E522.32 Demoboard 2 x Boost-to-Battery AN 0158 Headlight LED

Transcription

E522.32 Demoboard 2 x Boost-to-Battery
AN 0158
Dec 1, 2015
Headlight LED Demo Application using Elmos E522.32 Dual LED Controller
(2 x Boost-to-Battery Topology) for Low-Beam, High-Beam and Daytime
Running Light
Figure 1. Demoboard
1 What you get:
1. Demonstrator for dual constant current LED application using E522.32 Dual LED controller to drive 1A LED arrays (1st
channel High- and Low-Beam) and 750mA LED arrays (2nd channel Daytime Running Light) and output power up to
approx. 45W.
2 Advantages of E522.32 dual Boost-to-Battery Applications:
The Headlight LED Demo application is build using a single Elmos E522.32 Dual LED controller to drive three light functions
Low-Beam, High-Beam and Daytime Running Light. Both converters operate in Boost-to-Battery topology with spread-spectrum to improve electromagnetic compatibility. Small ceramic input and output capacitors are used to save space and cost.
This demoboard is designed for an input voltage range from 5.5V up to 18V. The 1st channel is optimized to drive 1A LED arrays for Low- and High-Beam with a LED output voltage between 5V and 50V (dependent on the input voltage and externally
configured over-voltage protection). The 2nd channel is optimized to drive 750mA LED arrays for Daytime Running Light with a
LED output voltage between 5V and 40V (dependent on the input voltage and externally configured over-voltage protection).
3 Features Demoboard:

LED over voltage protection, power-stage current limitation
short-circuit and open load proof application
status LED on each Channel
reverse polarity protection
Low- and High-Beam can be toggled “on” and “off”
Digital PWM Dimming to control the LED brightness of Daytime Running Light
Derating Mechanisms for either low V(VIN) or high temperatures via NTC reading
The maximum LED string length at both channels results from the LED forward voltage, the input voltage and the maximum
output voltage defined by the over voltage protection.
n (V OUT (max) V VIN )/(V LED(max) )
Elmos Semiconductor AG
Application Note 1/12
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
The LED string is protected against over voltage by the over OVP voltage divider for each channel. The OVP threshold is adjusted to approx. 60V on the 1st channel ( Low- and High-Beam) and approx. 50V on the 2nd channel (Daytime Running Light).
That means, an output voltage of > 60V at the 1st channel’s output will turn off the channel. Note that the OVP threshold is an
absolute value, so the usable output voltage is limited to (VOUT(max)-VIN ) in Boost-to-Battery configuration.
Both channels operate with the same switching frequency in phase shift of 180° to reduce EMI. The switching frequency is generated by the internal oscillator of the E522.32. The switching frequency is set to 480kHz by the resistor R5 (62 kOhms) at pin RT.
4 Low- and High Beam control:
Low- and High Beam can be toggled on and off via the pins DIS_LB and DIS_HB on the CON3 connector. The Low and High
Beam are connected in series. To switch both functions off, set PWDIM1 low via pin DIS_LB. By toggling the pin DIS_HB the
switch Q3 is opened and closed. This switches the High Beam on and off.
Table 1.Truth Table
DIS_LB
0V
3V3
0V
3V3
DIS_HB
0V
0V
3V3
3V3
Low-Beam
OFF
ON
OFF
ON
High-Beam
OFF
OFF
OFF
ON
5 Daytime Running Light control
The DRL_DIM pin on CON3 connector can be used to control the LED brightness of the Daytime Running Light with only marginal changes in the LED color. The average LED current can be controlled by digital PWM in a range of 1000:1 at 200 Hz PWM
frequency via DRL_DIM pin on the CON3. When DRL_DIM pin is Low, the 2nd channel is in sample-and-hold state, and the Daytime Running Light is switched off.
6 Voltage Derating and Temperature Derating
If the input voltage is low, higher losses could occur. Therefore the output current is linearityreduced between 5.5V and 7.5V.
Output Derating VS Input Voltage
100
LOAD (% )
95
90
85
80
75
70
65
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
INPUT VOLTAGE (V)
Figure 2. Output Derating VS Input Voltage
The Headlight LED Demo application includes temperature derating on board for each channel (47kOhm NTC resistor). The NTC
resistors measure the temperature near of the corresponding channel and reduce the output current. It is possible to use the
on Board NTCs (NTC1, NTC2) or external NTC (connected via CON3 connector).
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
Temperature Derating
100
90
LOAD (% )
80
70
60
50
40
30
20
10
0
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
AMBIENT TEMP. (°C)
Figure 3. Temperature Derating
7 High Voltage Option
If an absolute output voltage between 60V and 75V is required the over-voltage protection, diodes and MOSFETs must be
adapted. For an absolute output voltage up to 75V the value of R8 or R12 must be changed to 590kOhm.
