User's Guide SNVA334B - April 2008 - Revised January 2014 AN-1819 LM5118 Evaluation Board 1 Introduction The LM5118 evaluation board is designed to provide the design engineer with a fully functional, Emulated Current Mode Control, buck-boost power converter to evaluate the LM5118 controller IC. The evaluation board provides a 12 V output with 3 A of output current capability. The evaluation board's wide input voltage range is from 75 V to 5 V, with operation down to 3 V with some component changes. The evaluation board operates at 300 kHz, a good compromise between conversion efficiency, tradeoffs between buck and buck-boost mode requirements, and converter size. The board is constructed with FR4 material. This user's guide contains the evaluation board schematic and Bill of Materials (BOM). Refer to the LM5118 quick start (SNVU065) and for more complete circuit and design information, see Wide Voltage Range Buck-Boost Controller (SNVS566). The performance of the evaluation board is: * Input Range: 75 V to less than 5 V at full current * Operation to 3 V at reduced current and appropriate adjustments. Operation at full current to around 3 V is possible with current limit sense resistor, UVLO threshold, and corresponding Cramp adjustment. Additional input capacitance may be required. See the LM5118 datasheet (SNVS566) and quick start (SNVU065) for more details. * Output Voltage: 12 V * Output Current: 0 to 3 A * Frequency of Operation: 300 kHz * Board Size: 3.45 x 2.65 inches * Load Regulation: 1% * Line Regulation: 0.1% * Over-Current Limiting * Operation with VIN greater or less than VOUT 2 IC Features * * * * * * * * * * * * * Integrated high and low side driver Internal high voltage bias regulator Ultra-wide input voltage range: 5 V to 75 V Emulated current mode control Single inductor architecture VOUT operation below and above VIN Single resistor sets oscillator frequency Oscillator synchronization capability Programmable soft-start Ultra low (<10 A) shutdown current Enable input Wide bandwidth error amplifier Adjustable output voltage 1.23 V to 75 V All trademarks are the property of their respective owners. SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated AN-1819 LM5118 Evaluation Board 1 Package * * * 3 www.ti.com 1.5% feedback reference accuracy Thermal Shutdown No VIN to VOUT connection during fault protection Package HTSSOP-20EP (Exposed Pad) 4 Application Circuit See the detailed LM5118EVAL schematic at Figure 17 VIN 5V - 75V VCC VIN HB EN VIN HO SS VOUT HS LM5118 FB CS CSG COMP SYNC LO VOUT RT AGND 2 AN-1819 LM5118 Evaluation Board RAMP PGND SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated Efficiency www.ti.com 5 Efficiency Figure 1 illustrates the efficiency of the converter vs. input voltage and output current. These curves highlight the high efficiency of the converter, especially considering the simplicity of design offered by a non synchronous implementation. Note the discontinuity in the curves at approximately 17 V and 13 V which represent mode transition boundaries. The lower efficiencies in the buck-boost region reflect additional losses at higher input and inductor currents. The decrease in efficiency at higher input voltages represents higher switching losses. Figure 1. Efficiency 6 Air Flow Prolonged operation without airflow at low input voltage and at full power will cause the MOSFETs and diodes to overheat. A fan with a minimum of 200 LFM should always be provided. Figure 2 illustrates the temperature rise of various components with no airflow. The ambient was 25C, and VIN was 8 V. Figure 2. Temperature vs Load Current with No Airflow - 25C Ambient SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated AN-1819 LM5118 Evaluation Board 3 Powering Up 7 www.ti.com Powering Up Connecting the IC's enable pin to ground will allow powering up the source supply with a minimal output load. Set the current limit of the source supply to provide about 1.5 times the anticipated wattage of the load. Note that input currents become very high at low input voltages, which requires an appropriate input supply. As you remove the connection from the enable pin to ground, immediately check for 12 V at the output. A quick efficiency check is the best way to confirm that everything is operating properly. If something is amiss, you can be reasonable 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. 