Application Report

SNVA465A – March 2011 – Revised April 2013

AN-2102 LM3464 and LM5021 DHC 25W Reference

Designs
.....................................................................................................................................................

ABSTRACT
This evaluation board consists of a Texas Instruments LM5021-based 120Vac 24W AC/DC flyback
converter and a LM3464-based dynamic head room control (DHC) four channel LED driver IC. This
demonstration platform was developed so that the customers could evaluate the LM3464 with an AC/DC
supply.

Contents
1 Introduction .................................................................................................................. 2
2 Key Features ................................................................................................................ 2
3 Performance Specifications ................................................................................................ 2
4 LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic ............................................. 4
5 Bill of Materials (BOM) ..................................................................................................... 5
6 Typical Performance Characteristics ..................................................................................... 7
7 PCB Layout .................................................................................................................. 9
8 Design Information ........................................................................................................ 10
8.1 1ST Stage - DCM Flyback ........................................................................................ 10
8.2 2ND Stage - Dynamic Headroom Control ....................................................................... 10
8.3 Jumper/Fault Information ........................................................................................ 10
9 Electromagnetic Interference (EMI) ..................................................................................... 10
10 Thermal Analysis .......................................................................................................... 11
11 References ................................................................................................................. 12

List of Figures
1 Demo Board ................................................................................................................. 3
2 Efficiency vs. Line Voltage ................................................................................................. 7
3 Power Factor vs. Line Voltage ............................................................................................ 7
4 Total LED Current vs. LED Temperature ................................................................................ 7
5 Output Voltage & LED Forward Voltage vs. LED Temperature....................................................... 7
6 Ch1: Line Voltage (100 V/div); Ch3: Line Current (200 mA/div); Time (10 ms/div) ............................... 7
7 Ch1: Output Voltage (10 V/div); Ch3: Total LED Current (500 mA/div); Time (10 ms/div) ........................ 7
8 Ch1: Drain Voltage (100V/div) Time (4 µs/div) .......................................................................... 8
9 Ch1: Output Voltage (10 V/div); Ch3: Total LED Current (500 mV/div); Time (100 ms/div) ...................... 8
10 Top Layer .................................................................................................................... 9
11 Bottom Layer ................................................................................................................ 9
12 Peak Conductive EMI scan per CISPR-22, Class B Limits .......................................................... 11
13 Top Side Thermal Scan .................................................................................................. 11

List of Tables
1 Bill of Materials (BOM) ..................................................................................................... 5

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Introduction www.ti.com

1 Introduction
Once familiar with the operation of the LM3464 and its control of the AC/DC converter's control loop, the
type of AC/DC power supply and the converter's output power becomes less relevant. The evaluation
board contains eight CREE XLamp MC-E LEDs. Each XLamp MC-E LED has four separate LEDs in each
package for a total of 32 LEDs. The CREE MC-E LED allows for an easy demonstration of the LM3464
four channel operation with eight packaged LEDs. each LED string is regulated to 200mA. A heat sink is
mounted on the back of the PCB to dissipate the heat generated by the LEDs.The LM3464 regulates each
LED string current and adjust the secondary output voltage of the AC/DC power supply 0.9V above the
LED string forawrd voltage.The LM3464 monitors the output voltage and adjusts the feedback voltage to
the LM5021 primary control. This evaluation also demonstreates the LM3464 thermal fold-back feature
which reduces the average LED current when the LED temperature is over 80°C. The AC/DC flyback
power supply works in the discontinuous conduction mode and achieves power factor (PF) greater than
0.98.
The schematic, bill of materials, layout and measured performance characteristics are included.

2 Key Features
• Drive four strings of LEDs from 120Vac
• Overall Efficiency greater than 82%
• DC/LED Efficiency greater than 90%
• Power Factor greater than 0.98
• Dynamic Headroom Control (DHC)
• Thermal foldback control

3 Performance Specifications

Symbol Parameter Min Typ Max

VIN Input voltage 90 VRMS 120 VRMS 132 VRMS
VOUT LED string voltage 22 V 26 V 30 V
ILED LED string average current per - 200 mA -
string
POUT Output power - 21 W -
fsw Switching frequency - 67 kHz -

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www.ti.com Performance Specifications

Figure 1. Demo Board

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LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic www.ti.com

