User's Guide SNVA074A–May2004–RevisedMay2013 AN-1299 LM5041 Evaluation Board 1 Introduction TheLM5041evaluationboardisdesignedtoprovidethedesignengineerwithafullyfunctionalcurrentfed push-pullpowerconvertertoevaluatetheLM5041controller,andalsotheLM5101buckstagegatedriver, inatypicalenvironment.Anothernameoftenusedforthecurrentfedpush-pullisa“Cascaded”topology. Theperformanceoftheevaluationboardisasfollows: • Inputrange:35Vto80V • Outputvoltage:2.5V • Outputcurrent:0to50A • Measuredefficiency:89%at50A,91%at20A • Boardsize:2.3×3.0× 0.5inches • LoadRegulation:0.1% • LineRegulation:0.1% • LineUVLO,CurrentLimit Theprintedcircuitboardconsistsof4layersof3ouncecopperonFR4materialwithatotalthicknessof 0.050inches.Soldermaskhasbeenomittedfromsomeareastofacilitatecooling.Theunitisdesignedfor continuousoperationatratedloadat<40°Candaminimumairflowof200CFM. 2 Theory of Operation Thecurrentfedpush-pullconverterisabucktypeconverterconsistingofabuckregulationstagefollowed by(cascadedby)apush-pullisolationstagethatalsoprovidesvoltagereductioninthetransformer.The buckstageissynchronous,theupperandlowerMOSFETSarebothN-channel,whicharedrivenbythe LM5101highvoltagebuckstagedriver.ThesignalstothedriverareprovidedbytheLM5041,which drivesthepush-pullstagedirectly. Thepush-pullstageisfeddirectlyfromthebuckinductorcurrent.Thepush-pulldutycyclesactually overlapslightlysothatthereisalwaysacurrentpathforthebuckinductor.Onecycleofthebuckregulator isprovidedforeachofthepushandpullswitchingeventsprovidingproperfluxbalanceinthetransformer. Operatingthetransformerwithbothprimarywindingsactiveduringthebriefoverlaptimedoesnotpresent aproblemtoeitherthecurrentsourceorthetransformer.Whenbothwindingsareactivethe magnetomotiveforceofthetransformerbreaksdownandtheimpedanceattheVPPnodedecreases towardzero.Atthattime,theinductorsourcecurrentdividesevenlybetweentheprimarywindings.Some lossesareavoidedinthecurrentfedpush-pulltopologysinceswitchinglossesrequirethepresenceof bothvoltageandcurrent. Theoutputstageusessynchronousrectificationtoavoidconsumingalargepercentageofthe2.5volt outputbytheforwardvoltagedropofatypicalSchottkyrectifier. Feedbackfromtheoutputisprocessedbyanamplifierandreferenceandthencoupledbacktothe LM5041controllerthroughanoptocoupler. Alltrademarksarethepropertyoftheirrespectiveowners. SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 1 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

