MAXREFDES121C#

MAXREFDES121C# Datasheet

MAXREFDES121# Isolated 24V to 3.3V 33W Power Supply

Part	Datasheet
MAXREFDES121C#	MAXREFDES121C# (pdf)

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System Board 6309 MAXREFDES121# Isolated 24V to 3.3V 33W Power Supply Maxim’s power-supply experts have designed and built a series of isolated, industrial power-supply reference designs. Each of these power supplies efficiently converts 24V into useful voltage rails at a variety of power levels. Every power rail is isolated with a readily available transformer, providing quick, convenient transformer selection. Each design has been tested for load and line regulation, as well as efficiency and transient performance. Space optimized boards are available for purchase. Each board features high-current pins that allow the design to be mounted on a PCB, like a module, further accelerating development and production runs. As with all Maxim reference designs, the BOM, schematics, layout files, Gerber files are all available online. • Functional insulation • Compact and flexible • Low power dissipation • Minimal external components • Robust operation in adverse industrial environments • PLCs • Industrial process control and sensors • Telecom and datacom power supplies Introduction MAXREFDES121# is an efficient active-clamp topology design with 24V input, and a 3.3V output at 33W of power 10A . The design Figure 1 demonstrates the application of the MAX17599 low IQ, wide-input range, active clamp current-mode PWM controller. This entire design fits on a 70mm x 20mm circuit board. The MAX17599 contains all the control circuitry required for the design of wide-input isolated forward-converter industrial power supplies. The reference design operates over an 18V to 36V input-voltage range, and provides up to 10A at 3.3V output. The reference design features the active-clamp transformer reset topology for forward converters. This reset topology has several advantages including reduced voltage stress on the switches, transformer-size reduction due to larger allowable flux swing, and improved efficiency due to elimination of dissipative snubber circuitry. These features result in a compact and cost-effective isolated power supply. The design is set to switch at 250kHz. For EMI-sensitive applications, the user can program the frequency-dithering scheme, enabling low-EMI spread-spectrum operation. The input undervoltage lockout EN/UVLO is provided for programming the inputsupply start voltage set to 18V in the design and to ensure proper operation during brownout conditions. The EN/UVLO input is also used to turn on/off the IC. The overvoltage input OVI protection scheme is provided to make sure that the controller shuts down when the input supply exceeds its maximum allowed value set to 36V in the design . To control inrush current, the device incorporates a soft-start SS pin to set the softstart time for the regulator. Power dissipation under fault conditions is minimized by hiccup overcurrent protection hiccup mode . The soft-stop feature provides safe discharging of the clamp capacitor when the device is turned off, and allows the controller to restart in a well-controlled manner. Additionally, the negative current limit is provided in the current-sense circuitry, helping limit clamp switch current under dynamic operating conditions. An overtemperature protection OTP fault triggers thermal shutdown for reliable protection of the device. The reference design delivers a peak efficiency of with the supplied components when the input is 24V. This general-purpose power solution can be used in many different types of power applications, such as programmable logic controllers PLC , industrial process control, industrial sensors, telecom/datacom power supplies, isolated battery chargers, servers, and embedded computing. System Diagram Figure The MAXREFDES121# reference design block diagram. Detailed Circuit Description The MAX17599 low IQ active-clamp current-mode PWM controller contains all the control circuitry required for designing wide-input isolated forward converter industrial power supplies. The device includes an AUX driver that drives an auxiliary MOSFET clamp switch that helps implement the active-clamp transformer reset topology for forward converters. This reset topology has several advantages, including reduced voltage stress on the switches, transformersize reduction due to larger allowable flux swing, and improved efficiency due to elimination of dissipative snubber circuitry. Programmable dead time between the AUX and main driver allows for zero voltage switching. Primary Power Stage The active-clamp transformer primary side is