LM5039
Application Note 2025 LM5039 Evaluation Board
Literature Number: SNVA423C
LM5039 Evaluation Board National Semiconductor
Application Note 2025
Ajay Hari
February 17, 2010
Introduction
The LM5039 evaluation board is designed to provide the de-
sign engineer with a fully functional power converter based
on the half-bridge topology to evaluate the LM5039 controller.
The evaluation board is provided in an industry standard
quarter brick footprint. The performance of the evaluation
board is as follows:
•Input Operating Range: 36V to 75V
•Output Voltage: 3.3V
•Measured Efficiency: 89% @ 30A, 92% @ 15A
•Frequency of Operation: 400 kHz
•Board Size: 2.28 x 1.45x 0.5 inches
•Load Regulation: 0.2%
•Line Regulation 0.1%
•Line UVLO (31V/30V on/off)
•Constant Current Limit
The printed circuit board consists of 6 layers, 2 ounce copper
outer layers, and 3 ounce copper inner layers on FR4 mate-
rial, with a total thickness of 0.062 inches. The unit is designed
for continuous operation at rated load at <40°C and a mini-
mum airflow of 200 CFM.
Theory of Operation
Power converters based on the half-bridge topology offer
high-efficiency and good power handling capability up to
500W. A simplified half bridge circuit is illustrated below. The
capacitors C1 and C2, which form one-half of the bridge, are
arranged in series such that the mid-point is at half the input
voltage. The other half of the bridge is formed by the switches
Q1 and Q2. Switches Q1 and Q2 are turned on alternatively
with a pulse-width determined by the input and output volt-
ages and the transformer turns ratio. Each switch, when
turned on, applies one-half the input voltage to the primary of
the transformer. The resulting secondary voltage is then rec-
tified and filtered with an LC filter to provide a smoothened
output voltage. In half-bridge topology, the primary switches
are turned on alternatively energizing the windings in such a
way that the flux swings back and forth in the first and the third
quadrants of the B-H curve. The use of two quadrants allows
better utilization of the core resulting in a smaller core volume
compared to the single-ended topologies such as a forward
converter.
30112701
Simplified Half-Bridge Circuit
© 2010 National Semiconductor Corporation 301127 www.national.com
LM5039 Evaluation Board AN-2025
The secondary side employs synchronous rectification
scheme, which is controlled by the LM5039, during the soft-
start, the sync FET body diodes act as the secondary recti-
fiers. Once, the soft-start is finished, the synchronous
rectifiers are engaged with a non-overlap time programmed
by the DLY resistor. Feedback from the output is processed
by an amplifier and reference, generating an error voltage,
which is coupled back to the primary side control through an
opto-coupler. The LM5039 controller pulse width modulates
the error signal with a ramp signal derived from the line volt-
age (feed-forward) to reduce the response time. A standard
“type III” network is used for the compensator.
Powering and Loading
Considerations
When applying power to the LM5039 evaluation board, cer-
tain precautions need to be followed. A misconnection can
damage the assembly.
PROPER CONNECTIONS
When operated at low input voltages the evaluation board can
draw up to 3.5A of current at full load. The maximum rated
output current is 30A. Be sure to choose the correct connector
and wire size when attaching the source supply and the load.
Monitor the current into and out of the evaluation board. Mon-
itor the voltage directly at the output terminals of the evalua-
tion board. The voltage drop across the load connecting wires
will give inaccurate measurements. This is especially true for
accurate efficiency measurements.
SOURCE POWER
The evaluation board can be viewed as a constant power
load. At low input line voltage (36V) the input current can
reach 3.5A, while at high input line voltage (72V) the input
current will be approximately 1.5A. Therefore, to fully test the
LM5039 evaluation board a DC power supply capable of at
least 85V and 4A is required. The power supply must have
adjustments for both voltage and current.
The power supply and cabling must present low impedance
to the evaluation board. Insufficient cabling or a high
impedance power supply will droop during power supply ap-
plication with the evaluation board inrush current. If large
enough, this droop will cause a chattering condition upon
power up. This chattering condition is an interaction with the
evaluation board under voltage lockout, the cabling
impedance and the inrush current.
LOADING
An appropriate electronic load, with specified operation down
to 3.0V minimum, is desirable. The resistance of a maximum
load is 0.11Ω. The high output current requires thick cables!
If resistor banks are used there are certain precautions to be
taken. The wattage and current ratings must be adequate for
a 30A, 100W supply. Monitor both current and voltage at all
times. Ensure that there is sufficient cooling provided for the
load.
