UG332: Class 3 Non-Isolated Evaluation
Board for the Si3406
The Si3406 non-isolated Flyback topology based evaluation board
is a reference design for a power supply in a Power over Ethernet
(PoE) Powered Device (PD) application.
This Si3406-non-ISO-FB EVB maximum output level is Class 3 power (
The Si3406-non-ISO-FB EVB board is shown below. The Si3406 IC integrates an IEEE
802.03at compatible PoE interface as well as a current control based dc/dc converter.
The Si3406 PD integrates two diode bridges, which can be used up to 200 mA input current, detection circuit, classification circuit, dc/dc switch, hot-swap switch, TVS overvoltage protection, dynamic soft-start circuit, cycle-by-cycle current limit, syncrhonous gate
driver, maintain power signature (MPS), thermal shutdown and inrush current protection.
The switching frequency of the converter is tunable by an external resistor.
x 15.4 W).
η
KEY FEATURES
• IEEE 802.03at Compatible
• High Efficiency
•
High Integration
• Optional MPS Function
• Synchronous Gate Driver
• Low BOM Cost
• Transient Overvoltage Protection
• Thermal Shutdown Protection
• 5x5 mm 20-pin QFN
silabs.com | Building a more connected world.Rev. 0.1
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Kit Description
1. Kit Description
The Si3406-non-isolated Flyback topology based evaluation board is a reference design for power supplies in Power over Ethernet
(PoE) Powered Device (PD) applications. The Si3406 device is described more completely in the data sheet and application notes. This
document describes the evaluation board.
The Si3406-non-ISO-FB-C3 EVB board is shown on the cover page. The schematic is shown in Figure 2.3 Si3406-Non-Isolated Fly-
back EVB Schematic: 5 V, Class 3 PD on page 4, and the layout is in 17. Board Layout. The dc output is at connectors J11(+) and
J12(–).
Boards are shipped configured to produce 5 V output voltage but can be configured for different output voltages, such as 3.3 or 12 V,
by changing resistor R14 and a few other components. Refer to “AN1130: Using the Si3406/Si34061/Si34062 PoE+ and Si3404 PoE
PD Controller in Isolated and Non-Isolated Designs” for more information. The preconfigured Class 3 signature can also be modified,
which is described as well in AN1130.
The Si3406 includes integrated diode bridge for both CT and SP connection. The integrated diode bridge can be used up to 200 mA
input current. Above 200 mA input current the external diode bridge is required.
The external diode bridge can be Schottky or silicon type.
The Si3406 device can operate with CT/SP pins open, in this configuration the external bridge should be Schottky type diode bridge.
To compensate the reverse leakage of the Schottky type diode bridges at high temperature, the recommended detection resistor should
be adjusted to the values listed in the following table:
Table 1.1. Recommended Detection Resistor Values
External Diode BridgeR
Silicon Type24.3 kΩ
Schottky Type24.9 kΩ
DET
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Getting Started: Powering Up the Si3406-non-ISO-FB EVB
2. Getting Started: Powering Up the Si3406-non-ISO-FB EVB
Ethernet data and power are applied to the board through the RJ45 connector (J1). The board itself has no Ethernet data transmission
functionality, but, as a convenience, the Ethernet transformer secondary-side data is brought out to test points.
The design can be used in Gigabit (10/100/1000) systems as well by using PoE RJ45 Magjack, such as type L8BE-1G1T-BFH from Bel
Fuse.
