DEMO MANUAL DC2199A-A LTC3765/LTC3766 360W Isolated Forward Converter with Synchronous Rectification DESCRIPTION Demonstration circuit 2199A-A is a 360W isolated forward converter with synchronous rectification featuring the LTC3765/LTC3766. It produces a regulated 12V, 30A output from an input voltage range of 36V to 60V. This circuit was designed to demonstrate the high levels of performance, efficiency, and small solution size attainable using these parts in an active-clamp-reset forward converter power supply, suitable for telecom, industrial, and other applications. It has a 4.7in2 solution footprint area. Synchronous rectification helps to attain an effi- PERFORMANCE SUMMARY ciency exceeding 96%. Secondary-side control eliminates complex opto-coupler feedback, providing fast transient response with minimum output capacitance. For other output requirements, see the LTC3766 data sheet or contact the LTC sales. Design files for this circuit board are available at http://www.linear.com/demo/DC2199A-A L, LT, LTC, LTM, Linear Technology and the Linear logo are registered trademarks of Linear Technology Corporation. All other trademarks are the property of their respective owners. Specifications are at TA = 25C SYMBOL PARAMETER VIN Input Supply Range VOUT Output Voltage IOUT Output Current Range, Continuous fSW Switching (Clock) Frequency VOUT(P-P) Output Ripple VIN = 24V, IOUT = 30A (20MHz BW) IREG Output Regulation Line and Load (36VIN to 60VIN, 0AOUT to 30AOUT) POUT/PIN CONDITIONS MIN TYP 36 11.76 200LFM Efficiency (See Figure 3) VIN =48V, IOUT = 30A Isolation Basic Approximate Solution Size Component Area x Top Component Height 12.0 0 MAX UNITS 60 V 12.24 V 30 A 200 kHz 60 mVP-P 0.02 96 1500 4.7in2 x 0.6 % % VDC Inches dc2199aafa 1 DEMO MANUAL DC2199A-A OPERATING PRINCIPLES The LTC3765 active clamp forward controller and gate driver is used on the primary and provides start-up, gate drive, and protection functions. Once start-up is accomplished, the LTC3766 high efficiency, secondary-side synchronous forward controller takes over, and provides the LTC3765 with timing information and bias power through a small pulse transformer. When input voltage is applied, the LTC3765 commences soft-start of the output voltage. When the output reaches the RUN threshold, the LTC3766 comes alive and takes control by sending encoded PWM gate pulses to the LTC3765 through T2. These pulses also provide primary bias power efficiently over a wide input voltage range. The transition from primary to secondary control occurs at some fraction of the nominal output voltage. From then on, operation and design is reduced to that of a simple buck converter. Secondary control eliminates delays, tames large-signal overshoot, and reduces output capacitance needed to meet transient response requirements. An optional LC filter stage on the input lowers RMS input current. The filter must have output impedance that is less than the converter input impedance to assure stability. This may require a damping impedance, which is provided by R1. (See