driven by an n-channel MOSFET N3 and a pchannel MOSFET P1 . While N3 is on, power is delivered to the secondary side, and magnetizing energy is being stored in the transformer. During this time, P1 is off, and the clamp capacitor C10 is charged at a constant voltage level. When N3 turns off, the leakage and magnetizing currents charge up the drain-to-source capacitance of N3. Once the drain-to-source voltage of N3 exceeds the voltage across the clamp capacitor, the body diode of P1 begins to conduct. With the body diode of P1 conducting, the magnetizing current begins to charge the clamp capacitor. After P1 turns off, the clamp capacitor remains at a fixed voltage. There is a fixed delay before N3 turns on. During this delay, the energy in the parasitic components discharges the VDS of N3 towards VIN. This allows softer turnon and lower switching losses for N3. The MAX17599 NDRV pin drives the n-channel MOSFET while the AUXDRV pin is level shifted through C11, R9, R14, and D4, and then drives the p-channel MOSFET. Secondary Power Stage The secondary power stage consists of the synchronous rectifiers N1, N2 , the output filter L1, C4, C5, and C6 , and the gate driving circuit for N1 R3 and N2 R2 . When N3 is on, the voltage on the gate wiring of T1 ensures N2 is on, while N1 is off. During this time, a voltage equal to the input voltage multiplied by the NS:NP turns ratio of the transformer is applied across N3 the inductor and the load capacitor are charged and being stored with energy. The voltage on the input end of the filter inductor is a typical buck-converter square wave. The inductor and output capacitors filter the square wave to produce DC voltage on the output. Feedback Control Loop A feedback network is typical of most isolated forward converters. It is constructed using a TL431V programmable shunt regulator, a 3000V isolation optocoupler, and other RC components. Startup Voltage and Input Overvoltage Protection Setting EN/UVLO and OVI pins The EN/UVLO pin in the MAX17599 serves as an enable/disable input, as well as an accurate programmable undervoltage lockout UVLO pin. The MAX17599 does not begin startup operations unless the EN/UVLO-pin voltage exceeds 1.21V typ . The MAX17599 turns off if the EN/UVLO pin voltage falls below 1.15V typ . A resistor divider from the input DC bus to ground can be used to divide down and apply a fraction of the input DC voltage to the EN/ UVLO pin. The values of the resistor-divider can be selected so that the EN/UVLO-pin voltage exceeds the 1.21V typ turnon threshold at the desired input DC bus voltage. The same resistordivider can be modified with an additional resistor, ROVI, to implement overvoltage input protection in addition to the EN/UVLO functionality. When the voltage at the OVI pin exceeds 1.21V typ , the MAX17599 stops switching. Switching resumes with soft-start operation, only if the voltage at the OVI pin falls below 1.15V typ . For the expected values of the startup DC input voltage VSTART and overvoltage input protection voltage VOVI , the resistor values for the divider can be calculated as follows: VSTART = R4 + R7 + R5 / R4 + R7 x V VOVI = R4 + R7 + R5 /R4 x V If R4 = R5 = and R7 = then: VSTART = 18.2V, VOVI = 36.3V. Quick Start Required equipment: • MAXREFDES121# board • One adjustable DC power supply with a voltage output up to 37V and current up to 3A. • One electronic load • 2 voltmeters • 2 ammeters Procedure The MAXREFDES121# board is fully assembled and tested. Use the following steps below to verify board operation. Turn off the power supply. Connect the positive terminal of the power supply to the VIN connector of the MAXREFDES121# board. Connect the PGND connector of the MAXREFDES121# board to the positive terminal of one ammeter. Connect the negative terminal of the ammeter to the negative terminal of the power supply. Connect one voltmeter across the VIN and the PGND connectors of the MAXREFDES121# board. Connect the VOUT connector of the MAXREFDES121# board to the positive terminal of the electronic load. Connect the negative terminal of the electronic load to the positive terminal of the second ammeter. Connect the negative terminal of the ammeter to the GNDO connector of the MAXREFDES121# board. Connect the second voltmeter across the VOUT and the GNDO connectors of the MAXREFDES121# board. Turn on the power supply. Set the output to 24V. Set the electronic load to a constant current between 0A to 10A. Verify the second voltmeter reading is 3.3V ±0.15V . Lab Measurements The MAXREFDES121# design was verified and tested under full input range and different output load conditions. The power efficiency vs. load current is illustrated in Figure

