crossover frequency should be less than or equal to 1/5 the switching fre­quency (fSW) of the controller.
The loop-gain equation at the crossover frequency is:
VFB/V
OUT
x G
EA(fC)
x G
MOD(fC)
= 1
where G
EA(fc)
= g
mEA
× RC, and G
MOD(fc)
= G
MOD(DC)
× (f
PMOD
)2 / (f
ZESR
× fC).
The compensation resistor, RC, is calculated from:
RC= V
OUT
/ g
mEA
x VFBx G
MOD(fC)
where g
mEA
= 108µS.
Due to the underdamped (Q > 1) nature of the output LC double pole, the error-amplifier compensation zero should be approximately 0.2 f
PMOD
to provide good
phase boost. CCis calculated from:
A small capacitor, CF, can also be added from COMP to GND to provide high-frequency decoupling. CFadds another high-frequency pole, f
PHF
, to the error-amplifier response. This pole should be greater than 100 times the error-amplifier zero frequency to have negligible impact on the phase margin. This pole should also be less than 1/2 the switching frequency for effective decoupling.
100 f
ZEA
< f
PHF
< 0.5 f
sw
Select a value for f
PHF
in the range given above, then
solve for CFusing the following equation:
PC Board Layout Guidelines
Careful PC board layout is critical to achieve low switch­ing losses and stable operation. If possible, mount all the power components on the top side of the board with their
G
MOD DC
()
=
V
IN
V
RAMP
f
PMOD
f
ZESR
=
=
LC
2π
××
2π
1
OUT
1
ESR C
OUT
ESR
=
ESR
EACH
n
f
DPEA
=
2π
1
CRR
×× +
()
COC
f
ZEA
=
CR
××
2π
1
CC
ff
ZESR C
<≤
f
SW
5
C
=
C
2π
5
Rf
××
CPMOD
C
F
=
××
2π
1
Rf
C PHF
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
14 ______________________________________________________________________________________
ground terminals flush against one another. Follow these guidelines for good PC board layout:
1) Keep the high-current paths short, especially at the ground terminals. This practice is essential for sta­ble, jitter-free operation.
2) Connect the power and analog grounds close to the IC pin 7.
3) Keep the power traces and load connections short. This practice is essential for high efficiency. Using thick copper PC boards (2oz vs. 1oz) can enhance full-load efficiency by 1% or more. Correctly routing PC board traces is a difficult task that must be approached in terms of fractions of centimeters, where a few milohms of excess trace resistance cause a measurable efficiency penalty.
4) LX and GND connections to the low-side MOSFET for current sensing must be made using Kelvin sense connections to guarantee the current-limit accuracy. With SO-8 MOSFETs, this is best done by routing power to the MOSFETs from outside using the top copper layer, while connecting LX and GND inside (underneath) the SO-8 package.
5) When tradeoffs in trace lengths must be made, it’s preferable to allow the inductor charging current path to be longer than the discharge path. For example, its better to allow some extra distance between the inductor and the low-side MOSFET or between the inductor and the output filter capacitor.
6) Ensure that the connection between the inductor and C3 is short and direct.
7) Route switching nodes (BST, LX, DH, and DL) away from sensitive analog areas (COMP and FB).
Ensure the C1 ceramic bypass capacitor is immediately adjacent to the pins and as close to the device as possi­ble. Furthermore, the VINand GND pins of MAX8545/ MAX8546/MAX8548 must terminate at the two ends of C1 before connecting to the power switches and C2.