Linear Technology Application Note 19 for a discussion of input filter stability.) R1 is coupled through a tiny 2mm x 2mm inductor L1, and provides damping with arbitrarily low source impedance. For bench testing, an electrolytic capacitor has been added at the input terminals to provide suitable 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. QUICK START PROCEDURE Demonstration circuit 2199A-A is easy to set up to evaluate the performance of the LTC3765/LTC3766. Refer to Figure 1 for proper measurement equipment setup and follow the procedure below: b.If efficiency measurements are desired, an ammeter capable of measuring 15ADC or a resistor shunt can be put in series with the input supply in order to measure the DC2199A-A's input current. NOTE: When measuring the output voltage ripple, care must be taken to avoid a long ground lead on the oscilloscope probe. Measure the output voltage ripple by touching the probe tip and ground ring directly across the last output capacitor as shown in Figure 1. c. A voltmeter with a capability of measuring at least 60V can be placed across the input terminals in order to get an accurate input voltage measurement. 1.Set an input power supply that is capable of 36V to 60V to 36V. Then turn off the supply. 2.Direct an airflow of 200LFM across the unit for sustained operation at full load. 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 LTC3765/LTC3766. 4.Turn on the power at the input. NOTE: Make sure that the input voltage never exceeds 60V. 5.Check for the proper output voltage of 12V. Turn off the power at the input. 6.Once the proper output voltages are established, connect a variable load capable of sinking 30A at 12V to the output terminals +VOUT and -VOUT. Set the current for 0A. a. If efficiency measurements are desired, an ammeter or a resistor shunt that is capable of handling 30ADC can be put in series with the output load in order to measure the DC2199A-A's output current. dc2199aafa 2 DEMO MANUAL DC2199A-A QUICK START PROCEDURE b.A voltmeter with a capability of measuring at least 12V can be placed across the output terminals in order to get an accurate output voltage measurement. 7.Turn on the power at the input. 8.Once the proper output voltage is again established, adjust the load within the operating range and observe the output voltage regulation, ripple voltage, efficiency and other desired parameters. NOTE. If there is no output, temporarily disconnect the load to make sure that the load is not set too high. 98 18 97 16 96 14 95 12 94 10 93 8 92 36VIN 48VIN 60VIN 48VIN_PD 91 90 0 5 10 15 IOUT (A) 20 25 30 6 POWER DISSIPATION (W) EFFICIENCY? (%) Figure 1. Proper Measurement Equipment Setup 4 2 dc2199aa F02 Figure 2. Efficiency and Power Dissipation dc2199aafa 3 DEMO MANUAL DC2199A-A QUICK START PROCEDURE Figure 3. Output Ripple at 48VIN and 30AOUT (50mV, 10A, 2s/DIV, 20MHz) Figure 4. Transient Response Waveform at 48VIN and 15A to 30A to 15AOUT (10A, 500mV, 200s/DIV) dc2199aafa 4 DEMO MANUAL DC2199A-A QUICK START PROCEDURE Figure 5. Thermal Map, Front