178003

Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 1. Introduction In case an application requires a higher current than the nominal value of one module, two MagI³C power modules can operate in parallel, doubling the output current. For this reason and the purpose of better understanding of the topic ‘current sharing’, a reference design board (order code: 178003) is introduced here. The reference design consists of two MagI³C power modules (171021501) connected in parallel (with 2.5A rated current) with all complementary components needed to achieve current sharing. The two DC-DC converters can be controlled in two modes of operation, from the phase shift perspective, namely, interleaved mode (180° phase shift) and non-interleaved mode (0° phase shift). Figure 1. MagI³C Current Sharing Reference Design 2. Specifications Electrical Specifications      Input Voltage Range Output Voltage Range Output Current Maximum Output Power Switching Frequency DNS003 V1.0 Features 7V – 50V 2.5V – 15V 0A – 5A 75W Adjustable (500kHz – 1MHz)    Symmetrical current-sharing tolerance Superimposed output voltage ripple Selectable synchronization  Discrete clock generator  Pads for an LC input filter Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG ± 3% typ. < 4mVPP Interleaved or non interleaved Integrated on the board Integrated on the board Page 1/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 3. Functional Diagram Figure 2 shows the simplified block diagram of the two MagI³C Power Modules connected in parallel. VIN MagI³C Power Module 1 CIN1 CLK Generator 500kHz RT/CLK VIN + COUT VOUT MagI³C Power Module 2 AGND CIN2 RT/CLK COUT1 PGND + COUT2 PGND CIN VOUT VOUT AGND VIN Figure 2. Functional Diagram In addition, the input and output capacitors of the respective modules are shown. In order to operate the power modules in parallel, it is required to synchronize both devices to an external clock. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 2/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 4. Reference Design Description___________________________________________ The following pictures show the current-sharing reference design board with its features: Input trace Output trace Output trace Input trace Figure 3. Current-Sharing Reference Design with two MagI³C Power Modules in Parallel DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 3/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules  Discrete clock generator  Selection between interleaved (async) and noninterleaved (sync) mode  Shunt resistors for measuring the input and output current (optional) Figure 4. Features – clock, mode select, shunt  Optional input implementation  Electrolytic capacitor at input: To prevent undesired oscillations caused by series resonance of long supply wires with the ceramic input capacitors  Electrolytic capacitor at output: improves transient performance filter Figure 5. Feature – input filter, input / output capacitor DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 4/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Figure 6. Features – terminals, test points, adjustment  Solid screw terminals for VIN and VOUT  Allows for reliable connections and measurements  Standard wires can be used  Robust test points  Measuring wires can be connected separately  Easy access to relevant points  Easy adjustment of VOUT and switching frequency Values for different output voltages: VOUT R8 and R9 2.5V 3.3V 5V 9V 12V 15V 4.7kΩ 3.2kΩ 1.9kΩ 976Ω 714Ω 563Ω Values for different switching frequencies with C1 = 1nF: DNS003 V1.0 Switching frequency fCLK Capacitor value C1 Resistor value R1 500kHz 1nF 823Ω 600kHz 1nF 632Ω 700kHz 1nF 503Ω 800kHz 1nF 410Ω 900kHz 1nF 342Ω 1MHz 1nF 289Ω Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 5/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 5. Paralleling of MagI³C Power Modules______________________________________ There are three common ways to connect DC/DC-Converters in parallel for the purposes of current sharing and redundancy:    Brute-force current sharing (no additional circuitry) Forced current sharing (also known as active current sharing) Droop Regulation (output impedance increase to force the equal currents) This reference design (two MagI³C Power Module 171021501 in