LM5027
LM5027 Voltage Mode Active Clamp Controller
Literature Number: SNVS620B
LM5027
November 23, 2009
Voltage Mode Active Clamp Controller
General Description
The LM5027 pulse-width modulation (PWM) controller con-
tains all of the features necessary to implement power con-
verters utilizing the Active Clamp / Reset technique. With the
active clamp technique, higher efficiencies and greater power
densities can be realized compared to conventional catch
winding or RDC clamp / reset techniques. Three control out-
puts are provided: the main power switch control (OUTA), the
active clamp switch control (OUTB), and secondary side syn-
chronous rectifier control (OUTSR). The timing between the
control outputs is adjustable with external resistors that pro-
gram internal precision timers. This controller is designed for
high-speed operation including an oscillator frequency range
up to 1 MHz and total PWM propagation delays less than 50
ns. The LM5027 includes a high-voltage startup regulator with
a maximum input voltage rating of 105V. Additional features
include Line Under Voltage Lockout (UVLO), separate soft-
start of main and synchronous rectifier outputs, a timer for
hiccup mode current limiting, a precision reference, and ther-
mal shutdown.
Features
Voltage-Mode control
Line feed-forward PWM ramp
Internal 105V rated start-up bias regulator
Programmable line Under-Voltage Lockout (UVLO) with
adjustable hysteresis
Versatile dual mode over-current protection
Programmable volt-second limiter
Programmable soft-start
Programmable synchronous rectifier soft-start and stop
Precise 500mV over-current comparator
Current sense leading edge blanking
Programmable oscillator with 1 MHz maximum frequency
and synchronization capability
Precision 5V reference
Programmable time delays between outputs
Packages
eTSSOP-20
LLP-24
Typical Application Circuit
30099001
Simplified Active Clamp Converter
© 2009 National Semiconductor Corporation 300990 www.national.com
LM5027 Voltage Mode Active Clamp Controller
Connection Diagrams
30099002
20-Lead eTSSOP
30099090
24-Lead LLP
Ordering Information
Order Number Package Type NSC Package Drawing Package Marking Supplied As
LM5027MH eTSSOP-20 MXA20A LM5027MH 73 units per Rail
LM5027MHX eTSSOP-20 MXA20A LM5027MH 2500 Units per Tape and Reel
LM5027SQ LLP-24 SQA24B L5027 1000 Units per Tape and Reel
LM5027SQX LLP-24 SQA24B L5027 4500 Units per Tape and Reel
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LM5027
Pin Descriptions
Pin Name Description Application Information
1 VIN Input voltage source Input to the Start-up Regulator. Operating input range is 13V to 90V.
The Absolute Maximum Rating is 105V. For power sources outside of
this range, the LM5027 can be biased directly at VCC by an external
regulator.
2 RAMP Feed-forward modulation ramp An external RC circuit from VIN sets the PWM ramp slope. This pin is
discharged at the conclusion of every cycle by an internal FET. An
internal comparator terminates the PWM pulse if the RAMP pin
exceeds 2.5V thus limiting the maximum volt-second product to the
transformer primary.
3 TIME3 Overlap delay 3 An external resistor sets the overlap delay for the active clamp output.
The RTIME3 resistor connected between TIME3 and AGND sets the
OUTA turn-off (falling edge) to OUTB turn-on (falling edge) pulse delay.
See Fig. 9.
4 TIME2 Overlap delay 2 An external resistor sets the overlap delay for the OUTSR output. The
RTIME2 resistor connected between TIME2 and AGND sets the OUTA
turn-off (falling edge) to OUTSR turn-on (rising edge) pulse delay. See
Fig. 9.
5 TIME1 Overlap delay 1 An external resistor sets the overlap delay for the active clamp output.
The RTIME1 resistor connected between TIME1 and AGND sets the
OUTB and OUTSR turn-off to OUTA turn-on pulse delay. See Fig. 9.
6 AGND Analog ground Connect directly to Power Ground.
7 RT Oscillator frequency control and sync
clock input
Normally biased at 2V by an internal amplifier. An external resistor
connected between RT and AGND sets the internal oscillator
frequency. The internal oscillator can be synchronized to an external
clock with a frequency higher than the free running frequency set by
the RT resistor.
8 COMP Input to the pulse width modulator An external opto-coupler connected to the COMP pin sources current
into an internal NPN current mirror. The PWM duty cycle is at its
maximum value with zero input current, while 1mA reduces the duty
cycle to zero. The current mirror improves the frequency response by
reducing the ac voltage across the opto-coupler detector transistor.
9 REF Reference Output Output of a 5V reference. Maximum output current is 10 mA. Locally
decouple with a 0.1 µF capacitor.
10 OUTB Output driver Control output of the active clamp PFET gate. Capable of 1A peak
source and sink current.
11 OUTA Output driver Control output of the main PWM NFET gate. Capable of 2A peak
source and sink current.
12 OUTSR Output driver Control output of the secondary side synchronous rectifier FET gates.
Capable of 3A peak source and sink current.
13 PGND Power ground Connect directly to Analog Ground
14 VCC Start-up regulator output Output of the internal high voltage start-up regulator. Regulated at 9.5V
during start-up and 7.5V during run mode. If the auxiliary winding raises
the voltage on this pin above the regulation set point, the internal start-
up regulator will shutdown, thus reducing the IC power dissipation.
15 CS Current sense input Current sense input for cycle-by-cycle current limiting. If the CS pin
exceeds 500mV the output pulse will be terminated, entering cycle-by-
cycle current limit. An internal switch holds CS low for 100 ns after
OUTA switches high to blank leading edge transients.
16 SS Soft-start Input An internal 22 µA current source charges an external capacitor to set
the soft-start rate.
