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Default Slightly misbehaving switcher (from SED discussion)

These are some 'scope shots of a slightly misbehaving buck converter whereby
the duty cycle of the switch jitters around a bit when the input voltage is
~3V but doesn't do so at somewhat lower and higher voltages. (Output voltage
is 1.2V and maximum intended output current is around 150mA; the scope shots
were taken with a 20 ohm -- 60mA -- load connected. J6 and J7 are unjumpered
and R3 and C1 really are DNIed.)

I'm all ears for suggestions on how to improve this design, both the schematic
part and the layout. The layout is done with the idea that the four clustered
vias are the honest-to-God "ground" reference and that the controller's ground
and passive components' grounds don't see switching currents as much as
possible.

Things I've tried that didn't have a significant effect on the jitter:

-- Dropping 100nF from pin 5 to ground.
-- Increasing C3, up to at least 1nF. Actually, the design doesn't even seem
to need C3 -- I'm thinking it's there to improve the high-frequency response
of the regulator? Linear's datasheet uses a 20pF cap (with a resistor ~5x
larger) in all their examples.
-- Dropping 100nF from the R4/R5 junction to ground.
-- Changed both the input and output capacitors (C4/C5) to 10uF ceramics.
-- Raised C2 up to at least 1nF, which seriously cuts the loop bandwidth.
From doing some load step tests, down to about 2.8V the system is pretty
nicely damped and remains so at higher voltages; below 2.8V you do start to
see a handful of recovery cycles in the step response, but everything remains
stable. Dropping C2 to 100pF will make the loop unstable at voltage under
~3V.
-- Varied L1 anywhere from ~7.5uH to ~30uH. The size used -- 15uH -- is
larger than typically used, but was chosen based on staying in continuous
conduction mode down to a 20mA load with a 4.2V input.

I very much appreciate the time that people spend looking at stuff like this
on Usenet and thank you all for doing so!

---Joel




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