User's Guide SNVA398A - August 2009 - Revised May 2013 AN-1969 LM3424 Boost Evaluation Board 1 Introduction This evaluation board showcases the LM3424 NFET controller used with a boost current regulator. It is designed to drive 9 to 12 LEDs at a maximum average LED current of 1A from a DC input voltage of 10 to 26V. The evaluation board showcases many of the LM3424 features including thermal foldback, analog dimming, external switching frequency synchronization, and high frequency PWM dimming, among others. There are many external connection points to facilitate the full evaluation of the LM3424 device including inputs, outputs and test points. Refer to Table 1 for a summary of the connectors and test points. The boost circuit can be easily redesigned for different specifications by changing only a few components (see Alternate Designs). Note that design modifications can change the system efficiency for better or worse. This application note is designed to be used in conjunction with the LM3424 Constant Current N-Channel Controller with Thermal Foldback for Driving LEDs (SNVS603) data sheet as a reference for the LM3424 boost evaluation board and for a comprehensive explanation of the device, design procedures, and application information. 2 Key Features * * * * * * Input: 10V to 26V Output: 9 to 12 LEDs at 1A Thermal Foldback / Analog Dimming PWM Dimming up to 30 kHz External Synchronization > 360 kHz Input Under-voltage and Output Over-voltage Protection EFFICIENCY (%) 100 95 90 85 80 10 15 20 25 30 VIN (V) Figure 1. Efficiency with 6 Series LEDS AT 1A All trademarks are the property of their respective owners. SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 1 External Connection Descriptions 3 www.ti.com External Connection Descriptions Table 1. Connectors and Test Points Qty Name Application Information J1 VIN Input Voltage Connect to positive terminal of supply voltage. J2 GND Input Ground Connect to negative terminal of supply voltage (GND). J3 EN Enable On/Off Jumper connected enables device. J4 LED+ LED Positive Connect to anode (top) of LED string. J5 LED- LED Negative Connect to cathode (bottom) of LED string. J6 BNC Dimming Input Connect a 3V to 10V PWM input signal up to 10 kHz for PWM dimming the LED load. J7 OUT Output with NTC Alternative connector for LED+ and LED-. Pins 4 and 11 are used for connecting an external NTC thermistor. Refer to schematic for detailed connectivity. TP1 SW Switch Node Voltage Test point for switch node (where Q1, D1, and L1 connect). TP3 SGND Signal Ground Connection for GND when applying signals to TP5, TP8, and TP9. TP4 LED+ LED Positive Voltage Test point for anode (top) of LED string. TP5 nDIM Inverted Dim Signal Test point for dimming input (inverted from input signal). TP6 VIN Input Voltage Test point for input voltage. TP8 SYNC Synchronization Input Connect a 3V to 6V PWM clock signal > 500 kHz (pulse width of 100ns) to synchronize the LM3424 switching frequency to the external clock. TP9 NTC Temp Sense Input Connect a 0V to 1.24V DC voltage to analog dim the LED current. Power Ground Test point for GND when monitoring TP1, TP4, or TP6. TP10 PGND 2 Description AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Schematic www.ti.com 4 Schematic TP6 TP1 D1 VIN L1 C2, C3, C16, C18, C23 J1 GND R3 1 J2 HSP R8 20 TP4 C1 J3 2 C8 HSN EN C12 R7 19 R1 3 4 COMP SLOPE CSH IS R14 18 LED+ J4 17 R10 TP8 C14 C13 5 RT/SYNC VCC 16 LED- C9 R25 R5 R4 C7 R15 6 GATE nDIM J5 Q1 15 1 14 2 13 3 12 4 11 5 10 6 9 7 8 8 9 GND SS TGAIN DDRV OVP TSENSE NTC C4, C5, C6, C17, C19 J7 TP3 TP10 7 R9 R20 R2 C10 R13 LM3424 VIN R6 14 13 Q2 R17 12 DAP R19 C11 10 TREF VS R11 11 R21 C15 R22 TP5 NTC J6 C22 PWM Q3 R12 SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 3 LM3424 Pin Descriptions 5 LM3424 Pin Descriptions Pin Name Description Application Information Bypass with 100 nF capacitor to GND as close to the device as possible in the circuit board layout. 