CATALYST CAT4201

CAT4201
350mA High Efficiency Step Down LED Driver
FEATURES
DESCRIPTION
„ LED drive current up to 350mA
The CAT4201 is a high efficiency step-down converter
optimized to drive high current LEDs. A patented
switching control algorithm allows highly efficient and
accurate LED current regulation. A single RSET
resistor sets the full scale LED string current up to
350mA from supplies as high as 36V.
„ Compatible with 12V and 24V standard systems
„ Handles transients up to 40V
„ Single Pin Control and Dimming function
„ Power Efficiency up to 94%
„ Drives LED strings of up to 32V
The switching architecture of the CAT4201 results in
extremely low internal power dissipation allowing the
device to be housed in a tiny package without the
need for dedicated heat sinking. The device is
compatible with switching frequencies of up to 1MHz,
making it ideal for applications requiring small footprint
and low value external inductors.
„ Open and short LED protection
„ Parallel configuration for higher output current
„ RoHS-compliant TSOT-23 5-lead package
APPLICATIONS
„ 12V and 24V Lighting Systems
Analog dimming and LED shutdown control is
provided via a single input pin, CTRL. Additional
features include overload current protection and
thermal shutdown. The device is available in the low
profile 5-lead thin SOT23 package and is ideal for
space constrained applications.
„ Automotive and Aircraft Lighting
„ General lighting
„ High Brightness 350mA LEDs
ORDERING INFORMATION
Part Number
Quantity
per Reel
Package
Marking
CAT4201TD-GT3
3000
TF
For Ordering Information details, see page 14.
* Plated Finish: NiPdAu
TYPICAL APPLICATION CIRCUIT
PIN CONFIGURATION
TSOT-23 5-lead
CTRL
1
GND
2
5
Bulb Replacement
VBAT
9V
VBAT
C1
4.7µF
CAT4201
D
C2
VBAT
300mA
CAT4201
RSET
4
3
SW
R1
(Top View)
10kΩ
10µF
RSET
L
CTRL
SW
GND
22µH
D: Central Schottky CMDSH05-4
L: Sumida CDRH6D26-220
See Table 1 on page 6 for external component selection.
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
1
Doc. No. MD-5025 Rev. D
CAT4201
Absolute Maximum Ratings (1)
0F
Parameters
Ratings
Units
VBAT, SW, CTRL
-0.3 to +40
V
RSET
-0.3 to +5
V
1
A
Storage Temperature Range
-65 to +160
°C
Junction Temperature Range
-40 to +150
°C
300
°C
Switch SW peak current
Lead Temperature
Recommended Operating Conditions
Parameters
Ratings
(2) (3)
VBAT voltage
SW voltage
Ambient Temperature Range
LED Current
Switching Frequency
6.5 to 36
Units
(2)
V
0 to 36
V
-40 to +125
°C
50 to 350
mA
50 to 1000
kHz
ELECTRICAL CHARACTERISTICS
VIN = 13V, ambient temperature of 25ºC (over recommended operating conditions unless specified otherwise)
Symbol
IQ
Parameter
Operating Supply Current on
VBAT pin
Conditions
ISD
Idle Mode Supply Current on
VBAT pin
CTRL = GND
VFB
RSET Pin Voltage
2 LEDs with ILED= 300mA
1.15
1.2
1.25
V
ILED
Programmed LED Current
R1 = 33kΩ
R1 = 10kΩ
R1 = 8.25kΩ
270
100
300
350
330
mA
2.6
3.1
V
VCTRL-FULL
CTRL Voltage for 100%
Brightness
VCTRL-EN
CTRL Voltage to Enable
LEDs
LED enable voltage threshold
VCTRL-SD
CTRL Voltage to Shutdown
LEDs
LED disable voltage threshold
ICTRL
CTRL pin input bias
RSW
TSD
THYST
Switch “On” Resistance
Thermal Shutdown
Thermal Hysteresis
η
Efficiency
Min
Typ
Max
Units
0.4
1
mA
90
0.9
0.4
µA
1.2
0.9
VCTRL = 3V
VCTRL = 12V
ISW = 300mA
40
200
0.9
150
20
Typical Application Circuit
86
V
V
80
µA
1.5
Ω
ºC
ºC
%
Notes:
(1) Stresses above those listed under “Absolute Maximum Ratings” may cause permanent damage to the device. These are stress ratings
only, and functional operation of the device at these or any other conditions outside of those listed in the operational sections of this
specification is not implied. Exposure to any absolute maximum rating for extended periods may affect device performance and reliability.