Power may be applied in the following ways:
• Using an IEEE 802.3-2015-compliant, PoE-capable PSE, such as Trendnet TPE-1020WS
• Using a laboratory power supply unit (PSU):
• Connecting a dc source between blue/white-blue and brown/white-brown of the Ethernet cable (either polarity), (End-span) as
shown below:
• Connecting a
as shown below:
Figure 2.1. Endspan Connection using Laboratory Power Supply
dc source between green/white-green and orange/white-orange of the Ethernet cable (either polarity), (Mid-span)
Figure 2.2. Midspan Connection using Laboratory Power Supply
silabs.com | Building a more connected world.Rev. 0.1 | 3
Page 4
L5
330 Ohm
C6
100uF
R20
47K
J11
D19S1B
TP4 NI
D12S1B
T1
FA2924
2
9
178
10
J12
R14 9.1K
TP9
vss
NI
R21
0
R5
6.8
R15 3.24K
TP5 NI
C16 1nF
NI
R10 48.7
C32
1nF
J1
RJ-45
MX0+
1
MX0-
3
MX1+
4
PWR28PWR39PWR4
10
CT
2
LED_K2K2LED_A2A2LED_K1K1LED_A1
A1
PWR1
7
CT/MX1-
5
MX1-
6
PWR5
11
C10 1uF
Q1
FDMA8051L
TP6 NI
C17 1nF
NI
R13
0.62
C20
1nF
C9 100uF
NI
C12 1nF
NI
C4
0.01uF
+
C2
12uF
C13 1nF
NI
TP7 NI
C18 1nF
NI
R8 88.7K
C1
2.2uF
C14 1nF
NI
TP3 NI
C8
0.1uF
TP10
swo
NI
D18S1B
L4
330 Ohm
C5
1nF
+
C7 220uF
D15S1B
TP1
vpos
NI
TP8 NI
TP2
syncl
NI
U1
Si3406
FBH
1
EROUT
2
FBL
3
VDD
4
NSLEEP
5
RDET
6
HSO
7
RCL
8
RFREQ
9
SP2
10
SP111VPOS12CT213CT1
14
NT2P
15
SYNCL
16
V11
17
SWO
18
VSS
19
ISNS
20
VNEG
21
L1
330 Ohm
R2
330
R11 24.3k
C19 1nF
NI
D5
1N4148W
NI
C15 1nF
NI
D17S1B
C31
NI
C3
2.2uF
C22
0.1uF
D14S1B
L2
330 Ohm
R1
330
C11 100uF
NI
R4
27k
L3
1uH
TP12
vneg
NI
D4
RS1B
D16S1B
C21
0.22uF
D13S1B
swo
vposvss
v11
fbl
nt2p
nt2p
vdd
Vss
vout
vss
vpos
vneg
vout
gnds
vdd
vss
vpos
erout
isns
vneg
vpos
vpos
ct2
ct1
sp2
sp1
vss
vssgnds
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Getting Started: Powering Up the Si3406-non-ISO-FB EVB
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Overall EVB Efficiency
3. Overall EVB Efficiency
The overall efficiency measurement data of the Si3406-non-ISO-FB EVB board is shown below. The input voltage is 50 V, output voltage is 5 V.
Figure 3.1. Si3406-Non-Isolated Flyback Class 3 EVB Overall Efficiency: 50 V Input, 5 V Output, Class 3 PD
Note: The chart shows overall EVB efficiency. The voltage drop on the standard silicon diode bridge is included.
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
SIFOS PoE Compatibility Test Results
4. SIFOS PoE Compatibility Test Results
The Si3406-non-ISO-FB EVB board has been successfully tested with PDA-300 Powered Device Analyzer from SIFOS Technologies.
The PDA-300 Powered Device Analyzer is a single-box comprehensive solution for testing IEEE 802.3at PoE Powered Devices (PDs).
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Page 7
-180
-90
0
90
180
-80
-60
-40
-20
0
20
40
60
80
1001 00010 000100 000
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Feedback Loop Phase and Gain Measurement Results (Bode Plots)
5. Feedback Loop Phase and Gain Measurement Results (Bode Plots)
The Si3406 device integrates a current mode controlled switching mode power supply controller circuit. Therefore, the application is a
closed-loop system. To guarantee a stable output voltage of a power supply and to reduce the influence of input supply voltage variations and load changes on the output voltage, the feedback loop should be stable.
