User's Guide

SNVA397A August 2009 Revised May 2013

AN-1967 LM3424 Buck-Boost Evaluation Board

Introduction
This wide range evaluation board showcases the LM3424 NFET controller used with a buck-boost current regulator. It is designed to drive 4 to 10 LEDs at a maximum average LED current of 1A from a DC input voltage of 10 to 70V. 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 buck-boost circuit can be easily redesigned for different specifications by changing only a few components (see the Alternate Designs section). 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 datasheet as a reference for the LM3424 buck-boost evaluation board. Refer to the LM3424 Constant Current N-Channel Controller with Thermal Foldback for Driving LEDs (SNVS603) data sheet for a comprehensive explanation of the device, design procedures, and application information.

Key Features
Input: 10V to 70V Output: 4 to 10 LEDs at 1A Thermal Foldback / Analog Dimming PWM Dimming up to 10 kHz External Synchronization > 500 kHz Input Under-voltage and Output Over-voltage Protection

100 95 EFFICIENCY (%) 90 85 80 75 70

16

32 VIN (V)

48

64

80

Figure 1. Efficiency with 9 Series LEDS AT 1A

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External Connection Descriptions

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External Connection Descriptions

Table 1. Connectors and Test Points
Qty J1 J2 J3 J4 J5 J6 J7 TP1 TP3 TP4 TP5 TP6 TP8 TP9 TP10 Name VIN GND EN LED+ LEDBNC OUT SW SGND LED+ nDIM VIN SYNC NTC PGND Description Input Voltage Input Ground Enable On/Off LED Positive LED Negative Dimming Input Output with NTC Switch Node Voltage Signal Ground LED Positive Voltage Inverted Dim Signal Input Voltage Synchronization Input Temp Sense Input Power Ground Application Information Connect to positive terminal of supply voltage. Connect to negative terminal of supply voltage (GND). Jumper connected enables device. Connect to anode (top) of LED string. Connect to cathode (bottom) of LED string. Connect a 3V to 10V PWM input signal up to 10 kHz for PWM dimming the LED load. Alternative connector for LED+ and LED-. Pins 4 and 11 are used for connecting an external NTC thermistor. Refer to schematic for detailed connectivity. Test point for switch node (where Q1, D1, and L1 connect). Connection for GND when applying signals to TP5, TP8, and TP9. Test point for anode (top) of LED string. Test point for dimming input (inverted from input signal). Test point for input voltage. Connect a 3V to 6V PWM clock signal > 500 kHz (pulse width of 100ns) to synchronize the LM3424 switching frequency to the external clock. Connect a 0V to 1.24V DC voltage to analog dim the LED current. Test point for GND when monitoring TP1, TP4, or TP6.

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Schematic

Schematic
TP6 TP1 D1 TP4

VIN
J1

GND
J2

C2, C3, C16, C18, C23

L1 8

J7 7 6 5 4 3 2 1

LED+
J4

9 10 11 12

NTC

LEDJ5 R3 J3 1 C1 2 C8 R2 C10 R1 R10 C14 R25 C13 R4 5 RT/SYNC VCC 16 C9 3 COMP SLOPE 18 R14 EN HSN 19 R7 VIN

13 14

C4, C5, C6, C17, C19

LM3424

HSP

20

R8

DIM
C12

Q2

R9

VIN
R20 R26

R13 TP8

CSH

IS

17

R24

Q7

C20 R17

DIM
Q6 C21 6 nDIM GATE 15 TP3 TP10 7 SS GND 14 R6 R23 Q1 D2 Q4

VIN

Q5

R5

C7

R15

TGAIN

DDRV

13

TSENSE DAP

OVP

12

R19

C11 10 TREF VS 11 R21 R22

R11

C15 TP5 J6 Q3 R12

NTC PWM
C22

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LM3424 Pin Descriptions

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LM3424 Pin Descriptions

Pin 1 Name VIN Description Input Voltage Application Information Bypass with 100 nF capacitor to GND as close to the device as possible in the circuit board layout. 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. 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. 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 turnoff is provided by 20 A current source. Connect a capacitor to GND to extend start-up time. Connect a resistor to GND to set the foldback slope. Connect a resistor/ thermistor divider from VS to sense the temperature as explained in the Thermal Foldback / Analog Dimming section of the datasheet. Connect a resistor divider from VS to set the temperature foldback reference voltage. 2.45V reference for temperature foldback circuit and other external circuitry. Connect to a resistor divider from VO to program output over-voltage 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.