Side at 48VIN and 30AOUT (TA = 25C, 200LFM) Figure 6. Thermal Map, Back Side at 48VIN and 30AOUT (TA = 25C, 200LFM) dc2199aafa 5 DEMO MANUAL DC2199A-A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER PANASONIC, EEHZA1K330P Required Circuit Components 1 2 C1, C22 Cap., Alum., Elect., 33F, 80V, CAP-10X12.5 2 5 C2, C3, C4, C5, C6 CAP., X7R, 4.7F, 100V, 10%, 1210 MURATA, GRM32ER72A475KE14 3 4 C7, C31, C33, C68 CAP., POSCAP, 150F, 16V, 20%, 7343 PANASONIC, 16TQC150MYF 4 1 C10 CAP., X7R, 2.2nF, 630V, 5%, 1206 MURATA, GRM31A7U2J222JW31 5 1 C11 CAP., X7R, 0.015F, 25V, 10%, 0603 AVX, 06033C153KAT2A 6 2 C24, C71 CAP., X7R, 1.0F, 16V, 10%, 0805 MURATA, GRM21BR71C105KA01 7 1 C30 CAP., X7R, 2200pF, 250V, 10%, 1812 MURATA, GA343QR7GD222KW01L 8 1 C34 CAP., X5R, 22F, 16V, 20%, 1206/1210 MURATA, GRM32ER71C226MEA8L 9 1 C51 CAP., C0G, 470pF, 630V, 5%, 1206 MURATA, GRM31A5C2J471JW01 10 1 C66 CAP., X7R, 0.047F, 200V, X7R, 10% 1206 MURATA, GRM31CR72D473KW03 11 1 C69 CAP., X7R, 1.5nF, 630V, 5%, 1206 MURATA, GRM31A7U2J152JW31 12 2 C70, C76 CAP., X7R, 3.3nF, 25V, 10%, 0603 AVX, 06033C332KAT2A 13 2 C72, C102 CAP., X7R, 0.1F, 25V, 10%, 0805 AVX, 08053C104KAT2A 14 4 C55, C73, C80, C119 CAP., X7R, 1nF, 25V, 10%, 0603 MURATA, GRM188R71E102KA01 15 1 C75 CAP., NPO, 100pF, 25V, 5%, 0603 AVX, 06033A101JAT2A 16 1 C77 CAP., X7R, 4.7F, 25V, 10%, 1206 AVX, 12063C475KAT2A 17 1 C78 CAP., NPO, 0.033F, 25V, 5%, 0805 TDK, C2012C0G1E333J 18 1 C79 CAP., X7R, 4.7nF, 25V, 10%, 0603 MURATA, GRM188R71E472KA01 19 1 C101 CAP., NPO, 220pF, 25V, 5%, 0603 AVX, 06033A221JAT2A 20 1 C106 CAP., COG, 150pF, 250V, 5%, 0603 TDK, C1608C0G2E151J080AA 21 1 C112 CAP., X7R, 0.22F, 250V, 10%, 1206/1210 TDK C3225X7R2E224K 22 1 C113 CAP., X7R, 0.033F, 25V, 10%, 0603 AVX, 06033C333KAT2A 23 1 C118 CAP., NPO, 1500pF, 5%, 0603 AVX, 06033A152JAT2A 24 2 D1, D34 DIODE ULTRA FAST 1A, 200V, SMP VISHAY, ES1PD-M3 / 84A 25 3 D27, D29, D30 DIODE SCHOTTKY 60V, 0.5A, SOT23 DIODES INC, ZHCS506TA 26 1 D40 DIODE, 1N4148WS, SOD323 VISHAY, 1N4148WS-E3-08 27 1 L1 INDUCTOR, 1.0H, 20% COILCRAFT, XPL2010-102ML 28 1 L2 INDUCTOR, 2.0H, 20% VISHAY, IHLP4040DZER2R0M11 29 1 L3 INDUCTOR, 3.3H, 10% COILCRAFT, SER2915L-332KL 30 2 Q8, Q9 MOSFET N-CH 150V, POWERPAK-SO-8 INFINEON, BSC190N15NS3 G 31 4 Q12, Q13, Q14, Q15 MOSFET N-CH 80V, POWERPAK-SO-8 INFINEON, BSC028N06NS3 32 1 Q27 TRANS., NPN 40V, 1A, SOT-89 DIODE INC., FCX491ATA 33 1 Q28 MOSFET, N-CH, SUPER, SOT-6 FAIRCHILD, FDC2512-NL 34 1 Q29 MOSFET, P-CH, IRF6217, POWERPAK-SO-8 IR, IRF6217TRPBF 35 1 R1 RES., CHIP, 0.33, 1/4W, 5%, 2512 PANASONIC, ERJ-1TRQJR33U 36 1 R4 RES., CHIP, 8.2k, 1W, 5%, 2512 PANASONIC, ERJ-1TYJ822U 37 1 R18 RES., CHIP, 102k, 1/8W, 1%, 0805 VISHAY, CRCW0805102KFKEA 38 1 R22 RES., CHIP, 3.74k, 1/16W, 1%, 0603 VISHAY, CRCW06033K74FKEA 39 2 R23, R24 RES., CHIP, 8.2, 1/4W, 5%, 1206 VISHAY, CRCW12068R20JKEA 40 1 R29 RES., CHIP, 100k, 1/8W, 5%, 0805 VISHAY, CRCW0805100KJNEA 41 1 R41 RES., CHIP, 11.5k, 1/16W, 1%, 0603 VISHAY, CRCW060311K5FKEA dc2199aafa 6 DEMO MANUAL DC2199A-A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER 42 43 1 