AIR FLOW
Full power loading should never be attempted without pro-
viding the specified 200 CFM of air flow over the evaluation
board. A stand-alone fan should be provided.
POWERING UP
Using the ON/OFF pin provided will allow powering up the
source supply with the current level set low. It is suggested
that the load be kept low during the first power up. Set the
current limit of the source supply to provide about 1.5 times
the wattage of the load. As you remove the connection from
the ON/OFF pin to ground, immediately check for 3.3 volts at
the output.
A most common occurrence, that will prove unnerving, is
when the current limit set on the source supply is insufficient
for the load. The result is similar to having the high source
impedance referred to earlier. The interaction of the source
supply folding back and the evaluation board going into un-
dervoltage shutdown will start an oscillation, or chatter, that
may have undesirable consequences.
A quick efficiency check is the best way to confirm that ev-
erything is operating properly. If something is amiss you can
be reasonably sure that it will affect the efficiency adversely.
Few parameters can be incorrect in a switching power supply
without creating losses and potentially damaging heat.
30112702
FIGURE 1.
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OVER CURRENT PROTECTION
The evaluation board is not configured with over current pro-
tection and will be in continuous current limit condition. There-
fore, 200 CFM of airflow is a must during the over current
condition.
If the customer desires to configure the evaluation board with
the hiccup mode enabled, a 4700pF capacitor needs to be
connected from RES pin to AGND. In the event of an output
overload (approximately 35A) the unit will discharge the soft
start capacitor, which disables the power stage. After a delay
the softstart is released. The shutdown, delay and slow
recharge time of the soft start capacitor reduces the average
power consumption of the unit in an overload condition.
Average Current Limit
The major drawback of the half-bridge topology is that during
current limit condition, the center-point of the capacitor divider
tends to runaway either towards the input voltage rail or to-
wards the ground. This phenomenon saturates the trans-
former and requires the capacitors in the divider to be rated
to at least the input voltage. In an overload condition, the
PWM cycle is terminated by the current sense comparator
instead of the PWM comparator. This is similar to peak current
mode control, which inherently results in an on-time between
both the phases of the half-bridge topology. Any such imbal-
ance, for an extended period, will cause the voltage at the
center-point of the capacitor divider to drift either towards the
input voltage or the ground. However, in an average current
limit scheme, the PWM cycle is terminated through the PWM
comparator, by pulling down the PWM control input. Because
of its averaging nature, the PWM control input voltage is slow
moving and is essentially held at a constant dc voltage. This
results in the on-time between the both the phases to be equal
and thus balances the center-point of the capacitor divider.
Figure 2 shows the current limit waveforms in a soft-short
condition and Figure 3 shows the current limit waveforms in
a hard-short condition.
It can be observed from the Figures 2 and 3 that the center-
point of the half-bridge capacitor divider is balanced in both
soft-short and hard-short conditions. The response of aver-
age current limit circuit is same whether the short is soft or
hard. During an overload event, the average current limit
scheme converts the power supply from a constant voltage
source to a constant current source. This scheme is often
known as “brickwall current limiting.” A VOUT vs IOUT curve,
shown in Figure 4, illustrates the brickwall current limiting.
30112703
Trace 1 (C1) Output Voltage
Trace 2(C2): Voltage on the ACL Capacitor
Trace 3 (C3): Output current
Trace 4 (C4): Voltage at the center-point of the half-bridge capacitor divider
FIGURE 2.
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30112704
Trace 1 (C1) Output Voltage
Trace 2(C2): Voltage on the ACL Capacitor
Trace 3 (C4): Voltage at the center-point of the half-bridge capacitor divider
FIGURE 3.
The LM5039 evaluation board is configured to be in constant
current limiting. To configure the board for hiccup mode
restart, remove the zero ohm resistor from the RES pin to the
AGND and install a 4700pF capacitor from the RES pin to the
AGND. The RES capacitor should be selected such that the
time taken for the RES capacitor to reach 2.5V is greater than
the time taken for the average current mode control circuit to
be in control. This will ensure that center-point of the half-
bridge capacitor is balanced. Figure 5 illustrates a balanced
half-bridge capacitor divider at the inception of a hiccup mode
restart. While Figure 6 shows the same over multiple hiccup
mode restarts. The RES capacitor should be selected such
that the time taken for the RES capacitor to reach 2.5V and
hence start the hiccup mode is greater than the time taken for
the ACL pin to get into control.
30112705
FIGURE 4.