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LM5027
Pin Name Description Application Information
17 RES Restart timer If cycle-by-cycle current limit is reached during any cycle, a 22 µA
current is sourced into the RES capacitor. If the RES capacitor voltage
charges to 1.0V, a hiccup sequence is initiated. The SS and SSSR
capacitors are discharged and the control outputs are disabled. The
voltage on the RES capacitor is ramped between 4V and 2V eight
times. After the eighth cycle, the SS capacitor is released and the
normal start-up sequence begins.
18 SSSR Soft-start for synchronous rectifier
output.
An external capacitor and an internal 25 µA current source sets the
soft-start and soft-stop ramps for the synchronous rectifier output
(OUTSR).
19 OTP Over-Temperature Protection The OTP comparator can be used for over-temperature shutdown
protection with an external NTC thermistor voltage divider setting the
shutdown temperature. The OTP comparator threshold is 1.25V.
Hysteresis is set by an internal current source that sources 20 µA into
the external resistor divider when the OTP pin voltage is above the
threshold.
20 UVLO Line under-voltage lockout An external voltage divider from the power source sets the shutdown
and standby comparator levels. When UVLO reaches the 0.4V
threshold, the VCC and REF regulators are enabled. When UVLO
reaches the 2.0V threshold, the SS pin is released and the device
enters the active mode. Hysteresis is set by an internal current source
that pulls 20 µA from the external resistor divider when the UVLO pin
is below the 2.0V threshold.
EP Exposed pad, underside of package No electrical contact to the LM5027 integrated circuit. Connect to
system ground plane for reduced thermal resistance.
Note: The pin numbers shown are only for the eTSSOP package.
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LM5027
Absolute Maximum Ratings (Note 1)
If Military/Aerospace specified devices are required,
please contact the National Semiconductor Sales Office/
Distributors for availability and specifications.
VIN to GND -0.3V to 105V
VCC to GND -0.3V to 16V
UVLO to GND -0.3 to 8V
All other inputs to GND -0.3 to 7V
COMP Input Current 10 mA
COMP, REF (Note 2)
ESD Rating (Note 3)
Human Body Model 2kV
Storage Temperature Range -55°C to 150°C
Junction Temperature 150°C
Operating Ratings (Note 1)
VIN 13 to 90V
VCC 8 to 15V
Operating Junction Temperature -40°C to +125°C
Electrical Characteristics Limits in standard type are for TJ = 25°C only; limits in boldface type apply over the
junction temperature range of –40°C to +125°C. Unless otherwise specified, the following conditions apply: VIN = 48V, VCC = 10V,
RT= 27.4K , No Load on OUTA, OUTB and OUTSR unless otherwise stated.
Symbol Parameter Conditions Min Typ Max Units
VIN SUPPLY
Ibias VIN Operating Current COMP and VCC Open, UVLO and OTP = 3V 6mA
VIN Shutdown Current UVLO = 0V, Vin = 100 V 310 650 µA
VCC REGULATOR
VCC Regulation No Load (SS<4V) 9.1 9.5 9.9 V
VCC Current Limit VCC=9.5V 55 65 mA
VCC Regulator load regulation IVCCREG 0 to 15 mA 75 mV
VCC Under-voltage Lockout
Voltage
Positive going VCC VccReg
–180mV
VccReg –
100mV
V
VccReg VCC Regulation No Load 7.3 7.5 7.7 V
VCC Under-voltage Lockout
Voltage
Negative going Vcc 5.7 6.0 6.3 V
VCC Supply Current (Icc) Supply current into VCC form an external
source, CGATE = OPEN, VCC 10V
5.5 mA
REFERENCE SUPPLY
Reference Voltage IREF = 0mA 4.85 5.0 5.15 V
Reference Voltage Regulation IREF= 0 to 10mA 10 20 mV
Reference Current Limit 10 17.5 mA
REF Under-voltage Threshold UVLO >0.4V, VCC >9.5V 3.8 V
UVLO/OTP THRESHOLDS
UVLO Threshold 1.9 22.1 V
UVLO Hysteresis Current UVLO 16 20 25 µA
UVLO Shutdown Threshold ULVLO voltage falling 0.3 V
UVLO Standby Enable
Threshold
UVLO voltage rising 0.4 V
OTP Shutdown Threshold OTP rising 1.21 1.25 1.29 V
OTP Hysteresis Current OTP 15 20 24 µA
SOFT-START
SS Charging Current Source SS = 0V 17 22 26 µA
SS Rising Threshold for SSSR
charge current enable
3.8 44.2 V
SSSR Charging Current Source SSSR = 0V, SS>4V 18 25 30 µA
SSSR Discharge Current
Source in Soft Stop
14 20 26 µA
SSSR Falling Threshold for SS
Soft Stop
1.5 2.2 3.0 V
SS output low voltage Sinking 100 µA UVLO = 0 120 mV
SSSR output low voltage 100 mV
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LM5027
Symbol Parameter Conditions Min Typ Max Units
OSCILLATOR
Frequency1 RT = 27.4 k180 200 220 kHz
Frequency2 RT = 11 k420 490 550 kHz
Sync Threshold 2.85 V
Sync Pulse Width 15 150 ns
Sync Frequency Range 160 kHz
PWM COMPARATORS
Delay to Output 50 ns
COMP to PWM Offset 1.0 V
Duty Cycle Maximum OUTA, OUT_A = Tdelay_min 90 %
CURRENT LIMIT RESTART (RES Pin)
RES Threshold 1.1 V
Charge Source Current Level 1 VRES < 1.0V 22 25 µA
Charge Source Current Level 2 4.0V < VRES > 1.0V 45.0 6.5 µA
