Texas Instruments LM5185-Q1 Manual de usuario
EVM User's Guide: LM5185EVM-SIO
LM5185-Q1 Single-Isolated-Output Evaluation Module
Description
The LM5185-Q1 controller uses an external power
MOSFET and has adjustable loop compensation and
current limit. All these features bring flexibility and
design optimization for power scaling, transformer
design, and BOM optimization, as well as
overall performance and solution cost. Other user
programmabilities are also supported including
the input UVLO with hysteresis, soft-start, and
temperature compensation.
Get Started
1. Order the EVM at ti.com.
2. Read this user's guide carefully.
3. Prepare the bench setup per instructions. Take
cautions to prevent damage by ESD when
handling the EVM.
4. Power up the EVM by following the recommended
steps.
5. Run tests and measurements. Take cautions of
high voltage and hot temperature produced by the
EVM during test.
Features
• Wide input voltage range (default 20V to 60V,
extendable 6V to 90V)
• Tight voltage regulation of the isolated output
without opto-coupler: 16.4V ±1.5%
• Removal of the opto-coupler and transformer aux
winding saves solution size and cost.
• Peak conversion efficiency > 90%
• Programmable loop compensation, current limit,
input UVLO, and thermal compensation allowing
for flexible and optimal designs.
Applications
•Traction inverters
•Onboard charger (OBC)
•HEV/EV HVAC and heater
•Micro inverters
•Motor drives
• Battery Management Systems (BMS)
• Generic IGBT, MOSFET, GaN and SiC gate drivers
• PoE PD dc-dc converters
• Generic isolated bias power rails for industrial and
telecom systems
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1 Evaluation Module Overview
1.1 Introduction
The LM5185-Q1 single-isolated-output (SIO) evaluational module (EVM), otherwise known as LM5185EVM-SIO,
is designed to demonstrate the features and functionality of the LM5185-Q1 device. The device is a 100-VIN
Primary-Side-Regulated (PSR) flyback DC/DC controller based on sampling the primary winding voltage of the
transformer to achieve tight output regulation and high efficiency, without using the opto coupler nor tertiary bias
winding like in a conventional flyback converter.
This user's guide describes the characteristics and operation of the evaluataion module LM5185EVM-SIO.
This document provides examples and instructions on how to use the evaluation module, and presents typical
performance curves and key waveforms. Throughout this document, the terms of evaluation board, evaluation
module, and EVM are synonymous with the LM5185EVM-SIO. This document also includes a schematic,
reference printed circuit board (PCB) layout, and a complete bill of materials (BOM).
1.2 Kit Contents
Table 1-1 details the contents of the EVM kit. Contact the TI Product Information Center at (972) 644-5580 if any
component is missing. Download the latest versions of the related software on the TI website, www.ti.com.
Table 1-1. EVM Kit Contents
ITEM QUANTITY
LM5185EVM-SIO 1
1.3 Specification
Figure 1-1 shows the simplified schematic of the LM5185EVM-SIO circuit board. Table 1-2 shows the
specifications of the EVM in the factory default settings.
VIN
FB
RSET
TC
SS
AGND
EN/UVLO
DFLY
COUT
RSNB CSNB
DZ
RDMY
GATE
CS
PGND
COMP
VCC
RCS
Q1
CVCC
RFB
DCLAMP
DF
CIN
CSS
RSET
RTC
RCOMP
CCOMP CHF
RUVH
RUVL
RFLT
CFLT
T1
Figure 1-1. LM5185 PSR Flyback Converter Simplified Schematic
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Table 1-2. Electrical Performance Characteristics
PARAMETER TEST CONDITION MIN TYP MAX UNIT
INPUT CHARACTERISTICS
Input voltage range, VIN 20 60 V
Input voltage turn on, VIN_ON Adjustable using EN/UVLO divider resistors 19
Input voltage turnoff, VIN_OFF 18
Input current, operating with no load, IIN_NL IOUT = 0 A VIN = 20 V 5.57 mA
VIN = 60 V 3.32
Input current, disabled, IIN_OFF, excluding the
external UVLO resistor leak current
VEN = 0 V, removing R6 VIN = 20 V 5.0 µA
VIN = 40 V 10.0
VIN = 60 V 20.0
OUTPUT CHACTERISTICS
Output voltage, VOUT 16.154 16.400 16.646 V
Max output current, IOUT VIN = 20 V 1.0 A
VIN = 40 V 1.5 A
VIN = 60 V 1.8 A
Soft-start time, tSS IOUT = 1 A 25 ms
SYSTEM CHARACTERISTICS
Switching Frequency VIN = 48 V, IOUT = 0.5 A 350 kHz
Half-load efficiency, ηHALF IOUT = 0.5A VIN = 20 V 90.2
VIN = 40 V 84.3
VIN = 60 V 82.0
Full load efficiency, ηFULL IOUT = 1.0A VIN = 20 V 90.5
VIN = 40 V 89.9
VIN = 60 V 86.9
Isolation rating(3) RMS voltage 1500 V
LM5180 junction temperature, TJ-40 150 °C
1.4 Device Information
The factory default settings of the EVM allow the operation with an input voltage range from 20 V to 60 V. The
device produces a single isolated output voltage of 16.4 V ±1% @ 1 A load, and achieves > 90% peak efficiency.
