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Design Example Report
Title 20 W and 30 W Boost Converters with Constant Current Output using DPA423G and DPA424G
Input: 24 VDC Specification Board #1 Output: 40 V / 500 mA CC Board #2 Output: 60 V / 500 mA CC Application Author Document Number Date Revision LED (RGB) Backlight for LCD TV Power Integrations Applications Department DER-112 July 19, 2006 1.1
Summary and Features * * * * * Boost Converter using DPA423 (20 W) and DPA424 (30 W) Simple Low Component Count High Efficiency (> 90 %) CC/CV (Constant Current and Constant Voltage) 400 KHz operation
The products and applications illustrated herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com.
Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com
DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Table Of Contents
1 2 Introduction .................................................................................................................3 Power Supply Specification ........................................................................................6 2.1 Board 1 (40 V Output)..........................................................................................6 2.2 Board 2 (60 V Output)..........................................................................................6 Schematic ...................................................................................................................7 3.1 Schematic of Board 1 (40 V Output) ....................................................................7 3.2 Schematic of Board 2 (60 V Output) ....................................................................8 BOM............................................................................................................................9 4.1 Bill of Materials - Board 1 (40 V) .........................................................................9 4.2 Bill of Materials - Board 2 (60 V) .......................................................................10 Layout .......................................................................................................................11 Performance .............................................................................................................12 6.1 Efficiency ...........................................................................................................12 6.2 Regulation vs. Load (40 V) ................................................................................13 6.3 Regulation vs. Load (60 V) ................................................................................14 Performance .............................................................................................................15 7.1 Raw Performance Data - 60V Board.................................................................15 7.2 Raw Performance Data - 40 V Board................................................................15 Revision History........................................................................................................16
3
4
5 6
7
8
Important Note: This board is designed to be non-isolated. However the outputs are high voltage so please take the necessary safety precautions. Design Reports contain a power supply design specification, schematic, bill of materials, and transformer documentation. Performance data and typical operation characteristics are included. Typically only a single prototype has been built.
Page 2 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
1 Introduction
This document is an engineering report describing two constant current and constant voltage (CC/CV) power supplies utilizing DPA423G (at 20 W) and DPA424G (at 30 W). The power supplies operate from an input of 24 VDC. The power supply is constantcurrent regulated (to 500 mA) but operates as a voltage regulator at lower power. This document provides complete design information including specification, schematic, bill of material and layout information.
Figure 1 - Photograph - Top View - Board 1.
Page 3 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Figure 2 - Photograph - Bottom View - Board 1.
Figure 3 - Photograph - Top View - Board 2.
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Figure 4 - Photograph - Bottom View - Board 2.
Page 5 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
2 Power Supply Specification
2.1 Board 1 (40 V Output)
Description Input Voltage Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Average Output Power Full Load Efficiency Environmental Ambient Temperature Symbol VIN VOUT1 VRIPPLE1 IOUT1 Min Typ 24 40 500 Max Units VDC V mVp-p mA
3% 20 MHz bandwidth 20%
Comment
POUT1 TAMB 0
20 90 40
W %
o
C
2.2
Board 2 (60 V Output)
Description Symbol VIN VOUT1 VRIPPLE1 IOUT1 Min Typ 24 60 500 Max Units VDC V mVp-p mA
3% 20 MHz bandwidth 20%
Comment
Input Voltage Output Output Voltage 1 Output Ripple Voltage 1 Output Current 1 Total Output Power Average Output Power Full Load Efficiency Environmental Ambient Temperature
POUT1 TAMB 0
30 90 40
W %
o
C
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
3
3.1
Schematic
Schematic of Board 1 (40 V Output)
C6 6.8 nF R4 50 V 0.68 C4 1 uF 16 V ZMM5250B-7 ZMM5250B-7 Q2 C1 1 uF 100 V
D L C SXF
J1 1 CON1
L1 220 uH
D1 SS26
R3 0.56
MMBTA56LT1 MA2J11200L
J3 1 CON1
R2 10 k R5 10 k
R9 300 D2
VR1 20 V VR2 20 V C5 1 uF 100 V
CONTROL
U1 DPA423G J2 1 CON1
R1 C3 1 220 nF 25 V
C2 47 uF 10 V
J4 1 CON1
Figure 5 - Schematic.