Discharge Current Source VRES ramping down 457µA
Ratio of RES Threshold to SS
Low
VRES > 1V, Hiccup counter 125
CURRENT LIMIT
Cycle by cycle sense voltage
threshold
RAMP = 0 450 500 550 mV
CS prop Current limit propagation delay CS step from 0 to 0.6V time to onset of OUTA
transition (90%) Cgate = 0pen
30 ns
VOLTAGE FEED-FORWARD (RAMP Pin)
RAMP Discharge Device RDS(ON) 5
VOLT-SECOND CLAMP
Ramp Clamp Level Delta RAMP measured from onset of OUTA
to Ramp peak. Comp = 5V
2.3 2.5 2.6 V
OUTA GATE DRIVER
VOL OUTA Low-state Output Voltage IOUTA = 100 mA 0.15 0.5 V
VOH OUTA High-state Output
Voltage
IOUTA = -100 mA, VOHL = VCC -VLO 0.35 0.21 V
OUTA Rise Time C-load = 1000 pF 10 ns
OUTA Fall Time C-load = 1000 pF 13 ns
IOHL Peak OUTA Source Current VOUTA = 0V (VCC = 10V) 2 A
IOLL Peak OUTA Sink Current VOUTA = VCC= 10V 2 A
OUTB GATE DRIVER
VOL OUTB Low-state Output Voltage IOUTB = 100 mA 0.2 0.4 V
VOH OUTB High-state Output
Voltage
IOUTB = -100 mA, VOHL = VCC -VLO 0.5 0.31 V
OUTB Rise Time C-load = 1000 pF 15 ns
OUTB High Side Fall Time C-load = 1000 pF 13 ns
Peak OUTB Source Current VOUTB = 0V (VCC = 10V) 1 A
Peak OUTB Source Current VOUTB = VCC= 10V 1 A
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LM5027
Symbol Parameter Conditions Min Typ Max Units
OUTSR GATE DRIVER
VOL OUTSR Low-state Output
Voltage
IOUTSR = 100 mA 0.1 0.2 V
VOH OUTSR High-state Output
Voltage
IOUTSR = -100 mA, VOHL = VCC -VLO 0.25 0.11 V
OUTSR Rise Time C-load = 1000 pF 12 ns
OUTSR High Side Fall Time C-load = 1000 pF 10 ns
IOHH Peak OUTSR Source Current VOUTSR = 0V (VCC = 10V) 3 A
IOLH Peak OUTSR Source Current VOUTSR = VCC= 10V 3 A
OUTPUT TIMING CONTROL
T1 Delay Leading Range RTIME1=10 kΩ – 100 k30 300 ns
T1 Delay Leading Accuracy RTIME1 = 33.2 k75 100 125 ns
T2 Delay Trailing Range RTIME2 = 10 kΩ – 100 k30 300 ns
T2 Delay Trailing Accuracy RTIME2 = 28.7 k75 100 125 ns
T3 Delay Leading Range RTIME3 = 10 kΩ – 100 k30 300 ns
T3 Delay Leading Accuracy RTIME3 = 29.4 k75 100 125 ns
THERMAL
tsd Thermal Shutdown Temp. 150 165 °C
Thermal Shutdown Hysteresis 25 °C
RJA Junction to Ambient 40 °C/W
RJC Junction to Exposed Pad 4 °C/W
Note 1: Absolute Maximum Ratings are limits beyond which damage to the device may occur. Operating Ratings are conditions under which operation of the
device is intended to be functional. For guaranteed specifications and test conditions, see the Electrical Characteristics.
Note 2: It is not recommended that external power sources be connected to these pins.
Note 3: The human body model is a 100 pF capacitor discharged through a 1.5 k resistor into each pin.
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LM5027
Typical Performance Characteristics
Efficiency
30099040
VCC and VREF vs. VIN
30099024
VCC vs. ICC
30099025
VREF vs. IREF
30099026
Oscillator Frequency vs RT Resistor
30099027
Oscillator Frequency vs Temperature
30099028
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LM5027
Time1 Delay vs RTIME1 (kΩ)
30099029
Time2 Delay vs RTIME2 (kΩ)
30099030
Time3 Delay vs RTIME3 (kΩ)
30099031
Time1 Delay vs Temperature
RTIME1 = 33.2 k
30099032
Time2 Delay vs Temperature
RTIME2 = 28.7 k
30099033
Time3 Delay vs Temperature
RTIME3 = 29.4 k
30099034
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LM5027
SS Pin Current vs Temperature
30099035
SSSR Pin Charging Current vs Temperature
30099036
RES Pin Charging Current Level 1 vs Temperature
30099037
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LM5027
Block Diagram
30099003
FIGURE 1. Simplified Block Diagram
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LM5027
Detailed Operating Description
The LM5027 PWM controller contains all the features neces-
sary to implement power converters utilizing the Active Clamp
Reset technique with synchronous rectification. The device is
configured to control a P-Channel clamp switch. With the ac-
tive clamp technique higher efficiencies and greater power
densities can be realized compared to conventional catch
winding or RDC clamp / reset techniques. The LM5027 pro-
vides three gate driver outputs: one to drive the primary side
MOSFET (OUTA), one for the active clamp P-Channel MOS-
FET (OUTB), and one output to drive the synchronous recti-
fier through an isolation interface (OUTSR). This controller is
designed for high-speed operation including an oscillator fre-
quency range up to 1 MHz and total PWM and current sense
propagation delay less than 50 ns. The LM5027 includes a
high-voltage start-up regulator that operates over a wide input
range of 13V to 90V. Additional features include: Line Under-
Voltage lockout (UVLO), soft-start/soft-stop, oscillator with
synchronization capability, cycle-by-cycle current limit, hiccup
mode fault protection with adjustable delay, precision refer-
ence, and thermal shutdown.