R42 RES., CHIP, 1k, 1/16W, 1%, 0603 VISHAY, CRCW06031K00FKEA 1 R46 RES., CHIP, 604, 1/16W, 1%, 0603 VISHAY, CRCW0603604RFKEA 44 2 R51, R52 RES., CHIP, 3.0, 1/4W, 5%, 1206 PANASONIC, ERJ-8GEYJ3R0V 45 1 R53 RES., CHIP, 6.8, 1/2W, 1%, 1206 PANASONIC, ERJ-8RQF6R8V 46 1 R68 RES., CHIP, 2.15k, 1/16W, 1%, 0603 VISHAY, CRCW06032K15FKEA 47 1 R69 RES., CHIP, 46.4k, 1/16W, 1%, 0603 VISHAY, CRCW060346K4FKEA 48 1 R75 RES., CHIP, 215, 1/8W, 1%, 0805 VISHAY, CRCW0805215RFKEA 49 1 R76 RES., CHIP, 4.22, 1/8W, 1%, 0805 VISHAY, CRCW08054R22FKEA 50 1 R84 RES., CHIP, 1.21k, 1/8W, 1%, 0805 VISHAY, CRCW08051K21FKEA 51 4 R101, R148, R149, R151 RES., CHIP, 100, 1/16W, 1%, 0603 VISHAY, CRCW0603100RFKEA 52 1 R109 RES., CHIP, 10k, 1/16W, 1%, 0603 VISHAY, CRCW060310K0FKEA 53 1 R110 RES., CHIP, 1.20, 1/2W, 1%, 1206 SUSUMU, RL1632S-1R20-F 54 1 R114 RES., CHIP, 28.7k, 1/16W, 1%, 0603 VISHAY, CRCW060328K7FKEA 55 1 R117 RES., CHIP, 12.7k, 1/16W, 1%, 0603 VISHAY, CRCW060312K7FKEA 56 1 R118 RES., CHIP, 681k, 1/16W, 1%, 0603 VISHAY, CRCW0603681KFKEA 57 1 R121 RES., CHIP, 133k, 1/16W, 1%, 0603 VISHAY, CRCW0603133KFKEA 58 1 R123 RES., CHIP, 118k, 1/16W, 1%, 0603 VISHAY, CRCW0603118KFKEA 59 1 R125 RES., CHIP, 17.4k, 1/16W, 1%, 0603 VISHAY, CRCW060317K4FKEA 60 1 R136 RES., CHIP, 0.005, 1W, 1%, 1225 SUSUMU, KRL6432D-M-R005-F-T5 61 1 R139 RES., CHIP, 26.7k, 1/16W, 1%, 0603 VISHAY, CRCW060326K7FKEA 62 1 R140 RES., CHIP, 274, 1/8W, 1%, 0805 PANASONIC, ERJ-6ENF2740V 63 1 R150 RES., CHIP, 14.3k, 1/16W, 1%, 0603 VISHAY, CRCW060314K3FKEA 64 1 T1 TRANSFORMER CHAMPS TECH., LTC-PQ26-0402 65 1 T2 TRANSFORMER, 1.25:1 Pulse, PA3493NL 66 1 T3 TRANSFORMER, 1:100, CT02-100 ICE COMPONENTS, CT02-100 = 1:100 67 1 U1 I.C. LTC3765EMSE, MSOP-16PIN LINEAR TECH., LTC3765EMSE#PBF 68 1 U2 I.C. LTC3766EGN, SSOP-GN28 LINEAR TECH., LTC3766EGN#PBF Additional Demo Board Circuit Components 1 0 C12, C13, C14, C16, C20 CAP., OPT, 0603 OPT 2 0 C8, C9, C18, C19, C103, C111 CAP., OPT, 0603 OPT 3 0 C15, C21, C114 CAP., OPT, 0805 OPT 4 0 C17, C116 CAP., OPT, 1206 OPT 5 0 C23, C25, C26 CAP., OPT, CAP-SVPF-E12 OPT 6 2 C74, C105 CAP, 0, JUMPER 0603 VISHAY, CRCW06030000Z0EA 7 0 D2 DIODE TBD SOD323 OPT 8 0 D4, D35 DIODE OPT, SOD323 OPT 9 0 D28, D37, D38 DIODE OPT, SOT23 OPT 10 0 L4 INDUCTOR, OPT, DO1606T OPT 11 0 Q1, Q2 MOSFET, OPT, SOT23-6 OPT 12 0 Q4 MOSFET, OPT, D-PAK OPT 13 0 Q11, Q23, Q24 MOSFET, OPT, POWERPAK-SO-8 OPT 14 0 R5 RES., OPT, 2512/2010 OPT dc2199aafa 7 DEMO MANUAL DC2199A-A PARTS LIST ITEM QTY REFERENCE PART DESCRIPTION MANUFACTURER/PART NUMBER 15 13 R6, R7, R8, R9, R49, R103, R111, R112, R113, R122, R124, R137, R146 RES., CHIP, 0, 0603 VISHAY, CRCW06030000Z0EA 16 0 R10, R13, R14, R15 RES., OPT, 2512 OPT 17 0 R17, R108, R116, R127 RES., OPT, 1206 OPT 18 0 R25, R26, R27, R28, R30, R31, R32, R33, R34, R35, R43, R106, R107, R119, R120, R126, R138, R147 RES., OPT, 0603 OPT 19 1 R77 RES., CHIP, 0, 1/8W, 0805 VISHAY, CRCW08050000Z0EA 20 1 R102 RES., CHIP, 0, 1225 TEPRO,RN5326 21 1 R115 RES., CHIP, 0, 1/4W, 1206 VISHAY, CRCW12060000Z0EA 22 0 R152 RES., OPT, 0805 OPT 23 0 U3 I.C. OPT, SO16 