8 Over Current Protection The evaluation board is configured with over-current protection. The output current is limited to approximately 4.5 A in the buck-boost mode The 4.5 A value allows for component tolerances to guarantee a 3 A output current. Note this current will be almost double, or about 7 A in buck mode (VIN greater than 17 V) due to the difference in peak inductor currents in the two different modes. Figure 3. Short Circuit Current 9 VCCX A place for a jumper between VOUT and VCCX is provided on the PC board. If operation below about 5 V is required, connect the jumper to allow VCCX to power the converter (the exact voltage depends on the gate drive requirements of the switching FETs). The converter does require a minimum VIN of 5 V to initially start. When running, the input voltage can decrease to below 5 V at reduced current with VCCX connected to VOUT. Note that this design uses a current limit value to guarantee a full 3 A of output current at a minimum VIN of 5 V. For operation lower than 5 V, the current limit resistor, UVLO threshold, and ramp capacitor must be re-calculated. Caution: make sure the input supply can source the required input current. Operation at low VIN at full power may overheat and damage the MOSFETs and diodes supplied on the board. Note there is a limit of 14 V applied to VCCX. Never exceed this value if operating VCCX from an external source, or operating the board with VOUT greater than 12 V. To prevent oscillation, connect and additional 100 uF or greater electrolytic capacitor across VIN for input voltages less than 5 V. 4 AN-1819 LM5118 Evaluation Board SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated Mode Transition www.ti.com 10 Mode Transition With VOUT set at 12 V, the LM5118 applications board will operate in the buck mode with VIN greater than about 17 V. As VIN is reduced below 17 V, the converter begins to operate in a soft buck-boost mode. As VIN is decreased below 14 V, the converter smoothly transitions to a pure buck-boost mode. This method of mode transition insures a smooth, glitch free operation as VIN is varied over the transition region. Figure 4 illustrates soft mode transition. The boost switch pulse-width is relatively narrow compared to the buck switch waveform. The boost switch pulse-width will gradually increase as VIN decreases, and will eventually match and lock to the buck switch waveform. At this point, the converter enters full buck-boost operation. Figure 4. Mode Transition SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated AN-1819 LM5118 Evaluation Board 5 Typical Waveforms 11 www.ti.com Typical Waveforms Note: All waveforms refer to revision B design. 6 Figure 5. Illustrating Buck-Boost Operation VIN = 10 V, IOUT = 1 A CH1: VSW = 20V/div; CH2: Q1 = 20V/div; CH3: Q2 = 10V/div; CH4: IL = 5A/div Figure 6. Illustrating Buck Operation VIN = 18 V; IOUT = 3 A CH1: VSW = 20V/div; CH2: Q1 = 20V/div; CH3: Q2 = 10V/div; CH4: IL = 2A/div Figure 7. Buck Mode Transient Response CH2: VOUTripple (ac coupled); CH4: IOUT = IOUT Figure 8. Buck-Boost Mode Transient Response CH2 = VOUT ripple (ac coupled); CH4 = IOUT AN-1819 LM5118 Evaluation Board SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated Typical Waveforms www.ti.com Figure 9. Start Up Waveforms CH1 = VIN; CH2 = VOUT; CH3 = VCC; CH4 = VUVLO SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated AN-1819 LM5118 Evaluation Board 7 Bill of Materials 12 Bill of Materials Qty 8 www.ti.com Reference Value Device Part Number Manufacturer 5 C1, C2, C3, C4, C5 2.2uF, 100V, X7R SMD 1812 C4532X7R2A225K T TDK 2 C6, C8 0.1uF, 100V, X7R SMD 0805 GCM21BR72A104 KA37L MURATA 2 C7, C20 1uf, 25V, X7R SMD 0805 GCM21BR71E105 KA56L MURATA 2 C9, C10 47uF, 16V, X5R SMD 1210 ECJ-4YB1C476M PANASONIC 2 C11, C12 0.47uF, 25V, X7R SMD 0805 GRM21BR71E474 KC01L MURATA 2 C13, C14 180uF, 16V CAP, ELECTR POLY, SMD PXA160ARA181MJ NIPPON CHEMICON 80G 1 C15 330pF, 100V, COG CAP_SMDC0603 GRM1885C2A331J MURATA A01D 1 C16 0.1uF, 100V, X7R CAP_SMDC0603 GCM188R72A104 KA37D 1 C17 2200pf, 100V, COG CAP_SMDC0603 GRM1885C1H222J MURATA A01D 1 C18 (Rev A) 4700pF CAP_SMDC0603 C1608X7R2A472M TDK 1 C18 (Rev B) 0.1uF CAP_SMDC0603 C1608X7S2A104K TDK 0 C19, C22 DNP CAP_SMDC0603 1 C21 0.1uF CAP_SMDC0603 GRM188R72A104 KA35D MURATA 1 D1 SCHOTTKY 10A 35V DPAK TO-252 MBRD1035CTLT4 G ON-SEMI 1 D4 SCHOTTKY 40A 100V D2PAK TO263AB VB40100C-E3/4W VISHAY 0 D5 DNP SOT-23 1 J1, J2 INPUT TERMINAL_TUR RET 1503-2 KEYSTONE 1 J3, J4 OUTPUT TERMINAL15A 7693 KEYSTONE 1 L1 10uH IND_SER2800 SER2814H-103 COILCRAFT 2 Q1, Q2 NFET PPAK_SO8 SI7148DP-T1-E3 VISHAY 1 R1 75.0K, 1% SMD 0603 ERJ-3EKF7502V PANASONIC 1 R2 1M, 1% SMD 0603 ERJ-S03F1004V PANASONIC 1 R3 29.4K, 1% SMD 0603 ERJ-3EKF2942V PANASONIC 1 R4 10K, 1% SMD 0603 ERJ-3EKF1002V PANASONIC 0 R5 DNP SMD 0603 0 R6 DNP 1 R7 (Rev A) 16.2K, 1% SMD 0603 ERJ-3EKF1622V PANASONIC 1 R7 (Rev B) 18.2K, 1% SMD 0603 ERJ-3EKF1822V PANASONIC 1 R8 2.67K, 1% SMD 0603 ERJ-3EKF2671V PANASONIC 1 R9 309, 1% SMD 0603 ERJ-3EKF3090V PANASONIC 1 R10 0 OHM, 1% SMD 1206 ERJ-8GEY0R00V PANASONIC 1 R11 0 OHM, 1% SMD 0603 ERJ-3GEY0R00V PANASONIC 1 R12 10 OHM, 1% SMD 0603 ERJ-3EKF10R0V PANASONIC 1 R13 0.015 OHM, 2W, 2% SMD 7520 RL7520WT-R015-F SUSUMU 1 TP1, TP2, TP3, TP4, TP5, TEST TP6 TEST_POINT2 5012 KEYSTONE 1 U1 TSSOP 20 LM5118MH/NOPB Texas Instruments IC, PWM AN-1819 LM5118 Evaluation Board MURATA SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated Layout www.ti.com 13 Layout The printed circuit board consists of 4 layers with 2 ounce copper top and bottom, and 1 ounce copper on internal layers. Figure 10. Top Silkscreen Layer as Viewed from Top Figure 11. Top Layer as Viewed from Top Figure 12. Layer 2 as Viewed from Top Figure 13. Layer 3 as Viewed from Top SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated AN-1819 LM5118 Evaluation Board 9 Layout www.ti.com Figure 14. Bottom Layer as Viewed from Top Figure 15. Bottom Silkscreen Layer as Viewed from Top Figure 16. Drills and Dimensions as Viewed from Top 10 AN-1819 LM5118 Evaluation Board SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback Copyright (c) 2008-2014, Texas Instruments Incorporated Evaluation Board Schematic www.ti.com 14 Evaluation Board Schematic Figure 17. Evaluation Board Schematic SNVA334B - April 2008 - Revised January 2014 Submit Documentation Feedback AN-1819 LM5118 Evaluation Board Copyright (c) 2008-2014, Texas Instruments Incorporated 11 EVALUATION BOARD/KIT/MODULE (EVM) ADDITIONAL TERMS Texas Instruments (TI) provides the enclosed Evaluation Board/Kit/Module (EVM) under the following conditions: The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies TI from all claims arising from the handling or use of the goods. Should this evaluation board/kit not meet the specifications indicated in the User's Guide, the board/kit may be returned within 30 days from the date of delivery for a full refund. THE FOREGOING LIMITED WARRANTY IS THE EXCLUSIVE WARRANTY MADE BY SELLER TO BUYER AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED, IMPLIED, OR STATUTORY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. 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