PoweringandLoadingConsiderations www.ti.com Buck Stage Push-Pull Stage 35V - 80V VPP VOUT VDD VCC HB HI VIN HD HO HS LI LD LO LM5041 LM5101 VSS PUSH FEED BACK PULL FB Figure1.SimplifiedCascadedPush-PullConverter 3 Powering and Loading Considerations WhenapplyingpowertotheLM5041evaluationboardcertainprecautionsneedtobefollowed.125Wisa considerableamountofcontinuouspower.Afailureormistakecanpresentitselfinaveryalarming manner.Afewsimplerulescaneasilypreventanystartlingsurprises. 4 Proper Connections WhenoperatedatlowinputvoltagestheUUTcandrawover4Aofcurrentatfullload.Themaximum ratedoutputcurrentfortheevaluationboardis50A.Besuretochoosethecorrectconnectorandwiresize whenattachingthesourcesupplyandtheload.MonitorthecurrentintoandoutoftheUUT(evaluation boardorunitundertest).MonitorthevoltagedirectlyattheoutputterminalsoftheUUT.Thevoltagedrop acrosstheloadconnectingwireswillgiveinaccuratemeasurements.Foraccurateefficiency measurements,thesameprecautionsshouldbetaken,attachingameterdirectlyattheUUTinput terminals. 5 Source Power Theevaluationboardcanbeviewedasaconstantpowerload.Atlowinputlinevoltage(35V)theinput currentcanexceed4A,whileathighinputlinevoltagetheinputcurrentwillbeapproximately1.8A. ThereforetofullytesttheLM5041evaluationboardaDCpowersupplycapableofatleast80Vand5Ais required.Thepowersupplymusthaveadjustmentsforbothvoltageandcurrent.Anaccuratereadoutof outputcurrentisdesirablesincethecurrentisnotsubjecttolossinthecablesasinthevoltage. ThepowersupplyandcablingmustpresentalowimpedancetotheUUT.Insufficientcablingorahigh impedancepowersupplywilldroopduringpowersupplyapplicationwiththeUUTinrushcurrent.Iflarge enough,thisdroopwillcauseachatteringconditionuponpowerup.Thischatteringconditionisan interactionwiththeUUTundervoltagelockout,thecablingimpedanceandtheinrushcurrent. 2 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com Loading 6 Loading WARNING The high temperatures reached by even the most adequately rated resistors may burn you or melt your benchtop. Anappropriateelectronicloadspecifieddownto2.0Visdesirable.Theresistanceofamaximumloadis 0.050Ω.Youneedthickcables!Consultawirechartifneeded.Ifresistorbanksareusedtherearecertain precautionstobetaken.Thewattageandcurrentratingsmustbeadequatefora50A,125Wsupply. Monitorbothcurrentandvoltageatalltimes. 7 Air Flow Fullratedpowershouldneverbeattemptedwithoutprovidingthespecified200CFMofairflowoverthe UUT.Thiscanbeprovidedbyastand-alonefan. 8 Powering Up Usingtheshutdownpinprovidedwillallowpoweringupthesourcesupplywiththecurrentlevelsetlow.It issuggestedthattheloadbekeptquitenominalduringthefirstpowerup.Setthecurrentlimitofthe sourcesupplytoprovideabout11/2timesthewattageoftheload.Asyouremovetheconnectionfrom theshutdownpintoground,immediatelycheckfor2.5voltsattheoutput. Amostcommonoccurrence,thatwillproveunnerving,iswhenthecurrentlimitsetonthesourcesupplyis insufficientfortheload.Theresultissimilartohavingthehighsourceimpedancereferredtoearlier.The interactionofthesourcesupplyfoldingbackandtheUUTgoingintoundervoltageshutdownwillstartan oscillation,orchatter,thatmayhavehighlyundesirableconsequences. Aquickefficiencycheckisthebestwaytoconfirmthateverythingisoperatingproperly.Ifsomethingisa missyoucanbereasonablysurethatitwillaffecttheefficiencyadversely.Fewparameterscanbe incorrectinaswitchingpowersupplywithoutcreatinglossesandpotentiallydamagingheat. Scope Volt-meter Volt-meter Current-meter - Evaluation Board + 80 Volt, 5 Amp Pwoiwthe Cr uSrurpepnlty IN + (SHOUNT/DOOFWFN) OUT 20E0le Wctaritnt,i c6 L0o Aamdp Meter + - Jumper Figure2.TypicalEvaluationSetup SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 3 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