High Voltage Start-Up Regulator
The LM5027 contains an internal high voltage start-up regu-
lator that allows the input pin (VIN) to be connected directly
to the line voltage. The regulator output is internally current
limited to 55mA. When the UVLO pin potential is greater than
0.4V, the VCC regulator is enabled to charge an external ca-
pacitor connected to the VCC pin. The VCC regulator pro-
vides power to the voltage reference (REF) and the gate
drivers (OUTA, OUTB, and OUTSR). The controller outputs
are enabled when the voltage on the VCC pin reaches the
regulation point of 9.5V, the internal voltage reference (REF)
reaches its regulation point of 5V, the UVLO pin voltage is
greater than 2V, and the OTP pin voltage is greater than
1.25V. The outputs will remain enabled unless one of the fol-
lowing conditions occurs, VCC falls below 6.0V, UVLO is
below 2.0 V, or the OTP pin falls below 1.25V. The value se-
lected for the VCC capacitor depends on the total system
design and the start-up characteristics. The recommended
capacitance range for the VCC regulator is 0.1 µF to 100 µF.
In a typical application, an auxiliary transformer winding is
connected through a diode to the VCC pin. This winding must
raise the VCC voltage above the VCC regulation set point to
shut off the internal start-up regulator. The LM5027 lowers the
VCC regulation set point from 9.5V to 7.5V after the output of
the first OUTSR drive pulse. Powering VCC from an auxiliary
winding improves efficiency while reducing the controller
power dissipation. When the converter auxiliary winding is in-
active, external current draw on the VCC line should be limited
so the power dissipation in the start-up regulator does not ex-
ceed the maximum power dissipation of the LM5027 pack-
age. An external start-up regulator or other bias rail can be
used instead of the internal start-up regulator by connecting
the VCC and the VIN pins together and feeding the external
bias into the two pins.
Line Under-Voltage Detector
The LM5027 contains a dual level line Under Voltage Lock
Out (UVLO) circuit. When the UVLO pin voltage is greater
than 0.4V but less than 2.0V, the controller is in a standby
mode. In the standby mode the VCC and REF bias regulators
are active while the controller outputs are disabled. This fea-
ture allows the UVLO pin to be used as a remote enable/
disable function. Pulling the UVLO pin below the 2.0V thresh-
old initiates a soft-stop sequence described later in this doc-
ument. There is 100mV of hysteresis provided in the 0.4V
shutdown comparator. When the VCC and REF outputs ex-
ceed their respective under-voltage thresholds and the UVLO
pin voltage is greater than 2.0V and the OTP pin voltage is
greater than 1.25V, the outputs are enabled and normal op-
eration begins. An external set-point voltage divider from the
VIN to GND can be used to set the minimum operating voltage
of the converter. The divider must be designed such that the
voltage at the UVLO pin will be greater than 2.0V when Vin is
in the desired operating range. If the under-voltage threshold
is not met, all three outputs are disabled. UVLO hysteresis is
accomplished with an internal 20 µA current sink that is
switched on or off into the impedance of the set-point divider.
When the UVLO pin voltage exceeds 2.0V threshold, the cur-
rent sink is deactivated to quickly raise the voltage at the
UVLO pin. When the UVLO pin voltage falls below the 2.0V
threshold, the current sink is turned on causing the voltage at
the UVLO pin to quickly fall .
Reference
The REF pin is the output of a 5V linear regulator that can be
used to bias an opto-coupler transistor and external house-
keeping circuits. The regulator output is internally current
limited to 10 mA.
Cycle-by-Cycle Current Limit
The CS pin is to be driven by a signal representative of the
transformer primary current. If the voltage on the CS pin ex-
ceeds 0.5V, the current sense comparator terminates the
output driver pulse, with the duty cycle determined by the cur-
rent sense comparator instead of the PWM comparator. A
small R-C filter connected to the CS pin and located near the
controller is recommended to suppress noise. An internal
5 MOSFET discharges the external current sense filter ca-
pacitor at the conclusion of every cycle. The discharge MOS-
FET remains on for an additional 30 ns after either OUTA
driver switches high to blank leading edge transients in the
current sensing circuit. Discharging the CS pin filter each cy-
cle and blanking leading edge spikes reduces the filtering
requirements and improves the current sense response time.
The current sense comparator is very fast and may respond
to short duration noise pulses. Layout considerations are crit-
ical for the current sense filter and sense resistor. The ca-
pacitor associated with the CS filter must be placed very close
to the device and connected directly to the CS and AGND
pins. If a current sense transformer is used, both leads of the
transformer secondary should be routed to the filter network,
which should be located close to the IC. When designing with
a current sense resistor, all of the noise sensitive low power
ground connections should be connected together near the
AGND pin, and a single connection should be made to the
power ground (sense resistor ground point).
Restart Time Delay (Hiccup Mode)
The LM5027 provides a current limit restart timer to disable
the outputs and force a delayed restart (hiccup mode) if a
current limit condition is repeatedly sensed. The number of
cycle-by-cycle current limit events required to trigger the
restart is programmable by the external capacitor at the RES
pin. During each PWM cycle, the LM5027 either sources or
sinks current from the RES pin capacitor. If no current limit is
detected during a cycle, a 5 µA current sink is enabled to pull
the RES pin to ground. If a current limit is detected, the 5 µA
current sink is disabled and a 22 µA current source causes
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LM5027
the voltage at the RES pin to gradually increase. If the RES
voltage reaches the 1.0V threshold, the following restart se-
quence occurs (also see Figure 2).
• The SS and SSSR capacitors are fully discharged.
