CAT4201TD-GT3 - ON SEMICONDUCTOR

May, 2011 − Rev. 8

1Publication Order Number:

CAT4201/D

CAT4201

350 mA High Efficiency

Step Down LED Driver

Description

The CAT4201 is a high efficiency step−down converter optimized to

drive high current LEDs. A patented switching control algorithm

allows highly efficient and accurate LED current regulation. A single

RSET resistor sets the full scale LED string current up to 350 mA from

supplies as high as 36 V.

The switching architecture of the CAT4201 results in extremely low

internal power dissipation allowing the device to be housed in a tiny

package without the need for dedicated heat sinking. The device is

compatible with switching frequencies of up to 1 MHz, making it ideal for

applications requiring small footprint and low value external inductors.

Analog dimming and LED shutdown control is provided via a single

input pin, CTRL. Additional features include overload current protection

and thermal shutdown. The device is available in 8−lead SOIC package

and the low profile 5−lead thin SOT23 package ideal for space

constrained applications.

Features

•LED Drive Current up to 350 mA

•Compatible with 12 V and 24 V Standard Systems

•Handles Transients up to 40 V

•Single Pin Control and Dimming Function

•Power Efficiency up to 94%

•Drives LED Strings of up to 32 V

•Open and Short LED Protection

•Parallel Configuration for Higher Output Current

•TSOT−23 5−lead and SOIC 8−lead Packages

•These Devices are Pb−Free, Halogen Free/BFR Free and are RoHS

Compliant

Applications

•12 V and 24 V Lighting Systems

•Automotive and Aircraft Lighting

•General Lighting, High Brightness 350 mA LEDs

Figure 1. Typical Application Circuit

CTRL SW

GND

CAT4201

VBAT

4.7 mF

10 mF

R1 L

9 V

RSET

22 mH

300 mA

See Table 4 on page 6 for external component selection.

10 kW

D: ON Semiconductor MBR0540

L: Sumida CDRH6D26−220

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TSOT−23

TD SUFFIX

CASE 419AE

PIN CONNECTIONS AND

MARKING DIAGRAMS (Top Views)

TFYM

Device Package Shipping

ORDERING INFORMATION

CAT4201TD−GT3 TSOT−23

(Pb−Free)

3,000/

Tape & Reel

TF = Specific Device Code

Y = Production Year (Last Digit)

M = Production Month: (1−9, O, N, D)

VBAT

CTRL

GND

RSET

* Plated Finish: NiPdAu

SOIC−8**

V SUFFIX

CASE 751BD

CAT4201V−GT3** SOIC−8

(Pb−Free)

3,000/

Tape & Reel

** For availability, contact factory

TSOT−23

SOIC−8

PGND

CTRL

GND

RSET

PGND

VBAT

4201A = Specific Device Code

A = Assembly Location

Y = Production Year (Last Digit)

M = Production Month: (1−9, O, N, D)

XXX = Last Three Digits of Assembly Lot Number

G= Pb−Free Package

4201A

AYMXXX

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Table 1. ABSOLUTE MAXIMUM RATINGS

Parameters Ratings Units

VBAT, SW, CTRL −0.3 to +40 V

RSET −0.3 to +5 V

Switch SW peak current 1 A

Storage Temperature Range −65 to +160 _C

Junction Temperature Range −40 to +150 _C

Lead Temperature 300 _C

Stresses exceeding Maximum Ratings may damage the device. Maximum Ratings are stress ratings only. Functional operation above the

Recommended Operating Conditions is not implied. Extended exposure to stresses above the Recommended Operating Conditions may affect

device reliability.

Table 2. RECOMMENDED OPERATING CONDITIONS

Parameters Ratings Units

VBAT voltage (Notes 1, 2) 6.5 to 36 (Note 1) V

SW voltage 0 to 36 V

Ambient Temperature Range −40 to +125 _C

LED Current 50 to 350 mA

Switching Frequency 50 to 1000 kHz

1. The VBAT pin voltage should be at least 3 V greater than the total sum of the LED forward voltages in order to operate at nominal LED current.