In this high voltage range, please exercise caution!.
8 Electrical Characteristics
Description
Input Voltage Range
LED Current LB+HB
LED Current DRL
Recommended LED Output Voltage LB+HB
Maximum LED Output Voltage LB+HB
Recommended LED Output Voltage DRL
Maximum LED Output Voltage DRL
Efficiency
OVP Threshold LB+HB
OVP Threshold DRL
Switching Frequency
ADIM1 Input Voltage LB+HB
ADIM2 Input Voltage DRL
Over-Current Protection LB+HB
Over-Current Protection DRL
Condition
Recommended
R16=100mOhm
R25=130mOhm
Typ. VLED,HB + VLED,LB
VIN<=18V
VOUT(max),LB_HB-VIN
Typ. VLED,DRL
VIN<=18V
VOUT(max),DRL-VIN
VIN=13V
VLED,LB_HB=32V VLED(typ),LB_HB=13V
ILED,LB_HB=1A ILED,DRL=750mA
R8=470kOhm
R11=9,53kOhm
R12=390kOhm
R11=9,53kOhm
R5=62kOhm
Symbol
VIN
ILED,LB_HB
ILED,DRL
VLED(typ),LB_HB
Value (Typical)
5.5V-18V
1A
750mA
32V
VLED(max),LB_HB
42V
VLED(typ),DRL
13V
VLED(max),DRL
32V
Eff.
88.00%
VOUT(max),LB_HB
60V
VOUT(max),DRL
50V
fOSC,INT
VADIM1,EXT
VADIM2,EXT
480kHz
600mV
600mV
R22=20mOhm
R19=680Ohm, R21=18kOhm
R31=82mOhm
R29=680Ohm, R30=22kOhm
IOCP,LB_HB
15.25A
IOCP,DRL
3.97A
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
E522.32 Boost to Battery (HB LB DRL Demo)
Efficiency
90
88
86
84
Eff. [%]
82
80
78
76
74
72
70
5
7
9
11
13
15
17
19
21
23
25
27
29
Vin [V]
Figure 4. Efficiency diagram HB+LB+DRL
Iout [mA]
E522.32 Boost to VBAT (HB LB DRL Demo)
1000
980
960
940
920
900
880
860
840
820
800
780
760
740
720
700
680
660
640
620
600
580
560
540
520
500
Line Regulation
Iout_hb_lb [mA]
Iout_drl [mA]
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Vin [V]
Figure 5. Lineregulation IOUT versus VIN (Typ. VADIM = 0.581V)
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
9 What you need to start:
1. An external Power supply for input voltage VIN between 5.5V and 18V, with a recommended current capability of ~10A,
especially for low V VIN and high VLED operation.
10 Connectors:
1. Connector CON1 is for input supply voltage VIN and GND
2. Connector CON2 provides the output current for Low- and High-Beam. Connect the anode of the Low Beam LED arrays to
pin 3 (LB+) and the cathode to pin 1 (LB-). Connect the anode of the High Beam LED arrays to pin 2 (HB+) and the cathode
to pin 3 (HB-).
3. Connector CON4 provides the output current for Daytime Running Light. Connect the anode of the Daytime Running Light
LED arrays to pin 2 (DRL+) and the cathode to pin 1 (DRL-).
CON3
Pin No.
1
3
5
7
9
Function
VSM
GND
GND
NTC1_L
NTC2_L
Pin No.
2
4
6
8
10
Function
DIS_HB
DIS_LB
DRL_DIM
NTC1_H
NTC2_H
4. Pin TP1 and Pin TP4 are GND pins, intended for measurement probes etc..
5. The STATUS1 and STATUS2 LED turns on if E522.32 is active. The STATUS LEDs turn off, if a failure is detected at the corresponding channel (for failure states see data sheet E522.32 for details).
11 Start of operation:
1. Connect a LED capable of 1A to CON2 or LB+ and LB- and another to HB+ and HB- with a suitable forward voltage.
2. Connect a LED capable of 750mA to CON4 or DRL+ and DRL- with a suitable forward voltage.
3. Connect a power supply to VIN and GND.
3 a) Adjust the power supply to the desired input voltage within 5.5 and 18V, depending on LED count and forward voltage.
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
12 Schematic
Figure 6. Demoboard Schematic
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
13 Bill of material (BOM):
Used Pos.-No.
2
R17, R28
R19, R29,
4
R41, R46
3
R6, R7, R15
1
R27
R3, R4, R23,
5
R38, R44
2
R18, R20
1
R40
1
R13
1
R11
3
R14, R39, R45
1
R21
1
R30
1
R37
2
R35, R43
2
R34, R42
2
R24, R32
1
R5
1
R36
1
R12
1
R8
2
R1, R2
1
R33
1
R26
1
R22
1
R31
1
R16
1
R25
1
R10
1
R9
1
R48
1
R47
Value
10R, 1%
Order-No.