• The RES 20 µA current source is turned-off and the 5 µA
current source is turned-on.
• The voltage on the RES pin is allowed to charge up to 4.0V.
• When voltage on the RES pin reaches 4.0V the 5 µA current
source is turned-off and a 5 µA current sink is turned-on,
ramping the voltage on the RES capacitor down to 2.0V.
• The RES capacitor voltage is ramped between 4.0V and
2.0V eight times.
• When the counter reaches eight, the RES pin voltage is
pulled low and the Soft-Start capacitor is released to begin a
soft-start sequence. The SS capacitor voltage slowly increas-
es. When the SS voltage reaches 1.0V, the PWM comparator
will produce the first narrow output pulse at OUTA.
• When the SS voltage reaches 4.0V the capacitor on the
SSSR pin is released and is charged with a 25 µA current
source, soft-starting the free-wheeling synchronous rectifier.
• If the overload condition persists after restart, cycle-by-cycle
current limiting will begin to increase the voltage on the RES
capacitor again, repeating the hiccup mode sequence.
• If the overload condition no longer exists after restart, the
RES pin will be held at ground by the 5 µA current sink and
normal operation resumes.
30099004
FIGURE 2. Restart and Soft-Start Delay Timing
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LM5027
Soft-Start
The soft-start circuit allows the regulator to gradually increase
its output voltage until the steady state operating point is
reached; thereby reducing start-up stresses and surge cur-
rents. When bias power is supplied to the LM5027, the SS pin
capacitor is discharged by an internal MOSFET. When the
voltages on the UVLO, OTP, VCC, and REF pins reach the
operating thresholds, the soft-start capacitor is released and
is charged with a 22 µA current source. When the SS pin volt-
age reaches 1V, output pulses commence with a slowly in-
creasing duty cycle (refer to Figure 3, Figure 4 and Figure
5). The voltage on the SS pin eventually increases to 5V, while
the voltage at the PWM comparator is limited to the level re-
quired for regulation as determined by the voltage feedback
loop via the COMP pin. When the soft-start voltage reaches
4.0V, the capacitor on the SSSR pin is released and charged
with a 25 µA current source (refer to Figure 3, Figure 4 and
Figure 5) . When the SSSR pin voltage reaches approximate-
ly 2.5V (refer to Figure 6), the internal synchronous rectifier
PWM circuit gradually increases the synchronous rectifier
drive duty cycle (OUTSR) in proportion the rising SSSR pin
voltage. Delaying the start of the SSSR gate drive pulses until
after the main soft-start is completed allows the output voltage
to reach regulation before the synchronous rectifiers begins
operation. This delay prevents the synchronous rectifier from
sinking current from the output in applications where the out-
put voltage may be pre-biased.
Soft-Stop
If the UVLO pin voltage falls below the 2.0V standby thresh-
old, but above the 0.4V shutdown threshold, the synchronous
rectification soft-start capacitor is discharged with a 20 µA
current source which gradually disables the synchronous rec-
tifiers (refer to Figure 4). After the SSSR capacitor has been
discharged to 2.0V the soft-start and synchronous rectifica-
tion soft-start capacitors are quickly discharged to ground to
terminate PWM pulses at OUTA ,OUTB, and OUTSR. The
PWM pulses may cease before the SSSR voltage reduces
the synchronous rectifier duty cycle if the VCC or REF voltage
drops below the respective under-voltage thresholds during
the soft-stop process. This soft-stop method of turning off the
converter prevents oscillations in the synchronous rectifiers
during a shutdown sequence.
30099005
FIGURE 3. Soft-Start Timing
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LM5027
30099006
FIGURE 4. Soft-Start/Soft-Stop Timing
30099007
FIGURE 5. Soft-Start and Drive Enable
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LM5027
30099008
FIGURE 6. Soft-Start Synchronous Rectifier Timing
External Over-Temperature
Protection
An external set-point voltage divider between the REF, OTP,
and AGND pins, as shown in Figure 7, is one method to im-
plement over-temperature protection shutdown. Typically a
NTC thermistor is installed as the lower device of the voltage
divider. The divider must be designed such that the voltage
at the OTP pin will be greater than 1.25V when there is not
an over-temperature condition, and the OTP pin must drop
below 1.25V during an over-temperature event. OTP hystere-
sis is accomplished with an internal 20 µA current source that
is switched on or off into the impedance of the external set-
point divider. When the OTP pin voltage exceeds 1.25V
threshold, the current source is activated to quickly raise the
voltage at the OTP pin. When the OTP pin voltage falls below
the 1.25V threshold, the current source is turned off causing
the voltage at the OTP pin to quickly fall. When OTP falls be-
low 1.25V the LM5027 will go through a soft-stop turn-off
sequence.
30099009
FIGURE 7. External OTP Protection
Fault/Events Summary Table
Table 1 is a Truth Table which describes the faults and events
that control the LM5027 drive outputs. For example the first
event is with UVLO being pulled below 0.4V, a possible re-
mote shutdown condition. When this occurs the SS, and
SSSR capacitors are discharged, and the three drive outputs
will stop switching (outputs low). The last fault is if the OTP
pin is pulled low <1.25V, this would occur if an OTP protection
circuit is used, see Figure 7. In an OTP event, the LM5027
goes into a soft-stop shutdown.