parallel) uses the principle of the brute-force current sharing. This type of parallel connection has the advantage of scalability and is - compared to the other types - inexpensive. To realize this parallel circuitry several steps are necessary, which are explained in detail in the following chapter. This reference design achieves the advantage of doubling the current capability, independent of the selected mode (noninterleaved / interleaved-mode). Another advantage of connecting in parallel is the improved heat distribution compared to the case of using a single module rated at the full load, i.e. the MagI³C Power Module 171050601 (nominal rated output current of 5A). While this module forms one heat spot on the board due to the power dissipation, the power losses of the parallel version with two modules split and thus heat is distributed. This creates two hot spots that are lower in temperature than a single module with the same output current. In addition, the used modules of the parallel circuitry have a higher input voltage range (50Vmax) than compared to the single module (36Vmax), which results in a higher usability. Furthermore paralleling the MagI³C Power Module 171021501, it is possible to select between two different modes: interleaved and non-interleaved, which will be explained now. Parallel circuit  doubled power at the output  better thermal performance Interleavedmode  Non-interleavedmode reduced input voltage ripple  Better conducted EMI  reduced output voltage ripple  faster control of the load  high input and output voltage ripple  high pulse currents due to simultaneous switching of MOSFETS  high EMI results transient performance Figure 7. Overview of the Interleaved- and Non-Interleaved-Mode DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 6/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 5.1 Non-Interleaved Mode The non-interleaved mode means that both PWM signals, which drive the modules, are in phase. This mode can be used if an application has wide limits regarding electromagnetic emission and/or output voltage ripple. But if an application has strict limits the more complex mode must be used, which will be explained in the following. 5.2 Interleaved Mode If the PWM signals are 180° out of phase, as showing in figure 8 the power modules work in interleaved mode. Running the converter in interleaved manner brings several benefits. From an electromagnetic interference reduction standpoint, the input voltage ripple is reduced because of the phase shift. Therefore, the requirements for an input filter are more relaxed. The 180° phase shifted output voltage ripple results in a smaller superimposed output voltage ripple on the shared output. This smaller ripple also results in smaller value of the required output capacitor. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 7/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Vn1 switch node Voltage (Vn1) 0 Vn2 t Δϕ =180° switch node Voltage (Vn2) 0 t IL1 inductor current (IL1) Iout1 0 t IL2 inductor current (IL2) Iout2 0 t Figure 8. Signal Characteristics of Interleaved-Mode The first two waveforms show the switching nodes phase-shifted by 180°. Below, the corresponding inductor currents are shown, also phase-shifted by 180°. Additionally, current-sharing leads also to a faster control of the load transient, which can be described with figure 9 shown below. Therefore, statistically speaking, the possibility to meet the optimal recovery time (where the inductor current reaches its peak) is doubled since two peaks occur. This mode is therefore recommended due to the application limits concerning electromagnetic interference or output voltage ripple. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 8/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 6. Circuit Description 6.1 Parallel circuitry In the following circuit diagram, the basic connections for current-sharing (in green) and the connection of the clock generator (in red) are shown. The circuitry (number and size of input and output capacitors, synchronization configuration of R and C, etc.) is applied according to the “BILL OF MATERIAL” section. Layout rules (e.g. close placement of the input capacitor to VIN pin) also apply to each individual power module as recommended in their datasheet. C4 R5 29 28 + INTSS PM1 FB SS/TR VOUT 1 C7 C8 36 R9 2 J1 CLK RSET INT RT/CLK 12-15 AGND C 14 VOUT1 PGND C13 31 VIN1 COMP 26 VIN + CIN COUT C25 28 C3 29 R4 SS/TR INTSS AGND PM2 FB 31 RT/CLK 26 C9 PGND COMP 2 VIN2 RSET INT VOUT2 36 R8 1 12-15 C11 C 10 C12 Figure 9. Circuit Diagram of the Current-Sharing Reference Design Connections between the two MagI³C-Power-Modules:   Connect VOUT1 and VOUT2 together to operate as a single output Both FB pins have to be connected to get the same output voltage on both modules: (RSET has to be selected according to the table in the “BILL OF MATERIAL”)     Both COMP pins have to be connected to force the same duty cycles in both modules (CSHARE is recommended with 100pF and used to filter noise) Both SS/TRK pins have to be connected to reach the output voltage at the same time (CSS has to be selected according to the datasheet table or formula or use the pin INTSS) The AGND and PGND pins have to be connected to refer to the same ground level Synchronization to a clock generator DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 9/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 6.2 Clock Generator For paralleling two Power Modules (171021501) a clock generator with a rectangular signal is essential. Both RT/CLK-Pins have to be synchronized to this rectangular wave. Therefore the power modules can be - as already mentioned - driven in phase (non-interleaved mode) and 180° out-of-phase (interleaved-mode), which has different advantages considering technical issues. The implemented clock generator for interleaving-mode is shown as follows: LM293 6HV-5.0 VIN CIN 10µF VIN VOUT 8 3 20mΩ 1 GND 2 10µF 4 CVCC 100nF COUT LMC555CM VCC OUT Cbyp 100nF SN74LVC1G14 RT/CLK (31) RESET TRIGG ER 5 CLK 3 2 RCLK CVOLT THR 6 GND 1 RT/CLK (31) CCLK DIS 7 Setting the frequency Figure 10: Clock Generator Circuit The clock is generated by the timer LMC555CM. It is configured as a 50% duty cycle oscillator. Due to its limited maximum supply voltage of 15V a linear regulator LM2936HV is used to support supply voltages up to 60V same as the MagI³C module. The phase shift of 180° is realized by the Schmitt-trigger-inverter SN74LVC1614. The particular signal with a 180° phase shift is routed to each Pin RT/CLK of the power module. To reduce disturbances and have short traces, the discrete clock generator is included in the reference design. Therefore short traces and symmetrical distance to the MagI³C power modules are assured, see DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 10/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules S-T-Inverter ZOOM ZOOM LMC555CM LM2936HV Figure 11: Clock Generator zoom view Figure 12: Clock Generator on the Board The 171021501 power module can operate with a user selectable frequency. For this reason R1 and C1 have to be chosen. The recommended capacitor C1 value is 1nF. With this information, the resistor value of R1 can be calculated. For different frequencies, the following equation will be helpful to calculate the right resistor value: 𝑅1 ∙ 𝐶1 = DNS003 V1.0 1 1.4 ∙𝑓𝐶𝐿𝐾 ∙(1+ 𝑓𝐶𝐿𝐾 ) 680 𝑘𝐻𝑧 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 11/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 7. Filter Suggestions for Conducted EMI The input filter shown in the schematic below is recommended to achieve conducted compliance according to EN55032 Class B. For radiated EMI the input filter is not necessary. It is useful to comply with the setup recommended in the standard. If two or more modules are connected to a single rail, the individual module’s input has to be decoupled by an inductor in each input line in order to avoid mutual oscillations caused by the coupling and additional undesired antenna effect. To decouple these input lines and comply with the standard, two input LC filter designs are recommended: 7.1 LC Input Filter with a Common Filter Capacitor First of all a LC input filter with one common filter capacitor Cf is recommended: L1 VIN C13 MagI³C Power Module 1 C14 VIN GND Cin + Cf L2 VIN GND C9 C10 MagI³C Power Module 2 GND Input LC Filter Figure 13: Simplified Schematic with a LC Input Filter (Common Cf) Bill of Material of the Input LC Filter Designator Description Order Code Manufacturer C99 (Cf) Filter ceramic chip capacitor 4.7μF/50V