OPT Hardware: For Demo Board Only 1 4 E1, E2, E3, E4 TESTPOINT, TURRET, .094" MILL-MAX, 2501-2-00-80-00-00-07-0 2 3 E5, E6, E7 TESTPOINT, TURRET, .061" MILL-MAX, 2308-2-00-80-00-00-07-0 3 0 J1 HEADER, OPT, 2x7PIN, 0.079CC OPT, MOLEX, 87331-1420 4 2 J3, J4 STUD, TEST PIN PEM, KFH-032-10 5 4 J3, J4(2 EACH) NUT, BRASS, #10-32 ANY #10-32 6 2 J3, J4 WASHER, STAR #10 BRASS NICKEL ANY, #10EXT BZ TN 7 2 J3, J4 Ring, Lug Ring # 10 KEYSTONE, 8205 8 0 TP1-TP6 PAD-SMD PAD-SMD 9 4 (STAND-OFF) STAND-OFF, NYLON 0.25" KEYSTONE, 8831 (SNAP ON) 10 1 FAB, PRINTED CIRCUIT BOARD DEMO CIRCUIT 2199A dc2199aafa 8 A B C D R29 100K 0805 VIN IS+ D27 ZHCS506 U1 R139 26.7K UV LTC3765EMSE C118 1.5nF R148 100 R76 4.22 0805 1.21K 0805 3 4 R84 2 1 T3 CT02-100 R117 12.7K 1/16W = 0402, 1/10W = 0603, 1/8W = 0805, 1/4W = 1206, 1W = 2512. RCORE SSFLT RUN VCC R150 14.3K 11 13 12 3 C3,4,5,6 4x4.7uF 100V 1210 VIN 5 NOTE: 4.7uF 100V MURATA, GRM32ER72A475KE14 (X7R 1210) 4.7uF 25V AVX, 12063C475KAT2A (X7R 1206) 22uF 16V MURATA, GRM32ER71C226MEA8L (1210 X5R) 2.2nF 250V Murata GA343QR7GD222KW01L (X7R 1812) 150uF 16V PANASONIC, 16TQC150MYF 33uF 80V PANASONIC, EEHZA1K330P (10x12.5mm) L2 Vishay IHLP4040DZER2R0M11 L3 Coilcraft SER2915L-332KL Unless otherwise specified: 0.005 ohm Susumu KRL6432D-M-R005-F-T5 (1225) All resistors are in ohms 0603. R110 SUSUMU, RL1632S-1R20-F (1206) All capacitors are in microfarads 0603. T1 Champs, LTC-PQ26-0402 All capacitors are 25V. T2 Pulse, PA3493NL PSS VCP Q28 FDC2512 D29 ZHCS506 2512 R1 0.33 C113 33nF L2 2.0uH C2 4.7uF 100V 1210 C24 1uF 16V 0805 SGNDP C55 1nF -VIN 2x33uF 80V + C1,22 R18 102K 0805 SGNDP R22 3.74K -VIN 36V-60VIN +VIN 1 3 1 3 4 D30 ZHCS506 4 16 15 100 R151 R109 10K C102 0.1uF 0805 R101 100 Q29 IRF6217 C101 0.1uF 220pF 0805 C72 250V 1812 C30 2.2nF -VOUT RS- C66 47nF 200V 1206 4 1T 6 C11 15nF D34 ES1PD ND T2 R110 1.20 1206 1/2W 3 1.25T 1 FG R140 274 1/8W 0805 C112 0.22uF 200V 1210 1uF 16V 0805 C71 3 +VOUT 25 26 C73 1nF PT- PT+ 28.7K R118 681K SGND C10 2.2nF 630V 1206 D1 ES1PD SGND PGND R23,24 2x8.2 1206 R114 Q15 BSC028N06NS3 BSC028N06NS3 R51,52 Q14 2x3.0 Q24 OPT 1206 TRANS-PA3493NL -VIN SGNDP R136 0.005 1225/2512 PGNDP C106 150pF 250V R53 6.8 1206 C69 1.5nF 630V 1206 12 13 6 5 C51 470pF 630V 1206 R121 133K COG 0805 C78 33nF R75 215 0805 FG L3 3.3uH 1 C34 22uF 16V 1210 2 LTC3766EGN28 R123 118K PGND C77 4.7uF 1206 Q27 FCX491A R69 46.4K 2 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. IS+ C75 100pF SCALE = NONE DAVID B. LT APPROVALS R125 17.4K LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES. VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. CUSTOMER NOTICE U2 Q12 BSC028N06NS3 Q13 BSC028N06NS3 Q23 OPT R4 8.2K 2512 Simplified Schematic (without Unneeded Components) SGNDP C119 1nF C80 1nF AG IN- IN+ R149 100 Q8 BSC190N15NS3 Q9 BSC190N15NS3 Q11 OPT SGND ND 9 10 32 14 T1 LTCP26-0402 8 3 2 1 L1 14 NDRV PGND 1 GND 17 FS/UV 10 GND2 9 2 PG 8 IS+ DELAY 6 7 ISISMAG 5 23 1.0uH 1 3 20 FGD/SWB RUN 8 3 VSEC SS 9 SW 2 14 REGSD 16 FG GND 1 SG 24 PHASE 5 IPK 10 2 3 28 4 4 PGND 27 VAUX 22 VIN 21 NDRV MODE VCC