PerformanceCharacteristics www.ti.com 9 Performance Characteristics 9.1 Turn-on Waveforms WhenapplyingpowertotheLM5041evaluationboardacertainsequenceofeventsmustoccur.Soft-start capacitorvaluesandothercomponentsallowforaminimaloutputvoltageforashorttimeuntilthe feedbackloopcanstabilizewithoutovershoot.Figure3andFigure4showtypicalturn-onwaveformsatno loadandataloadof50A.Inputvoltage,outputvoltageandoutputcurrentareshown. 9.2 Output Ripple Waveforms Figure5showsoutputrippleforaloadof40A.Thewaveformsshouldbemeasureddirectlyacrossthe outputcapacitorsusingashorttip-typegroundleadonthescopeprobe.Bandwidthlimitingmayalso proveuseful. Trace1:InputVoltage,noloadVolts/div=10.0V Trace2:OutputVoltage,noloadVolts/div=1.0V Trace3:OutputCurrent,noloadAmps/div=20.0A HorizontalResolution=1µs/div Figure3.TypicalTurn-onWaveformatNoLoad Trace1:InputVoltage,noloadVolts/div=10.0V Trace2:OutputVoltage,noloadVolts/div=1.0V Trace3:OutputCurrent,noloadAmps/div=20.0A HorizontalResolution=1µs/div Figure4.TypicalTurn-onWaveformataLoadof50A 4 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com PerformanceCharacteristics Conditions:InputVoltage=48VDC OutputCurrent=40A BandwidthLimit=25MHz MeasuredRipple=90mVpp Trace1:OutputRippleVoltageVolts/div=50mV HorizontalResolution=5µs/div Figure5.OutputRippleforaLoadof40A. Figure6showstypicalwaveformsseenatthebuckstageswitchingnodeattheinputtoL2inductor,trace 3.Italsoshowsthetypicalwaveformsatthepush-pullterminalsofthemaintransformer,traces1and2. Theinputvoltagewas60VDCandtheloadcurrentwas20.0A. Figure7andFigure8showthetypicalwaveformsseenwhenmeasuringthedrain-sourcevoltageand currentofthepush-pullMOSFETS.Theuppertwotracesarethedrain-sourcevoltagesandthelowertwo tracesarethecorrespondingdrain-sourcecurrents.Theinputvoltagewas48VDCandtheloadcurrent was20.0A.Figure8isidenticaltoFigure7exceptfortheexpandedtimescale.Thecurrentwaveforms showthecharacteristicrampimpartedbythebuckstagewhichisresponsibleforregulationoftheoutput voltage. Trace1:Push-pullattransformer,SideA,load=20.0AVolts/div=20.0V Trace2:Push-pullattransformer,SideB,load=20.0AVolts/div=20.0V Trace3:BuckStageSwitchingNode,Load=20.0AVolts/div=50.0V HorizontalResolution=2µs/div Figure6.TypicalWaveformsseenattheBuckStageSwitchingNode SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 5 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