4 LM3464 120VAC, 24W Isolated 4 LED Driver Demo Board Schematic

L2
LINE
J1
L1

VR1 C1 BR1 V+

F1
NEUTRAL
J2

INPUT EMI FILTER AND RECTIFIER CIRCUIT J11

V+
T1
3 LED+
D5
D3
D4
C18 C3 R3 1 9
D2
+ +
C9 C10
R1 4
7 R10
C19 5
Q2
U1
R4
2 VIN OUT 4 D6

+ R7
C4 7 RT CS 6
C2 R13
R2 C7
8 SS COMP 1 R5 R9
D7 DHC
C5
3 VCC GND 5 U3
R26
C6
LM5021 C12 R12
R8
U4
C8 R11
C11
LED+

LED+ D8
J7 J8 J9 J10
R25
C17

DHC R14 U2 JP1

R15
OutP VIN
DR1
VLedFB
DR2
CDHC
C15 DR3
R16 Fltcp DR4
C14
GD1 Q3
EN JP2
J5 VDHC SE1
R19
DIM
J3 GD2 Q4
SYNC JP3
J4 Faultb SE2

VCC
C13 GD3 Q5
R18
SE3
Therm
J6
DMIN
GD4 Q6
Thmcp
R20 RT1
SE4
C16
AGND PGND

R21 R22 R23 R24

J12
LM3464

4 AN-2102 LM3464 and LM5021 DHC 25W Reference Designs SNVA465A – March 2011 – Revised April 2013
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www.ti.com Bill of Materials (BOM)

WARNING
The LM3464 evaluation board has exposed high voltage
components that present a shock hazard. Caution must be taken
when handling the evaluation board. Avoid touching the evaluation
board and removing any cables while the evaluation board is
operating.

WARNING
The ground connection on the evaluation board is NOT referenced
to earth ground. If an oscilloscope ground lead is connected to the
evaluation board ground test point for analysis and the mains AC
power is applied (without any isolation), the fuse (F1) will fail open.
For bench evaluation, either the input AC power source or the
bench measurement equipment should be isolated from the earth
ground connection. Isolating the evaliation board (using 1:1
isolation line isolation transformer) rather than the oscilloscope is
highly recommended.

5 Bill of Materials (BOM)

Table 1. Bill of Materials (BOM)

Designator Description Manufacturer Part Number
C1 CAP .10UF 305VAC EMI SUPPRESSION EPCOS B32921C3104M
C2 CAP, CERM, 0.33uF, 50V, +/-10%, X7R, 0805 MuRata GRM219R71H334KA88D
C3, C18 CAP, CERM, 0.22uF, 250V, +/-10%, X7R, 1210 MuRata GRM32DR72E224KW01L
C4 CAP, 33UF, 35V, ELECT, 5mmx11mm Panasonic EEUFM1V330
C5, C14,C15 CAP, CERM, 0.22uF, 100V, +/-10%, X7R, 0805 MuRata GRM21AR72A224KAC5L
C6, C13 CAP, CERM, 1uF, 25V, +/-10%, X5R, 0805 AVX 08053D105KAT2A
C7 CAP, CERM, 47pF, 50V, +/-5%, C0G/NP0, 0805 Yageo America CC0805JRNP09BN470
C8, C16 CAP, CERM, 0.068uF, 50V, +/-10%, X7R, 0805 AVX 08055C683KAT2A
C9, C10 CAP, 1000UF, 35V, ELECT, 12.5mmx25mm Panasonic EEU-FC1V102
C11 CAP, CERM, 1000pF, 250VAC, +/-10%, X7R, 1808 Syfer Technology 1808JA250102KXBSY2
C12 CAP, CERM, 0.15uF, 50V, +/-10%, X7R, 0805 Murata GRM21BR71H154KA01L
C17 CAP, CERM, 1uF, 50V, +/-10%, X7R, 1206 TDK C3216X7R1H105K
C19 CAP, CERM, 220pF, 500V, +/-10%, X7R, 1206 Vishay VJ1206Y221KXEAT5Z
D1 Diode, Switching-Bridge, 400V, 0.8A, MiniDIP Diodes Inc. HD04-T
D2, D7 Diode, Schottky, 100V, 0.2A, SOD-123 ST BAT41ZFILM
Microelectronics
D3 DIODE TVS 150V 600W UNI 5% SMA Littlefuse SMAJ150A
D4 DIODE, 1000V, 1A, Mini SMA Comchip CGRM4007-G
Technology
D5 Diode, Schottky, 100V, 2A, SMB Diodes Inc. B2100-13-F
D6 Diode, Zener, 10V, 500mW, SOD-123 ON MMSZ4697T1G
Semiconductor
D8 Diode, Zener, 8.2V, 500mW, SOD-123 Central CMHZ4694
Semiconductor
F1 CMHZ4694 Cooper/Bussman 6125FA1A

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Table 1. Bill of Materials (BOM) (continued)