2. During power−up, the slew rate of the input supply should be greater than 1 ms for every 5 V increase of VBAT.

Table 3. ELECTRICAL CHARACTERISTICS

(VIN = 13 V, ambient temperature of 25°C (over recommended operating conditions unless otherwise specified))

Symbol Parameter Conditions Min Typ Max Units

IQOperating Supply Current on VBAT pin 0.4 1 mA

ISD Idle Mode Supply Current on VBAT pin CTRL = GND 90 mA

VFB RSET Pin Voltage 2 LEDs with ILED = 300 mA 1.15 1.2 1.25 V

ILED Programmed LED Current R1 = 33 kW

R1 = 10 kW

R1 = 8.25 kW

270

100

300

350

330

VCTRL−FULL CTRL Voltage for 100% Brightness 2.6 3.1 V

VCTRL−EN CTRL Voltage to Enable LEDs LED enable voltage threshold 0.9 1.2 V

VCTRL−SD CTRL Voltage to Shutdown LEDs LED disable voltage threshold 0.4 0.9 V

ICTRL CTRL pin input bias VCTRL = 3 V

VCTRL = 12 V

200

80 mA

RSW Switch “On” Resistance ISW = 300 mA 0.9 1.5 W

TSD Thermal Shutdown 150 °C

THYST Thermal Hysteresis 20 °C

hEfficiency Typical Application Circuit 86 %

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TYPICAL OPERATION CHARACTERISTICS

(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C 2 = 10 mF, TAMB = 25°C unless otherwise specified)

Figure 2. Input Operating Supply Current Figure 3. Idle Mode Supply Current

(CTRL = 0 V)

INPUT VOLTAGE (V) INPUT VOLTAGE (V)

222018161412108

0.2

0.4

0.6

0.8

1.0

24201612840

100

150

200

Figure 4. CTRL Input Bias Current Figure 5. RSET Voltage vs. Temperature

CTRL VOLTAGE (V) TEMPERATURE (°C)

121086420

100

150

200

250

12080400−40

1.10

1.15

1.20

1.25

1.30

Figure 6. RSET Voltage vs. CTRL Voltage Figure 7. LED Current vs. RSET

CTRL VOLTAGE (V) RSET (kW)

43210

0.2

0.4

0.6

0.8

1.0

1.2

1.4

3530252015105

100

200

300

400

QUIESCENT CURRENT (mA)

IDLE CURRENT (mA)

CTRL BIAS CURRENT (mA)

RSET VOLTAGE (V)

LED CURRENT (mA)

VIN = 13 V

+25°C

−40°C

+85°C

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TYPICAL OPERATION CHARACTERISTICS

(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C 2 = 10 mF, TAMB = 25°C unless otherwise specified)

Figure 8. Switching Frequency vs. Input

Voltage (1 LED)

Figure 9. Switching Frequency vs. Input

Voltage (2 LEDs)

INPUT VOLTAGE (V) INPUT VOLTAGE (V)

28242016128

100

200

300

400

500

28242016128

100

200

300

400

500

600

700

Figure 10. Switching Frequency vs.

Temperature

Figure 11. Switch ON Resistance vs. Input

Voltage

TEMPERATURE (°C) INPUT VOLTAGE (V)

12080400−40

100

200

300

400

500

242018161412108

0.4

0.8

1.2

1.6

2.0

Figure 12. Efficiency vs. Input Voltage (1 LED) Figure 13. Efficiency vs. Input Voltage

(2 LEDs)

INPUT VOLTAGE (V) INPUT VOLTAGE (V)

222018161412108

100

222018161412108

100

SWITCHING FREQUENCY (kHz)

SW RESISTANCE (W)

EFFICIENCY (%)

150 mA

300 mA 300 mA

150 mA

VIN = 13 V

150 mA

300 mA

24 24

150 mA

300 mA

150 mA

300 mA

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TYPICAL OPERATION CHARACTERISTICS

(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C 2 = 10 mF, TAMB = 25°C unless otherwise specified)

Figure 14. Efficiency vs. LED Current Figure 15. LED Current Regulation vs.

