Flyback Controller Improves Cross Regulation for Multiple

Output Applications – Design Note 344

Tom Hack
Introduction Also, outputs remain uncoupled when the rectifiers
Flyback converters are often used in power supplies are off, which contributes to poor cross regulation.
requiring low to medium output power at several output The LTC ®3806 is a new flyback controller that improves
voltages. With a flyback, multiple outputs incur little addi- load and cross regulation for multiple output flyback
tional cost or complexity—each additional output requires converters. Multi-output systems that previously used
only another transformer winding, rectifier and output post regulators, multiple switching supplies or other
filter capacitor. Power over Ethernet (PoE) applications methods to provide tight output voltage tolerances can
may require several low to medium power outputs now use lower cost flyback converters. The LTC3806
and are good candidates for multiple output flyback uses forced continuous conduction operation improving
converters. cross regulation by keeping the rectifiers on and the
While multiple output flyback converters are simple outputs coupled (via transformer action) for a larger
and inexpensive, they often suffer from poor cross fraction of each power conversion cycle. The LTC3806
regulation. Usually, one output is tightly regulated also uses synchronous rectification to reduce rectifier
via feedback, while the other outputs are controlled voltage drops, improving converter efficiency and load
via less accurate transformer action. Schottky diode regulation.
voltage drops, transformer leakage inductances and 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
transformer winding resistances degrade regulation. respective owners.
VOUT1
12V
D2 R1 400mA
D1 C4
L1 1A 60V (OPT)
VIN 1N4148W T1 10μF
3.3μH B260A
25V TO 60V XFMR EFD20 FB
7
+ C1
C2
C3 12
10μF R3 R4 2.2μF VOUT2
220nF 232k 47k 11 6
63V 100V 5V
R2 C5 400mA
10
(OPT) 47μF
8
1 9 FB
VOUT3
2 4 3.3V
5 + C6 C7
3A
3 470μF 100μF
4V POSCAP

Q1
Si4490 VOUT4
2.5V
1 LTC3806 12
+ C10 C11 R5 2A
RUN SENSE R8 470μF 100μF (OPT)
C12 0.033Ω
2 11 4V POSCAP
R6 ITH NC 220nF FB
12.4k R7 3 10
33k C9 C8 FB SS Q2 Q3 Q4
100pF 1nF 4 9 Si7806DN Si7806DN Si7806DN
NC G1
5 8
VIN G2
6
INTVCC
+ C13
C14
GND
20V 100μF
35V 220nF C15 13
TANT 4.7μF
10V R10
20.5k
DN344 F01

FB
R9
12.4k

Figure 1. Multiple Output Synchronous Flyback Converter

08/04/344_conv
Improved Load and Cross Regulation rectification does not. To get reasonable regulation in a
Figure 1 shows a multiple output flyback converter that nonsynchronous design, all outputs require preloading
takes full advantage of the features of the LTC3806. of several percent of maximum IOUT.
Performance of this design was compared against a Efficiency
nonsynchronous version created by replacing Q2 with
Peak efficiency for this design is 87.6% at 60% of
an SL13 Schottky rectifier, and Q3 and Q4 with B540C
maximum output power (Figure 2). Such high efficiency
Schottky rectifiers.
is possible because of the significant reduction in con-
Load regulation measurements were taken with one duction loss afforded by the synchronous rectification,
output swept from no load to maximum output current particularly with low voltage outputs. At full load (21.4W
while all other outputs delivered maximum output cur- total output power), supply dissipation is only 3.38W. For
rent. Table 1 shows how load regulation is improved in the nonsynchronous design, peak efficiency is 81.9%
the synchronous design. Load regulation for output 1 and power dissipation is 5.31W. If light load regulation is
and output 4 in the nonsynchronous design are given required, this degrades to 78.9% due to preloading.
only from 20% to 100% of maximum output current
90
because load regulation rapidly deteriorates below 20%
of maximum output current.
Cross regulation measurements were taken under the
same conditions as the load regulation measurements. 85

Table 2 shows the superior cross regulation performance EFFICIENCY (%)

of the synchronous design.

Table 1. Load Regulation (% VOUT) 80

OUTPUT OUTPUT OUTPUT OUTPUT

1 2 3 4
Synchronous 7.86% 6.31% 1.39% 9.47% 75
10 20 30 40 50 60 70 80 90 100
Nonsynchronous 8.88% 6.42% 2.43% 10.32%
% OF MAXIMUM OUTPUT POWER
(20%-100% (20%-100%
of IMAX) of IMAX) DN344 F02

Figure 2. Efficiency vs Output Power

Table 2. Cross Regulation (% VOUT)
(Nonsynchronous Results in Parenthesis) Composite Feedback Provides Additional Design
OUTPUT 1 OUTPUT 2 OUTPUT 3 OUTPUT 4 Flexibility
Swept* 0.87% 0.22% 0.29% In Figure 1, only output 3 is controlled via feedback while
(2.02%) (0.42%) (0.43%) the remaining outputs are set via transformer action. To
0.31% Swept 0.16% 0.17% further improve load and cross regulation on these other
(0.94%) (0.23%) (0.30%) outputs (though at the expense of degraded load and
–5.49% –4.88% Swept –4.43% cross regulation on output 3), composite feedback may
(–8.52%) (–8.20%) (–8.61%) be used by adding optional resistors R1, R2, and R5.
–0.63% –0.12% 0.16% Swept*
(–0.36%) (0.13%) (0.39%) Conclusion
*20% to 100% of IMAX for nonsynchronous The LTC3806 makes cost effective multiple output fly-
back converters attractive for low and medium power
The case for using synchronous rectification is even applications such as Power over Ethernet devices.
stronger when load and cross regulation measure- Improved load and cross regulation eliminates the need
ments are taken with one output swept, and all other for additional switching supplies or post regulators.
outputs unloaded. Synchronous rectification provides Synchronous rectification improves efficiency and
acceptable load and cross regulation while Schottky lowers power dissipation.

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