FS/SYNC 15 SGD 19 17 IS- 18 IS+ ITH 7 VSOUT 11 5 C70 6 13 12 DATE: N/A SIZE DATE 1 SHEET 1 LTC3765EMSE / LTC3766EGN28 DC2199A OF 2 REV. 2 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only 8-18-14 ACTIVE CLAMP FORWARD CONVERTER WITH DIRECT FLUX LIMIT Friday, October 31, 2014 IC NO. R42 1K C76 3.3nF -VOUT 12VOUT / 30A TECHNOLOGY SGND R46 604 R41 11.5K +VOUT -VOUT 4x150uF 16V 7343 + C7,31,33,68 +VOUT DAVID B. +VOUT APPROVED PRODUCTION 2 1 DESCRIPTION REVISION HISTORY REV TITLE: SCHEMATIC C79 4.7nF R68 2.15K FB VS- VS+ 3.3nF SGND __ ECO A B C D DEMO MANUAL DC2199A-A SCHEMATIC DIAGRAM dc2199aafa 9 A B C D 1 D40 SGNDP R22 3.74K 2 33uF 80V + C22 R18 102K 0805 -VIN 33uF 80V + C1 1N4148WS E7 E2 E1 PSS VCP 3 C24 1uF 16V 0805 SGNDP C55 1nF C113 33nF C6 4.7uF 100V 1210 Q28 FDC2512 D29 ZHCS506 C2 4.7uF 100V 1210 L2 2.0uH C4 4.7uF 100V 1210 R29 100K 0805 VIN IS+ D27 ZHCS506 1210 C5 4.7uF 100V R139 26.7K UV 5 1 C118 1.5nF R148 100 R117 12.7K 4 AG IN- IN+ 4 16 15 4 FG AS R109 10K C102 0.1uF 0805 AG1 R8 0 AG SGNDP C119 1nF D30 ZHCS506 C80 1nF AS 1 SGND Q3 OPT Q8 BSC190N15NS3 Q9 BSC190N15NS3 Q11 OPT R149 100 R9 0 R76 4.22 0805 D28 OPT 1.21K 0805 3 4 R84 2 1 LTC3765EMSE U1 0 R49 3 OPT 2512 T3 CT02-100 1/16W = 0402, 1/10W = 0603, 1/8W = 0805, 1/4W = 1206, 1W = 2512. RCORE SSFLT RUN VCC R150 14.3K 11 13 12 3 C3 4.7uF 100V 1210 VIN NOTE: 4.7uF 100V MURATA, GRM32ER72A475KE14 (X7R 1210) 4.7uF 25V AVX, 12063C475KAT2A (X7R 1206) 22uF 16V MURATA, GRM32ER71C226MEA8L (1210 X5R) 2.2nF 250V Murata GA343QR7GD222KW01L (X7R 1812) 150uF 16V PANASONIC, 16TQC150MYF 33uF 80V PANASONIC, EEHZA1K330P (10x12.5mm) L2 Vishay IHLP4040DZER2R0M11 L3 Coilcraft SER2915L-332KL Unless otherwise specified: 0.005 ohm Susumu KRL6432D-M-R005-F-T5 (1225) All resistors are in ohms 0603. R110 SUSUMU, RL1632S-1R20-F (1206) All capacitors are in microfarads 0603. T1 Champs, LTC-PQ26-0402 All capacitors are 25V. T2 Pulse, PA3493NL RUN -VIN 36V-60VIN +VIN 2512 1 3 R10 3 2 1.0uH 1 3 6 5 2 1 4 C72 -VIN R151 ND C11 15nF D34 ES1PD C66 47nF 200V 1206 4 1T 6 1uF 16V 0805 C71 FG SW C51 470pF 630V 1206 R140 274 1/8W 0805 3 C112 0.22uF 200V 1210 +VOUT PT- 25 26 R114 C73 1nF RUN PT- PT+ 28.7K R118 681K SGND OPT 1206 R108 R23 R121 133K SSS R111 0 PGND C10 2.2nF 630V 1206 C78 33nF COG 0805 R112 0 R77 0 0805 FG 321 8765 R75 215 0805 D1 ES1PD 8.2 1206 8.2 1206 R24 R146 0 SGND 4 RS- R102 RS+ 321 Q15 BSC028N06NS3 0 Q14 BSC028N06NS3 1225 Q24 OPT 8765 -VOUT RS- R52 3.0 1206 SWB PGND VA Full Schematic, Page 1 R110 1.20 1206 1/2W Q31 OPT 4 Q29 IRF6217 3 1.25T 1 T2 1 AG1 AG R101 100 250V 1812 C30 2.2nF R51 3.0 1206 C69 1.5nF 630V 1206 OPT R3 R2 OPT TRANS-PA3493NL SGNDP C101 0.1uF 220pF 0805 100 C106 150pF 200V R136 0.005 1225/2512 PGNDP 123 R53 6.8 1206 12 13 6 5 5678 ND 9 10 32 14 T1 LTCP26-0402 8 2 1 R1 0.33 GND 17 PGND 1 FS/UV 10 GND2 9 14 NDRV 2 PG 8 IS+ DELAY 6 2 7 ISISMAG 5 C8 OPT VAUX R138 OPT PGND OPT R147 OPT 0 LTC3766EGN R122 0 R123 118K OPT 1206 R116 1 R124 0 R43 OPT VCC C34 22uF 16V 1210 0603 0 R113 VCC R69 46.4K SYNC 2 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. 