PerformanceCharacteristics www.ti.com Trace1:Push-pullMosfetdrain-sourcevoltage,sideA,load=20.0AVolts/div=20.0V Trace2:Sameastrace1,sideB Trace3:Push-pullMosfetdrain-sourcecurrent,sideB,load=20.0AAmps/div=1.0A Trace4:Sameastrace3,sideA HorizontalResolution=1µs/div Figure7.TypicalWaveforms Trace1:Push-pullMosfetdrain-sourcevoltage,sideA,load=20.0AVolts/div=20.0V Trace2:Sameastrace1,sideB Trace3:Push-pullMosfetdrain-sourcecurrent,sideB,load=20.0AAmps/div=1.0A Trace4:Sameastrace3,sideA HorizontalResolution=1µs/div Figure8.TypicalWaveforms 6 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com BillofMaterials 10 Bill of Materials TheBillofMaterialsislistedinTable1andincludesthemanufacturerandpartnumber. Table1.BillofMaterials Item Qty PartNumber Description Value C 1 C4532X7R2A225M CAPACITOR,CER,TDK 2.2µ,100V C 2 C4532X7R2A225M CAPACITOR,CER,TDK 2.2µ,100V C 3 C4532X7R2A225M CAPACITOR,CER,TDK 2.2µ,100V C 4 C4532X7R2A225M CAPACITOR,CER,TDK 2.2µ,100V C 5 C4532X7R3A103K CAPACITOR,CER,TDK 0.01µ,1000V C 6 C0805C471J5GAC CAPACITOR,CER,KEMET 470p,50V C 7 C3216X7R2E104K CAPACITOR,CER,TDK 0.1µ,250V C 8 C4532X7R1E156M CAPACITOR,CER,TDK 15µ,25V C 9 C2012X7R2A103K CAPACITOR,CER,TDK 0.01µ,100V C 10 C2012X7R2E472K CAPACITOR,CER,TDK 4700p,250V C 11 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 12 C3216X7R2E104K CAPACITOR,CER,TDK 0.1µ,250V C 13 C0805C101J1GAC CAPACITOR,CER,KEMET 100p,100V C 14 C0805C101J1GAC CAPACITOR,CER,KEMET 100p,100V C 15 C0805C101J1GAC CAPACITOR,CER,KEMET 100p,100V C 16 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 17 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 18 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 19 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 20 C3216X7R1H334K CAPACITOR,CER,TDK 0.33µ,50V C 21 PCC1986CT-ND CAPACITOR,CER,PANASONIC 1500p,100V C 22 PCC1986CT-ND CAPACITOR,CER,PANASONIC 1500p,100V C 23 C3216X7R1H334K CAPACITOR,CER,TDK 0.33µ,50V C 24 C3216X7R1H334K CAPACITOR,CER,TDK 0.33µ,50V C 25 C0805C471J5GAC CAPACITOR,CER,KEMET 470p,50V C 26 C0805C471J5GAC CAPACITOR,CER,KEMET 470p,50V C 27 C3216X7R1H334K CAPACITOR,CER,TDK 0.33µ,50V C 28 T520D337M006AS4350 CAPACITOR,TANT,KEMET 330µ,6.3V C 29 T520D337M006AS4350 CAPACITOR,TANT,KEMET 330µ,6.3V C 30 C4532X7S0G686M CAPACITOR,CER,TDK 68µ,4V C 31 C4532X7S0G686M CAPACITOR,CER,TDK 68µ,4V C 32 C4532X7S0G686M CAPACITOR,CER,TDK 68µ,4V C 33 C4532X7S0G686M CAPACITOR,CER,TDK 68µ,4V C 34 C2012X7R2A102K CAPACITOR,CER,TDK 1000p,100V C 35 C0805C221J5GAC CAPACITOR,CER,KEMET 220p,50V C 36 C2012X7R2A103K CAPACITOR,CER,TDK 0.01µ,100V C 37 C2012X7R1H104K CAPACITOR,CER,TDK 0.1µ,50V C 38 PCC1996CT-ND CAPACITOR,CER,PANASONIC 680p,200V C 39 C2012X7R1H104K CAPACITOR,CER,TDK 0.01µ,50V C 40 C0805C331J5GAC CAPACITOR,CER,KEMET 330p,50V C 41 C2012X7R2A102K CAPACITOR,CER,TDK 1000p,100V C 42 C1206223K5RAC CAPACITOR,CER,KEMET 0.022µ,50V D 1 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 2 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 3 CMPSH-3C-NSA DIODE,SIGNAL,CENTRAL SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 7 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