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LM5027
TABLE 1. Fault/Event Summary
Fault/Event Vcc UVLO OTP SS SSSR OUTA OUTB OUTSR
UVLO<0.4V >6.2V - >1.25V Fast
discharge
Fast
discharge
Low Low Low
2.0V<UVLO
>0.4V
>6.2V - >1.25V Fast
discharge
after
SSSR<2V
Slow
discharge
Low Low Low
SS< 1V >6.2V >2.0V >1.25V - Fast
discharge
Low Low Low
SSSR <2.0V >6.2V >2.0V >1.25V >4.0V - Switching Switching Low
OTP
<1.25V
>6.2V >2.0V - Fast
discharge
after
SSSR<2V
Slow
discharge
Low Low Low
PWM Comparators
The pulse width modulator (PWM) comparator compares the
voltage ramp signal at the RAMP pin to the loop error signal.
The loop error signal is received from the external feedback
and isolation circuit in the form of a control current into the
matched pair of NPN transistors which sink current through a
5 k resistor connected to the 5V reference. The resulting
control voltage is compared at the PWM input to a 1V level
shifted ramp signal. An opto-coupler detector can be con-
nected directly between the REF pin and the COMP pin. Since
the COMP pin is a current mirror input, the potential difference
across the opto-coupler detector is nearly constant. The
bandwidth limiting phase delay which is normally introduced
by the significant capacitance of the opto-coupler is thereby
greatly reduced. Higher loop bandwidths can be realized
since the bandwidth-limiting pole associated with the opto-
coupler is now at a much higher frequency. The PWM com-
parator polarity is configured such that with no current into the
COMP pin, the controller produces maximum duty cycle at the
main gate drive output (OUTA).
Feed-Forward Ramp
An external resistor (RFF) and capacitor (CFF) connected to
VIN, AGND, and the RAMP pins is required to create the
PWM ramp signal as shown in Figure 8. The slope of the sig-
nal at the RAMP pin will vary in proportion to the input line
voltage. This varying slope provides line feed-forward infor-
mation necessary to improve line transient response with
voltage mode control. The RAMP signal is compared to the
error signal by the pulse width modulator comparator to con-
trol the duty cycle of the outputs. With a constant error signal,
the on-time (tON) varies inversely with the input voltage (VIN)
to stabilize the volt-second product of the transformer prima-
ry. The power path gain of the conventional voltage-mode
pulse with modulator (oscillator generated ramp) varies di-
rectly with input voltage. The use of a line generated ramp
(input voltage feed-forward) nearly eliminates the gain varia-
tion. As a result, the feedback loop is only required to make
very small corrections for large changes in input voltage. At
the end of each clock period, an internal MOSFET with an
RDS(ON) of 10Ω (typical) is enabled to reset the CFF capacitor
voltage to ground.
17 www.national.com
LM5027
30099010
FIGURE 8. Feed-Forward Voltage Mode Configuration
Volt-Second Clamp
An external resistor (RFF) and a capacitor (CFF) connected
between the VIN, RAMP and AGND pins is required to create
a saw-tooth modulation ramp signal as shown in Figure 8. The
slope of the RAMP will vary in proportion to the input line volt-
age. Varying the PWM ramp slope inversely with the input
voltage provides line feed-forward information necessary to
improve line transient response with voltage mode control.
With a constant error signal, the on time (tON) varies inversely
with the input voltage (VIN) to stabilize the volt-second prod-
uct of the transformer primary.
The volt-second clamp compares the ramp signal (RAMP) to
a fixed 2.5V reference. By proper selection of RFF and CFF,
the maximum on-time of the main switch can be set to the
desired duration. An example will illustrate the use of the volt-
second clamp comparator to achieve a 90% duty cycle limit
at 200 kHz and 18V line input: A 90% duty cycle at 200 kHz
requires a 4.5 µs on-time. At 18V input the volt-second prod-
uct is 81µs (18V x 4.5 µs). To achieve this clamp level:
RFF x CFF = VIN x tON / 2.5V
18V x 4.5 µs/ 2.5V = 32.4µ
Select CFF = 470 pF
RFF = 68.9 kΩ (closest standard value 68.1 kΩ)
The recommended capacitor value range for CFF is 100 pF
to 1000 pF. The CFF ramp capacitor is discharged at the con-
clusion of every cycle by an internal discharge switch con-
trolled by either the PWM comparator, the CS comparator or
by the volt-second clamp comparator, which ever occurs first.
Oscillator and Sync Capability
The LM5027 oscillator frequency is set by the external resistor
connected between the RT pin and the ground (AGND). To
set a desired oscillator frequency, the necessary RT resistor
is calculated from:
For example, if the desired oscillator frequency is 200 kHz, a
27.4 k resistor would be the nearest standard one percent
value. The RT resistor should be located as close as possible
to the IC and connected directly to the pins (RT and AGND).
The tolerance of the external resistor and the frequency tol-
erance indicated in the Electrical Characteristics must be
taken into account when determining the worst case operat-
ing frequency. The LM5027 can be synchronized to an exter-
nal clock by applying a narrow pulse to the RT pin. The
external clock must be at least 10% higher than the free-run-
ning oscillator frequency set by the RT resistor. If the external
clock frequency is less than the RT resistor programming fre-
quency, the LM5027 will ignore the synchronizing pulses. The
synchronization pulse should be coupled to the RT pin
through a 100 pF capacitor with a pulse width of 15 ns to 150
ns. When a synchronizing pulse transitions from low-to-high
(rising edge), the voltage at the RT pin must be driven to ex-
ceed 3.2V from its nominal 2.85V level. During the clock
signal low time, the voltage at the RT pin will be clamped at
2V by an internal regulator. The output impedance of the RT
regulator is approximately 100. The RT resistor is always
required, whether the oscillator is free running or externally
synchronized.
www.national.com 18
LM5027
Gate Drive Outputs
The LM5027 contains three unique gate drivers. OUTA, the
primary switch driver, is designed to drive the gate of an N-
Channel MOSFET and is capable of sourcing and sinking a
peak current of 2A. The active clamp drive, OUTB, is de-
signed to drive a P-Channel MOSFET and is capable of
sourcing and sinking peak currents of 1A. The third driver,
OUTSR, is designed to drive the gate of a synchronous rec-
tification MOSFET through a gate drive transformer. OUTSR
gate driver has a source and sink capability of 3A.