X7R, 1210 885012209048 Würth Elektronik L1, L2 Filter inductor, 4.7µH, PD2 family 744773047 Würth Elektronik DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 12/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Interleaved Mode: Test conditions Value Unit Input voltage VIN 24 V Output voltage VOUT 5 V Switching frequency fSW 500 kHz Output current IOUT 5 A Filter capacitor Cf 4.7 µF Filter inductor L1, L2 4.7 µH Ambient temperature TAMB 22 °C Conducted EMI Results measured on the reference design board: 80 70 Conducted Emissions 178003 VIN = 24V, VOUT = 5V, ILOAD = 5A with input filter 4.7µF (885012209048) common and 4.7µH (744773047) Average Quasi peak Conducted Emissions [dBµV] 60 EN55022 Class B Quasi Peak limit 50 EN55022 Class B Average limit 40 30 20 10 0 -10 0.15 0.5 1 10 30 Frequency [MHz] Figure 14: Conducted EMI The used filter complies with the standard EN55022 Class B. The reference design board allows also a splitting of the filter capacitor C f, which is now shown below. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 13/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 7.2 LC Input Filter with a Filter Capacitor in Each Input Line A LC input filter with a separated filter capacitor C17, C18 in each input trace: L1 VIN C18 C13 MagI³C Power Module C14 VIN GND C1 + L2 VIN C17 GND C9 MagI³C Power Module C10 GND Input LC Filter Figure 15: Simplified Schematic with a LC Input Filter (Separated Cf) Bill of Material of the input LC Filter Designator Description C17, C18 Filter ceramic chip capacitor 2.2μF/100V X7R, 1210 L1, L2 Filter inductor, 4.7µH, PD2 family DNS003 V1.0 Order Code 744773047 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Manufacturer Various Würth Elektronik Page 14/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Interleaved Mode: Test conditions Value Unit Input voltage VIN 24 V Output voltage VOUT 5 V Switching frequency fSW 500 kHz Output current IOUT 5 A Filter capacitor C17, C18 2.2 µF Filter inductor L1, L2 4.7 µH Ambient temperature TAMB 22 °C Conducted EMI Results measured on the reference design board: 80 70 Conducted Emissions 178003 VIN = 24V, VOUT = 5V, ILOAD = 5A with input filter 2.2µF separated and 4.7µH (744773047) Average Quasi peak Conducted Emissions [dBµV] 60 EN55022 Class B Quasi Peak limit 50 EN55022 Class B Average limit 40 30 20 10 0 -10 0.15 0.5 1 10 30 Frequency [MHz] Figure 16: Conducted EMI Dividing the filter capacitor Cf leads to a minimal (approximately 6-7dBµV) improvement of the EMC. With these results the following final recommendation can be given: With two separated filter capacitors, there is more safety (higher filtering effect) with the layout, if the input lines are not exactly symmetrical because of e.g. space reasons. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 15/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 8. Thermal Performance and Layout Section When creating the layout, special care must be taken for the input and output traces. The critical points for a symmetrical current-sharing are the input and output traces. The length and width and therefore the impedance of the input and output trace have to be identical. Additionally the section LAYOUT in the datasheet of the MagI³C Power Module (171021501) is recommended. The PCB consists of four layer (copper thickness 70µm) which are connected through vias under each power module. Test conditions Value Unit Input voltage VIN 24 V Output voltage VOUT 5 V Switching frequency fSW 500 kHz Output current IOUT 5 A Power losses 10.55 W Ambient temperature TAMB 22 °C Figure 15 below shows the top side of the current-sharing reference design. Figure 17: Thermo picture with IR Camera CONCLUSION    Both power modules are at the same temperature level Symmetrical distribution of the heat on the PCB Optimal utilization of PCB area to ensure heat spreading DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 16/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Figure 18: Top View CONCLUSION     Symmetrical routing of power paths Clock generator placed in center Shunt resistors for current measurements Input filter option in each path The next two chapters show the “SCHEMATIC” and the “BILL OF MATERIAL” of the reference design. DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 