Temperature

LED CURRENT (mA) TEMPERATURE (°C)

350300250200150100

100

12080400−40

−10

−8

−4

−2

Figure 16. LED Current vs. Input Voltage

(1 LED)

Figure 17. LED Current vs. Input Voltage

(2 LEDs)

INPUT VOLTAGE (V) INPUT VOLTAGE (V)

24 28201612840

100

150

200

250

300

350

24 28201612840

100

150

200

250

300

350

Figure 18. Switching Waveforms Figure 19. CTRL Power−up

2 ms/div 40 ms/div

EFFICIENCY (%)

LED CURRENT VARIATION (%)

LED CURRENT (mA)

5V/div

Inductor

Current

200mA/

div

CTRL

5V/div

LED

Current

200mA/

div

1 LED

2 LEDs

−6

VIN = 13 V

VF = 3.3 V

VF = 3.1 V

300 mA

150 mA

VF = 3.3 V

VF = 3.1 V

300 mA

150 mA

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TYPICAL OPERATION CHARACTERISTICS

(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C 2 = 10 mF, TAMB = 25°C unless otherwise specified)

Figure 20. RSET Transient Response Figure 21. Line Transient Response

(10 V to 13 V)

External Component Selection

Table 4 provides the recommended external components L and C2 that offer the best performance relative to the LED current

accuracy, LED ripple current, switching frequency and component size.

Table 4. EXTERNAL COMPONENT SELECTION

1 LED 2 LEDs

LED Current (mA) L Inductor (mH) C2 Capacitor (mF) L Inductor (mH) C2 Capacitor (mF)

≥150 22 4.7 22 4.7

< 150 33 4.7 47 2.2

47 10

NOTE: Larger C2 capacitor values allow to reduce further the LED ripple current if needed.

Table 5. INDUCTOR SELECTION DEPENDING ON VBAT SUPPLY VOLTAGE

VBAT Supply Voltage (V) Minimum Inductor L (mH)

< 26 22

≥ 26 33

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Table 6. PIN DESCRIPTION

Pin Name Function

1 CTRL Analog dimming control and shutdown pin.

2 GND Ground reference.

3 RSET RSET pin. A resistor connected between the pin and ground sets the average LED current.

4 SW Interface to the inductor.

5 VBAT Supply voltage for the device.

Pin Function

VBAT is the supply input to the device. Typical current

conduction into this pin is less than 1 mA and voltage

transients of up to 40 V can be applied. To ensure accurate

LED current regulation, the VBAT voltage should be 3 V

higher than the total forward voltage of the LED string. A

bypass capacitor of 4.7 mF or larger is recommended

between VBAT and GND.

CTRL is the analog dimming and control input. An internal

pull−down current of 20 mA allows the LEDs to shutdown

if CTRL is left floating. Voltages of up to 40 V can be safely

handled by the CTRL input pin.

When the CTRL voltage is less than 0.9 V (typ), the LEDs

will shutdown to zero current. When the CTRL voltage is

greater than about 2.6 V, full scale brightness is applied to the

LED output. At voltages of less than around 2.6 V, the LED

current is progressively dimmed until shutdown.

For lamp replacement applications, or applications where

operation in dropout mode is expected, it is recommended

that the CTRL pin voltage be derived from the LED cathode

terminal.

GND is the ground reference pin. This pin should be

connected directly to the ground plane on the PCB.

SW pin is the drain terminal of the internal low resistance

high−voltage power MOSFET. The inductor and the

Schottky diode anode should be connected to the SW pin.

Voltages of up to 40 V can be safely handled on the SW pin.

Traces going to the SW pin should be as short as possible

with minimum loop area. The device can handle safely

“open−LED” or “shorted−LED” fault conditions.

RSET pin is regulated at 1.2 V. A resistor connected

between the RSET pin and ground sets the LED full−scale

brightness current. The external resistance value and the

CTRL pin voltage determine the LED current during analog

dimming. The RSET pin must not be left floating. The

highest recommended resistor value between RSET and

ground is 90 kW.