Designator Description Manufacturer Part Number
H1 Heat Sink CUI Inc. VHS-45
J1, J2, J3, J4, Terminal, Turret, TH, Double Keystone 1502-2
J5, J6, J12 Electronics
J7, J8, J9, J10, Test Point, SMT Keystone 5016
J11 Electronics
JP1, JP2, JP3 Jumper Samtec TSW-102-07-G-S
L1 Common Mode Choke, 10mH, 0.3A Coilcraft BU09-103R25BL
L2 Inductor, Shielded Drum Core, 1mH, 0.45A,SMD Coilcraft MSS1038-105KLB
LED1 - LED8 LED Cree MCE4WT-A2-0000-000M02
Q1 MOSFET, N-CH, 500V, 6A, DPAK Fairchild FDD6N50TM
Semiconductor
Q2 Transistor, NPN, 40V, 0.2A, SOT-23 Fairchild MMBT3904
Semiconductor
Q3, Q4, Q5, Q6 MOSFET, N-CH, 100V, 32A, DPAK Fairchild FDD3682
Semiconducto
R1 RES, 150k ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW1206150KFKEA
R2 RES, 100k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW0805100KFKEA
R3, R4 RES, 10.0 ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080510R0FKEA
R5 RES, 0.1 ohm, 5%, 0.25W, 1206 Panasonic ERJ-8RSJR10V
R7 RES, 10.5k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060310K5FKEA
R8, R12 RES, 1.00k ohm, 1%, 0.125W, 0805 Vishay/Dale CRCW08051K00FKEA
R9 RES, 5.11k ohm, 1%, 0.125W, 0805 Vishay/Dale CRCW08055K11FKEA
R10, R11 RES, 10.0k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080510K0FKEA
R13 RES, 105k ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW0603105KFKEA
R14, R15 RES, 25.5k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080525K5FKEA
R16 RES, 2.67k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW08052K67FKEA
R18 RES, 3.01k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW08053K01FKEA
R19 RES, 8.06k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW08058K06FKEA
R20 RES, 0 ohm, 5%, 0.125W, 0805 Vishay-Dale CRCW08050000Z0EA
R21, R22, R23, RES, 1.0 ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW08051R00FKEA
R24
R25 RES, 0 ohm, 5%, 0.25W, 1206 Vishay-Dale CRCW12060000Z0EA
R26 RES, 22.1k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080522K1FKEA
RT1 Thermistor NTC, 10k ohm, 2%, 0603 Panasonic ERT-J1VG103GA
T1 Transformer, Flyback, 540UH Wurth Elektornik 750311959
U1 AC-DC Current Mode PWM Controller Texas LM5021-1
Instruments
U2 Dynamic Headroom Controller w/Therm Control Texas LM3464
Instruments
U3 Opto Coupler NEC PS2501L-1-Q-A
U4 Low-Voltage Adjustable Precision Shunt Regulator Texas LMV431
Instruments
VR1 Varistor, 150V, 25J, 10mm Littlefuse V150LA5P

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www.ti.com Typical Performance Characteristics

6 Typical Performance Characteristics

85 1.000
84 0.995
83 0.990

POWER FACTOR
EFFICIENCY (%)

82 0.985
81 0.980
80 0.975
79 0.970
78 0.965
77 0.960
76 0.955
75 0.950
90 100 110 120 130 140 90 100 110 120 130 140
INPUT VOLTAGE (VAC) INPUT VOLTAGE (VAC)

Figure 2. Efficiency vs. Line Voltage Figure 3. Power Factor vs. Line Voltage

1.00 26.5
0.95
26.0
TOTAL LED CURRENT (A)

OUTPUT VOLTAGES (V)

0.90
0.85 25.5 Vout
0.80
0.75 25.0
VLED
0.70
24.5
0.65
0.60 24.0
0.56
23.5
0.50
77 79 81 83 85 87 89 91 30 40 50 60 70 80
LED TEMPERATURE (C) LED TEMPERATURE (C)

Figure 4. Total LED Current vs. LED Temperature Figure 5. Output Voltage & LED Forward Voltage vs.
LED Temperature

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Line Voltage and Line Current Output Voltage and LED Current
(VIN = 120VRMS) (VIN = 120VRMS)

Figure 6. Ch1: Line Voltage (100 V/div); Figure 7. Ch1: Output Voltage (10 V/div);
Ch3: Line Current (200 mA/div); Ch3: Total LED Current (500 mA/div);
Time (10 ms/div) Time (10 ms/div)

Power MOSFET Q1 Drain to Source Voltage Start Up Voltage and Current

(VIN = 120VRMS) (VIN=120VRMS)