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
3.2
Schematic of Board 2 (60 V Output)
C6 6.8 nF R4 50 V 0.68 C4 1 uF 16 V ZMM5256B-7 ZMM5256B-7 Q2 C1 1 uF 100 V
D L C SXF
J1 1 CON1
L1 150 uH
D1 30BQ100
R3 0.56
MMBTA56LT1 MA2J11200L
J3 1 CON1
R2 10 k R5 33 k
R9 2k D2
VR1 30 V VR2 30 V C5 1 uF 100 V
CONTROL
U1 DPA424G J2 1 CON1
R1 C3 1 220 nF 25 V
C2 47 uF 10 V
J4 1 CON1
Figure 6 - Schematic.
Page 8 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
4 BOM
4.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Bill of Materials - Board 1 (40 V)
Ref. C1 C5 C2 C3 C4 C6 D1 D2 Description 1 uF, 100 V, Ceramic, X7R, 1210 47 uF, 10 V, Tant Electrolytic, B Case, SMD 220 nF, 25 V, Ceramic, X7R, 0603 1 uF, 16 V, Ceramic, X5R, 0603 6.8 nF, 50 V, Ceramic, X7R, 0805 60 V, 2 A, Schottky, SMD, DO-214AA Mfg Part Number 12101C105KAT2A T491B476M010AS 06033D224KAT2A GRM188R61C105KA 93D ECJ-2VB1H682K SS26 MA2J11200L 1248-580-SP P1171.224T MMBTA56LT1 ERJ-3GEYJ1R0V ERJ-3GEYJ103V ERJ-8RQJR56V ERJ-8RQJR68V ERJ-8GEYJ301V DPA423G ZMM5250B-7 Mfg AVX Kemet AVX Murata Panasonic Vishay Panasonic Zierick Pulse On Semiconductor Panasonic Panasonic Panasonic Panasonic Panasonic Power Integrations Diodes Inc 2 1 1 1 1 1 1 4 1 1 1 2 1 1 1 1 2 23
Item Qty.
40 V, 0.2 A, Switching, 50 ns, Smini 2p Test Point, 0.060 (1.529mm) Dia X 0.580 J1 J2 J3 J4 (14.73 mm) long Brass, Ti over Cu, SMT L1 Q2 R1 R2 R5 R3 R4 R9 U1 220 uH, 1.00 A, SMD PNP, Small Signal BJT, 80 V, 0.5 A, SOT23 1 R, 5%, 1/10 W, Metal Film, 0603 10 K, 5%, 1/10 W, Metal Film, 0603 0.56 R, 1%, 1/4 W, Metal Film, 1206 0.68 R, 1%, 1/4 W, Metal Film, 1206 300 R, 5%, 1/4 W, Metal Film, 1206 DPA-Switch, DPA423G, SMD-8
VR1 VR2 20 V, 5%, 500 mW, DO-213AA (MELF) Total
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
4.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Bill of Materials - Board 2 (60 V)
Ref. C1 C5 C2 C3 C4 C6 D1 D2 Description 1 uF, 100 V, Ceramic, X7R, 1210 47 uF, 10 V, Tant Electrolytic, B Case, SMD 220 nF, 25 V, Ceramic, X7R, 0603 1 uF, 16 V, Ceramic, X5R, 0603 6.8 nF, 50 V, Ceramic, X7R, 0805 100V, 3 A, Schottky, SMC Mfg Part Number 12101C105KAT2A T491B476M010AS 06033D224KAT2A GRM188R61C105KA 93D ECJ-2VB1H682K 30BQ100 MA2J11200L 1248-580-SP P1171.154T MMBTA56LT1 ERJ-3GEYJ1R0V ERJ-3GEYJ103V ERJ-8RQJR56V ERJ-8RQJR68V ERJ-3GEYJ333V ERJ-8GEYJ202V DPA424G ZMM5256B-7 Mfg AVX Kemet AVX Murata Panasonic Internation Rectifier Panasonic Zierick Pulse On Semiconductor Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Power Integrations Diodes Inc 2 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 2 23
Item Qty.