17/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 9. Schematic Figure 19: Schematic of the Reference Design DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 18/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 10. Assembly Drawing Figure 20: Assembly Drawing DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 19/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules 11. Bill of Material Designator Description Quantity Order Code Manufacturer IC3, IC4 MagI³C Power Module 2 171021501 Würth Elektronik R2, R3 SMD bridge 0Ω resistance 2 - Various 4.7kΩ for VOUT = 2,5V 2 - Various 3.2kΩ for VOUT = 3,3V 2 - Various 1.9kΩ for VOUT = 5V 2 - Various 976Ω for VOUT = 9V 2 - Various 714Ω for VOUT = 12V 2 - Various 2 - Various 4 - Various 4 - Various R10 (Rin1), R11 (Rin2) 563Ω for VOUT = 15V Ceramic chip capacitor 2.2µF/100V, X7R, 1210 Ceramic chip capacitor 22µF/25V, X7R, 1210 Aluminium electrolytic capacitor 27µF/100V Shunt resistor 1mΩ 2 - Various R12 (Rout1), R13 (Rout2) Shunt resistor 1mΩ 2 - Various C25 Ceramic chip capacitor 100pF/10V, X7R, 0805 1 R8, R9 C9, C10, C13, C14 C7, C8, C11, C12 C15 (Cin), C16 (Cout) 2 860040874001 Würth Elektronik 885012207004 Würth Elektronik Order Code LMC555CMX/NOPBCTND SN74LVC1G14DBVR LM2936HVMAX5.0/NOPBCT-ND Manufacturer 885012207086 Würth Elektronik Clock generator components: Designator Description IC1 Timer 1 IC2 Schmitt-Trigger Inverter 1 IC5 Linear Voltage Regulator 1 C1 R1 C2, C20 C3, C4 R4, R5 C5 C6 R6, R7 DNS003 V1.0 Ceramic chip capacitor 1nF/50V, X7R, 0805 823Ω for f = 500kHz Quantity 1 Texas Instruments Texas Instruments Texas Instruments 1 - Various 632Ω for f = 600kHz 1 - Various 503Ω for f = 700kHz 1 - Various 410Ω for f = 800kHz 1 - Various 342Ω for f = 900kHz 1 - Various 289Ω for f = 1000kHz Ceramic chip capacitor 100nF/50V, X7R, 0805 Ceramic chip capacitor 470pF/10V, C0G, 0805 1kΩ Ceramic chip capacitor 2.2µF/100V, X7R, 1210 Ceramic chip capacitor 10µF/10V, X7R, 0805 Shunt resistor 20mΩ 1 - Various 2 885012207098 Würth Elektronik 2 885012007007 Würth Elektronik 2 - Various 1 - Various 1 2 885012207026 - Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Würth Elektronik Various Page 20/21 Reference Design Note MagI3C Power Modules DNS003 Current-sharing with MagI³C Power Modules Important Notes The Reference Design Note / Application Note is based on our knowledge and experience of typical requirements concerning these areas. It serves as general guidance and should not be construed as a commitment for the suitability for customer applications by Würth Elektronik eiSos GmbH & Co. KG. The information in the Application Note is subject to change without notice. This document and parts thereof must not be reproduced or copied without written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Würth Elektronik eiSos GmbH & Co. KG and its subsidiaries and affiliates (WE) are not liable for application assistance of any kind. Customers may use WE’s assistance and product recommendations for their applications and design. 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In certain customer applications requiring a very high level of safety and in which the malfunction or failure of an electronic component could endanger human life or health, customers must ensure that they have all necessary expertise in the safety and regulatory ramifications of their applications. Customers acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements concerning their products and any use of WE products in such safety-critical applications, notwithstanding any applications-related information or support that may be provided by WE. CUSTOMERS SHALL INDEMNIFY WE AGAINST ANY DAMAGES ARISING OUT OF THE USE OF WE PRODUCTS IN SUCH SAFETY-CRITICAL APPLICATIONS. USEFUL LINKS CONTACT INFORMATION Application Notes / Reference Design Notes https://www.we-online.com/app-notes Technical Support powermodules@we-online.com REDEXPERT Design Tool https://www.we-online.com/redexpert Würth Elektronik eiSos GmbH & CO. KG Max-Eyth-Str. 1, 74638 Waldenburg Germany Toolbox https://www.we-online.com/toolbox Tel.: +49 7942 945 0 we-online.com MagI3C Product Catalog https://katalog.we-online.com/en/pm DNS003 V1.0 Markus Roppel - February 2019 Copyright © Würth Elektronik eiSos GmbH & Co. KG Page 21/21