(2) The VBAT pin voltage should be at least 3V greater than the total sum of the LED forward voltages in order to operate at nominal LED
current.
(3) During power-up, the slew rate of the input supply should be greater than 1µs for every 5V increase of VBAT.
Doc. No. MD-5025 Rev. D
2
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
Typical Operation Characteristics
VIN = 13V, ILED = 300mA, L = 22μH, C1= 4.7μF, C2 = 10μF, TAMB = 25°C unless otherwise specified
Idle Mode Supply Current (CTRL = 0V)
Input Operating Supply Current
200
0.8
IDLE CURRENT [μA]
QUIESCENT CURRENT [mA]
1.0
0.6
0.4
0.2
0.0
8
100
50
0
10 12 14 16 18 20 22 24
INPUT VOLTAGE [V]
0
CTRL Input Bias Current
4
8
12 16
20
INPUT VOLTAGE [V]
24
RSET Voltage vs. Temperature
250
1.30
200
RSET VOLTAGE [V]
CTRL BIAS CURRENT [μA] .
150
150
100
50
VIN = 13V
1.25
1.20
1.15
1.10
0
0
2
4
6
8
10
CTRL VOLTAGE [V]
-40
12
RSET Voltage vs. CTRL Voltage
0
40
80
TEMPERATURE [°C]
120
LED Current vs. RSET
1.4
400
1.0
LED CURRENT [mA]
RSET VOLTAGE [V]
1.2
+25°C
-40°C
+ 85°C
0.8
0.6
0.4
0.2
300
200
100
0
0.0
0
1
2
3
CTRL VOLTAGE [V]
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
5
4
3
10
15 20 25
RSET [kΩ]
30
35
Doc. No. MD-5025 Rev. D
CAT4201
Typical Operation Characteristics
VIN = 13V, ILED = 300mA, L = 22μH, C1= 4.7μF, C2 = 10μF, TAMB = 25°C unless otherwise specified
Switching Frequency vs. Input Voltage (2 LEDs)
500
SWITCHING FREQUENCY [kHz]
SWITCHING FREQUENCY [kHz]
Switching Frequency vs. Input Voltage (1 LED)
400
150mA
300
200
300mA
100
0
8
12
16
20
24
INPUT VOLTAGE [V]
400
300mA
300
200
100
0
12
16
20
24
INPUT VOLTAGE [V]
28
2
SW RESISTANCE [Ω]
300
300mA
200
100
1.6
1.2
0.8
0.4
0
0
40
80
TEMPERATURE [°C]
120
8
10 12 14 16 18 20 22 24
INPUT VOLTAGE [V]
Efficiency vs. Input Voltage (1 LED)
Efficiency vs. Input Voltage (2 LEDs)
100
100
95
95
EFFICIENCY [%]
SWITCHING FREQUENCY [kHz]
500
Switch ON Resistance vs. Input Voltage
150mA
-40
EFFICIENCY [%]
150mA
8
VIN = 13V
400
600
28
Switching Frequency vs. Temperature
500
700
90
150mA
85
80
300mA
150mA
90
85
300mA
80
75
75
70
70
8 10 12 14 16 18 20 22 24
INPUT VOLTAGE [V]
Doc. No. MD-5025 Rev. D
8 10 12 14 16 18 20 22 24
INPUT VOLTAGE [V]
4
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
Typical Operation Characteristics
VIN = 13V, ILED = 300mA, L = 22μH, C1= 4.7μF, C2 = 10μF, TAMB = 25°C unless otherwise specified
LED Current Regulation vs. Temperature
Efficiency vs. LED Current
EFFICIENCY [%]
95
LED CURRENT VARIATION [%] .