1 VIN Input Voltage 2 EN Enable 3 COMP Compensation 4 CSH Current Sense High 5 RT Resistor Timing Connect a resistor to GND to set the switching frequency. Can also be used to synchronize external clock as explained in the Switching Frequency section of the datasheet. Not DIM input Connect a PWM signal for dimming as detailed in the PWM Dimming section of the datasheet and/or a resistor divider from VIN to program input under-voltage lockout (UVLO). Turn-on threshold is 1.24V and hysteresis for turn-off is provided by 20 A current source. 6 4 www.ti.com nDIM Connect to > 2.4V to enable the device or to < 0.8V for low power shutdown. Connect a capacitor to GND to compensate control loop. Connect a resistor to GND to set the signal current. Can also be used to analog dim as explained in the Thermal Foldback / Analog Dimming section of the datasheet. 7 SS Soft-start Connect a capacitor to GND to extend start-up time. 8 TGAIN Temperature Foldback Gain Connect a resistor to GND to set the foldback slope. 9 TSENSE Temperature Sense Input 10 TREF Temperature Foldback Reference Connect a resistor divider from VS to set the temperature foldback reference voltage. 11 VS Voltage Reference 2.45V reference for temperature foldback circuit and other external circuitry. 12 OVP Over-Voltage Protection 13 DDRV Dimming Gate Drive Output 14 GND Ground 15 GATE Gate Drive Output 16 VCC Internal Regulator Output 17 IS Main Switch Current Sense 18 SLOPE Slope Compensation 19 HSN High-Side LED Current Sense Negative Connect through a series resistor to the negative side of the LED current sense resistor. 20 HSP High-Side LED Current Sense Positive Connect through a series resistor to the positive side of the LED current sense resistor. DAP (21) DAP Thermal pad on bottom of IC Connect to GND and place 6 - 9 vias to bottom layer ground pour. AN-1969 LM3424 Boost Evaluation Board Connect a resistor/ thermistor divider from VS to sense the temperature as explained in the Thermal Foldback / Analog Dimming section of the datasheet. Connect to a resistor divider from VO to program output overvoltage lockout (OVLO). Turn-off threshold is 1.24V and hysteresis for turn-on is provided by 20 A current source. Connect to gate of dimming MosFET. Connect to DAP to provide proper system GND Connect to gate of main switching MosFET. Bypass with a 2.2 F-3.3 F, ceramic capacitor to GND. Connect to the drain of the main N-channel MosFET switch for RDS-ON sensing or to a sense resistor installed in the source of the same device. Connect a resistor to GND to set slope of additional ramp. SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Bill of Materials www.ti.com 6 Bill of Materials Qty Part ID Part Value Manufacturer Part Number 3 C1, C5, C23 0.1 F X7R 10% 100V TDK C2012X7R2A104K 4 C2, C3, C16, C18 6.8 F X7R 10% 50V TDK C5750X7R1H685K 4 C4, C6, C17, C19 10 F X7R 10% 50V TDK C5750X7R1H106K 2 C7, C22 0.47 F X7R 10% 16V MURATA GRM21BR71C474KA01L 0 C8 DNP 1 C9 2.2 F X7R 10% 16V MURATA GRM21BR71C225KA12L 1 C10 1 F X7R 10% 16V MURATA GRM21BR71C105KA01L 1 C11 47 pF COG/NPO 5% 50V AVX 08055A470JAT2A 1 