40 V, 0.2 A, Switching, 50 ns, Smini 2p Test Point, 0.060 (1.529mm) Dia X 0.580 J1 J2 J3 J4 (14.73 mm) long Brass, Ti over Cu, SMT L1 Q2 R1 R2 R3 R4 R5 R9 U1 150 uH, 1.20 A, SMD PNP, Small Signal BJT, 80 V, 0.5 A, SOT-23 1 R, 5%, 1/10 W, Metal Film, 0603 10 K, 5%, 1/10 W, Metal Film, 0603 0.56R, 1%, 1/4 W, Metal Film, 1206 0.68 R, 1%, 1/4 W, Metal Film, 1206 33 K, 5%, 1/10 W, Metal Film, 0603 2 K, 5%, 1/4 W, Metal Film, 1206 DPA-Switch, DPA424G, SMD-8
VR1 VR2 30 V, 5%, 500 mW, DO-213AA (MELF) Total
Page 10 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
5 Layout
Figure 7 - Layout
Note: Please note that the layout above was used, but several component changes occurred. The schematic correctly reflects these changes. The photograph of the board will help in identifying these changes also.
Page 11 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
6 Performance
6.1 Efficiency
Efficiency vs Line/Load
100%
Efficiency (%)
90%
80%
60V board 40V board
70% 0 5 10 15 20 Pout (W) 25 30 35
Figure 8 - Efficiency vs. Input Voltage and Output Load, Room Temperature.
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DER-112 6.2
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Regulation vs. Load (40 V)
Regulation vs Load
45.0 40.0
Vout (V)
35.0 30.0 25.0 20.0 0.00
24 Vin
0.25
0.50
0.75
Iout (A)
Figure 9 - Board 1 (40 V), Output Regulation vs. Output Load, Room Temperature.
Page 13 of 17
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DER-112 6.3
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Regulation vs. Load (60 V)
Regulation vs Load
70.0 60.0
Vout (V)
50.0 40.0 30.0 20.0 0.00
24 Vin
0.25
0.50
0.75
Iout (A)
Figure 10 - Board 2 (60 V), Output Regulation vs. Output Load, Room Temperature.
Page 14 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
7 Performance
7.1 Raw Performance Data - 60V Board
Vin (DC) 24.12 24.11 24.09 24.07 24.04 24 23.98 23.99 24 24.01 24.02 24.03 24.04 Iin (A) 0.031 0.109 0.286 0.567 0.843 1.124 1.369 1.276 1.188 1.089 0.941 0.859 0.804 Vout1 (V) 63.1 64 63.6 63 62.3 61.8 60.9 55.1 50.3 44.9 35.7 30.13 26.73 Iout1 (A) 0 0.03 0.1 0.2 0.3 0.4 0.49 0.5 0.52 0.54 0.58 0.63 0.67 Pin (W) 0.748 2.628 6.890 13.648 20.266 26.976 32.829 30.611 28.512 26.147 22.603 20.642 19.328 Eff (%) 0.0% 73.1% 92.3% 92.3% 92.2% 91.6% 90.9% 90.0% 91.7% 92.7% 91.6% 92.0% 92.7% Iin (A) 0.031 0.109 0.286 0.567 0.843 1.124 1.369 1.276 1.188 1.089 0.941 0.859 0.804 Pout (W) 0.0 1.9 6.4 12.6 18.7 24.7 29.8 27.6 26.2 24.2 20.7 19.0 17.9
7.2
Raw Performance Data - 40 V Board
Vin (DC) 24.12 24.12 24.11 24.09 24.08 24.06 24.03 24.04 24.04 24.05 24.06 Iin (A) 0.017 0.058 0.186 0.372 0.544 0.727 0.98 0.93 0.852 0.794 0.74 Vout1 (V) 40.1 41.4 41.2 40.7 40.5 40.3 39.6 37 33.6 30.1 27.38 Iout1 (A) 0 0.03 0.1 0.2 0.3 0.4 0.54 0.55 0.56 0.58 0.6 Pin (W) 0.410 1.399 4.484 8.961 13.100 17.492 23.549 22.357 20.482 19.096 17.804 Eff (%) 0.0% 88.8% 91.9% 90.8% 92.8% 92.2% 90.8% 91.0% 91.9% 91.4% 92.3% Iin (A) 0.017 0.058 0.186 0.372 0.544 0.727 0.980 0.930 0.852 0.794 0.740 Pout (W) 0.0 1.2 4.1 8.1 12.2 16.1 21.4 20.4 18.8 17.5 16.4
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
8 Revision History
Date Author December 20, 2005 RM July 19, 2006 PV Revision 1.0 1.1 Description & changes Initial release Minor edits to spec table Reviewed VC KM
Page 16 of 17
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DER-112
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NONINFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, EcoSmart, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. (c)Copyright 2005 Power Integrations, Inc.
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