100
2 LEDs
90
85
80
1 LED
75
70
100
150 200 250 300
LED CURRENT [mA]
350
VIN = 13V
-40
0
40
80
TEMPERATURE [°C]
350
350
VF = 3.3V
300
LED CURRENT [mA]
200
V F = 3.1V
150
VF = 3.3V
300
300mA
250
120
LED Current vs. Input Voltage (2 LEDs)
LED Current vs. Input Voltage (1 LED)
LED CURRENT [mA]
10
8
6
4
2
0
-2
-4
-6
-8
-10
150mA
100
50
0
300mA
250
200
VF = 3.1V
150
150mA
100
50
0
0
4
8 12 16 20 24
INPUT VOLTAGE [V]
28
0
8 12 16 20 24
INPUT VOLTAGE [V]
28
CTRL Power-up
Switching Waveforms
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
4
5
Doc. No. MD-5025 Rev. D
CAT4201
Typical Operation Characteristics
VIN = 13V, ILED = 300mA, L = 22μH, C1= 4.7μF, C2 = 10μF, TAMB = 25°C unless otherwise specified
Line Transient Response (10V to 13V)
RSET Transient Response
External Component Selection
Table 1 provides the recommended external
components L and C2 that offer the best performance
relative to the LED current accuracy, LED ripple
current, switching frequency and component size.
1 LED
LED current
(mA)
≥150
< 150
2 LEDs
L inductor
(µH)
C2 Capacitor
(µF)
10
2.2
22
4.7
33
4.7
47
10
L inductor
(µH)
C2 Capacitor
(µF)
22
4.7
47
2.2
Table 1. External Component Selection
Note: Larger C2 capacitor values allow to reduce further the LED ripple current if needed.
Doc. No. MD-5025 Rev. D
6
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
PIN DESCRIPTION
Pin
Name
Function
1
CTRL
Analog dimming control and shutdown pin.
2
GND
Ground reference.
3
RSET
RSET pin. A resistor connected between the pin and ground sets the average LED current.
4
SW
5
VBAT
Interface to the inductor.
Supply voltage for the device.
PIN FUNCTION
VBAT is the supply input to the device. Typical current
conduction into this pin is less than 1mA and voltage
transients of up to 40V can be applied. To ensure
accurate LED current regulation, the VBAT voltage
should be 3V higher than the total forward voltage of
the LED string. A bypass capacitor of 4.7µF or larger
is recommended between VBAT and GND.
GND is the ground reference pin. This pin should be
connected directly to the ground plane on the PCB.
SW pin is the drain terminal of the internal low
resistance high-voltage power MOSFET. The inductor
and the Schottky diode anode should be connected to
the SW pin. Voltages of up to 40V can be safely
handled on the SW pin. Traces going to the SW pin
should be as short as possible with minimum loop
area. The device can handle safely “open-LED” or
“shorted-LED” fault conditions.
CTRL is the analog dimming and control input. An
internal pull-down current of 20µA allows the LEDs to
shutdown if CTRL is left floating. Voltages of up to
40V can be safely handled by the CTRL input pin.
When the CTRL voltage is less than 0.9V (typ), the
LEDs will shutdown to zero current. When the CTRL
voltage is greater than about 2.6V, full scale
brightness is applied to the LED output. At voltages of
less than around 2.6V, the LED current is
progressively dimmed until shutdown.
For lamp replacement applications, or applications
where operation in dropout mode is expected, it is
recommended that the CTRL pin voltage be derived
from the LED cathode terminal.
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
RSET pin is regulated at 1.2V. A resistor connected
between the RSET pin and ground sets the LED fullscale brightness current. The external resistance
value and the CTRL pin voltage determine the LED
current during analog dimming.
7
Doc. No. MD-5025 Rev. D
CAT4201
SIMPLIFIED BLOCK DIAGRAM
12V/24V
VBAT
30kΩ
CTRL
7V
20µA
OFF-Time Control
SW
EN
PWM
Controller
1.2V
Reference
+
ON-Time Control
EN
R2
–
1Ω
1.2V
GND
RSET
Figure 1. CAT4201 Simplified Block Diagram
BASIC OPERATION
LED Pin Current
The LED current is set by the external RSET resistor
connected to the regulated output of the RSET pin. An
overall current gain ratio of approximately 2.5A/mA
exists between the average LED current and the
RSET current, hence the following equation can be
used to calculate the LED current.