C12 0.22 F X7R 10% 16V MURATA GRM219R71C224KA01D 2 C13, C14 100 pF COG/NPO 5% 50V MURATA GRM2165C1H101JA01D 1 C15 1 F X7R 10% 16V MURATA GRM21BR71C105MA01L 1 D1 Schottky 100V 12A VISHAY 12CWQ10FNPBF 4 J1, J2, J4, J5 Banana Jack KEYSTONE 575-8 1 J3 1x2 Header Male SAMTEC TSW-102-07-T-S 1 J6 BNC connector AMPHENOL 112536 1 J7 2x7 Header Male Shrouded RA SAMTEC TSSH-107-01-SDRA 1 L1 33 H 20% 6.3A COILCRAFT MSS1278-333MLB 2 Q1, Q2 NMOS 100V 32A FAIRCHILD FDD3682 1 Q3 NMOS 60V 260mA ON-SEMI 2N7002ET1G 2 R1, R11 12.4 k 1% VISHAY CRCW080512K4FKEA 0 R2 DNP 2 R3, R20 10 1% VISHAY CRCW080510R0FKEA 1 R4 17.4 k 1% VISHAY CRCW080517K4FKEA 1 R5 1.43 k 1% VISHAY CRCW08051K43FKEA 1 R6 0.04 1% 1W VISHAY WSL2512R0400FEA 2 R7, R8 1.0 k 1% VISHAY CRCW08051K00FKEA 1 R9 0.1 1% 1W VISHAY WSL2512R1000FEA 1 R10 20.0 k 1% VISHAY CRCW080520K0FKEA 4 R12, R13, R14, R15 10.0 k 1% VISHAY CRCW080510K0FKEA 1 R17 499 k 1% VISHAY CRCW0805499KFKEA 3 R19, R21, R22 49.9 k 1% VISHAY CRCW080549K9FKEA 1 R25 150 1% VISHAY CRCW0805150RFKEA 8 TP1, TP3, TP4, TP5, TP6, TP8, TP9, TP10 Turret Keystone 1502-2 1 U1 Boost controller NSC LM3424MH SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 5 PCB Layout 7 www.ti.com PCB Layout Figure 2. Top Layer Figure 3. Bottom Layer 6 AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Design Procedure www.ti.com 8 Design Procedure 8.1 Specifications N=6 VLED = 3.5V rLED = 325 m VIN = 24V VIN-MIN = 10V VIN-MAX = 70V fSW = 500 kHz VSNS = 100 mV ILED = 1A iL-PP = 700 mA iLED-PP = 12 mA vIN-PP = 100 mV ILIM = 6A VTURN-ON = 10V VHYS = 3V VTURN-OFF = 40V VHYSO = 10V TBK = 70C TEND= 120C tTSU = 30 ms 8.2 Operating Point Solve for VO and rD: VO = N x VLED = 9 x 3.5V = 31.5V (1) rD = N x rLED = 9 x 325 m: = 2.925: (2) Solve for D, D', DMAX, and DMIN: VO - VIN D= VO 31.5V - 24V = 0.238 31.5V = (3) D' = 1 - D = 1 - 0.238 = 0.762 VO - VIN-MAX DMIN = VO = 31.5V - 26V = 0.175 31.5V (5) = 31.5V - 10V = 0.683 31.5V (6) VO - VIN-MIN DMAX = 8.3 VO (4) Switching Frequency Solve for RT: R10 = 1 + 1.95e-8 x fSW 1.40e -10 x fSW = 1 + 1.95e-8 x 360 kHz = 19.99 k: 1.40e-10 x 360 kHz SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback (7) AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 7 Design Procedure www.ti.com The closest standard resistor is 14.3 k therefore fSW is: fSW = 1 1.40e-10 x R10 - 1.95e-8 fSW = 1 = 360 kHz 1.40e-10 x 20.0 k: - 1.95e-8 (8) The chosen component from step 2 is: R10 = 20 k: 8.4 (9) Average LED Current Solve for RSNS: R9 = VSNS ILED = 100 mV = 0.1: 1A (10) Assume RCSH = 12.4 k and solve for RHSP: R8 = ILED x R1 x R9 1.24V = 1A x 1.24 k: x 0.1: = 1.0 k: 1.24V (11) The closest standard resistor for RSNS is actually 0.1 and for RHSP is actually 1 k therefore ILED is: ILED = 1.24V x R8 1.24V x 1.0 k: = = 1.0A 0.1: x 1.24 k: R9 x R1 (12) The chosen components from step 3 are: R9 = 0.1: R1 = 12.4 k: R8 = R7 = 1 k: 8.5 (13) Thermal Foldback Using a standard 100k NTC thermistor (connected to pins 4 and ll), find the resistances corresponding to TBK and TEND (RNTC-BK = 243 k and RNTC-END = 71.5 k) from the manufacturer's datasheet. Assuming RREF1 = RREF2 = 49.9 k, then RBIAS = RNTC-BK= 243 k. Solve for RGAIN: R GAIN = * R NTC - END RREF1 RREF1 + R REF2 - R NTC - END + RBIAS x 2.45V (c) ICSH 1 * 71.5 k: x 2.45V (c) 2 71.5 k: + 243 k: R GAIN = = 6.68 k: 100 PA (14) The chosen components from step 4 are: R GAIN = 6.81 k : R BIAS = 243 k : R REF1 = R REF2 = 49.9 k : 8.6 (15) Inductor Ripple Current Solve for L1: L1 = VIN x D 'iL-PP x fSW = 24V x 0.238 = 31.7 PH 500 mA