AN-2102 LM3464 and LM5021 DHC 25W Reference Designs Application Report

AN-2102 LM3464 and LM5021 DHC 25W Reference Designs Application Report
Application Report
SNVA465A – March 2011 – Revised April 2013
AN-2102 LM3464 and LM5021 DHC 25W Reference
Designs
.....................................................................................................................................................
ABSTRACT
This evaluation board consists of a Texas Instruments LM5021-based 120Vac 24W AC/DC flyback
converter and a LM3464-based dynamic head room control (DHC) four channel LED driver IC. This
demonstration platform was developed so that the customers could evaluate the LM3464 with an AC/DC
supply.
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8
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10
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Contents
Introduction .................................................................................................................. 2
Key Features ................................................................................................................ 2
Performance Specifications ................................................................................................ 2
LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic ............................................. 4
Bill of Materials (BOM) ..................................................................................................... 5
Typical Performance Characteristics ..................................................................................... 7
PCB Layout .................................................................................................................. 9
Design Information ........................................................................................................ 10
8.1
1ST Stage - DCM Flyback ........................................................................................ 10
8.2
2ND Stage - Dynamic Headroom Control ....................................................................... 10
8.3
Jumper/Fault Information ........................................................................................ 10
Electromagnetic Interference (EMI) ..................................................................................... 10
Thermal Analysis .......................................................................................................... 11
References ................................................................................................................. 12
List of Figures
1
Demo Board ................................................................................................................. 3
2
Efficiency vs. Line Voltage ................................................................................................. 7
3
Power Factor vs. Line Voltage ............................................................................................ 7
4
Total LED Current vs. LED Temperature ................................................................................ 7
5
Output Voltage & LED Forward Voltage vs. LED Temperature....................................................... 7
6
Ch1: Line Voltage (100 V/div); Ch3: Line Current (200 mA/div); Time (10 ms/div)
7
Ch1: Output Voltage (10 V/div); Ch3: Total LED Current (500 mA/div); Time (10 ms/div) ........................ 7
8
Ch1: Drain Voltage (100V/div) Time (4 µs/div) .......................................................................... 8
9
Ch1: Output Voltage (10 V/div); Ch3: Total LED Current (500 mV/div); Time (100 ms/div) ...................... 8
10
Top Layer .................................................................................................................... 9
11
Bottom Layer
12
Peak Conductive EMI scan per CISPR-22, Class B Limits .......................................................... 11
13
Top Side Thermal Scan
...............................
................................................................................................................
..................................................................................................
7
9
11
List of Tables
1
Bill of Materials (BOM) ..................................................................................................... 5
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AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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1
Introduction
1
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Introduction
Once familiar with the operation of the LM3464 and its control of the AC/DC converter's control loop, the
type of AC/DC power supply and the converter's output power becomes less relevant. The evaluation
board contains eight CREE XLamp MC-E LEDs. Each XLamp MC-E LED has four separate LEDs in each
package for a total of 32 LEDs. The CREE MC-E LED allows for an easy demonstration of the LM3464
four channel operation with eight packaged LEDs. each LED string is regulated to 200mA. A heat sink is
mounted on the back of the PCB to dissipate the heat generated by the LEDs.The LM3464 regulates each
LED string current and adjust the secondary output voltage of the AC/DC power supply 0.9V above the
LED string forawrd voltage.The LM3464 monitors the output voltage and adjusts the feedback voltage to
the LM5021 primary control. This evaluation also demonstreates the LM3464 thermal fold-back feature
which reduces the average LED current when the LED temperature is over 80°C. The AC/DC flyback
power supply works in the discontinuous conduction mode and achieves power factor (PF) greater than
0.98.
The schematic, bill of materials, layout and measured performance characteristics are included.
