DER-112 - Power Integrations - AC

Design Example Report
20 W and 30 W Boost Converters with
Constant Current Output using DPA423G
and DPA424G
Title
Input: 24 VDC
Specification Board #1 Output: 40 V / 500 mA CC
Board #2 Output: 60 V / 500 mA CC
Application
LED (RGB) Backlight for LCD TV
Author
Power Integrations Applications Department
Document
Number
DER-112
Date
July 19, 2006
Revision
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
3
4
5
6
7
8
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
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
Power Integrations
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
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
Power Integrations
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
Figure 2 – Photograph – Bottom View – Board 1.
Figure 3 – Photograph – Top View – Board 2.
Page 4 of 17
Power Integrations
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
Figure 4 - Photograph - Bottom View – Board 2.
Page 5 of 17
Power Integrations
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
2 Power Supply Specification
2.1
Board 1 (40 V Output)
Description
Symbol
Min
Typ
Max
Units
Input
Voltage
Output
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
VIN
24
VDC
VOUT1
VRIPPLE1
IOUT1
40
500
V
mVp-p
mA
Total Output Power
Average Output Power
Full Load Efficiency
POUT1
η
20
90
W
%
Environmental
Ambient Temperature
TAMB
2.2
0
40
Comment
± 3%
20 MHz bandwidth
± 20%
o
C
Board 2 (60 V Output)
Description
Symbol
Min
Typ
Max
Units
Input
Voltage
Output
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
VIN
24
VDC
VOUT1
VRIPPLE1
IOUT1
60
500
V
mVp-p
mA
Total Output Power
Average Output Power
Full Load Efficiency
POUT1
η
30
90
W
%
Environmental
Ambient Temperature
TAMB
Page 6 of 17
0
40
Comment
± 3%
20 MHz bandwidth
± 20%
o
C
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-112
3
3.1
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Schematic
Schematic of Board 1 (40 V Output)
C6
L1
D1
1
CON1
220 uH
SS26
MMBTA56LT1
J1
6.8 nF R4
50 V 0.68
C4 1 uF
16 V
D
L
CONTROL
U1
DPA423G
J2
1
C
S X F
MA2J11200L
C1
1 uF
100 V
R1
C3 1
220 nF
25 V
ZMM5250B-7 ZMM5250B-7
Q2
R9
300
D2
R3
0.56
1
CON1
R2
10 k
R5
10 k
VR1
20 V
VR2
20 V
C2
47 uF
10 V
CON1
C5
1 uF
100 V
J4
1
CON1
Figure 5 – Schematic.
Page 7 of 17
J3
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-112
3.2
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Schematic of Board 2 (60 V Output)
C6
L1
D1
1
CON1
150 uH
30BQ100
6.8 nF R4
50 V 0.68
C4 1 uF
16 V
Q2
D
L
CONTROL
U1
DPA424G
J2
1
C
S X F
MA2J11200L
C1
1 uF
100 V
R1
C3 1
220 nF
25 V
R9
2k
D2
ZMM5256B-7 ZMM5256B-7
MMBTA56LT1
J1
R3
0.56
CON1
R2
10 k
R5
33 k
VR1
30 V
VR2
30 V
C2
47 uF
10 V
CON1
C5
1 uF
100 V
J4
1
CON1
Figure 6 – Schematic.
Page 8 of 17
J3
1
Power Integrations
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
4 BOM
4.1
Bill of Materials – Board 1 (40 V)
Item Qty.
Ref.