Figure 8. Ch1: Drain Voltage (100V/div) Figure 9. Ch1: Output Voltage (10 V/div);
Time (4 µs/div) Ch3: Total LED Current (500 mV/div);
Time (100 ms/div)

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7 PCB Layout

Figure 10. Top Layer

Figure 11. Bottom Layer

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8 Design Information

8.1 1ST Stage - DCM Flyback

The evaluation board is considered a two stage LED driver system. The first stage is the AC/DC flyback
converter and the second stage is the LM3464 LED currenr regulator. The first stage employs a NSC
LM5021-1 in a discontinuous mode flyback and operates at fixed switching frequency and constant duty
cycle. The input current follows the rectified AC input voltage and achieves power factor of 0.98 and
higher. To ensure LM5021-1 operates at constant duty cycle, R7 and R1 need to be properly sized so that
the slope compensation ramp is bigger than the current sense voltage. In this design, R7 is chosend to be
10.5Kohm and R1 is chosen to be 0.1 ohm. At 40% duty cycle, the peak ramp voltage is 246mV and the
peak current sense voltage is around 150mV.
The transformer is designed to keep the flyback converter operating in discontinuous mode at peak output
power. For a single stage PFC flyback converter, the peak output power occurs at peak input voltage and
is twice the average output power. The transformer used in the evaluation board can handle up to 48W
peak output power without saturation.
The feedback loop of the flyback converter includes U4 the LMV431 shunt regulator and U3 the opto
coupler. When LM3464 is not controlling the output voltage (during initial power up), the flyback converter
output voltage is set by resistor divider R13, R26 and R11 (approximately 17V). Once the LM3464 begins
to control the LM5021 and therefore the output voltage by sink/source current through OutP pin and
pushes the output voltage up to as high as 33V. In order to have good power factor, the control loop
bandwidth has to be lower than 120Hz. For further explanation of LM3464 operation, see the LM3464,
LM3464A LED Driver With Dynamic Headroom Control and Thermal Control Interfaces Data Sheet
(SNVS652).

8.2 2ND Stage - Dynamic Headroom Control

The second stage of the evaluation board features the LM3464 which is a linear LED driver controller. The
LM3464 is a four string controller, and in this particular demonstration board the LM3464 controls four
strings of eight LEDs at 200mA. The internal ampiliers of LM3464 compare the voltages of the current
sense resistors to a 200mV reference voltage and control the gate voltages of four external MOSFETs (
Q3 - Q6 ) to achieve linear current regulations.
The voltage headroom which the voltage difference between the seondary output voltage of the AC/DC
power supply and the LED string forward voltage is minimized by the LM3464 controller.By minimizing this
voltage, the efficiency of the system is maximized. The LM3464 regulates the drain voltage of the external
MOSFET to the voltage of the VDHC pin which is equal to 0.9V, therefore the headroom is about 0.9V.
LM3464 has thermal fold-back function to prevent the LEDs from overheating. When the voltage at the
thermal pin ( pin #3 ) is less than 3.25V, the average LED current is reduced by PWM dimming. For this
evaluation board, the thermal foldback function starts to kick in when the resistance of the NTC thermistor
RT1 reaches 3.2kohm.

8.3 Jumper/Fault Information

Jumpers JP1, JP2 and JP3 are provided for the customers to short or disconnect LED strings. One string
of LED can be disconnected to the power supply by open connector JP1. One LED each on LED string
number one can be shorted by short connctors JP2 or JP3.

LM3464 will continue to regulate the currents of the remaining strings of LEDs when one or more strings
of LEDs are shorted or disconnected. It will also continue to regulate the LED current when one or more
LEDs in that string are shorted.

9 Electromagnetic Interference (EMI)

In order to get a quick estimate of the EMI filter performance, only the PEAK conductive EMI scan was
measured and the data was compared to the Class B conducted EMI limits published in FCC – 47, section
15.

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110.0

100.0

90.0
AMPLITUDE IN dBuV

80.0

70.0

60.0

50.0

40.0

30.0

20.0
100.0k 1.0M 10.0M 100.0M
FREQUENCY

Figure 12. Peak Conductive EMI scan per CISPR-22, Class B Limits

10 Thermal Analysis
The board temperature was measured using an IR camera (HIS-3000, Wahl) while running under the
following conditions:
VIN = 120 VRMS
The results are shown in Figure 13.

Figure 13. Top Side Thermal Scan

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References www.ti.com

11 References
LM3464, LM3464A LED Driver With Dynamic Headroom Control and Thermal Control Interfaces Data
Sheet (SNVS652)

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