2 3

EN COMP

Enable Compensation

CSH

Current Sense High

RT

Resistor Timing

nDIM

Not DIM input

7 8

SS TGAIN

Soft-start Temperature Foldback Gain

TSENSE

Temperature Sense Input

10

TREF

Temperature Foldback Reference Voltage Reference

11

VS

12

OVP

Over-Voltage Protection

13 14 15

DDRV GND GATE

Dimming Gate Drive Output Ground Gate Drive Output

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www.ti.com Pin 16 Name VCC Description Internal Regulator Output

Bill of Materials
Application Information Bypass with a 2.2 F3.3 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. Connect through a series resistor to the negative side of the LED current sense resistor. Connect through a series resistor to the positive side of the LED current sense resistor. Connect to GND and place 6 9 vias to bottom layer ground pour.

17

IS

Main Switch Current Sense

18 19

SLOPE HSN

Slope Compensation High-Side LED Current Sense Negative High-Side LED Current Sense Positive Thermal pad on bottom of IC

20

HSP

DAP (21)

DAP

Bill of Materials
Qty 4 4 4 2 0 1 1 1 1 3 1 1 1 4 1 1 1 1 2 1 1 1 1 1 2 0 3 1 1 Part ID C1, C5, C20, C23 C2, C3, C16, C18 C4, C6, C17, C19 C7, C22 C8 C9 C10 C11 C12 C13, C14, C21 C15 D1 D2 J1, J2, J4, J5 J3 J6 J7 L1 Q1, Q2 Q3 Q4 Q5 Q6 Q7 R1, R11 R2 R3, R20, R26 R4 R5 Part Value 0.1 F X7R 10% 100V 4.7 F X7R 10% 100V 10 F X7R 10% 50V 0.47 F X7R 10% 16V DNP 2.2 F X7R 10% 16V 1 F X7R 10% 16V 47 pF COG/NPO 5% 50V 0.22 F X7R 10% 16V 100 pF COG/NPO 5% 50V 1 F X7R 10% 16V Schottky 100V 12A Zener 10V Banana Jack 1x2 Header Male BNC connector 2x7 Header Male Shrouded RA 33 H 20% 6.3A NMOS 100V 32A NMOS 60V 260mA PNP 40V 200mA PNP 150V 600 mA NPN 300V 600mA NPN 40V 200mA 12.4 k 1% DNP 10 1% 17.4 k 1% 1.43 k 1% VISHAY VISHAY VISHAY CRCW080510R0FKEA CRCW080517K4FKEA CRCW08051K43FKEA MURATA MURATA AVX MURATA MURATA MURATA VISHAY ON-SEMI KEYSTONE SAMTEC AMPHENOL SAMTEC COILCRAFT FAIRCHILD ON-SEMI FAIRCHILD FAIRCHILD FAIRCHILD FAIRCHILD VISHAY GRM21BR71C225KA12L GRM21BR71C105KA01L 08055A470JAT2A GRM219R71C224KA01D GRM2165C1H101JA01D GRM21BR71C105MA01L 12CWQ10FNPBF BZX84C10LT1G 575-8 TSW-102-07-T-S 112536 TSSH-107-01-SDRA MSS1278-333MLB FDD3682 2N7002ET1G MMBT5087 MMBT5401 MMBTA42 MMBT6428 CRCW080512K4FKEA Manufacturer TDK TDK TDK MURATA Part Number C2012X7R2A104K C5750X7R2A475K C5750X7R1H106K GRM21BR71C474KA01L

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Bill of Materials
1 2 1 1 4 1 3 1 1 1 8 R6 R7, R8 R9 R10 R17 R19, R21, R22 R23 R24 R25 TP1, TP3, TP4, TP5, TP6, TP8, TP9, TP10 U1 0.04 1% 1W 1.0 k 1% 0.1 1% 1W 14.3 k 1% 499 k 1% 49.9 k 1% 499 1% 4.99 k 1% 150 1% Turret VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY VISHAY Keystone WSL2512R0400FEA