150uF 16V 7343 + C33 OPT C103 R125 17.4K SCALE = NONE DAVID B. LT APPROVALS ITH- C75 100pF ITH IS+ R126 OPT C77 4.7uF 1206 DATE: N/A SIZE SGND C9 OPT R42 1K DATE 10-29-14 1 SHEET 1 LTC3765EMSE / LTC3766EGN DC2199A 2 OF 2 REV. ACTIVE CLAMP FORWARD CONVERTER WITH DIRECT FLUX LIMIT 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only R46 604 R41 11.5K C76 3.3nF -SENSE +SENSE - -VOUT 12VOUT / 30A +VOUT + Wednesday, October 29, 2014 IC NO. R127 OPT 1/4W 1206 R115 0 1/4W 1206 C74 0 +VOUT E6 E5 E4 J4 150uF 16V 7343 + C68 TECHNOLOGY PGND VCC VS- TITLE: SCHEMATIC C79 4.7nF OPT OPT R120 R119 6 13 12 R68 2.15K FB VS- VS+ VS+ -VOUT OPT C23 C25 + C26 J3 E3 DAVID B. +VOUT APPROVED PRODUCTION 2 1 DESCRIPTION REVISION HISTORY REV 150uF 16V 7343 + C7 __ ECO 3.3nF SGND C70 R107 OPT VCC 150uF 16V 7343 + C31 RS+ R106 OPT R7 RS0 Q27 FCX491A VPK R5 OPT 2512 CUSTOMER NOTICE U2 RUN C111 0603 R6 0 R137 R4 8.2K 2512 2 LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES. VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. C105 0 R103 0 4 CLAMP L3 3.3uH Q12 BSC028N06NS3 Q13 BSC028N06NS3 Q23 OPT -VOUT 1 L1 3 2 20 FGD/SWB RUN 8 3 VSEC SS 9 23 16 2 3 28 3 5 SW REGSD 24 VAUX PHASE FG GND 14 22 VIN IPK 10 SG PGND 27 21 NDRV MODE 4 VCC FS/SYNC 15 17 4 1 3 5 6 7 8 1 2 3 SGD 19 ISITH 18 IS+ VSOUT 7 10 11 5 A B C D DEMO MANUAL DC2199A-A SCHEMATIC DIAGRAM dc2199aafa Information furnished by Linear Technology Corporation is believed to be accurate and reliable. However, no responsibility is assumed for its use. Linear Technology Corporation makes no representation that the interconnection of its circuits as described herein will not infringe on existing patent rights. A B C 5 AG C18 OPT PGNDP AG CRX 5 2 Q2 OPT PGNDP 3 4 6 1 VCCP Q1 4 AG1 OPT C19 7 Q1 3 4 6 1 ZXGD3002E6 5 2 PGNDP AG1 C16 56pF C14 0.1uF VCC C15 0.1uF 0805 C20 0.1uF ACTIVE SNUBBER D2 OPT RS- OPTIONAL CIRCUITS SO16 U3 HEF4528BT AC DRIVER C13 10pF 2 R12 4.99K 47pF C12 FG 5 R11 1.00K 4 A1 VSS 1 16 VDD 3 B1 RES VSS1 8 2 1 VSS2 15 4 RS- +VOUT 2 R14 6.8 2512 R15 6.8 2512 OPT D4 R17 100K 1206 Q4 FQD4P25 6.8 2512 R13 C17 15nF 200V 1206 1 SW 3 CLAMP C21 OPT 0805 VA Full Schematic, page 2 R19 1.5K SW 3 VA R31 OPT VS- 1 3 PGND C116 OPT 1206 2 OPT D35 1 2 THIS CIRCUIT IS PROPRIETARY TO LINEAR TECHNOLOGY AND SUPPLIED FOR USE WITH LINEAR TECHNOLOGY PARTS. C114 OPT 0805 PGND VPK SCALE = NONE DAVID B. LT APPROVALS OPT 0805 R152 PEAK CHARGE VCC R33 OPT SYNC VA R32 OPT R28 OPT VS+ PT- CUSTOMER NOTICE D38 OPT OPT SYNC PT- VS+ ITH R27 OPT OPT R34 OPT R25 ITH PSS SGNDP 2 LINEAR TECHNOLOGY HAS MADE A BEST EFFORT TO DESIGN A CIRCUIT THAT MEETS CUSTOMER-SUPPLIED SPECIFICATIONS; HOWEVER, IT REMAINS THE CUSTOMER'S RESPONSIBILITY TO PCB DES. VERIFY PROPER AND RELIABLE OPERATION IN THE ACTUAL APP ENG. APPLICATION. COMPONENT SUBSTITUTION AND PRINTED CIRCUIT BOARD LAYOUT MAY SIGNIFICANTLY AFFECT CIRCUIT PERFORMANCE OR RELIABILITY. CONTACT LINEAR TECHNOLOGY APPLICATIONS ENGINEERING FOR ASSISTANCE. OPT D37 VAUX R30 OPT ITH- L4 R35 OPT R26 OPT PSS SGNDP SSS VCC FROM T1 VS- ITH- SSS SGND 3 1 D 5 14 13 12 11 10 9 