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System Board 6309

MAXREFDES121# Isolated 24V to 3.3V 33W Power Supply

Maxim’s power-supply experts have designed and built a series of isolated, industrial power-supply reference designs. Each of these power supplies efficiently converts 24V into useful voltage rails at a variety of power levels. Every power rail is isolated with a readily available transformer, providing quick, convenient transformer selection. Each design has been tested for load and line regulation, as well as efficiency and transient performance. Space optimized boards are available for purchase. Each board features high-current pins that allow the design to be mounted on a PCB, like a module, further accelerating development and production runs. As with all Maxim reference designs, the BOM, schematics, layout files, Gerber files are all available online.
• Functional insulation
• Compact and flexible
• Low power dissipation
• Minimal external components
• Robust operation in adverse industrial environments
• PLCs
• Industrial process control and sensors
• Telecom and datacom power supplies

Introduction

MAXREFDES121# is an efficient active-clamp topology design with 24V input, and a 3.3V output at 33W of power 10A . The design Figure 1 demonstrates the application of the MAX17599 low IQ, wide-input range, active clamp current-mode PWM controller. This entire design fits on a 70mm x 20mm circuit board.

The MAX17599 contains all the control circuitry required for the design of wide-input isolated forward-converter industrial power supplies. The reference design operates over an 18V to 36V input-voltage range, and provides up to 10A at 3.3V output. The reference design features the active-clamp transformer reset topology for forward converters. This reset topology has several advantages including reduced voltage stress on the switches, transformer-size reduction due to larger allowable flux swing, and improved efficiency due to elimination of dissipative snubber circuitry. These features result in a compact and cost-effective isolated power supply. The design is set to switch at 250kHz. For EMI-sensitive applications, the user can program the frequency-dithering scheme, enabling low-EMI spread-spectrum operation.

The input undervoltage lockout EN/UVLO is provided for programming the inputsupply start voltage set to 18V in the design and to ensure proper operation during brownout conditions. The EN/UVLO input is also used to turn on/off the IC. The overvoltage input OVI protection scheme is provided to make sure that the controller shuts down when the input supply exceeds its maximum allowed value set to 36V in the design .

To control inrush current, the device incorporates a soft-start SS pin to set the softstart time for the regulator. Power dissipation under fault conditions is minimized by hiccup overcurrent protection hiccup mode . The soft-stop feature provides safe discharging of the clamp capacitor when the device is turned off, and allows the controller to restart in a well-controlled manner.

Additionally, the negative current limit is provided in the current-sense circuitry, helping limit clamp switch current under dynamic operating conditions. An overtemperature protection OTP fault triggers thermal shutdown for reliable protection of the device.

The reference design delivers a peak efficiency of with the supplied components when the input is 24V. This general-purpose power solution can be used in many different types of power applications, such as programmable logic controllers PLC , industrial process control, industrial sensors, telecom/datacom power supplies, isolated battery chargers, servers, and embedded computing.

System Diagram

Figure The MAXREFDES121# reference design block diagram.

Detailed Circuit Description The MAX17599 low IQ active-clamp current-mode PWM controller contains all the control circuitry required for designing wide-input isolated forward converter industrial power supplies. The device includes an AUX driver that drives an auxiliary MOSFET clamp switch that helps implement the active-clamp transformer reset topology for forward converters. This reset topology has several advantages, including reduced voltage stress on the switches, transformersize reduction due to larger allowable flux swing, and improved efficiency due to elimination of dissipative snubber circuitry. Programmable dead time between the AUX and main driver allows for zero voltage switching. Primary Power Stage The active-clamp transformer primary side is driven by an n-channel MOSFET N3 and a pchannel MOSFET P1 . While N3 is on, power is delivered to the secondary side, and magnetizing energy is being stored in the transformer. During this time, P1 is off, and the clamp capacitor C10 is charged at a constant voltage level. When N3 turns off, the leakage and magnetizing currents charge up the drain-to-source capacitance of N3. Once the drain-to-source voltage of N3 exceeds the voltage across the clamp capacitor, the body diode of P1 begins to conduct. With the body diode of P1 conducting, the magnetizing current begins to charge the clamp capacitor.