Description
Mfg Part Number
Mfg
1 uF, 100 V, Ceramic, X7R, 1210
12101C105KAT2A
AVX
T491B476M010AS
Kemet
06033D224KAT2A
GRM188R61C105KA
93D
AVX
Murata
ECJ-2VB1H682K
Panasonic
SS26
Vishay
MA2J11200L
Panasonic
1248-580-SP
Zierick
P1171.224T
Pulse
MMBTA56LT1
On Semiconductor
1
2
C1 C5
2
1
C2
47 uF, 10 V, Tant Electrolytic, B Case, SMD
3
1
C3
220 nF, 25 V, Ceramic, X7R, 0603
4
1
C4
1 uF, 16 V, Ceramic, X5R, 0603
5
1
C6
6.8 nF, 50 V, Ceramic, X7R, 0805
6
1
D1
60 V, 2 A, Schottky, SMD, DO-214AA
7
1
D2
8
4
9
1
L1
10
1
Q2
220 uH, 1.00 A, SMD
PNP, Small Signal BJT, 80 V, 0.5 A, SOT23
11
1
R1
1 R, 5%, 1/10 W, Metal Film, 0603
ERJ-3GEYJ1R0V
Panasonic
12
2
R2 R5
10 K, 5%, 1/10 W, Metal Film, 0603
ERJ-3GEYJ103V
Panasonic
13
1
R3
0.56 R, 1%, 1/4 W, Metal Film, 1206
ERJ-8RQJR56V
Panasonic
14
1
R4
0.68 R, 1%, 1/4 W, Metal Film, 1206
ERJ-8RQJR68V
Panasonic
15
1
R9
300 R, 5%, 1/4 W, Metal Film, 1206
ERJ-8GEYJ301V
Panasonic
16
1
U1
DPA-Switch, DPA423G, SMD-8
DPA423G
Power Integrations
17
2
ZMM5250B-7
Diodes Inc
23
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
VR1 VR2 20 V, 5%, 500 mW, DO-213AA (MELF)
Total
Page 9 of 17
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-112
4.2
20 W / 30 W Constant Current LED Backlight Driver
July 19, 2006
Bill of Materials – Board 2 (60 V)
Item Qty.
Ref.
Description
1
2
C1 C5
2
1
C2
1 uF, 100 V, Ceramic, X7R, 1210
47 uF, 10 V, Tant Electrolytic, B Case,
SMD
3
1
C3
220 nF, 25 V, Ceramic, X7R, 0603
4
1
C4
1 uF, 16 V, Ceramic, X5R, 0603
5
1
C6
6.8 nF, 50 V, Ceramic, X7R, 0805
6
1
D1
100V, 3 A, Schottky, SMC
7
1
D2
8
4
9
1
L1
10
1
Q2
150 uH, 1.20 A, SMD
PNP, Small Signal BJT, 80 V, 0.5 A,
SOT-23
11
1
R1
12
1
13
Mfg Part Number
Mfg
12101C105KAT2A
AVX
T491B476M010AS
Kemet
06033D224KAT2A
GRM188R61C105KA
93D
AVX
30BQ100
Panasonic
Internation
Rectifier
MA2J11200L
Panasonic
1248-580-SP
Zierick
P1171.154T
Pulse
MMBTA56LT1
On Semiconductor
1 R, 5%, 1/10 W, Metal Film, 0603
ERJ-3GEYJ1R0V
Panasonic
R2
10 K, 5%, 1/10 W, Metal Film, 0603
ERJ-3GEYJ103V
Panasonic
1
R3
0.56R, 1%, 1/4 W, Metal Film, 1206
ERJ-8RQJR56V
Panasonic
14
1
R4
0.68 R, 1%, 1/4 W, Metal Film, 1206
ERJ-8RQJR68V
Panasonic
15
1
R5
33 K, 5%, 1/10 W, Metal Film, 0603
ERJ-3GEYJ333V
Panasonic
16
1
R9
2 K, 5%, 1/4 W, Metal Film, 1206
ERJ-8GEYJ202V
Panasonic
17
1
U1
DPA-Switch, DPA424G, SMD-8
DPA424G
Power Integrations
18
2
ZMM5256B-7
Diodes Inc
23
ECJ-2VB1H682K
Murata
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
VR1 VR2 30 V, 5%, 500 mW, DO-213AA (MELF)
Total
Page 10 of 17
Power Integrations
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
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
Power Integrations
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
6 Performance
6.1
Efficiency
Efficiency vs Line/Load
Efficiency (%)
100%
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.