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CRCW08051K00FKEA WSL2512R1000FEA CRCW080514K3FKEA CRCW080510K0FKEA CRCW0805499KFKEA CRCW080549K9FKEA CRCW0805499RFKEA CRCW08054K99FKEA CRCW0805150RFKEA 1502-2

R12, R13, R14, R15 10.0 k 1%

Buck-boost controller

TI

LM3424

AN-1967 LM3424 Buck-Boost Evaluation Board

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PCB Layout

PCB Layout

Figure 2. Top Layer

Figure 3. Bottom Layer

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Design Procedure

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8 8.1

Design Procedure 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 = 50V VHYSO = 10V TBK = 45C TEND= 125C tTSU = 40 ms

8.2

Operating Point
Solve for VO and rD:
VO = N x VLED = 6 x 3.5V = 21V
rD = N x rLED = 6 x 325 m: = 1. 95:

(1) (2)

Solve for D, D', DMAX, and DMIN:

D= VO 21V = = 0.467 VO + VIN 21V + 24V

(3) (4) (5) (6)

D' = 1 - D = 1 - 0. 467 = 0. 533

DMIN = 21V = = 0.231 VO + VIN-MAX 21V + 70V VO

VO 21V DMAX = = = 0.677 VO + VIN-MIN 21V + 10V

8.3

Switching Frequency
Solve for RT:
R10 = 1 + 1.95e-8 x fSW 1.40e
-10

x fSW

1 + 1.95e-8 x 500 kHz = 14.4 k: 1.40e-10 x 500 kHz

(7)
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Design Procedure

The closest standard resistor is 14.3 k therefore fSW is:

fSW = fSW = 1 1.40e-10 x R10 - 1.95e-8 1 = 504 kHz 1.40e-10 x 14.3 k: - 1.95e-8

(8)

The chosen component from step 2 is:

R10 = 14.3 k:

(9)

8.4

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:

(13)

8.5

Thermal Foldback
Using a standard 100k NTC thermistor (connected to pins 4 and 11 of J7), 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:
RNTC-END R19 x 2.45V R19 + R21 RNTC-END + R22 ICSH 6.34 k: 1 x 2.45V 2 6.34 k: + 49.9 k: 100 PA

RGAIN =

RGAIN =

= 9.49 k:

(14)

The chosen components from step 4 are:

R15 = 10 k: R19 = R21 = R22 = 49.9 k:

(15)

8.6

Inductor Ripple Current

Solve for L1:
L1 = VIN x D 24V x 0. 467 = = 32 PH 'iL- PP x fSW 700 mA x 504 kHz

(16)

The closest standard inductor is 33 H therefore iL-PP is:

'iL- PP = VIN x D 24V x 0. 467 = 674 mA = L1 x fSW 33 PH x 504 kHz

(17)
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Design Procedure

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Determine minimum allowable RMS current rating:

x Dc 'i I 1 x L - PP IL - RMS = LED x 1+ 12 Dc ILED
2

IL - RMS =

1 674 mA x 0.533 1.89A 1A x x 1+ = 12 1A 0. 533

(18)

The chosen component from step 5 is:

L1 = 33 PH

(19)

8.7

Output Capacitance
Solve for CO:
CO = ILED x D rD x 'iLED- PP x fSW 1A x 0. 467 = 39.6 PF 1.95: x 12 mA x 5 04 kHz

CO =

(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. 467 = 12 mA 1.95 : x 40 PF x 5 04 kHz

(21)

Determine minimum allowable RMS current rating:

ICO- RMS = ILED x DMAX 0.677 = 1.45A = 1A x 1- DMAX 1- 0.677

(22)

The chosen components from step 6 are:

C4 = C6 = C17 = C19 = 10 PF

(23)

8.8

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:

(26)

8.9

Slope Compensation
Solve for RSLP:
R15 = 1.5e13 x L1 VO x R10 x R9 1.5e13 x 33 PH 35V x 14.3 k: x 0.1: = 9.9 k:

R15 =

(27)

The chosen component from step 8 is:

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RSLP = 10 k:

Design Procedure (28)

