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Maxrefdes1022 5V/2A, Synchronous No-Opto Isolated Flyback DC-DC Converter Using MAX17690 and MAX17606 MAXREFDES1022 Introduction Hardware Specification Due to its simplicity and low cost, the flyback converter is An isolated no-opto flyback DC-DC converter using the the preferred choice for low-to-medium isolated DC-DC MAX17690 and MAX17606 is demonstrated for a 5V DC power-conversion applications. However, the use of output application. The power supply delivers up to 2A at an optocoupler or an auxiliary winding on the flyback 5V. Table 1 shows an overview of the design specification. transformer for voltage feedback across the isolation barrier increases the number of components and design Table 1. Design Specification complexity. The MAX17690 eliminates the need for an optocoupler or auxiliary transformer winding and achieves PARAMETER SYMBOL MIN MAX ±5% output voltage regulation over line, load, and tem- Input Voltage VIN 10V 50V perature variations. Frequency fSW 128kHz The MAX17690 implements an innovative algorithm to Efficiency at Full Load ηMAX 85% accurately determine the output voltage by sensing the Efficiency at Minimum η 55% reflected voltage across the primary winding during the Load MIN flyback time interval. By sampling and regulating this Output Voltage V 4.9V 5.1V reflected voltage when the secondary current is close to O zero, the effects of secondary-side DC losses in the trans- Output Voltage Ripple ∆VO(SS) 100mV former winding, the PCB tracks, and the rectifying diode Output Current IO 0.2A 2.0A on output voltage regulation can be minimized. Maximum Output Power PO 10W The MAX17690 also compensates for the negative tem- perature coefficient of the rectifying diode. Designed–Built–Tested Other features include the following: This document describes the hardware shown in Figure 1. ● 4.5V to 60V Input Voltage Range It provides a detailed systematic technical guide to design- ● Programmable Switching Frequency from 50kHz to ing an isolated no-opto flyback DC-DC converter using 250kHz Maxim’s MAX17690 controller. The power supply has been built and tested. ● Programmable Input Enable/UVLO Feature ● Programmable Input Overvoltage Protection ● Adjustable Soft-Start ● 2A/4A Peak Source/Sink Gate Drive Capability ● Hiccup Mode Short-Circuit Protection ● Fast Cycle-by-Cycle Peak Current Limit ● Thermal Shutdown Protection ● Space-Saving, 16-Pin, 3mm x 3mm TQFN Package ● -40°C to +125°C Operating Temperature Range Figure 1. MAXREFDES1022 hardware. Rev 0; 10/17 Maxim Integrated │ 1 The Isolated No-Opto Flyback Converter the isolated output voltage by examining the voltage on One of the drawbacks encountered in most isolated the primary-side winding of the flyback transformer. DC-DC converter topologies is that information relating to Other than this uniquely innovative method for regulating the output voltage on the isolated secondary side of the the output voltage, the no-opto isolated flyback converter transformer must be communicated back to the primary using the MAX17690 follows the same general design side to maintain output voltage regulation. In a regular process as a traditional flyback converter. To under- isolated flyback converter, this is normally achieved using stand the operation and benefits of the no-opto flyback an optocoupler feedback circuit or an additional auxiliary converter it is useful to review the schematic and typical winding on the flyback transformer. Optocoupler feedback waveforms of the traditional flyback converter (using the circuits reduce overall power-supply efficiency, and the MAX17595), shown in Figure 2. extra components increase the cost and physical size The simplified schematic in Figure 2 illustrates how infor- of the power supply. In addition, optocoupler feedback mation about the output voltage is obtained across the circuits are difficult to design reliably due to their limited isolation barrier in traditional isolated flyback converters. bandwidth, nonlinearity, high CTR variation, and aging The optocoupler feedback mechanism requires at least effects. Feedback circuits employing auxiliary transformer 10 components including an optocoupler and a shunt reg- windings also exhibit deficiencies. Using an extra wind- ulator, in addition to a primary-side bias voltage, VBIAS, to ing adds to the flyback transformer’s complexity, phys- drive the photo-transistor. The error voltage FB2 connects ical size, and cost, while load regulation and dynamic to the FB pin of the flyback controller. response are often poor. The transformer feedback method requires an additional The MAX17690 is a peak current-mode controller winding on the primary side of the flyback transformer, designed specifically to eliminate the need for optocou- a diode, a capacitor, and two resistors to generate a pler or auxiliary transformer winding feedback in the tra- voltage proportional to the output voltage. This voltage