BillofMaterials www.ti.com Table1.BillofMaterials(continued) Item Qty PartNumber Description Value D 4 BAS56-NSA DIODE,SIGNAL,CENTRAL D 5 BAS56-NSA DIODE,SIGNAL,CENTRAL D 6 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 7 BAS56-NSA DIODE,SIGNAL,CENTRAL D 8 BAS56-NSA DIODE,SIGNAL,CENTRAL D 9 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 10 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 11 CMPD2838-NSA DIODE,SIGNAL,CENTRAL D 12 CMPD6001S-NSA DIODE,SIGNAL,CENTRAL D 13 CRH01CT-ND DIODE,SIGNAL,TOSHIBA L 1 SLF12575-100M5R4 INPUTCHOKE,TDK 10µH,5A L 2 A9787-A,Coilcraft PRIMARYCHOKE 60µH,7.5A EQ30,GappedforAl=400,12Turns,3C92material Q 1 SI7456DP FET,SILICONIX 100V,25m Q 2 SI7456DP FET,SILICONIX 100V,25m Q 3 SI7852DP FET,SILICONIX 80V,17m Q 4 SI7852DP FET,SILICONIX 80V,17m Q 5 SI7858DP FET,SILICONIX 12V,3m Q 6 SI7858DP FET,SILICONIX 12V,3m Q 7 SI7858DP FET,SILICONIX 12V,3m Q 8 SI7858DP FET,SILICONIX 12V,3m Q 9 SI7858DP FET,SILICONIX 12V,3m Q 10 SI7858DP FET,SILICONIX 12V,3m Q 11 ZXMN2A03E6 FET,ZETEX 20V,55m Q 12 ZXMN2A03E6 FET,ZETEX 20V,55m Q 13 ZXMN2A03E6 FET,ZETEX 20V,55m Q 14 ZXMN2A03E6 FET,ZETEX 20V,55m Q 15 CMPT591E-NSA PNP,CENTRAL 60V,1A Q 16 CMPT591E-NSA PNP,CENTRAL 60V,1A R 1 CRCW12061002F RESISTOR 10K R 2 CRCW120610R0F RESISTOR 10 R 3 CRCW120620R0F RESISTOR 20 R 4 CRCW12062000F RESISTOR 200 R 5 CRCW120649R9F RESISTOR 49.9 R 6 CRCW12061003F RESISTOR 100K R 7 CRCW12061001F RESISTOR 1K R 8 CRCW12068061F RESISTOR 8.06K R 9 CRCW12061652F RESISTOR 16.5K R 10 CRCW12062372F RESISTOR 23.7K R 11 CRCW12062001F RESISTOR 2K R 12 CRCW12064990F RESISTOR 499 R 13 CRCW12067500F RESISTOR 750 R 14 CRCW12067500F RESISTOR 750 R 15 CRCW12065R1J RESISTOR 5.1 R 16 CRCW12065R1J RESISTOR 5.1 R 17 CRCW12061002F RESISTOR 10K R 18 CRCW12061002F RESISTOR 10K 8 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com BillofMaterials Table1.BillofMaterials(continued) Item Qty PartNumber Description Value R 19 CRCW12065R1J RESISTOR 5.1 R 20 CRCW12065R1J RESISTOR 5.1 R 21 CRCW2512100J RESISTOR 10,1W R 22 CRCW2512100J RESISTOR 10,1W R 23 CRCW120610R0F RESISTOR 10 R 24 CRCW120610R0F RESISTOR 10 R 25 CRCW120610R0F RESISTOR 10 R 26 CRCW120610R0F RESISTOR 10 R 27 CRCW12061002F RESISTOR 10K R 28 CRCW12061002F RESISTOR 10K R 29 CRCW2512100J RESISTOR 10,1W R 30 CRCW2512100J RESISTOR 10,1W R 31 CRCW120610R0F RESISTOR 10 R 32 CRCW12062102F RESISTOR 21K R 33 CRCW12062002F RESISTOR 20K R 34 CRCW120610R0F RESISTOR 10 R 35 CRCW12062002F RESISTOR 20K R 36 CRCW12064991F RESISTOR 4.99K R 37 CRCW12064991F RESISTOR 4.99K R 38 CRCW12061002F RESISTOR 10K R 39 CRCW12062002F RESISTOR 20K R 40 CRCW2512100J RESISTOR 10,1W R 41 CRCW120610R0F RESISTOR 10 R 42 CRCW12064991F RESISTOR 4.99K R 43 CRCW12061000F RESISTOR 100 T 1 P8208T,Pulse CURRENTXFR,PULSEENG 100:1 T 2 A9786-A,Coilcraft POWERXFR,COILCRAFT EQ30,3C94,8T,8T,1T,1T,4T T 3 SM76925,Datatronic ISOLATIONXFR 1:1:1 T 4 SM76925,Datatronic ISOLATIONXFR 1:1:1 U 1 LM5041 CONTROLLER,TEXASINSTRUMENTS U 2 LM5101 DUALHVGATEDRIVER,TEXASINSTRUMENTS U 3 MOCD207M OPTO-COUPLER,QTOPTO U 4 LM6132 OPAMP,TEXASINSTRUMENTS U 5 LM4041 REFERENCE,TEXASINSTRUMENTS (4)1/2inchSTANDOFFs#4 RB01/21/04 SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 9 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

PCBLayouts www.ti.com 11 PCB Layouts Thelayersoftheprintedcircuitboardareshownintopdownorder.Viewisfromthetopdownexceptfor thebottomsilkscreenwhichisshownviewedfromthebottom.ScaleisapproximatelyX1.5.Theprinted circuitboardconsistsof4layersof3ouncecopperonFR4materialwithatotalthicknessof0.050inches. 10 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com PCBLayouts SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 11 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

PCBLayouts www.ti.com 12 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

www.ti.com PCBLayouts SNVA074A–May2004–RevisedMay2013 AN-1299LM5041EvaluationBoard 13 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

ApplicationCircuit www.ti.com 12 Application Circuit Figure9.ApplicationCircuit:Input35Vto80V,Output2.5V,50A 14 AN-1299LM5041EvaluationBoard SNVA074A–May2004–RevisedMay2013 SubmitDocumentationFeedback Copyright©2004–2013,TexasInstrumentsIncorporated

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