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Simplified Block Diagram

Figure 22. CAT4201 Simplified Block Diagram

1.2 V

Reference +

–

ON−Time Control

OFF−Time Control

1.2 V 1 W

7 V

30 kW

20 mA

GND

RSET

CTRL

VBAT

12 V/24 V

PWM

Controller

Basic Operation

The CAT4201 is a high efficiency step−down regulator

designed to drive series connected high−power LEDs. LED

strings with total forward voltages of up to 32 V can be

driven with bias currents of up to 350 mA.

During the first switching phase, an integrated high

voltage power MOSFET allows the inductor current to

charge linearly until the peak maximum level is reached, at

which point the MOSFET is switched off and the second

phase commences, allowing the inductor current to then

flow through the Schottky diode circuit and discharge

linearly back to zero current.

The switching architecture ensures the device will always

operate at the cross−over point between Continuous

Conduction Mode (CCM) and Discontinuous Conduction

Mode (DCM). This operating mode results in an average

LED current which is equal to half of the peak switching

current.

LED Pin Current

The LED current is set by the external RSET resistor

connected to the regulated output of the RSET pin. An

overall current gain ratio of approximately 2.5 A/mA exists

between the average LED current and the RSET current,

hence the following equation can be used to calculate the

LED current.

LED Current (A) ^2.5

VRSET (V)

RSET (kW)

Table 7 lists the various LED currents and the associated

RSET resistors.

Table 7. RSET RESISTOR SELECTION

LED Current (A) RSET (kW)

0.10 33

0.15 21

0.20 15

0.25 12

0.30 10

0.35 8.25

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APPLICATION INFORMATION

Input Voltage Range

The minimum supply voltage required to maintain

adequate regulation is set by the cathode terminal voltage of

the LED string (i.e., the VBAT voltage minus the LED string

voltage). When the LED cathode terminal falls below 3 V,

a loss of regulation occurs.

For applications which may occasionally need to

experience supply “dropout” conditions, it is recommended

that the CTRL input be used to sense the LED cathode

voltage. The CTRL pin can either be tied directly to the

cathode terminal (for Lamp Replacement) or connected via

a pass−transistor for PWM lighting applications.

Figure 23 shows the regulation performance obtained in

dropout, when the CTRL pin is configured to sense the LED

cathode voltage.

100

200

300

400

0123456

CTRL VOLTAGE [V]

LED CURRENT [mA]

150 mA

300 mA

Figure 23. “Dropout” Configured LED Current

(as shown in Typical Application on page 1)

Inductor Selection

A 22 mH minimum inductor value is required to provide

suitable switching frequency across a wide range of input

supply values. For LED current of 150 mA or less, a 33 mH

or 47 mH inductor is more suitable. Inductor values below

22 mH should not be used.

An inductor with at least 700 mA current rating must be

used. Minor improvements in efficiency can be achieved by

selecting inductors with lower series resistance.

Table 8. SUMIDA INDUCTORS

Part Number L (mH) I Rated (A) LED Current (A)

CDRH6D26−220 22 1.0 0.35

CDRH6D28−330 33 0.92 0.35

CDRH6D28−470 47 0.8 0.35

CDRH6D28−560 56 0.73 0.35

Capacitor Selection

A 10 mF ceramic capacitor C2 across the LED(s) keeps the

LED ripple current within ±15% of nominal for most

applications. If needed, a larger capacitor can be used to

further reduce the LED current ripple. Any resistance in

series with the LED (0.5 W or more) contributes to reduce

the ripple current. The capacitor voltage rating should be

equivalent to the maximum expected supply voltage so as to

allow for “Open−LED” fault conditions. The capacitor

value is independent of the switching frequency or the

overall efficiency.

A 4.7 mF ceramic input capacitor C1 is recommended to

minimize the input current ripple generated on the supply.

Using a larger capacitor value further reduces the ripple

noise appearing on the supply rail.

If a constant capacitance is needed across temperature and

voltage, X5R or X7R dielectric capacitors are recommended.