2
Key Features
•
•
•
•
•
•
3
Drive four strings of LEDs from 120Vac
Overall Efficiency greater than 82%
DC/LED Efficiency greater than 90%
Power Factor greater than 0.98
Dynamic Headroom Control (DHC)
Thermal foldback control
Performance Specifications
Symbol
2
Parameter
Min
Typ
Max
VIN
Input voltage
90 VRMS
120 VRMS
132 VRMS
VOUT
LED string voltage
22 V
26 V
30 V
ILED
LED string average current per
string
-
200 mA
-
POUT
Output power
-
21 W
-
fsw
Switching frequency
-
67 kHz
-
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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Performance Specifications
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Figure 1. Demo Board
SNVA465A – March 2011 – Revised April 2013
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AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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3
LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic
4
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LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic
L2
LINE
J1
L1
BR1
C1
VR1
V+
F1
NEUTRAL
J2
INPUT EMI FILTER AND RECTIFIER CIRCUIT
J11
V+
T1
3
D3
C18
C3
R3
D4
1
D2
R1
9
C9
4
C19
LED+
D5
+
+
C10
7 R10
5
Q2
U1
R4
2 VIN
C4
D6
OUT 4
R7
+
CS
7 RT
6
R13
C2
C7
R2
8
SS
R5
COMP 1
R9
D7
DHC
C5
3 VCC
GND 5
U3
R26
C6
LM5021
C12
R12
R8
U4
C8
R11
C11
LED+
LED+
D8
J8
J7
J9
J10
R25
C17
U2
DHC R14
R15
OutP VIN
VLedFB
CDHC
C15
R16
Fltcp
C14
GD1
EN
J5
JP1
DR1
DR2
DR3
DR4
Q3
JP2
SE1
VDHC
R19
DIM
J3
GD2
SYNC
VCC
C13
GD3
Q5
R18
SE3
Therm
J6
DMIN
R20
GD4
Q6
Thmcp
RT1
C16
AGND
SE4
PGND
R21
R22
LM3464
4
JP3
SE2
Faultb
J4
Q4
R23
R24
J12
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Bill of Materials (BOM)
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WARNING
The LM3464 evaluation board has exposed high voltage
components that present a shock hazard. Caution must be taken
when handling the evaluation board. Avoid touching the evaluation
board and removing any cables while the evaluation board is
operating.
WARNING
The ground connection on the evaluation board is NOT referenced
to earth ground. If an oscilloscope ground lead is connected to the
evaluation board ground test point for analysis and the mains AC
power is applied (without any isolation), the fuse (F1) will fail open.
For bench evaluation, either the input AC power source or the
bench measurement equipment should be isolated from the earth
ground connection. Isolating the evaliation board (using 1:1
isolation line isolation transformer) rather than the oscilloscope is
highly recommended.
5
Bill of Materials (BOM)
Table 1. Bill of Materials (BOM)
Designator
Description
Manufacturer
Part Number
C1
CAP .10UF 305VAC EMI SUPPRESSION
EPCOS
B32921C3104M
C2
CAP, CERM, 0.33uF, 50V, +/-10%, X7R, 0805
MuRata
GRM219R71H334KA88D
C3, C18
CAP, CERM, 0.22uF, 250V, +/-10%, X7R, 1210
MuRata
GRM32DR72E224KW01L
CAP, 33UF, 35V, ELECT, 5mmx11mm
Panasonic
EEUFM1V330
CAP, CERM, 0.22uF, 100V, +/-10%, X7R, 0805
MuRata
GRM21AR72A224KAC5L
CAP, CERM, 1uF, 25V, +/-10%, X5R, 0805
AVX
08053D105KAT2A
C4
C5, C14,C15
C6, C13
C7
CAP, CERM, 47pF, 50V, +/-5%, C0G/NP0, 0805
Yageo America
CC0805JRNP09BN470
C8, C16
CAP, CERM, 0.068uF, 50V, +/-10%, X7R, 0805
AVX
08055C683KAT2A
C9, C10
CAP, 1000UF, 35V, ELECT, 12.5mmx25mm
Panasonic
EEU-FC1V102
C11
CAP, CERM, 1000pF, 250VAC, +/-10%, X7R, 1808
Syfer Technology
1808JA250102KXBSY2
C12
CAP, CERM, 0.15uF, 50V, +/-10%, X7R, 0805
Murata
GRM21BR71H154KA01L
C17
CAP, CERM, 1uF, 50V, +/-10%, X7R, 1206
TDK
C3216X7R1H105K
C19
CAP, CERM, 220pF, 500V, +/-10%, X7R, 1206
Vishay
VJ1206Y221KXEAT5Z
D1
Diode, Switching-Bridge, 400V, 0.8A, MiniDIP
Diodes Inc.