Figure 3. Compensation Scheme
V
IN
RAMP
GENERATOR
PWM
COMP/EN
R2
C10
MAX8545 MAX8546 MAX8548
ERROR
AMPLIFIER
0.8V
DH
LX
DL
FB
N
L
N
V
OUT
C
OUT
R3
R4
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
______________________________________________________________________________________ 15
Table 1a. Component Selection for Standard Applications for VIN= 2.7V to
5.5V, V
OUT
= 1.8V / 3A (Figure 1)
(MAX8546 Only)
Table 1b. Component Selection for Standard Applications for V
IN
= 2.7V to
5.5V, V
OUT
= 1.8V / 6A (Figure 1)
(MAX8546 Only)
COMPONENT QTY DESCRIPTION
C1, C4 2
C2 0 Not installed
C3 1
C5, C8, C9 3
C6, C7 2
C10 1
C11 0 Not installed
D1, D2 2
L1 1
Q1 1
R1 1 10 ±5% resistor R2 1 150kΩ ±5% resistor R3 1 5.11kΩ ±1% resistor R4 1 4.02kΩ ±1% resistor
1µF, 10V X7R ceramic capacitors Taiyo Yuden LMK212BJ105MG
1200µF, 10V, 44m, 1.25A aluminum electrolytic capacitor Sanyo 10MV1200AX (10 x 16 case size)
0.1µF, 10V X7R ceramic capacitors Kemet C0603C104M8RAC
1000µF, 6.3V, 69m, 0.8A aluminum electrolytic capacitors Sanyo 6.3MV1000AX (8 x 20 case size)
1.5nF, 10V X7R ceramic capacitor Kemet C0603C152M8RAC
30V, 100mA Schottky diodes Central Semiconductor CMPSH-3
4.7µH, 5.7A, 18m inductor Sumida CDRH124-4R7
20V/30V, 35m dual N-channel 8-pin SO V i shay S i 4966D Y ( f o r 2.7 V t o 3.6 V Fair chil d FD S 6912A ( f or 4 .5 V t o 5 .5 V
IN
)
IN
COMPONENT QTY DESCRIPTION
C1, C4 2
C2, C3 2
C5, C8, C9 3
C6, C7 2
C10 1
C11 0 Not installed
D1, D2 2
L1 1
Q1 1
R1 1 10 ±5% resistor
)
R2 1 110kΩ ±5% resistor R3 1 5.11kΩ ±1% resistor R4 1 4.02kΩ ±1% resistor
1µF, 10V X7R ceramic capacitors Taiyo Yuden LMK212BJ105MG
1200µF, 10V, 44m, 1.25A aluminum electrolytic capacitors Sanyo 10MV1200AX (10 x 16 case size)
0.1µF, 10V X7R ceramic capacitors Kemet C0603C104M8RAC
1500µF, 6.3V, 44m Ω, 1.25A al um i num el ectr ol ytic cap acitor s S anyo 6.3M V1500AX (10 x 20 case si ze)
1.5nF, 10V X7R ceramic capacitor Kemet C0603C152M8RAC
30V, 100mA Schottky diodes Central Semiconductor CMPSH-3
2.1µH, 8A, 11.6m inductor Sumida CEP122-2R1
20V, 18m Ω d ual N- channel 8- pi n SO Fair chil d FD S 6898A ( f or 2 .7 V t o 3 .6 V Fair chil d FD S 6890A ( f or 4 .5 V t o 5 .5 V
IN
IN
) )
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
16 ______________________________________________________________________________________
Table 2a. Component Selection for Standard Applications for VIN= 10V to 24V, V
OUT
= 2.5V / 3A (Figure 2)
(MAX8546 Only)
Table 2b. Component Selection for Standard Applications for V
IN
= 10V to
24V, V
OUT
= 2.5V / 6A (Figure 2)
(MAX8546 Only)
COMPONENT QTY DESCRIPTION
C1 1
C2 0 Not installed
C3 1
C4, C12 2
C5, C8, C9 3
C6, C7 2
C10 1
C11 0 Not installed
D1, D2 2
L1 1
Q1 1
R1 1 10 ±5% resistor R2 1 82kΩ ±5% resistor R3 1 8.66kΩ ±1% resistor R4 1 4.02kΩ ±1% resistor
1µF, 10V X7R ceramic capacitor Taiyo Yuden LMK212BJ105MG
470µF, 35V, 39m, 1.45A aluminum electrolytic capacitor Sanyo 35MV470AX (10 x 22 case size)