To verify the stability of the loop, the loop gain and loop phase shift has been measured.
Figure 5.1. Si3406-Non-ISOFB-EVB-C3 Measured Loop-Gain and Phase Shift
Table 5.1. Measured Loop Gain and Phase Shift
FrequencyGainPhase
Cursor 1 (Phase Margin)19.1 kHz0 dB78°
Cursor 2 (Gain Margin)47.1 kHz–7 dB0 °
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Step Load Transient Measurement Results
6. Step Load Transient Measurement Results
The Si3406-non-ISO-FB EVB board's output has been tested with a step load function to verify the converters output dynamic response.
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Output Voltage Ripple
7. Output Voltage Ripple
The Si3406-non-ISO-FB output voltage ripple has been measured in both no load and heavy load conditions.
Figure 7.1. Si3406-Non-Isolated Flyback C3 EVB Output Voltage Ripple No Load (Left) and Heavy Load (Right) Conditions
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Soft Start Protection
8. Soft Start Protection
The Si3406 device has an integrated dynamic soft-start protection mechanism to avoid stressing the components by the sudden current
or voltage changes associated with the initial charging of the output capacitors.
Figure 8.1. Si3406-Non-Isolated Flyback C3 EVB Input Current and Output Voltage Soft-Start at Low Load (Left) and Heavy
Load (Right) Conditions
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Output Short Protection
9. Output Short Protection
The Si3406 device has an integrated output short protection mechanism, which protects the IC itself and the surrounding external components from overheating in the case of electrical short on the output.
Figure 9.1. Si3406-Non-Isolated Flyback C3 EVB Output Voltage and Input Current when Output is Shorted
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Pulse Skipping at No-Load Condition
10. Pulse Skipping at No-Load Condition
The Si3406 device has an integrated pulse skipping mechanism to ensure ultra-low power consumption at no load condition.
Figure 10.1. Si3406 Pulse Skipping at No-load Condition: SWO Waveform
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Adjustable EVB Current Limit
11. Adjustable EVB Current Limit
For additional safety, the Si3406 has an adjustable EVB current limit feature. The EVB current limit through the ISNS pin measures the
voltage on R
The EVB current limit for this Class 3 application can be calculated with the following formula:
SENSE
. When V
= -270 mV (referenced to Vss), the current limit circuit restarts the circuit to protect the application.
RSENSE
E
NSE
= 0.62Ω
R
S
I
LIMIT
270mV
=
0.62Ω
= 435m
A
Equation 1. EVB Current Limit
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Page 14
12. Tunable Switching Frequency
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Tunable Switching Frequency
The switching frequency of the oscillator is selected by choosing an external resistor (R
VPOS pins. The following figure will aid in choosing the R
Figure 12.1. Switching Frequency vs R
value to achieve the desired switching frequency.
FREQ
FREQ
) connected between the RFREQ and
FREQ
The selected switching frequency for this application is 220 kHz, which is achieved by setting the RFREQ resistor to 88.7 kΩ.
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Synchronous Rectification
13. Synchronous Rectification
The Si3406 device has synchronous gate driver (SYNCL) to drive the rectifier MOSFET. At low-load the converter works in discontinuous current mode (DCM); at heavy load, the converter runs in continuous current mode (CCM). At low-load the SWO voltage waveform
has a ringing waveform, which is typical for a DCM operation.
Figure 13.1. SWO and SYNCL Voltage Waveforms at Discontinuous Current Mode (DCM) (Left) and in Continuous Current
Mode (CCM) (Right)
The device operates in non-synchronous mode at light load (IIN < 25
its switching operation from "Non-Synchronous" to "Synchronous". The dynamic operation adjustment maximizes overall power efficien-
cy.
mA). As the input current increases, Si3406 automatically changes
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Page 16
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Maintain Power Signature
14. Maintain Power Signature
The Si3406 device integrates an MPS circuit which ensures connection with the PSE if the PD application current drops below PSE
threshold level.