The CAT4201 is a high efficiency step-down regulator
designed to drive series connected high-power LEDs.
LED strings with total forward voltages of up to 32V
can be driven with bias currents of up to 350mA.
During the first switching phase, an integrated high
voltage power MOSFET allows the inductor current to
charge linearly until the peak maximum level is
reached, at which point the MOSFET is switched off
and the second phase commences, allowing the
inductor current to then flow through the Schottky
diode circuit and discharge linearly back to zero
current.
LED Current (A) ≅ 2.5 x VRSET (V) / RSET (kΩ)
Table 2 lists the various LED currents and the
associated RSET resistors.
LED current (A)
0.10
0.15
0.20
0.25
0.30
0.35
The switching architecture ensures the device will
always operate at the cross-over point between
Continuous Conduction Mode (CCM) and Discontinuous Conduction Mode (DCM). This operating
mode results in an average LED current which is
equal to half of the peak switching current.
RSET (kΩ)
33
21
15
12
10
8.25
Table 2. RSET Resistor Selection
Doc. No. MD-5025 Rev. D
8
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
APPLICATION INFORMATION
Input Voltage Range
The minimum supply voltage required to maintain
adequate regulation is set by the cathode terminal
voltage of the LED string (i.e the VBAT voltage minus
the LED string voltage). When the LED cathode
terminal falls below 3V, a loss of regulation occurs.
For applications which may occasionally need to
experience supply “dropout” conditions, it is
recommended that the CTRL input be used to sense
the LED cathode voltage. The CTRL pin can either be
tied directly to the cathode terminal (for Lamp
Replacement) or connected via a pass-transistor for
PWM lighting applications.
LED CURRENT [mA]
I rated
(A)
LED current
(A)
CDRH6D26-100
10
1.5
0.35
CDRH6D26-220
22
1.0
0.35
CDRH6D28-330
33
0.92
0.35
CDRH6D28-470
47
0.8
0.35
CDRH6D28-560
56
0.73
0.35
Capacitor Selection
A 10μF ceramic capacitor C2 across the LED(s)
keeps the LED ripple current within ± 15% of nominal
for most applications. If needed, a larger capacitor can
be used to further reduce the LED current ripple. Any
resistance in series with the LED (0.5Ω or more)
contributes to reduce the ripple current. The capacitor
voltage rating should be equivalent to the maximum
expected supply voltage so as to allow for “OpenLED” fault conditions. The capacitor value is
independent of the switching frequency or the overall
efficiency.
400
300mA
A 4.7μF ceramic input capacitor C1 is recommended
to minimize the input current ripple generated on the
supply. Using a larger capacitor value further reduces
the ripple noise appearing on the supply rail.
200
150mA
100
L
(µH)
Table 3. Sumida inductors
Figure 2 shows the regulation performance obtained
in dropout, when the CTRL pin is configured to sense
the LED cathode voltage.
300
Part Number
If a constant capacitance is needed across
temperature and voltage, X5R or X7R dielectric
capacitors are recommended.
0
0
1
2
3
4
5
CTRL VOLTAGE [V]
6
Schottky Diode
The peak repetitive current rating of the Schottky
diode must be greater than the peak current flowing
through the inductor. Also the continuous current
rating of the Schottky must be greater than the
average LED current. The voltage rating of the diode
should be greater than the peak supply voltage
transient preventing any breakdown or leakage.
Central Semiconductor Schottky diode CMDSH05-4
(40V, 500mA rated) is recommended. Schottky diodes
rated at 400mA (or higher) continuous current are fine
for most applications.
Figure 2. “Dropout” configured LED Current
(as shown in Typical Application on page 1)
Inductor Selection
For 350mA LED current drive levels, a 22µH inductor
value is recommended to provide suitable switching
frequency across a wide range of input supply values.
For LED current of 150mA or less, a 33µH or 47µH
inductor is more suitable.