Schottky Diode

The peak repetitive current rating of the Schottky diode

must be greater than the peak current flowing through the

inductor. Also the continuous current rating of the Schottky

must be greater than the average LED current. The voltage

rating of the diode should be greater than the peak supply

voltage transient preventing any breakdown or leakage.

ON Semiconductor Schottky diode MBR0540 (40 V,

500 mA rated) is recommended. Schottky diodes rated at

400 mA (or higher) continuous current are fine for most

applications.

NOTE: Schottky diodes with extremely low forward voltages

(VF) are not recommended, as they may cause an

increase in the LED current.

Dimming Methods

Two methods for PWM dimming control on the LEDs are

described below. The first method is to PWM on the control

pin, the other method is to turn on and off a second resistor

connected to the RSET pin and connected in parallel with R1.

PWM on CTRL Pin

A PWM signal from a microprocessor can be used for

dimming the LEDs when tied to the CTRL pin. The duty

cycle which is the ratio between the On time and the total

cycle time sets the dimming factor. The recommended PWM

frequency on the CTRL pin is between 100 Hz and 2 kHz.

Figure 24. PWM at 1 kHz on CTRL Pin

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Figure 25. LED Current vs. Duty Cycle

100

150

200

250

300

020406080100

DUTY CYCLE [%]

LED CURRENT [mA]

Figure 26. Circuit for PWM on CTRL

RSET

GND

CAT4201

VBAT

PWM

control

4.7 mF

10 mF

NPN

12 V

0 V

5 V

CTRL

22 mH

1 kW

47 kW

10 kW

1 kW

PWM on RSET Pin

Another dimming method is to place in parallel to R1

another resistor with a FET in series, as shown on Figure 27.

R1 sets the minimum LED current corresponding to 0% duty

cycle. The combined resistor of R1 and Rmax sets the

maximum LED current corresponding to 100% duty cycle.

Figure 27. Circuit for PWM on RSET

RSET

GND

CAT4201

VBAT

PWM

control

Rmax

4.7 mF

10 mF

NPN

R1 L

13 V

CTRL 22 mH

1 kW

OFF ON

A resistor value for R1 of less than 90 kW is recommended

to provide better accuracy.

Operation from High Supply Voltage Above 14 V

For operation from a supply voltage above 14 V, it is

recommended to have a slew rate of 1 ms or more for every

5 V increase in VBAT supply. When using a high supply

voltage of 24 V, a 1 W or 2 W resistor in series with the supply,

as shown on Figure 28, is recommended to limit the slew rate

of the supply voltage. A 4.7 mF minimum ceramic capacitor

is placed between the VBAT pin and ground. The

combination of the series resistor R3 and input capacitor C1

acts as a low pass filter limiting the excessive in−rush

currents and overvoltage transients which would otherwise

occur during “hot−plug” conditions, thereby protecting the

CAT4201 driver.

CTRL SW

GND

CAT4201

VBAT

4.7 mF

10 kW

1 kW

1 W

24 V

RSET

33 mH300 mA

Figure 28. 24 V Application with 5 LEDs

Operation from High Supply Voltage of 36 V

When powering from a high supply voltage of 36 V, a 2 W

resistor in series with the supply is recommended, as shown

on Figure 29, to limit the slew rate of the supply voltage.

Inductor value should be 33 mH or higher.

CTRL SW

GND

CAT4201

VBAT

4.7 mF

2.2 mF

10 kW

1 kW

2 W

36 V

RSET

47 mH300 mA

Figure 29. 36 V Application with 6 LEDs

Parallel Configuration for Driving LEDs Beyond

350 mA

Several CAT4201 devices can be connected in parallel for

driving LEDs with current in excess of 350 mA. The

CAT4201 driver circuits are connected to the same LED

cathode. Figure 30 shows the application schematic for

driving 1 A into one LED with three CAT4201 connected in

parallel. Each CAT4201 is driving the LED with a current set

by its RSET resistor. The resulting LED current is equal to

the sum of each driver current.