is ditional isolated flyback topology, therefore reducing size, compared to an internal reference in a traditional flyback cost, and design complexity. It derives information about controller to generate the error voltage. IIN ILP ILS DFR ILO ICIN TRANSFORMER FEEDBACK ICO VO DAUX RZ CIN VAUX LP LS CO NDRV VIN RL RU GNDP FB1 CAUX DZ GNDS RL VIN(MAX) x dMAX GNDP GNDS GNDS ΔILP(MAX) = LP x fSW GNDP 1: nSP OPTO-COUPLER FEEDBACK ΔILP GNDS VBIAS VO LLK VFLYBACK FB 2 x IO(MAX) MAX17595 QP ΔILS(MAX) = (1 – d ) NDRV MAX FB2 ΔILS CS GNDP RCS GNDP GNDP VO + VDFR + (ΔILS x RS) GNDP VIN + VFLYBACK nSP VIN GNDS t1 t3 t0 t2 t4 t5 t6 Figure 2. Isolated flyback converter topology with typical waveforms. www.maximintegrated.com Maxim Integrated │ 2 By including additional innovative features internally in the where: MAX17690 no-opto flyback controller, Maxim has enabled VFLYBACK is the QP drain voltage relative to primary ground power-supply designers to eliminate the additional com- ponents, board area, complexity, and cost associated with VDFR(T) is the forward voltage drop of DFR, which has a both the optocoupler and transformer feedback methods. negative temperature coefficient Figure 3 illustrates a simplified schematic and typical ILS(t) is the instantaneous secondary transformer current waveforms for an isolated no-opto flyback DC-DC con- RS(T) is the total DC resistance of the secondary circuit, verter using the MAX17690. which has a positive temperature coefficient By comparing Figure 3 with Figure 2, it is evident that nSP is the secondary to primary turns ratio of the flyback there is no difference in the voltage and current wave- transformer forms in the traditional and no-opto flyback topologies. The voltage of interest is (V - V ) since this is a The difference is in the control method used to maintain FLYBACK IN measure of V . An internal voltage to current amplifier V at its target value over the required load, line, and O O generates a current proportional to (V - V ). This temperature range. The MAX17690 achieves this with FLYBACK IN current then flows through R to generate a ground minimum components by forcing the voltage V SET FLYBACK referenced voltage, V , proportional to (V - V ). during the conduction period of DFR to be precisely the SET FLYBACK IN This requires that: voltage required to maintain a constant VO. When QP turns off, DFR conducts and the drain voltage of Q , rises P V− VV to a voltage V above V . After initial ringing due to FLYBACK IN= SET FLYBACK IN RR transformer leakage inductance and the junction capaci- FB SET tance of DFR and output capacitance of QP, the voltage VFLYBACK is given by: Combining this equation with the previous equation for VFLYBACK, we have: (VO+ V DFR( T) +× I LS( tRT) S( )) VV= + FLYBACK IN n RFB SP VVO= SET × ×−nSP V DFR( T) − I LS( tRT) × S( ) RSET DFR IIN ILP ILS ILO ICIN TRANSFORMER FEEDBACK ICO VO DAUX RZ CIN VAUX LP LS CO NDRV VIN RL RU GNDP FB1 CAUX DZ GNDS RL VIN(MAX) x dMAX GNDP GNDS GNDS ΔILP(MAX) = LP x fSW GNDP 1: nSP OPTO-COUPLER FEEDBACK ΔILP GNDS VBIAS VO LLK RFB VIN VFLYBACK 2 x IO(MAX) ΔILS(MAX) = VIN FB QP (1 – dMAX) FB2 V TO I NDRV ΔILS CONVERTER GNDP TO E/A CS SAMPLING CIRCUIT RCS GNDP RSET MAX17690 VO + VDFR + (ΔILS x RS) VIN + GNDP VFLYBACK V nSP GNDP IN GNDS RTC RRIN RVCM t1 t3 t0 t2 t4 t5 t6 GNDP GNDP GNDP Figure 3. Isolated no-opto flyback converter topology with typical waveforms. www.maximintegrated.com Maxim Integrated │ 3 Temperature Compensation The effect of adding the positive temperature coefficient We need to consider the effect of the temperature depen- current, TC, to the current in RFB is equivalent to adding a positive temperature coefficient voltage in series with dence of VDFR and the time dependence of ILS on the VDFR on the secondary side of value: control system. If VFLYBACK is sampled at a time when ILS is very close to zero, then the term ILS(t) x RS(T) is VTC negligible and can be assumed to be zero in the previous ××RnFB SP expression. This is the case when the flyback converter R TC is operating in, or close to, discontinuous conduction mode. It is very important to sample the VFLYBACK voltage Substituting from the previous expression, this becomes: before the secondary current reaches zero since there is a very large oscillation on V due to the resonance δVDFR δT FLYBACK -VTC ×× between the primary magnetizing inductance of the fly- δδTVTC back transformer and the output capacitance of QP as soon as the current reaches zero in the secondary, as We can now substitute this expression into the expression shown in Figures 2 and 3. The time at which VFLYBACK is for VO as follows: sampled is set by resistor RVCM. δδ The VDFR term has a significant negative temperature RFB VTDFR VVo = SET × ×−nSP V DFR−× V tc × coefficient that must be compensated to ensure accept- RSET δδTVtc able output voltage regulation over the required tem- perature range.
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