After P1 turns off, the clamp capacitor remains at a fixed voltage. There is a fixed delay before N3 turns on. During this delay, the energy in the parasitic components discharges the VDS of N3 towards VIN. This allows softer turnon and lower switching losses for N3.

The MAX17599 NDRV pin drives the n-channel MOSFET while the AUXDRV pin is level shifted through C11, R9, R14, and D4, and then drives the p-channel MOSFET.

Secondary Power Stage The secondary power stage consists of the synchronous rectifiers N1, N2 , the output filter L1, C4, C5, and C6 , and the gate driving circuit for N1 R3 and N2 R2 .

When N3 is on, the voltage on the gate wiring of T1 ensures N2 is on, while N1 is off. During this time, a voltage equal to the input voltage multiplied by the NS:NP turns ratio of the transformer is applied across N3 the inductor and the load capacitor are charged and being stored with energy.

The voltage on the input end of the filter inductor is a typical buck-converter square wave. The inductor and output capacitors filter the square wave to produce DC voltage on the output.

Feedback Control Loop A feedback network is typical of most isolated forward converters. It is constructed using a TL431V programmable shunt regulator, a 3000V isolation optocoupler, and other RC components.

Startup Voltage and Input Overvoltage Protection Setting EN/UVLO and OVI pins The EN/UVLO pin in the MAX17599 serves as an enable/disable input, as well as an accurate programmable undervoltage lockout UVLO pin. The MAX17599 does not begin startup operations unless the EN/UVLO-pin voltage exceeds 1.21V typ . The MAX17599 turns off if the EN/UVLO pin voltage falls below 1.15V typ . A resistor divider from the input DC bus to ground can be used to divide down and apply a fraction of the input DC voltage to the EN/ UVLO pin. The values of the resistor-divider can be selected so that the EN/UVLO-pin voltage exceeds the 1.21V typ turnon threshold at the desired input DC bus voltage. The same resistordivider can be modified with an additional resistor, ROVI, to implement overvoltage input protection in addition to the EN/UVLO functionality. When the voltage at the OVI pin exceeds 1.21V typ , the MAX17599 stops switching. Switching resumes with soft-start operation, only if the voltage at the OVI pin falls below 1.15V typ . For the expected values of the startup DC input voltage VSTART and overvoltage input protection voltage VOVI , the resistor values for the divider can be calculated as follows:

VSTART = R4 + R7 + R5 / R4 + R7 x V

VOVI = R4 + R7 + R5 /R4 x V

If R4 = R5 = and R7 = then:

VSTART = 18.2V, VOVI = 36.3V.

Quick Start

Required equipment:
• MAXREFDES121# board
• One adjustable DC power supply with a voltage output up to 37V and current up to 3A.
• One electronic load
• 2 voltmeters
• 2 ammeters

Procedure

The MAXREFDES121# board is fully assembled and tested. Use the following steps below to verify board operation.

Turn off the power supply. Connect the positive terminal of the power supply to the VIN connector of the MAXREFDES121#
board. Connect the PGND connector of the MAXREFDES121# board to the positive terminal of one
ammeter. Connect the negative terminal of the ammeter to the negative terminal of the power supply. Connect one voltmeter across the VIN and the PGND connectors of the MAXREFDES121# board. Connect the VOUT connector of the MAXREFDES121# board to the positive terminal of the
electronic load. Connect the negative terminal of the electronic load to the positive terminal of the second
ammeter. Connect the negative terminal of the ammeter to the GNDO connector of the MAXREFDES121#
board. Connect the second voltmeter across the VOUT and the GNDO connectors of the

MAXREFDES121# board. Turn on the power supply. Set the output to 24V. Set the electronic load to a constant current between 0A to 10A. Verify the second voltmeter reading is 3.3V ±0.15V .

Lab Measurements

The MAXREFDES121# design was verified and tested under full input range and different output load conditions.

The power efficiency vs. load current is illustrated in Figure

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Datasheet ID: MAXREFDES121C# 647470