Driver Delay Timing
The three independent time delay adjustments allow a great
deal of flexibility for the user to optimize the efficiency of the
system. The active clamp output (OUTB) is in phase with the
main output (OUTA), with the active clamp output overlapping
the main output. The overlap time provides dead-time be-
tween the operation of the main switch and the P-Channel
active clamp switch at both the rising and falling edges. The
rising edge control is set by a resistor from the TIME1 pin to
the AGND pin. The falling edge control is set with a resistor
from the TIME3 pin to the AGND pin.
The rising edge of the PWM comparator output coincides with
the rising edge of OUTB and the falling edge of the OUTSR
output without delay, as shown in Figure 9. The rising edge
control for turning on the OUTSR output after the main output
(OUTA) has turned off is set with a resistor from the TIME2
pin to the AGND pin.
30099011
FIGURE 9. LM5027 Driver Output Timing
Thermal Protection
Internal Thermal Shutdown circuitry is provided to protect the
integrated circuit in the event the maximum rated junction
temperature is exceeded. When activated, typically at 165°C,
the controller is forced into a low power standby state with the
output drivers (OUTA, OUTB, and OUTSR), the bias regula-
tors (VCC and REF) disabled. The thermal protection feature
is provided to prevent catastrophic failures from accidental
device overheating. During a restart, after thermal shutdown,
the soft-start capacitors (SS and SSSR) are fully discharged
and the controller follows a normal start-up sequence after the
junction temperature falls below the Thermal Shutdown hys-
teresis threshold (typically 145°C).
VIN
The voltage applied to the VIN pin, normally the same as the
system voltage applied to the power transformer’s primary
(VPWR), can vary in the range of the 13 to 90V with transient
capability of 105V. The current into VIN depends primarily on
the output driver capacitive loads, the switching frequency,
and any external loads on the VCC pin. If the power dissipa-
tion associated with the VIN current exceeds the package
capability, an external voltage should be applied to the VCC
pin (see Figure 10) to disable the internal start-up regulator.
The VCC regulation set point voltage is initially internally reg-
ulated to 9.5V. After the first OUTSR pulse, the VCC set point
voltage is reduced to 7.5V. If an external voltage is applied to
the VCC pin the required range is 8V to 15V . The VIN to VCC
series pass regulator includes a parasitic diode between VIN
and VCC. This diode should not be forward biased in normal
operation. The VCC voltage should never exceed the VIN
voltage. It is recommended the circuit of Figure 10 be used to
suppress transients which may occur at the input supply, in
particular where VIN is operated close to the maximum op-
erating rating of the LM5027.
30099012
FIGURE 10. Start-up Regulator Power Reduction
19 www.national.com
LM5027
For Applications > 100V
For applications where the system input voltage (VPWR) ex-
ceeds 100V, VIN can be powered from an external start-up
regulator as shown in Figure 11. Connecting the VIN and VCC
pins together allows the LM5027 to be operated with VIN be-
low 13V. To turn-off the internal start-up regulator the VCC
voltage must be raised above 9.9V. The voltage at the VCC
pin must not exceed 15V. The voltage source at the right side
of Figure 11 is typically derived from the power stage, and
becomes active when the LM5027 outputs are active.
30099014
FIGURE 11. Start-up Regulator for VPWR > 100V
UVLO
The under-voltage lockout threshold (UVLO) is internally set
to 2.0V at the UVLO pin. With two external resistors as shown
in Figure 12, the LM5027 is enabled when VPWR causes the
UVLO pin to exceed threshold voltage of 2V. When VPWR is
below the threshold, the internal 20 µA current sink is enabled
to reduce the voltage at the UVLO pin. When the UVLO pin
voltage exceeds the 2V threshold, the 20 µA current sink is
turned off causing the UVLO voltage to increase and provid-
ing hysteresis. The values of R1 and R2 can be determined
from the following equation:
R1 = VHYS/20 µA
Where VHYS is the desired UVLO hysteresis at VPWR, and
VPWR in the second equation is the turn-on voltage. For ex-
ample, if the LM5027 is to be enabled when VPWR reaches
34V, and the hysteresis is 1.8V, then R1 is 90 k and 5.6
k. For this application R1 was selected to be 90.0 k, R2
was selected to be 6.19 k. The LM5027 can be remotely
shutdown by taking the UVLO pin below 0.4V with an external
open collector or open drain device, as shown in Figure 12.
The outputs and the VCC regulator are disabled in shutdown
mode.
www.national.com 20
LM5027
30099016
FIGURE 12. UVLO Circuit with Shutdown Control
Oscillator
The oscillator frequency is generally selected in conjunction
with the system magnetic components and any other aspects
of the system which may be affected by the frequency. The
RT resistor selection equation is specified in the Oscillator and
Sync Capability section. If the required frequency tolerance is
critical in particular application, the tolerance of the external
resistor and the frequency tolerance specified in the Electrical
Characteristics table must be considered when selecting the
RT resistor.
Voltage Feedback
The COMP pin is designed to accept a current input typically
from an opto-coupler. A typical configuration is shown in Fig-
ure 13, where the emitter of the opto-coupler transistor is
connected to the COMP pin and the collector is connected to
the REF pin of the LM5027. When the output voltage is below
regulation, no current flows into the COMP pin and the
LM5027 operates at maximum duty cycle. At the secondary
side, VOUT is compared to a reference by the error amplifier
which has an appropriate frequency compensation network.