8.10 Loop Compensation

P1 is approximated:
ZP1 = rad 1.467 1+ D = = 19 k sec rD x CO 1.95: x 40 PF

(29)

Z1 is approximated:
ZZ1 = rD x Dc2 1.95: x 0.5332 rad = = 36k D x L1 0.467 x 33 PH sec

(30)

TU0 is approximated:
TU0 = D' x 620V 0.533 x 620V = = 5630 (1 + D) x ILED x R6 1.467 x 1A x 0.04:

(31)

To ensure stability, calculate P2:

rad 19k min(ZP1, ZZ1) ZZ1 sec rad ZP2 = = = = 0. 675 5 x 5630 5 x 5630 5 x TU0 sec

(32)

Solve for CCMP:

C10 = 1

ZP2 x 5e6:

1 = 0.30 PF rad 0.675 sec x 5e6:

(33)

To attenuate switching noise, calculate P3:

ZP3 = (max ZP1, ZZ1) x 10 = ZP 1 x 10 ZP3 = 36 k rad rad x 10 = 360k sec sec

(34)

Assume RFS = 10 and solve for CFS:

C12 = 1 = 10: x ZP3 1 10: x 360k rad sec = 0.28 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 = ILED x D 1A x 0. 467 = = 9.27 PF 'vIN- PP x fSW 100 mV x 504 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. Determine minimum allowable RMS current rating:
IIN- RMS = ILED x DMAX 0.677 = 1.45A = 1A x 1- DMAX 1- 0.677

(38)

The chosen components from step 10 are:

C2 = C3 = C16 = C18 = 4.7 PF

(39)
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Design Procedure

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8.12 NFET
Determine minimum Q1 voltage rating and current rating:
VT - MAX = VIN - MAX + VO = 70V + 21V = 91V
IT- MAX = 0. 677 x 1A = 2.1A 1- 0.677

(40)

(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 1A x D= x 0.467 = 1. 28A 0. 533 Dc

(42) (43)

PT =

2 IT- RMS

x RDSON = 1. 28A x 50 m: = 82 mW

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 = VIN - MAX + VO = 70V + 21V = 91V
ID - MAX = ILED = 1A

(45) (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 = R4 = R5 x (VHYS - 20 PA x R13) 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:

R5 = 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 = VTURN-ON = 1.24V x (R5 + R13) R5 1.24V x (1.43 k: + 10 k:) = 9.91V 1.43 k:

(52)
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Design Procedure

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:
tSU = 168: x C9 + 36 k: x C10 + VO ILED x CO 21V x 40 PF 1A

tSU = 168: x 2.2 PF + 36 k: x 1.0 PF + tSU = 37.2 ms

(59)

If tSU is less than tTSU, solve for tSU-SS-BASE:

tSU-SS-BASE = 168: x C9 + 28 k: x C10 + VO ILED x CO 21V x 40 PF 1A

tSU-SS-BASE = 168: x 2.2 PF + 28 k: x 1.0 PF + tSU-SS-BASE = 29.2 ms

(60)

Solve for CSS:

(tTSU - tSU-SS-BASE) CSS = 20 k: = (40 ms - 29.2 ms) 20 k: = 540 nF

(61)

The chosen component from step 15 is:

CSS = 0.47 PF

(62)

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Typical Waveforms

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Typical Waveforms
TA = +25C, VIN = 24V and VO = 21V.

1.0 ILED (A) ILED 60 40 VSW (V) 20 0 VSW 2 Ps/DIV Figure 4. Standard Operation TP1 Switch Node Voltage (VSW) LED Current (ILED) 0.5 0.0
VDIM (V) ILED

1.0 0.0 -1.0 ILED (A)

10 5 0

VDIM 4 ms/DIV Figure 5. 200Hz 50% PWM Dimming TP5 Dim Voltage (VDIM) LED Current (ILED)

10

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
Specification / Component VIN VO fSW ILED R9 R10 L1 Design 1 10V - 45V 14V 600kHz 2A 0.05 12.1 k 22H Design 2 15V - 50V 21V 700kHz 500mA 0.2 10.2 k 68H Design 3 20V - 55V 28V 500kHz 2.5A 0.04 14.3 k 15H Design 4 25V - 60V 35V 700kHz 1.25A 0.08 10.2 k 33H

14

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