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30112706
Trace 1 (C1): Output voltage
Trace 2(C2): Voltage on the ACL capacitor
Trace 3(C3): Voltage on the RES capacitor
Trace 4(C4): Voltage at the center-point of the half-bridge capacitor divider
FIGURE 5.
30112707
Trace 1 (C1): Output voltage
Trace 2(C2): Voltage on the ACL capacitor
Trace 3(C3): Voltage on the RES capacitor
Trace 4(C4): Voltage at the center-point of the half-bridge capacitor divider
FIGURE 6.
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Other Performance Characteristics
When applying power to the LM5039 evaluation board a cer-
tain sequence of events occurs. Soft-start capacitor values
and other components allow for a minimal output voltage for
a short time until the feedback loop can stabilize without over-
shoot. Figure 7 shows the output voltage during a typical start-
up with a 48V input and a load of 30A. There is no overshoot
during start-up.
Figure 8 shows the transient response for a load of change
from 5A to 25A. The upper trace shows minimal output volt-
age droop and overshoot during the sudden change in output
current shown by the lower trace.
30112708
Conditions: Input Voltage=48V
Output Current=5A
Trace 1: Output Voltage Volts/div=500mV
Horizontal Resolution =2.0 ms/div
FIGURE 7.
30112709
Conditions: Input Voltage=48V
Output Current=15A to 22.5A
Upper Trace: Output Voltage Volts/div=50mV
Lower Trace: Output Current = 15A to 22.5A to 15A
Horizontal Resolution =0.5 ms/div
FIGURE 8.
Figures 9 and 10 show the drain voltage of Q1 with a 25A
load. Figure 9 represents an input voltage represents an input
voltage of 36V and Figure 10 represents an input voltage of
72V.
30112710
Conditions: Input Voltage =36V
Output Current=5A
Trace 1: Q1 Drain Voltage Volts/div=10V
Horizontal Resolution= 1 us/div
FIGURE 9.
30112721
Conditions: Input Voltage =72V
Output Current=5A
Trace 1: Q1 Drain Voltage Volts/div=10V
Horizontal Resolution= 1 us/div
FIGURE 10.
Figure 11 shows typical output ripple seen directly across the
output capacitor, for an input voltage of 48V and a load of 30A.
This waveform is typical of most loads and input voltages.
30112724
Conditions: Input Voltage =48V
Output Current=5A
Trace 1: Output Voltage Volts/div=20mV
Horizontal Resolution= 1 us/div
FIGURE 11.
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30112711
FIGURE 12.
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Bill of Materials
# Designator Qty Part # Description
1 U1 1 NSC LM5039MH LM5039 Controller
2 U2 1 NSC LM5110-1M LM5110-1M Dual Driver
3 U3 1 NSC LM8261M5 LM8261M5 Op Amp
4 U5 1 NSC LM4041AIM3-.12 LM4041AIM3-1.2 Ref Amp
5 U4 1 NEC PS2811-1M Opto-Coupler PS2811-1M
6 C21 1 TDK C1608COG1H470J Cer Cap 47pF 50V COG
7 C26 1 TDK C1608COG1H151J Cer Cap 150pF 50V COG
8 C34 1 TDK C1608COG1H471J Cer Cap 470pF 50V COG
9 C19, C37 2 TDK C1608X7R1H102K Cer Cap 1000pF 50V X7R
10 C27 2 TDK C1608COG1H222J Cer Cap 2200pF 50V COG
11 C28 1 TDK C1608COG1H682J Cer Cap 6800pF 50V COG
12 C20, C23, C29,
C30
1 TDK C1608X7R1E473K Cer Cap 0.047uF 25V COG
13 C2, C33, C31,
C35
3 TDK C1608X7R1H104K Cer Cap 0.1uF 50V X7R
14 C25 2 TDK C1608X7R1C105K Cer Cap 1.0uF 16V X7R