Page 12 of 17
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
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
Vout (V)
40.0
35.0
30.0
24 Vin
25.0
20.0
0.00
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
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
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
Vout (V)
60.0
50.0
40.0
24 Vin
30.0
20.0
0.00
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
Power Integrations
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
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
7.2
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)
Iout1
(A)
Pin
(W)
63.1
64
63.6
63
62.3
61.8
60.9
55.1
50.3
44.9
35.7
30.13
26.73
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
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
(%)
Iin
(A)
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%
Pout
(W)
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
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
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
Page 15 of 17
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)
Iout1
(A)
Pin
(W)
40.1
41.4
41.2
40.7
40.5
40.3
39.6
37
33.6
30.1
27.38
0
0.03
0.1
0.2
0.3
0.4
0.54
0.55
0.56
0.58
0.6
0.410
1.399
4.484
8.961
13.100
17.492
23.549
22.357
20.482
19.096
17.804
Eff
(%)
Iin
(A)
0.0%
88.8%
91.9%
90.8%
92.8%
92.2%
90.8%
91.0%
91.9%
91.4%
92.3%
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
Power Integrations
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
8 Revision History
Date
Author
December 20, 2005 RM
July 19, 2006
PV
Page 16 of 17
Revision
1.0
1.1
Description & changes
Initial release
Minor edits to spec table
Reviewed
VC
KM
Power Integrations
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
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. ©Copyright 2005 Power Integrations, Inc.
Power Integrations Worldwide Sales Support Locations
WORLD HEADQUARTERS
5245 Hellyer Avenue
San Jose, CA 95138, USA.
Main:
+1-408-414-9200
Customer Service:
Phone:
+1-408-414-9665
Fax:
+1-408-414-9765
e-mail: usasales@powerint.com
GERMANY
Rueckertstrasse 3
D-80336, Munich
Germany
Phone:
+49-89-5527-3910
Fax:
+49-89-5527-3920
e-mail: eurosales@powerint.com
JAPAN
Keihin Tatemono 1st Bldg
2-12-20
Shin-Yokohama, Kohoku-ku,
Yokohama-shi, Kanagawa ken,
Japan 222-0033
Phone:
+81-45-471-1021
Fax:
+81-45-471-3717
e-mail:
japansales@powerint.com
TAIWAN
5F, No. 318, Nei Hu Rd., Sec. 1
Nei Hu Dist.
Taipei, Taiwan 114, R.O.C.
Phone:
+886-2-2659-4570
Fax:
+886-2-2659-4550
e-mail:
taiwansales@powerint.com
CHINA (SHANGHAI)
Rm 807-808A,
Pacheer Commercial Centre,
555 Nanjing Rd. West
Shanghai, P.R.C. 200041
Phone:
+86-21-6215-5548
Fax:
+86-21-6215-2468
e-mail: chinasales@powerint.com
INDIA
261/A, Ground Floor
7th Main, 17th Cross,
Sadashivanagar
Bangalore, India 560080
Phone:
+91-80-5113-8020
Fax:
+91-80-5113-8023
e-mail: indiasales@powerint.com
KOREA
RM 602, 6FL
Korea City Air Terminal B/D,
159-6
Samsung-Dong, Kangnam-Gu,
Seoul, 135-728, Korea
Phone:
+82-2-2016-6610
Fax:
+82-2-2016-6630
e-mail:
koreasales@powerint.com
EUROPE HQ
1st Floor, St. James’s House
East Street, Farnham
Surrey, GU9 7TJ
United Kingdom
Phone:
+44 (0) 1252-730-140
Fax:
+44 (0) 1252-727-689
e-mail: eurosales@powerint.com
CHINA (SHENZHEN)
Room 2206-2207, Block A,
Elec. Sci. Tech. Bldg.
2070 Shennan Zhong Rd.
Shenzhen, Guangdong,
China, 518031
Phone:
+86-755-8379-3243
Fax:
+86-755-8379-5828
e-mail: chinasales@powerint.com
ITALY
Via Vittorio Veneto 12
20091 Bresso MI
Italy
Phone: +39-028-928-6000
Fax: +39-028-928-6009
e-mail: eurosales@powerint.com
SINGAPORE
51 Newton Road,
#15-08/10 Goldhill Plaza,
Singapore, 308900
Phone:
+65-6358-2160
Fax:
+65-6358-2015
e-mail:
singaporesales@powerint.com
APPLICATIONS HOTLINE
World Wide +1-408-414-9660
Page 17 of 17
APPLICATIONS FAX
World Wide +1-408-414-9760
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com