HD04-T
D2, D7
Diode, Schottky, 100V, 0.2A, SOD-123
ST
Microelectronics
BAT41ZFILM
D3
DIODE TVS 150V 600W UNI 5% SMA
Littlefuse
SMAJ150A
D4
DIODE, 1000V, 1A, Mini SMA
Comchip
Technology
CGRM4007-G
D5
Diode, Schottky, 100V, 2A, SMB
Diodes Inc.
B2100-13-F
D6
Diode, Zener, 10V, 500mW, SOD-123
ON
Semiconductor
MMSZ4697T1G
D8
Diode, Zener, 8.2V, 500mW, SOD-123
Central
Semiconductor
CMHZ4694
F1
CMHZ4694
Cooper/Bussman
6125FA1A
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Bill of Materials (BOM)
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Table 1. Bill of Materials (BOM) (continued)
Designator
H1
Description
Part Number
CUI Inc.
VHS-45
J1, J2, J3, J4,
J5, J6, J12
Terminal, Turret, TH, Double
Keystone
Electronics
1502-2
J7, J8, J9, J10,
J11
Test Point, SMT
Keystone
Electronics
5016
JP1, JP2, JP3
Jumper
Samtec
TSW-102-07-G-S
L1
Common Mode Choke, 10mH, 0.3A
Coilcraft
BU09-103R25BL
L2
Inductor, Shielded Drum Core, 1mH, 0.45A,SMD
Coilcraft
MSS1038-105KLB
LED1 - LED8
LED
Cree
MCE4WT-A2-0000-000M02
Q1
MOSFET, N-CH, 500V, 6A, DPAK
Fairchild
Semiconductor
FDD6N50TM
Q2
Transistor, NPN, 40V, 0.2A, SOT-23
Fairchild
Semiconductor
MMBT3904
Fairchild
Semiconducto
FDD3682
Q3, Q4, Q5, Q6 MOSFET, N-CH, 100V, 32A, DPAK
R1
RES, 150k ohm, 1%, 0.25W, 1206
Vishay-Dale
CRCW1206150KFKEA
R2
RES, 100k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW0805100KFKEA
R3, R4
RES, 10.0 ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW080510R0FKEA
R5
RES, 0.1 ohm, 5%, 0.25W, 1206
Panasonic
ERJ-8RSJR10V
R7
RES, 10.5k ohm, 1%, 0.1W, 0603
Vishay/Dale
CRCW060310K5FKEA
R8, R12
RES, 1.00k ohm, 1%, 0.125W, 0805
Vishay/Dale
CRCW08051K00FKEA
R9
RES, 5.11k ohm, 1%, 0.125W, 0805
Vishay/Dale
CRCW08055K11FKEA
R10, R11
RES, 10.0k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW080510K0FKEA
RES, 105k ohm, 1%, 0.1W, 0603
Vishay-Dale
CRCW0603105KFKEA
R14, R15
RES, 25.5k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW080525K5FKEA
R16
RES, 2.67k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW08052K67FKEA
R18
RES, 3.01k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW08053K01FKEA
R19
RES, 8.06k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW08058K06FKEA
R20
RES, 0 ohm, 5%, 0.125W, 0805
Vishay-Dale
CRCW08050000Z0EA
RES, 1.0 ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW08051R00FKEA
R25
RES, 0 ohm, 5%, 0.25W, 1206
Vishay-Dale
CRCW12060000Z0EA
R26
RES, 22.1k ohm, 1%, 0.125W, 0805
Vishay-Dale
CRCW080522K1FKEA
RT1
Thermistor NTC, 10k ohm, 2%, 0603
Panasonic
ERT-J1VG103GA
T1
Transformer, Flyback, 540UH
Wurth Elektornik
750311959
U1
AC-DC Current Mode PWM Controller
Texas
Instruments
LM5021-1
U2
Dynamic Headroom Controller w/Therm Control
Texas
Instruments
LM3464
U3
Opto Coupler
NEC
PS2501L-1-Q-A
U4
Low-Voltage Adjustable Precision Shunt Regulator
Texas
Instruments
LMV431
Varistor, 150V, 25J, 10mm
Littlefuse
V150LA5P