667-ERJ-3EKF10R0V
Supplier
MOUSER
Remark
0603, 1/10W
Manufacturer
Panasonic
680R, 1%
667-ERJ-3EKF6800V
MOUSER
0603, 1/10W
Panasonic
1k2, 1%
1k8, 1%
667-ERJ-3EKF1201V
667-ERJ-3EKF1801V
MOUSER
MOUSER
0603, 1/10W
0603, 1/10W
Panasonic
Panasonic
3k3, 1%
667-ERJ-3EKF3301V
MOUSER
0603, 1/10W
Panasonic
4k7, 1%
5k1, 1%
5k6, 1%
9k53, 1%
10k, 1%
18k, 1%
22k, 1%
36k, 1%
42k2, 1%
47k, 1%
56k, 1%
62k, 1%
180k, 1%
390k, 1%
470k, 1%
opt.
33R, 1%
opt.
R020, 1%
R082, 1%
R100, 1%
R130, 1%
R680, 1%
1R5, 1%
5R6 , 1%
6R8 , 1%
667-ERJ-3EKF4701V
667-ERJ-3EKF5101V
667-ERJ-3EKF5601V
667-ERJ-3EKF9531V
667-ERJ-3EKF1002V
667-ERJ-3EKF1802V
667-ERJ-3EKF2202V
667-ERJ-3EKF3602V
667-ERJ-3EKF4222V
667-ERJ-3EKF4702V
667-ERJ-3EKF5602V
667-ERJ-3EKF6202V
667-ERJ-3EKF1803V
667-ERJ-3EKF3903V
667-ERJ-3EKF4703V
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
0603, 1/10W
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
667-ERJ-6ENF33R0V
MOUSER
Panasonic
754-PRL1632-R020-FT1
754-PRL1632-R082-FT1
667-ERJ-8RSFR10V
667-ERJ-8RSFR13V
667-ERJ-8RQFR68V
667-ERJ-8RQF1R5V
667-ERJ-8BQF5R6V
667-ERJ-8BQF6R8V
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
0805, 1/8W
0805
1206_ wide , 1W
1206_ wide , 1W
1206, 1/4W
1206, 1/4W
1206 / 1/4W
1206 / 1/4W
1206, 1/2W
1206, 1/2W
2
2
1
1
1
2
2
1
4.7nF
22nF
47nF
56nF
100nF
1uF
220pF
33nF
81-GCM188R71H472K37D
81-GCM188R71H223K37D
81-GCM188R71H473K55D
81-GRM188R71H563KA93
81-GCM188R71H104KA7D
81-GCM188R71E105KA4D
81-GCM2165C2A221JA6D
81-GCM219R71H333KA7D
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
0603, X7R, 50V
0603, X7R, 50V
0603, X7R, 50V
0603, X7R, 50V
0603, X7R, 50V
0603, X7R, 25V
0805,NP0, 100V
0805, X7R, 50V
Murata
Murata
Murata
Murata
Murata
Murata
Murata
Murata
47nF, 10%
81-GCM21BR71H473KA7L
MOUSER
0805, X7R, 50V
Murata
100nF, 10%
100nF, 10%
100nF
1uF
2,2uF
4,7uF (2uF||2uF)
100V
81-GCM21BR71H104KA37
81-GCJ21BR71H104KA1L
81-GRJ21BC72A105KE1L
81-GCM21BR7YA105KA5L
81-GCM32DR72A225K64L
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
0805, X7R, 50V
0805, X7R, 50V
0805, X7S, 100V
0805, X7R, 35V
1210, X7R, 100V
Murata
Murata
Murata
Murata
Murata
81-GCM32DR72A225K64L
MOUSER
1210, X7R, 100V
Murata
1
1
1
1
1
C2, C4
C24, C25
C3
C1
C7
C5, C6
C26, C27
C18
C10, C16,
C21
C11
C8
C23
C13
C22
1
C17
3
Susumu
Susumu
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
Panasonic
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
Used
3
2
1
Pos.-No.
C9, C15, C20
C14, C19
C12
Value
4,7uF, 10%
10uF
33uF
Order-No.