There are two modes of MPS operation:
• Automatic mode MPS (consumption-based)
• User mode MPS
Automatic Mode MPS (Consumptions Based):
If nSLEEP is low at startup, MPS generation depends on chip current consumption:
• MPS pulses are enabled below a certain level of total PD current consumption to ensure connection with the PSE
• MPS pulses are disabled above a certain level of total PD current consumption not to degrade overall board efficiency
I
IN
nSLEEP = low
Figure 14.1. Automatic MPS Mode, nSLEEP is Low; MPS is Enabled when PD Consumption is Low; MPS is Disabled when PD
Consumption is Higher
User Mode MPS:
If nSLEEP is high at startup, MPS generation depends on nSLEEP.
• if nSLEEP is high, MPS disabled (independently of the current consumption)
• if nSLEEP is low, MPS enabled (independently of the current consumption)
At startup, nSLEEP was high
I
IN
nSLEEP = high
nSLEEP = low
Figure 14.2. With nSLEEP High, MPS is Disabled (Left); with nSLEEP Low, MPS is Enabled (Right); MPS
silabs.com | Building a more connected world.Rev. 0.1 | 16
Generation is Fully Controlled by the User
Page 17
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Radiated Emissions Measurement Results
15. Radiated Emissions Measurement Results
Radiated emissions have been measured of the Si3406-non-ISO-FB EVB board with 50 V input voltage and full load connected to the
output – 12.5 W.
As shown below, the Si3406-non-ISO-FB EVB is fully compliant with the international EN 55022 class B emissions standard.
Figure 15.1. Si3406-Non-Isolated Flyback EVB Radiated Emissions Measurement Results; 50 V Input, 5 V Output, 12.5 W Out-
put Load
15.1 Radiated EMI Measurement Process
EVB
The
produces a red curve (vertical polarization) and a blue curve (horizontal polarization). Next, specific frequencies are selected (red stars)
for quasi-peak measurements. The board is measured again at those specific frequencies with a quasi-peak detector, which is a very
slow but accurate measurement. The results of this quasi-peak detector measurement are the blue rhombuses.
The blue rhombuses represent the final result of the measurement process. To have passing results, the blue rhombuses should be
below the highlighted EN 55022 Class B limit.
is measured at full load with peak detection in both vertical and horizontal polarizations. This is a relatively fast process that
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Conducted Emissions Measurement Results
16. Conducted Emissions Measurement Results
The Si3406-non-ISO-FB EVB board's conducted emissions have been measured, the result is shown below.
Figure 16.1. Si3406-Non-Isolated Flyback EVB Conducted Emissions Measurements Results; 50 V Input, 5 V Output, 12.5 W
Output Load
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Page 19
17. Board Layout
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Board Layout
Figure 17.1. Top Silkscreen
silabs.com | Building a more connected world.Rev. 0.1 | 19
Figure 17.2. Top Layer
Page 20
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Figure 17.3. Internal 1 (Layer 2)
Board Layout
silabs.com | Building a more connected world.Rev. 0.1 | 20
Figure 17.4. Internal 2 (Layer 3)
Page 21
Figure 17.5. Bottom Layer
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Board Layout
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Page 22
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
18. Bill of Materials
The following table is the BOM listing for the standard 5 V output evaluation board with option PoE Class 3.
Table 18.1. Si3406FBC3 Evaluation Board Bill of Materials
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Page 24
UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Bill of Materials
1330 pFC31100 V±20%X7RC0805C0805X7R101-331MVenkel
11N4148WD5300 mA100 VSingleSOD-1231N4148W-7-FDiodes Inc.
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UG332: Class 3 Non-Isolated Evaluation Board for the Si3406
Appendix—Si3406-Non-ISO-FB Design and Layout Checklist
19. Appendix—Si3406-Non-ISO-FB Design and Layout Checklist
Although the EVB design is pre-configured as a Class 3 PD with 5 V output, the schematics and layouts can easily be adapted to meet
a wide variety of common output voltages and power levels.