R13
R21, R22, R23,
R24
VR1
6
Manufacturer
Heat Sink
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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Typical Performance Characteristics
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Typical Performance Characteristics
85
1.000
84
0.995
83
0.990
POWER FACTOR
EFFICIENCY (%)
6
82
81
80
79
78
0.985
0.980
0.975
0.970
0.965
77
0.960
76
0.955
75
0.950
90
100
110
120
130
INPUT VOLTAGE (VAC)
140
90
Figure 2. Efficiency vs. Line Voltage
100
110
120
130
INPUT VOLTAGE (VAC)
140
Figure 3. Power Factor vs. Line Voltage
1.00
26.5
OUTPUT VOLTAGES (V)
TOTAL LED CURRENT (A)
0.95
0.90
0.85
0.80
0.75
0.70
0.65
0.60
26.0
25.5
Vout
25.0
VLED
24.5
24.0
0.56
0.50
77
23.5
79 81 83 85 87 89
LED TEMPERATURE (C)
91
Figure 4. Total LED Current vs. LED Temperature
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30
40
50
60
70
LED TEMPERATURE (C)
80
Figure 5. Output Voltage & LED Forward Voltage vs.
LED Temperature
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
Copyright © 2011–2013, Texas Instruments Incorporated
7
Typical Performance Characteristics
8
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Line Voltage and Line Current
(VIN = 120VRMS)
Output Voltage and LED Current
(VIN = 120VRMS)
Figure 6. Ch1: Line Voltage (100 V/div);
Ch3: Line Current (200 mA/div);
Time (10 ms/div)
Figure 7. Ch1: Output Voltage (10 V/div);
Ch3: Total LED Current (500 mA/div);
Time (10 ms/div)
Power MOSFET Q1 Drain to Source Voltage
(VIN = 120VRMS)
Start Up Voltage and Current
(VIN=120VRMS)
Figure 8. Ch1: Drain Voltage (100V/div)
Time (4 µs/div)
Figure 9. Ch1: Output Voltage (10 V/div);
Ch3: Total LED Current (500 mV/div);
Time (100 ms/div)
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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PCB Layout
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7
PCB Layout
Figure 10. Top Layer
Figure 11. Bottom Layer
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Design Information
8
Design Information
8.1
1ST Stage - DCM Flyback
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The evaluation board is considered a two stage LED driver system. The first stage is the AC/DC flyback
converter and the second stage is the LM3464 LED currenr regulator. The first stage employs a NSC
LM5021-1 in a discontinuous mode flyback and operates at fixed switching frequency and constant duty
cycle. The input current follows the rectified AC input voltage and achieves power factor of 0.98 and
higher. To ensure LM5021-1 operates at constant duty cycle, R7 and R1 need to be properly sized so that
the slope compensation ramp is bigger than the current sense voltage. In this design, R7 is chosend to be
10.5Kohm and R1 is chosen to be 0.1 ohm. At 40% duty cycle, the peak ramp voltage is 246mV and the
peak current sense voltage is around 150mV.