x 360 kHz (16) The closest standard inductor is 33 H therefore iL-PP is: 8 AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Design Procedure www.ti.com 'iL-PP = VIN x D L1 x fSW = 24V x 0.238 = 481 mA 33 PH x 360 kHz (17) Determine minimum allowable RMS current rating: D' x 1+ 1A x 0.762 'IL-PP x D' * 2 1 x 12 ILED 1+ 2 1 481 mA x 0.762 * x = 1.32A 1A 12 * IL-RMS = ILED * IL-RMS = (18) The chosen component from step 5 is: L1 = 33 PH 8.7 (19) Output Capacitance Solve for CO: CO = ILED x D rD x 'iLED-PP x fSW CO = 1A x 0.238 = 38 PF 2.925: x 6 mA x 360 kHz (20) The closest capacitance totals 40 F therefore iLED-PP is: 'iLED-PP = 'iLED-PP = ILED x D rD x CO x fSW 1A x 0.238 = 5.7 mA 2.925: x 40 PF x 360 kHz (21) Determine minimum allowable RMS current rating: ICO-RMS = ILED x DMAX 1 - DMAX = 1A x 0.683 = 1.47A 1 - 0.683 (22) The chosen components from step 6 are: C4 = C6 = C17 = C19 = 10 PF 8.8 (23) Peak Current Limit Solve for RLIM: R6 = 245 mV 245 mV = = 0.041: ILIM 6A (24) The closest standard resistor is 0.04 therefore ILIM is: ILIM = 245 mV 245 mV = = 6.13A R6 0.04: (25) The chosen component from step 7 is: R6 = 0.04: 8.9 (26) Slope Compensation Solve for RSLP: SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 9 Design Procedure www.ti.com R SLP = 1.5 e13 x L1 VO x R T x RSNS R SLP = 1. 5 e13 x 33 PH = 16.5 k: 21V x 14.3 k: x 0.1: (27) The chosen component from step 8 is: R SLP = 16.5 k: (28) 8.10 Loop Compensation P1 is approximated: ZP1 = 2 rD x CO = 2 rad = 17 k sec 2.925: x 40 PF (29) Z1 is approximated: rD x D'2 ZZ1 = L1 = 2.925: x 0.7622 rad = 52 k sec 33 PH (30) TU0 is approximated: D' x 310V 0.762 x 310V = = 5900 ILED x R6 1A x 0.04: TU0 = (31) To ensure stability, calculate P2: min(ZP1, ZZ1) ZP2 = 5 x TU0 rad 17k sec rad = = = 0.58 sec 5 x 5900 5 x 5900 ZP1 (32) Solve for CCMP: C10 = 1 ZP2 x 5e6: = 1 = 0.35 PF rad 0.58 sec x 5e6: (33) To attenuate switching noise, calculate P3: ZP3 = (maxZP1, ZZ1) x 10 = ZZ1 x 10 rad rad ZP3 = 52k sec x 10 = 520k sec (34) Assume RFS = 10 and solve for CFS: C12 = 1 = 10: x ZP3 1 10: x 520k rad sec = 0.19 PF (35) The chosen components from step 9 are: C10 = 1 PF R20 = 10: C12 = 0.22 PF (36) 8.11 Input Capacitance Solve for the minimum CIN: CIN = 'iL-PP 8 x 'vIN-PP x fSW = 481 mA = 3.4 PF 8 x 50 mV x 360 kHz (37) To minimize power supply interaction a 200% larger capacitance of approximately 20 F is used, therefore the actual vIN-PP is much lower. Since high voltage ceramic capacitor selection is limited, four 4.7 F X7R capacitors are chosen. 10 AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Design Procedure www.ti.com Determine minimum allowable RMS current rating: IIN-RMS = 'iL-PP = 12 481 mA = 139 mA 12 (38) The chosen components from step 10 are: C2 = C3 = C16 = C18 = 6.8 PF (39) 8.12 NFET Determine minimum Q1 voltage rating and current rating: VT-MAX = VO = 31.5V IT-MAX = (40) 0.683 x 1A = 2.2A 1 - 0.683 (41) A 100V NFET is chosen with a current rating of 32A due to the low RDS-ON = 50 m. Determine IT-RMS and PT: IT-RMS = ILED D' x D= 1A x 0.762 0.238 = 640 mA (42) 2 2 PT = IT-RMS x RDSON = 640 mA x 50 m: = 20 mW (43) The chosen component from step 11 is: Q1 o 32A, 100V, DPAK (44) 8.13 Diode Determine minimum D1 voltage rating and current rating: VRD-MAX = VO = 31.5V (45) ID - MAX = ILED = 1A (46) A 100V diode is chosen with a current rating of 12A and VD = 600 mV. Determine PD: PD = ID x VFD = 1A x 600 mV = 600 mW (47) The chosen component from step 12 is: D1 o 12A, 100V, DPAK (48) 8.14 Input UVLO Solve