The inductor must have a maximum current rating
which equals or exceeds twice the programmed LED
current. For example, when driving LEDs at 350mA,
an inductor with at least 700mA current rating must be
used. Minor improvements in efficiency can be
achieved by selecting inductors with lower series
resistance.
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
Note: Schottky diodes with extremelly low forward voltages (VF) are
not recommended, as they may cause an increase in the
LED current.
9
Doc. No. MD-5025 Rev. D
CAT4201
Dimming Methods
Two methods for PWM dimming control on the LEDs
are described below. The first method is to PWM on
the control pin, the other method is to turn on and off a
second resistor connected to the RSET pin and
connected in parallel with R1.
VBAT
12V
C1
4.7µF
D
VBAT
C2
10µF
CAT4201
RSET
PWM on CTRL Pin
A PWM signal from a microprocessor can be used for
dimming the LEDs when tied to the CTRL pin. The
duty cycle which is the ratio between the On time and
the total cycle time sets the dimming factor. The
recommended PWM frequency on the CTRL pin is
between 100Hz and 2kHz.
L
R1
10kΩ
SW
CTRL
22µH
GND
5V
Q1
R2
PWM
control
R4
0V
NPN
1kΩ
1kΩ
R5
47kΩ
Figure 5. Circuit for PWM on CTRL
PWM on RSET Pin
Another dimming method is to place in parallel to R1
another resistor with a FET in series, as shown on
Figure 6. R1 sets the minimum LED current corresponding to 0% duty cycle. The combined resistor of
R1 and Rmax sets the maximum LED current
corresponding to 100% duty cycle.
VBAT
13V
C1
4.7µF
Figure 3. PWM at 1kHz on CTRL Pin
D
VBAT
CAT4201
RSET
Rmax
300
R1
LED CURRENT [mA]
22µH
Q1
R2
PWM
control
200
10µF
L
SW
CTRL
GND
250
C2
OFF ON
NPN
1kΩ
150
100
Figure 6. Circuit for PWM on RSET
50
0
100
80
60
40
20
DUTY CYCLE [%]
0
Figure 4. LED Current vs. Duty Cycle
Doc. No. MD-5025 Rev. D
10
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
Operation from high supply voltage above 14V
For operation from a supply voltage above 14V, it is
recommended to have a slew rate of 1µs or more for
every 5V increase in VBAT supply. When using a high
supply voltage of 24V, a 1Ω or 2Ω resistor in series
with the supply, as shown on Figure 7, is
recommended to limit the slew rate of the supply
voltage. A 4.7µF minimum ceramic capacitor is placed
between the VBAT pin and ground. The combination
of the series resistor R3 and input capacitor C1 atcs
as a low pass filter limiting the excessive in-rush
currents and overvoltage transients which would
otherwise occur during “hot-plug” conditions, thereby
protecting the CAT4201 driver.
Parallel configuration for driving LEDs beyond
350mA
Several CAT4201 devices can be connected in
parallel for driving LEDs with current in excess of
350mA. The CAT4201 driver circuits are connected to
the same LED cathode. Figure 9 shows the
application schematic for driving 1A into one LED with
three CAT4201 connected in parallel. Each CAT4201
is driving the LED with a current set by its RSET
resistor. The resulting LED current is equal to the sum
of each driver current.
VIN
R5
1Ω
C1
C4
U1
4.7µF
D1
10µF
VBAT
VBAT
24V
R3
1Ω
CAT4201
C1
R1
4.7µF
D1
VBAT
CAT4201
R1
10kΩ
8.3kΩ
C2
1A
RSET
L1
CTRL
R4
SW
22µH
GND
1kΩ
4.7µF
RSET
L
CTRL
300mA
SW
C2
33µH
GND
U2
4.7µF
R1
D2
VBAT
CAT4201
1kΩ
R2
Figure 7. 24V Application with 5 LEDs
8.3kΩ
Operation from high supply voltage of 36V
When powering from a high supply voltage of 36V, a
2Ω resistor in series with the supply is recommended,
as shown on Figure 8, to limit the slew rate of the
supply voltage.