The amplifier output drives the opto-coupler, which in turn
drives the LM5027 COMP pin current mirror.
30099017
FIGURE 13. Typical COMP Configuration
21 www.national.com
LM5027
Current Sense
The CS pin receives an input signal representative of the
transformer primary current, either from a current sense
transformer or from a resistor in series with the source of the
primary switch, as shown in Figure 14 and Figure 15. In both
cases the sensed current creates a ramping voltage across
RSENSE, and the RF/CF filter suppresses noise and leading
edge transients. The filtering components RSENSE, RF and
CF should be physically as close to the LM5027 as possible.
The current sense components must be scaled for 0.5V at the
CS pin when an over-current condition exists.
If the voltage on the CS pin reaches 0.5V, the present cycle
will be immediately terminated. If the over-load event contin-
ues and the RES pin reaches 1V, the soft-start capacitor is
discharged and the LM5027 will go through an auto re-start
(Hiccup Mode). The Hiccup Mode time is set by the capacitor
on the RES pin.
30099018
FIGURE 14. Transformer Current Sense
www.national.com 22
LM5027
30099019
FIGURE 15. Resistor Current Sense
Soft-Start
The capacitor on the SS pin determines the time required for
the output duty cycle to increase from zero to its final value
for regulation. The minimum acceptable time is dependent on
the output capacitance and the response of the feedback loop
that controls the COMP pin. If the soft-start time is too quick,
the output could significantly overshoot its intended voltage
before the feedback loop has a chance to regulate the PWM
controller. After power is applied and VCC has passed its up-
per UV threshold (9.5V), the voltage at the SS pin ramps up
as the external capacitor is charged with an internal 20 μA
current source. The voltage at the internal PWM comparator
input node follows the voltage at the SS pin. When the voltage
on the SS pin has reached 1.0V, PWM pulses appear at the
drive output with a very low duty cycle. The voltage at the SS
pin eventually increases to approximately 5.0V. The voltage
at the input to the PWM comparator and the PWM duty cycle
increase to the value required for regulation as determined by
the voltage regulation loop.
Hiccup Mode Current Limit Restart
Hiccup mode operation is described in the Restart Time Delay
(Hiccup Mode) section. In the case of continuous current limit
detection at the CS pin, the time required to reach the 1.0V
RES pin threshold is:
For example, if CRES = 0.047 µF the time tCS in Figure 16 is
approximately 2.14 ms. After the voltage on the RES pin
reaches 1.0V, the 22 µA current source is turned-off and a 5
µA current source is turned-on. The Hiccup Mode time is:
where ΔV is 2.0V. With a CRES = 0.047 µF, the Hiccup Mode
time is 179 ms. After the Hiccup Mode off time is complete,
the RES pin voltage is pulled low and soft-start capacitor is
released allowing a soft-start sequence to commence.
The soft-start time trestart is set by the internal 22 µA current
source, and is equal to:
If CSS = 0.1 µF, trestart is = 6.41 ms
23 www.national.com
LM5027
The hiccup mode provides the periodic cool-down time for the
power converter in the event of a sustained overload or short
circuit. This off time results in lower average input current and
lower power dissipation within the power components.
30099023
FIGURE 16. Hiccup Mode Timing
Printed Circuit Board Layout
The LM5027 Current Sense and PWM comparators are very
fast and respond to short duration noise pulses. The compo-
nents at the CS, COMP, SS, UVLO, TIME1, TIME2, and
TIME3 pins should be physically close as possible to the IC,
thereby minimizing noise pickup on the PC board trace in-
ductance. Layout consideration is critical for the current sense
filter. If a current sense transformer is used, both leads of the
transformer secondary should be routed to the sense filter
components and to the IC pins. The ground side of the trans-
former should be connected via a dedicated PC board trace
to the AGND pin, rather than through the ground plane.
If the current sense circuit employs a sense resistor in the
drive transistor source, low inductance resistors should be
used. In this case, all the noise sensitive, low-current ground
trace should be connected in common near the IC, and then
a single connection made to the power ground (sense resistor
ground point). The gate drive outputs of the LM5027 should
have short, direct paths to the power MOSFETs in order to
minimize inductance in the PC board. The two ground pins
(AGND, PGND) must be connected together with a short, di-
rect connection, to avoid jitter due to relative ground bounce.
Application Circuit Example
The following schematic shows an example of the LM5027
controlling a 100W active clamp forward power converter.
The input voltage range (VPWR) is 36V to 76V, and the output
voltage is 3.3V. The output current capability is 30 Amps.
Current sense transformer T3 provides information to the CS
pin for current limit protection. The error amplifier and refer-
ence U3 and U5 provide voltage feedback via opto-coupler
U2. Synchronous rectifiers Q3-Q6 minimize rectification loss-
es in the secondary. An auxiliary winding on the power trans-
former T1 provides power to the LM5027 VCC pin when the
output is in regulation. The input UVLO levels are 34V for in-
creasing VPWR, and approximately 32V for decreasing VPWR.
The circuit can be shutdown by forcing the ON/OFF input J2
below 0.4V. An external synchronizing frequency can be ap-
plied to the Oscillator input. The converter output current limit
is limited at 32A.
Special care was taken in this design such that the converter
will turn on with the output pre-biased without sinking current
from the output. More information is available in AN-1976.
www.national.com 24
LM5027
30099039
25 www.national.com
LM5027
Physical Dimensions inches (millimeters) unless otherwise noted
20 Lead eTSSOP
NS Package Number MXA20A
24 Lead LLP
NS Package Number SQA24B
www.national.com 26
LM5027
Notes
27 www.national.com
LM5027
Notes
LM5027 Voltage Mode Active Clamp Controller
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