8 7 6 5 4 3 2 1 DATE: N/A SIZE 1 SHEET 2 LTC3765EMSE / LTC3766EGN DC2199A 2 OF 2 REV. ACTIVE CLAMP FORWARD CONVERTER WITH DIRECT FLUX LIMIT TECHNOLOGY 1630 McCarthy Blvd. Milpitas, CA 95035 Phone: (408)432-1900 www.linear.com Fax: (408)434-0507 LTC Confidential-For Customer Use Only Wednesday, October 29, 2014 IC NO. TITLE: SCHEMATIC OPT HD2X7-MOLEX 14 13 12 11 10 9 8 7 6 5 4 3 2 1 J1 1 A B C D DEMO MANUAL DC2199A-A SCHEMATIC DIAGRAM dc2199aafa 11 DEMO MANUAL DC2199A-A DEMONSTRATION BOARD IMPORTANT NOTICE Linear Technology Corporation (LTC) provides the enclosed product(s) under the following AS IS conditions: This demonstration board (DEMO BOARD) kit being sold or provided by Linear Technology is intended for use for ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY and is not provided by LTC for commercial use. As such, the DEMO BOARD herein may not be complete in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including but not limited to product safety measures typically found in finished commercial goods. As a prototype, this product does not fall within the scope of the European Union directive on electromagnetic compatibility and therefore may or may not meet the technical requirements of the directive, or other regulations. If this evaluation kit does not meet the specifications recited in the DEMO BOARD manual the kit may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY THE SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. EXCEPT TO THE EXTENT OF THIS INDEMNITY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER FOR ANY INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user releases LTC from all claims arising from the handling or use of the goods. Due to the open construction of the product, it is the user's responsibility to take any and all appropriate precautions with regard to electrostatic discharge. Also be aware that the products herein may not be regulatory compliant or agency certified (FCC, UL, CE, etc.). No License is granted under any patent right or other intellectual property whatsoever. LTC assumes no liability for applications assistance, customer product design, software performance, or infringement of patents or any other intellectual property rights of any kind. LTC currently services a variety of customers for products around the world, and therefore this transaction is not exclusive. Please read the DEMO BOARD manual prior to handling the product. Persons handling this product must have electronics training and observe good laboratory practice standards. Common sense is encouraged. This notice contains important safety information about temperatures and voltages. For further safety concerns, please contact a LTC application engineer. Mailing Address: Linear Technology 1630 McCarthy Blvd. Milpitas, CA 95035 Copyright (c) 2004, Linear Technology Corporation dc2199aafa 12 Linear Technology Corporation LT 1114 REV A * PRINTED IN USA 1630 McCarthy Blvd., Milpitas, CA 95035-7417 (408) 432-1900 FAX: (408) 434-0507 www.linear.com LINEAR TECHNOLOGY CORPORATION 2014