81-GCM32ER71H475KA5L
81-GRM32ER71H106MA2L
667-EEE-FP1V330AP
Supplier
MOUSER
MOUSER
MOUSER
Remark
1210, X7R, 50V
1210, X7R, 50V
SMD 33UF 35V ELECT
Manufacturer
Murata
Murata
Panasonic
2
NTC1, NTC2
47k NTC
594-NTCS0603E3473JHT
MOUSER
NTC 47k 0603
VISHAY
1
L1
XAL6060472MEB
XAL6060-472MEB
Coilcraft
4.7 uH 20 % 11 A
Coilcraft
1
L2
XAL1010103MED
XAL1010-103MED
Coilcraft
10 uH 20 % 15.5 A
Coilcraft
1
L3
XAL1010153MED
XAL1010-153MED
Coilcraft
15 uH 20 % 13.8 A
Coilcraft
1
1
1
2
1
D1
D2
D3
D4, D5
D6
STATUS1
STATUS2
BZX84-C10
PMEG6030
SM4T35CAY
859-LTST-C150KGKT
859-LTST-C150KGKT
78-BZX84C10-E3-08
771-PMEG6030EP-115
511-SM4T35CAY
MOUSER
MOUSER
MOUSER
MOUSER
MOUSER
SMD LED 1206 GREEN
SMD LED 1206 GREEN
50V 0.35W 5%
60V 3A SOD128
TVS-Diode
2
D7, D8
TS4148-0805
821-TS4148-0805-RY
MOUSER
DIODE
LITEON
LITEON
VISHAY
NXP
ST
Taiwan Semiconductor
1
Z1
5,6V
621-MMSZ5232B-F
MOUSER
Zener-Diode 5.6V
500mW
DIODES
1
Q1
SI7463DP-T1GE3
781-SI7463DP-T1-GE3
MOUSER
VISHAY
5
BC846
833-BC846B-TP
MOUSER
2
Q2, Q5, Q8,
Q9, Q10
Q3, Q6
FDC5614
512-FDC5614P
MOUSER
2
Q4, Q7
BUK9Y25-60E
771-BUK9Y25-60E115
MOUSER
MOSFET 40V 18.6A
5.4W 9.2mohm @ 10V
NPN 65V 100mA SOT23
MOSFET SSOT-6 P-CH
MOSFET N-channel 60
V 25 mo FET
1
U1
522.32
522.32
ELMOS
ELMOS 521.32
ELMOS
2
1
1
CON1, CON4 ARK130/2
CON2
ARK130/3
CON3
WSL10G
ARK130/2
ARK130/3
WSL10G
Schukat
Schukat
Reichelt
ARK130/2
ARK130/3
WSL 6G
PTR
PTR
4
TP1, TP2,
TP3, TP3
12H6164
Bürklin
Solder pin
Ettinger
GND
MCC
Fairchild
NXP
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
14 Layout Hints:
Figure 7. Bottom layer
Figure 8. Middle layer 2
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
Figure 9. Middle layer 1
Figure 10. Top layer
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
Figure 11. Multilayer composite print
QM-No.: 25AN0158E.00
AN 0158
Dec 1, 2015
Usage Restrictions
Elmos Semiconductor AG provide the E522.32 Demonstration Board simply and solely for IC evaluation purposes in laboratory.
The Kit or any part of the Kit must not be used for other purposes or within non laboratory environments. Especially the use or
the integration in production systems, appliances or other installations is prohibited.
The pcb´s are delivered to customer are for the temporary purpose of testing, evaluation and development of the Elmos IC´s only.
Elmos will not assume any liability for additional applications of the pcb.
Disclaimer
Elmos Semiconductor AG shall not be liable for any damages arising out of defects resulting from (1) delivered hardware or software, (2) non observance of instructions contained in this document, or (3) misuse, abuse, use under abnormal conditions or
alteration by anyone other than Elmos Semiconductor AG. To the extend permitted by law Elmos Semiconductor AG hereby expressively disclaims and user expressively waives any and all warranties of merchantability and of fitness for a particular purpose,
statutory warranty of non-infringement and any other warranty or product liability that may arise by reason of usage of trade,
custom or course of dealing.
Elmos Semiconductor AG – Headquarters
Heinrich-Hertz-Str. 1 | 44227 Dortmund | Germany
Phone + 49 (0) 231 - 75 49 - 100 | Fax + 49 (0) 231 - 75 49 - 159
sales-germany@elmos.com | www.elmos.com
Note Elmos Semiconductor AG (below Elmos) reserves the right to make changes to the product contained in this publication without notice. Elmos assumes no responsibility for the use of any circuits described herein, conveys no licence under any patent or other right, and makes no representation that the circuits are free of patent infringement. While the information in this publication has been checked,
no responsibility, however, is assumed for inaccuracies. Elmos does not recommend the use of any of its products in life support applications where the failure or malfunction of the product can reasonably be
expected to cause failure of a life-support system or to significantly affect its safety or effectiveness. Products are not authorized for use in such applications.
Copyright © 2015 Elmos Reproduction, in part or whole, without the prior written consent of Elmos, is prohibited.
QM-No.: 25AN0158E.00