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. 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