Fine-tuning of the output voltage can be realized by adjusting the external resistor values at the FB pin. In
addition, the users can modify the EVM to enable the operation under a VIN down to 6 V with derated output
current of 0.4A by changing the EN/UVLO set point. Further lower input voltage down to 4.5V is supported by
the LM5185-Q1 but the EVM requires a different transformer. However, the maximum VIN voltage of the EVM
can be increased to 90 V if the power MOSFET is changed to a 150 V or higher rated device, and if the input
bulk capacitor is replaced with at least a 100 V rated part. Multiple isolated output can also be supported by the
LM5185-Q1 but requires a different transformer. Please refer to the Quick Start Design Calculator to help design.
Refer to TI product data sheet SNVSBT4 for more detailed information of the LM5185-Q1 PSR flyback controller.
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2 Hardware
2.1 Setup
Figure 2-1 shows the diagram of EVM bench test setup. Refer to Section 2.2 and Section 2.3 in this user's guide
for detailed information of headers, jumpers and test points. Refer to Section 2.4 for the setup assembly and test
procedure. Refer to Section 2.5 for the important notice on safety concerns when handling the EVM.
Power Supply
- +
Ammeter 1
ACOM
Voltmeter 1
VCOM
Load
-+
Ammeter 2
ACOM
Voltmeter 2
VCOM
Figure 2-1. EVM Test Setup
The test setup consists the following instruments in addition to the EVM board.
•Power Supply: The input dc voltage source capable of at least 0-80-V and 2 A.
•Load: The load must be electronic constant-resistance (CR) or constant-current (CC) mode load, capable of
0 Adc to 2 Adc up to 20 V. For a no-load input current measurement, disconnect the electronic load as the
load can draw a small residual current.
•Multimeters:
–Voltmeter 1: Input voltage at VIN+ to VIN–. Set voltmeter to an input impedance of 100 MΩ.
–Voltmeter 2: Output voltage at VOUT+ to VOUT-. Set voltmeter to an input impedance of 100 MΩ.
–Ammeter 1: Input current. Set ammeter to 1-second aperture time.
–Ammeter 2: Output current. Set ammeter to 1-second aperture time
•Oscilloscope: With the scope set to 20-MHz bandwidth and AC coupling, measure the output voltage ripple
directly across an output capacitor with a short ground lead normally provided with the scope probe. Place
the oscilloscope probe tip on the positive terminal of the output capacitor, holding the ground barrel of the
probe through the ground lead to the negative terminal of the capacitor. TI does not recommend using
a long-leaded ground connection because this can induce additional noise given a large ground loop. To
measure other waveforms, adjust the oscilloscope as needed.
2.2 Header Information
Table 2-1 lists the header information of the EVM.
Table 2-1. Header Information
HEADER SIGNAL DESCRIPTION
J1-1 VIN+ Voltage source input port.
J1-2 VIN- Voltage source input return.
J2 VOUT+ Output voltage port.
J3 VOUT- Output voltage return port, and also the isolated ground reference ISO-GND.
J4 PGND Primary side power ground reference.
J5-1 EN/UVLO Enable and UVLO control signal. Closing J5-1 and J5-2 disables the EVM.
J5-2 AGND Analog signal reference ground.
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2.3 Test Points
The EVM has a variety of test points available for measuring and debugging purposes. Table 2-2 explains the
purpose of each test point.
Table 2-2. EVM Test Points
TEST POINT SIGNAL DESCRIPTION
TP1 VIN PSR Flyback dc-dc stage input voltage
TP2 PGND Primary side power ground reference
TP3 VOUT Isolated output voltage
TP4 COMP Compensation circuit node for the error amplifier
TP5 RSET Output voltage set pin
TP6 ISO-GND Isolated output ground reference
2.4 Assembly Instructions
Refer to Section 2.5 of this user's guide for the important notice on safety concerns when handling the EVM. The
following are the recommended instructions for the EVM test setup assembly.