RSET
L2
CTRL
SW
22µH
GND
C3
U3
4.7µF
D3
VBAT
CAT4201
VBAT
R3
36V
2Ω
R3
C1
8.3kΩ
4.7µF
D1
CAT4201
10kΩ
SW
GND
22µH
2.2µF
Figure 9. Three CAT4201 in Parallel for 1A LED
RSET
L
CTRL
L3
CTRL
C2
VBAT
R1
RSET
300mA
SW
47µH
GND
R2
1kΩ
Figure 8. 36V Application with 6 LEDs
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
11
Doc. No. MD-5025 Rev. D
CAT4201
Open LED Behavior
If the LEDs are not connected, the CAT4201 stops
switching and draws very little current.
Board Layout
In order to minimize EMI and switching noise, the
Schottky diode, the inductor and the output capacitor
C2 should all be located close to the driver IC. The
input capacitor C1 should be located close to the
VBAT pin and the Schottky diode cathode. The
CAT4201 ground pin should be connected directly to
the ground plane on the PCB. A recommended PCB
layout with component location is shown on Figure 11.
The LEDs are connected by two wires tied to both
sides of the output capacitor C2. The LEDs can be
located away from the driver if needed.
At power-up with no load connected, the capacitor C2
is charged-up by the CAT4201. As soon as the bottom
side of the capacitor (C2-) reaches 0 volt, as shown
on Figure 10, the CAT4201 stops switching and
remains in the idle mode only drawing about 0.4mA
current from the supply.
Figure 10. Open LED mode
Figure 11. Recommended PCB Layout
In order to further reduce the ripple on the supply rail,
an optional Pi style filter (C-L-C) can be used. A 10µH
inductor rated to the maximum supply current can be
used.
Doc. No. MD-5025 Rev. D
12
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
CAT4201
PACKAGE OUTLINE DRAWING
TSOT-23 5-Lead (TD) (1)(2)
1F
SYMBOL
D
MIN
NOM
A1
0.01
0.05
A2
0.80
0.87
b
0.30
c
0.12
A
e
E1
E
MAX
1.00
0.15
2.90 BSC
E
2.80 BSC
E1
1.60 BSC
e
0.95 TYP
0.30
0.40
L1
0.60 REF
L2
0.25 BSC
θ
0.90
0.45
D
L
0.10
0º
0.20
0.50
8º
TOP VIEW
A2 A
b
θ
L
A1
c
L2
L1
SIDE VIEW
END VIEW
For current Tape and Reel information, download the PDF file from:
http://www.catsemi.com/documents/tapeandreel.pdf.
Notes:
(1) All dimensions are in millimeters. Angles in degrees.
(2) Complies with JEDEC standard MO-193.
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
13
Doc. No. MD-5025 Rev. D
CAT4201
EXAMPLE OF ORDERING INFORMATION (1)
2F
Prefix
CAT
Device #
4201
Company ID
Suffix
TD
-G
T3
Package
TD: TSOT
Plated Finish
G: NiPdAu
Tape & Reel
T: Tape & Reel
3: 3000/Reel
Product Number
4201
ORDERING PART NUMBER
CAT4201TD-GT3
Notes:
(1) All packages are RoHS-compliant (Lead-free, Halogen-free).
(2) The standard plated finish is NiPdAu on all pins.
(3) The device used in the above example is a CAT4201TD-GT3 (TSOT-23, NiPdAu, Tape & Reel).
(4) For additional package and temperature options, please contact your nearest Catalyst Semiconductor Sales office.
Doc. No. MD-5025 Rev. D
14
© Catalyst Semiconductor, Inc.
Characteristics subject to change without notice
REVISION HISTORY
Date
Revision
Reason
24-Jul-07
A
Initial Issue
02-Aug-07
B
Updated Typical Application Circuit
Added “External Component Selection” Table
Added “Capacitor Selection” information
Updated Figures 5, 6, 7, 8
21-Feb-08
C
Update Description, change patent-pending to patented
Update Package Outline Drawing
17-Jun-08
D
Update Supply Voltage
Copyrights, Trademarks and Patents
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0H
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Document No: MD-5025
Revision:
D
Issue date:
02/21/08