15 C36 3 TDK C1608X7R1C474K Cer Cap 0.47uF 50V X7R
16 C32 1 Vishay CRCW06030000Z0TA Res 0 Ohm 0.1W,5%
17 C39 2 TDK C2012x714224K Cer Cap 0.22uF 25V COG
18 C15, C16 2 KEMT C0805C471M5RAC Cer Cap 470pF 50V COG
19 C17, C24 2 TDK C2012X7R2A104K Cer Cap 0.1uF 100V X7R
20 C7 1 TDK C2012X7R1H334K Cer Cap 0.33uF 50V X7R
21 C1, C22 2 TDK C2012X7R1C225K Cer Cap 2.2uF 16V X7R
22 C18 1 TDK C3216X7R1C475K Cer Cap 4.7uF 16V X7R
23 C11–C14 4 TDK C3216X5R0J226M Cer Cap 22uF 6.3V X5R
24 C38 1 TDK C4532X7R3D222K Cer Cap 2200pF 2000V X7R
25 C3–C6 4 TDK C4532X7R1H685M Cer Cap 6.8uF 50V X7R
26 C8–C10 3 Sanyo 6TPE220MI POSCAP 220uF 6.3V
27 R12 1 Vishay CRCW06035R60FKTA Res 5.6 Ohm 0.1W 1%
28 R17, R35 2 Vishay CRCW060310R0F Res 10 Ohm 0.1W 1%
29 R25, R27, R28 3 Vishay CRCW06031000F Res 100 Ohm 0.1W 1%
30 R21 1 Vishay CRCW06035490F Res 549 Ohm 0.1W 1%
31 R13–14, R18–19 4 Vishay CRCW06031001F Res 1K Ohm 0.1W 1%
32 R24 1 NU NU
33 R31 1 Vishay CRCW06032001F Res 2.0K Ohm 0.1W 1%
34 R20 1 Vishay CRCW06034121F Res 4.12K Ohm 0.1W 1%
35 R32 1 Vishay CRCW06035111F Res 5.11K Ohm 0.1W 1%
36 R22 1 Vishay CRCW06038061F Res 8.06K Ohm 0.1W 1%
37 R7, R30 2 Vishay CRCW06031002F Res 10K Ohm 0.1W 1%
38 R26 1 Vishay CRCW06031022F Res 10.2K Ohm 0.1W 1%
39 R33 1 Vishay CRCW06032492F Res 24.9K Ohm 0.1W 1%
40 R29 1 Vishay CRCW06031502F Res 15K Ohm 0.1W 1%
41 R34 1 Vishay CRCW06032002F Res 20K Ohm 0.1W 1%
42 R23 1 Vishay CRCW06032552F Res 25.5K Ohm 0.1W 1%
43 R3, R4 2 Vishay CRCW06031003F Res 100K Ohm 0.1W 1%
44 R1, R11, R15 3 Vishay CRCW080510R0F Res 10 OHM 1/10W 1%
45 R5 1 Vishay CRCW080549R9F Res 49.9 OHM 1/10W 1%
46 R2 1 Vishay CRCW08052001F Res 2K OHM 1/10W 1%
47 R6 1 Vishay CRCW08051002F Res 10K OHM 1/10W 1%
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48 R16 1 Vishay CRCW08056492F Res 64.9K OHM 1/10W 1%
49 R10 2 Vishay CRCW08051003F Res 100K OHM 1/10W 1%
50 R8, R9 2 Vishay CRCW201010R0F Res 10 OHM 1%
51 D1 1 BAV70-TP Schottky, Diode, 75V 150mA
52 D2, D4 2 Central CMDD4448 Diode, 75V 250mA
53 D3 1 BAT54A Schottky Diode, 30V 200mA
54 BR1 1 BAT54BRW Diodes, Rectifier, Bridge, 30V
55 Z1 1 Central CMPZ4694 Zener 8.2V 5%
56 Z2 1 Central CMPZ4698 Zener 11V 5%
57 Q1, Q2 2 Vishay Si7456DP N-FET 100V 25m ohm
58 Q4–7 4 Vishay Si7336ADP N-FET 30V 3m ohm
59 Q3, Q8 2 ZETEX FCX690B NPN, ZETEX 45V 2A
60 L1 1 TDK RLF7030T-2R2M5R4 Inductor 2.2uH 5.4A
61 L2 1 Coilcraft SER2010-122MX Inductor 1.2uH 37A
62 T1 1 Coilcraft DA2025-AL Transformer 8:5:2:2
63 T2 1 Pulse Engr P8208 Current XFR 100:1, 10A
64 T3, T4 2 Coilcraft DA2319-ALB Gate XFR 1:1
65 J1–3, J5–7 6 Mill-Max 3104-2-00-80-00-00-08-0. Test Pin, Brick
66 J4, J8 2 Mill-Max 3231-2-00-01-00-00-08-0 Test Pin, Brick
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PCB Layouts
30112713
Top Silk
30112714
Bottom Silk
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30112715
Top Side
30112716
Layer 2
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30112717
Layer 3
30112718
Layer 4
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30112719
Layer 5
30112720
Bottom
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Notes
AN-2025 LM5039 Evaluation Board
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