for RUV2: R4 = R5 x (VHYS - 20 PA x R13) R4 = 20 PA x (R5 + R13) 1.43 k: x (3V - 20 PA x 10 k:) = 17.5 k: 20 PA x (1.43 k: + 10 k:) (49) The closest standard resistor is 150 k therefore VHYS is: VHYS = VHYS = 20 PA x R4 x (R5 + R13) + 20 PA x R13 R5 20 PA x 17.4 k: x (1.43 k: + 10 k:) 1.43 k: + 20 PA x 10 k: = 2.98V (50) Solve for RUV1: SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 11 Design Procedure R5 = www.ti.com 1.24V x R13 1.24V x 10 k: = 1.42 k: = 10V - 1.24V VTURN-ON - 1.24V (51) The closest standard resistor is 21 k making VTURN-ON: VTURN-ON = 1.24V x (R5 + R13) R5 VTURN-ON = 1.24V x (1.43 k: + 10 k:) = 9.91V 1.43 k: (52) The chosen components from step 13 are: R5 = 1.43 k: R13 = 10 k: R4 = 17.4 k: (53) 8.15 Output OVLO Solve for ROV2: R17 = VHYSO 20 PA = 10V = 500 k: 20 PA (54) The closest standard resistor is 499 k therefore VHYSO is: VHYSO = R17 x 20 PA = 499 k: x 20 PA = 9.98V (55) Solve for ROV1: R11 = 1.24V x 499 k: 1.24V x R17 = = 12.5 k: 50V - 620 mV VTURN-OFF - 1.24V (56) The closest standard resistor is 15.8 k making VTURN-OFF: VTURN-OFF = VTURN-OFF = 1.24V x (R11 + R17) R11 1.24V x (12.4 k: + 499 k:) = 51.1V 12.4 k: (57) The chosen components from step 14 are: R11 = 12.4 k: R17 = 499 k: (58) 8.16 Soft-Start Solve for tSU: t SU = 168: x CBYP + 36 k: x CCMP + VO x CO ILED t SU = 168: x 2.2 PF + 36 k: x 0. 33 PF + 21V x 40 PF 1A t SU = 13.1 ms (59) If tSU is less than tTSU, solve for tSU-SS-BASE: t SU - SS - BASE = 168: x CBYP + 28 k: x CCMP + VO x CO ILED t SU SS BASE = 168: x 2.2 PF + 28 k: x 0. 33 PF + t SU SS BASE = 10.5 ms 21V x 40 PF 1A (60) Solve for CSS: 12 AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated Design Procedure www.ti.com CSS = (t TSU - t SU - SS - BASE) (30 ms - 10.5 ms) 20 k : = 20 k : = 975 nF (61) The chosen component from step 15 is: CSS = 1 PF (62) SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback AN-1969 LM3424 Boost Evaluation Board Copyright (c) 2009-2013, Texas Instruments Incorporated 13 Typical Waveforms 9 www.ti.com Typical Waveforms TA = +25C, VIN = 24V and VO = 32V. 40 0.0 20 ILED 0.0 -1.0 10 5 0 0 10 ILED (A) 0.5 VDIM (V) VSW (V) 60 ILED (A) 1.0 1.0 ILED VSW VDIM 2 Ps/DIV Figure 4. Standard Operation TP1 Switch Node Voltage (VSW) LED Current (ILED) 4 ms/DIV Figure 5. 200Hz 50% PWM Dimming TP5 Dim Voltage (VDIM) LED Current (ILED) Alternate Designs Alternate designs with the LM3429 evaluation board are possible with very few changes to the existing hardware. The evaluation board FETs and diodes are already rated higher than necessary for design flexibility. The input UVLO, output OVP, input and output capacitance can remain the same for the designs shown below. These alternate designs can be evaluated by changing only R9, R10, and L1. Table 2 gives the main specifications for four different designs and the corresponding values for R9, R10, and L1. PWM dimming can be evaluated with any of these designs. Table 2. Alternate Design Specifications 14 Specification / Component Design 1 Design 2 Design 3 Design 4 VIN 10V 15V 20V 25V VO 14V 21V 28V 35V fSW 600kHz 700kHz 500kHz 700kHz ILED 2A 500mA 2.5A 1.25A R9 0.05 0.2 0.04 0.08 R10 12.1 k 10.2 k 14.3 k 10.2 k L1 22H 68H 15H 33H AN-1969 LM3424 Boost Evaluation Board SNVA398A - August 2009 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2009-2013, Texas Instruments Incorporated IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. Buyers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. 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