The complete EVB design databases for the standard 5 V/Class 3 configuration are located at www.silabs.com/PoE link. Silicon Labs
strongly recommends using these EVB schematics and layout files as a starting point to ensure robust performance and avoid common
mistakes in the schematic capture and PCB layout processes.
Below is a recommended design checklist that can assist in trouble-free development of robust PD designs.
Refer also to the Si3406-non-ISO-FB data sheet and AN1130 when using the following checklist.
1. Design Planning checklist:
a. Determine if your design requires an isolated or non-isolated topology. For more information, see AN1130.
b. Silicon Labs strongly recommends using the EVB schematics and layout files as a starting point as you begin integrating the
Si3406-non-ISO-FB into your system design process.
c. Determine your load’s power requirements (i.e., VOUT and IOUT consumed by the PD, including the typical expected transi-
ent surge conditions). In general, to achieve the highest overall efficiency performance of the Si3406-non-isolated Flyback,
choose the highest output voltage option used in your PD and then post regulate to the lower supply rails, if necessary.
d. Based on your required PD power level, select the appropriate class resistor RCLASS value by referring to AN1130.
2. General Design checklist:
a. ESD caps (C12–C19 in Figure 2.3 Si3406-Non-Isolated Flyback EVB Schematic: 5 V, Class 3 PD on page 4) are strongly
recommended for designs where system-level ESD (IEC6100-4-2) must provide >15 kV tolerance.
b. If your design uses an AUX supply, be sure to include a 3 Ω surge limiting resistor in series with the AUX supply for hot inser-
tion. Refer to AN1130 when AUX supply is 48 V.
3. Layout Guidelines:
a. Make sure VNEG pin of the Si3406 is connected to the backside of the QFN package with an adequate thermal plane, as
noted in the data sheet and AN1130.
b. Keep the trace length from SWO to VSS as short as possible. Make all of the power (high current) traces as short, direct, and
thick as possible. It is a good practice on a standard PCB board to make the traces an absolute minimum of 15 mils (0.381
mm) per ampere.
c. Usually, one standard via handles 200 mA of current. If the trace needs to conduct a significant amount of current from one
plane to the other, use multiple vias.
d. Keep the circular area of the loop from the Switcher FET output to the inductor or transformer and returning from the input filter
capacitors (C1–C3) to VSS as small a diameter as possible. Also, minimize the circular area of the loop from the output of the
inductor or transformer to the Schottky diode and returning through the first stage output filter capacitor back to the inductor or
transformer as small as possible. If possible, keep the direction of current flow in these two loops the same.
e. Keep the high power traces as short as possible.
f. Keep the feedback and loop stability components as far from the transformer/inductor and noisy power traces as possible.
g. If the outputs have a ground plane or positive output plane, do not connect the high current carrying components and the filter
capacitors through the plane. Connect them together, and then connect to the plane at a single point.
To help ensure first-pass success, contact our customer support by submitting a help ticket and uploading your schematics and layout
files for review.
silabs.com | Building a more connected world.Rev. 0.1 | 25
Page 26
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Disclaimer
Silicon Labs intends to provide customers with the latest, accurate, and in-depth documentation of all peripherals and modules available for system and software implementers using or
intending to use the Silicon Labs products. Characterization data, available modules and peripherals, memory sizes and memory addresses refer to each specific device, and "Typical"
parameters provided can and do vary in different applications. Application examples described herein are for illustrative purposes only. Silicon Labs reserves the right to make changes
without further notice and limitation to product information, specifications, and descriptions herein, and does not give warranties as to the accuracy or completeness of the included
information. Silicon Labs shall have no liability for the consequences of use of the information supplied herein. This document does not imply or express copyright licenses granted
hereunder to design or fabricate any integrated circuits. The products are not designed or authorized to be used within any Life Support System without the specific written consent of
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