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Figure 30. Three CAT4201 in Parallel for 1 A LED

CTRL SW

GND

CAT4201

VBAT

VIN

4.7 μF

10 μF

1 A

8.3 kΩ

1 kΩ

1 W

RSET

22 μH

CTRL SW

GND

CAT4201

VBAT

4.7 μF

R2 8.3 kΩL2

RSET

22 μH

CTRL SW

GND

CAT4201

VBAT

4.7 μF

8.3 kΩL3

RSET

22 μH

Open LED Behavior

If the LEDs are not connected, the CAT4201 stops

switching and draws very little current.

At power−up with no load connected, the capacitor C2 is

charged−up by the CAT4201. As soon as the bottom side of

the capacitor (C2−) reaches 0 volt, as shown on Figure 31,

the CAT4201 stops switching and remains in the idle mode

only drawing about 0.4 mA current from the supply.

Figure 31. Open LED Mode

Board Layout

In order to minimize EMI and switching noise, the

Schottky diode, the inductor and the output capacitor C2

should all be located close to the driver IC. The input

capacitor C1 should be located close to the VBAT pin and the

Schottky diode cathode. The CAT4201 ground pin should be

connected directly to the ground plane on the PCB. A

recommended PCB layout with component location is

shown on Figure 32. The LEDs are connected by two wires

tied to both sides of the output capacitor C2. The LEDs can

be located away from the driver if needed.

Figure 32. Recommended PCB Layout

In order to further reduce the ripple on the supply rail, an

optional Pi style filter (C−L−C) can be used. A 10 mH

inductor rated to the maximum supply current can be used.

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PACKAGE DIMENSIONS

TSOT−23, 5 LEAD

CASE 419AE−01

ISSUE O

E1 E

TOP VIEW

SIDE VIEW END VIEW

LL2

Notes:

(1) All dimensions are in millimeters. Angles in degrees.

(2) Complies with JEDEC MO-193.

SYMBOL

MIN NOM MAX

0º 8º

0.01

0.80

0.30

0.12

0.30

0.05

0.87

0.15

2.90 BSC

2.80 BSC

1.60 BSC

0.95 TYP

0.40

0.60 REF

0.25 BSC

1.00

0.10

0.90

0.45

0.20

0.50

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PACKAGE DIMENSIONS

SOIC 8, 150 mils

CASE 751BD−01

ISSUE O

E1 E

PIN # 1

IDENTIFICATION

TOP VIEW

SIDE VIEW END VIEW

Notes:

(1) All dimensions are in millimeters. Angles in degrees.

(2) Complies with JEDEC MS-012.

SYMBOL MIN NOM MAX

0º 8º

0.10

0.33

0.19

0.25

4.80

5.80

3.80

1.27 BSC

1.75

0.25

0.51

0.25

0.50

5.00

6.20

4.00

L0.40 1.27

1.35

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Example of Ordering Information (Note 5)

Prefix Device # Suffix

Company ID

CAT 4201

Product Number

4201

T: Tape & Reel

3: 3,000 / Reel

Tape & Reel (Note 7)

(Optional)

Package

− G

G: NiPdAu

Plated Finish

TD: TSOT

V: SOIC (Note 8)

3. All packages are RoHS−compliant (Lead−free, Halogen−free).

4. The standard plated finish is NiPdAu on all pins.

5. The device used in the above example is a CAT4201TD−GT3 (TSOT−23, NiPdAu, Tape & Reel, 3,000 / Reel).

6. For additional package and temperature options, please contact your nearest ON Semiconductor Sales office.

7. For information on tape and reel specifications, including part orientation and tape sizes, please refer to our Tape and Reel Packaging

Specifications Brochure, BRD8011/D.

8. For availability, contact factory.

ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice

to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does SCILLC assume any liability

arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages.

“Typical” parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All

operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. SCILLC does not convey any license under its patent rights

nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications

intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should

Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and its officers, employees, subsidiaries, affiliates,

and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death

associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part. SCILLC is an Equal

Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner.

CAT4201/D

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