1µF, 35V X7R ceramic capacitors Taiyo Yuden GMK316BJ105ML
0.1µF, 10V X7R ceramic capacitors Kemet C0603C104M8RAC
1000µF, 6.3V, 69m, 0.8A aluminum electrolytic capacitors Sanyo 6.3MV1000AX (8 x 20 case size)
6.8nF, 10V X7R ceramic capacitor Kemet C0603C6822M8RAC
30V, 100mA Schottky diodes Central Semiconductor CMPSH-3
8.2µH, 5.8A, 9.5m inductor Sumida CEP125-8R2
30V, 35m dual N-channel 8-pin SO Fairchild FDS6912A
COMPONENT QTY DESCRIPTION
C2, C3 2
C4, C12 2
C5, C8, C9 3
C6, C7 2
D1, D2 2
C1 1
C10 1
C11 0 Not installed
L1 1
Q1 1
R1 1 10 ±5% resistor R2 1 68kΩ ±5% resistor R3 1 8.66kΩ ±1% resistor R4 1 4.02kΩ ±1% resistor
1µF, 10V X7R ceramic capacitor Taiyo Yuden LMK212BJ105MG
470µF, 35V, 39m, 1.45A aluminum electrolytic capacitors Sanyo 35MV470AX (10 x 22 case size)
1µF, 35V X7R ceramic capacitors Taiyo Yuden GMK316BJ105ML
0.1µF, 10V X7R ceramic capacitors Kemet C0603C104M8RAC
1500µF, 6.3V, 44m, 1.25A aluminum electrolytic capacitors Sanyo 6.3MV1500AX (10 x 20 case size)
6.8nF, 10V X7R ceramic capacitor Kemet C0603C682M8RAC
30V, 100mA Schottky diodes Central Semiconductor CMPSH-3
4µH, 8.3A, 6.6m inductor Sumida CEP125-4R0
30V, 18m (LSFET)/35m (HSFET) dual N-channel 8-pin SO Fairchild FDS6982
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down
Controllers with Foldback Current Limit
______________________________________________________________________________________ 17
Pin Configuration
Chip Information
TRANSISTOR COUNT: 3351
PROCESS: BiCMOS
TOP VIEW
COMP/EN
V
1
2
MAX8545 MAX8546
3
CC
IN
MAX8548
4
56
µMAX
109BST
DHFB
8
LX
7
GNDV
DLVL
MAX8545/MAX8546/MAX8548
Low-Cost, Wide Input Range, Step-Down Controllers with Foldback Current Limit
Maxim cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Maxim product. No circuit patent licenses are implied. Maxim reserves the right to change the circuitry and specifications without notice at any time.
18 ____________________Maxim Integrated Products, 120 San Gabriel Drive, Sunnyvale, CA 94086 408-737-7600
© 2003 Maxim Integrated Products Printed USA is a registered trademark of Maxim Integrated Products.
Package Information
(The package drawing(s) in this data sheet may not reflect the most current specifications. For the latest package outline information go to www.maxim-ic.com/packages
.)
0.6±0.1
e
10
ÿ 0.50±0.1
1
0.6±0.1
TOP VIEW
D2
A2
b
D1
FRONT VIEW
4X S
10
H
1
BOTTOM VIEW
GAGE PLANE
A
A1
α
E2
E1
SIDE VIEW
INCHES
MAX
MIN
DIM
A1 A2 0.030 0.037 0.75 0.95 D1 D2 E1 E2 H L
L1 b e
c
S
α
c
L
L1
PROPRIETARY INFORMATION
TITLE:
0.043
-A
0.006
0.002
0.116
0.120
0.114
0.118
0.116
0.120
0.114
0.118
0.187
0.199
0.0157
0.0275
0.037 REF
0.007
0.0106
0.0197 BSC
0.0035
0.0078
0.0196 REF 6∞
0∞ 0∞ 6∞
PACKAGE OUTLINE, 10L uMAX/uSOP
21-0061
MILLIMETERS
MAX
MIN
1.10
-
0.15
0.05
3.05
2.95
3.00
2.89
3.05
2.95
2.89
3.00
4.75
5.05
0.40
0.70
0.940 REF
0.177
0.270
0.500 BSC
0.090
0.200
0.498 REF
10LUMAX.EPS
REV.DOCUMENT CONTROL NO.APPROVAL
1
I
1
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