The transformer is designed to keep the flyback converter operating in discontinuous mode at peak output
power. For a single stage PFC flyback converter, the peak output power occurs at peak input voltage and
is twice the average output power. The transformer used in the evaluation board can handle up to 48W
peak output power without saturation.
The feedback loop of the flyback converter includes U4 the LMV431 shunt regulator and U3 the opto
coupler. When LM3464 is not controlling the output voltage (during initial power up), the flyback converter
output voltage is set by resistor divider R13, R26 and R11 (approximately 17V). Once the LM3464 begins
to control the LM5021 and therefore the output voltage by sink/source current through OutP pin and
pushes the output voltage up to as high as 33V. In order to have good power factor, the control loop
bandwidth has to be lower than 120Hz. For further explanation of LM3464 operation, see the LM3464,
LM3464A LED Driver With Dynamic Headroom Control and Thermal Control Interfaces Data Sheet
(SNVS652).
8.2
2ND Stage - Dynamic Headroom Control
The second stage of the evaluation board features the LM3464 which is a linear LED driver controller. The
LM3464 is a four string controller, and in this particular demonstration board the LM3464 controls four
strings of eight LEDs at 200mA. The internal ampiliers of LM3464 compare the voltages of the current
sense resistors to a 200mV reference voltage and control the gate voltages of four external MOSFETs (
Q3 - Q6 ) to achieve linear current regulations.
The voltage headroom which the voltage difference between the seondary output voltage of the AC/DC
power supply and the LED string forward voltage is minimized by the LM3464 controller.By minimizing this
voltage, the efficiency of the system is maximized. The LM3464 regulates the drain voltage of the external
MOSFET to the voltage of the VDHC pin which is equal to 0.9V, therefore the headroom is about 0.9V.
LM3464 has thermal fold-back function to prevent the LEDs from overheating. When the voltage at the
thermal pin ( pin #3 ) is less than 3.25V, the average LED current is reduced by PWM dimming. For this
evaluation board, the thermal foldback function starts to kick in when the resistance of the NTC thermistor
RT1 reaches 3.2kohm.
8.3
Jumper/Fault Information
Jumpers JP1, JP2 and JP3 are provided for the customers to short or disconnect LED strings. One string
of LED can be disconnected to the power supply by open connector JP1. One LED each on LED string
number one can be shorted by short connctors JP2 or JP3.
LM3464 will continue to regulate the currents of the remaining strings of LEDs when one or more strings
of LEDs are shorted or disconnected. It will also continue to regulate the LED current when one or more
LEDs in that string are shorted.
9
Electromagnetic Interference (EMI)
In order to get a quick estimate of the EMI filter performance, only the PEAK conductive EMI scan was
measured and the data was compared to the Class B conducted EMI limits published in FCC – 47, section
15.
10
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
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Thermal Analysis
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110.0
AMPLITUDE IN dBuV
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0
100.0k
1.0M
10.0M
100.0M
FREQUENCY
Figure 12. Peak Conductive EMI scan per CISPR-22, Class B Limits
10
Thermal Analysis
The board temperature was measured using an IR camera (HIS-3000, Wahl) while running under the
following conditions:
VIN = 120 VRMS
The results are shown in Figure 13.
Figure 13. Top Side Thermal Scan
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References
11
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References
LM3464, LM3464A LED Driver With Dynamic Headroom Control and Thermal Control Interfaces Data
Sheet (SNVS652)
12
AN-2102 LM3464 and LM5021 DHC 25W Reference Designs
Copyright © 2011–2013, Texas Instruments Incorporated
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Microcontrollers
microcontroller.ti.com
Video and Imaging
www.ti.com/video
RFID
www.ti-rfid.com
OMAP Applications Processors
www.ti.com/omap
TI E2E Community
e2e.ti.com
Wireless Connectivity
www.ti.com/wirelessconnectivity
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Copyright © 2013, Texas Instruments Incorporated
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