Input Connections
• Prior to connecting the DC input source, set the current limit of the input supply to 100 mA maximum. Verify
the input source is initially set to 0 V and connected to the VIN+ and VIN– connection points, as shown in
Figure 2-1. An additional input bulk capacitor is recommended to provide damping if long input lines are used.
• Connect Voltmeter 1 at VIN+ and VIN– connection points to measure the input voltage.
• Connect Ammeter 1 to measure the input current and set to at least 1-second aperture time.
Output Connections
• Connect electronic load to VOUT+ and VOUT- connection points as shown in Figure 2-1. Set the load to
constant-resistance mode or constant-current mode at 0 A before applying input voltage.
• Connect Voltmeter 2 at VOUT+ and VOUT- connection points to measure the output voltage.
• Connect Ammeter 2 measure the output current.
Test Procedure
• Set up the EVM as described above.
• Set load to constant resistance or constant current mode and to sink 10 mA.
• Increase input source from 0 V to 20 V; use voltmeter 1 to measure the input voltage.
• Increase the current limit of the input supply to 1000 mA.
• Use voltmeter 2 to measure the output voltage, vary the load from 10 mA to 1000 mA DC; VOUT must
remain within the load regulation specification.
• Set the load current to 500 mA (50% rated load) and vary the input source voltage from 20 V to 60 V; VOUT
must remain within the line regulation specification.
• Use the oscilloscope to probe different signals of interest. Be careful of the probe ground reference.
• Decrease load to 10 mA. Decrease input source voltage to 0 V.
• Shut down both the input source and load, and then the voltmeters and ammeters.
2.5 Best Practices
Please take caution when handling the EVM. Operating the EVM board with up to 60 VIN can generate >75 V
voltage at certain circuit nodes as marked by the high voltage symbol on the PCB. Operating the EVM board
with the maximum load can generate hot spots in certain areas of the PCB as marked by the hot surface
symbols. Please read the following notices carefully.
WARNING
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Always follow TI’s set-up and application instructions, including use of all interface components within their
recommended electrical rated voltage and power limits. Always use electrical safety precautions to help ensure
your personal safety and the safety of those working around you. Contact TI’s Product Information Center http://
support.ti.com for further information.
Save all warnings and instructions for future reference.
Failure to follow warnings and instructions can result in personal injury, property damage, or death due
to electrical shock and/or burn hazards.
The term TI HV EVM refers to an electronic device typically provided as an open framed, unenclosed printed-
circuit board assembly. It is intended strictly for use in development laboratory environments, solely for qualified
professional users having training, expertise, and knowledge of electrical safety risks in development and
application of high-voltage electrical circuits. Any other use and/or application are strictly prohibited by Texas
Instruments. If you are not suitably qualified, you should immediately stop from further use of the HV EVM.
•Work Area Safety:
– Maintain a clean and orderly work area.
– Qualified observers must be present anytime circuits are energized.
– Effective barriers and signage must be present in the area where the TI HV EVM and interface electronics
are energized, indicating operation of accessible high voltages can be present, for the purpose of
protecting inadvertent access.
– All interface circuits, power supplies, evaluation modules, instruments, meters, scopes, and other related
apparatus used in a development environment exceeding 50 VRMS/75 VDC must be electrically located
within a protected Emergency Power Off (EPO) protected power strip.
– Use a stable and non-conductive work surface.
– Use adequately insulated clamps and wires to attach measurement probes and instruments. No freehand
testing whenever possible.
•Electrical Safety:
As a precautionary measure, it is always a good engineering practice to assume that the entire EVM can
have fully accessible and active high voltages.
– De-energize the TI HV EVM and all inputs, outputs, and electrical loads before performing any electrical or
other diagnostic measurements. Confirm that TI HV EVM power has been safely de-energized.
– With the EVM confirmed de-energized, proceed with required electrical circuit configurations, wiring,
measurement equipment hook-ups, and other application needs, while still assuming the EVM circuit and
measuring instruments are electrically live.
– When EVM readiness is complete, energize the EVM as intended.
WARNING
WARNING: While the EVM is energized, never touch the EVM or its electrical circuits as
the EVM and circuits can be at high voltages capable of causing electrical shock hazard.
•Personal Safety:
– Wear personal protective equipment, for example, latex gloves and/or safety glasses with side shields or
protect EVM in an adequate lucent plastic box with interlocks from accidental touch.
•Limitation for Safe Use:
– EVMs are not to be used as all or part of a production unit.
Safety and Precautions
The EVM is designed for professionals who have received the appropriate technical training, and is designed
to operate from an AC power supply or a high-voltage DC supply. Please read this user guide and the safety-
related documents that come with the EVM package before operating this EVM.
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CAUTION
!
Do not leave the EVM powered when unattended.
WARNING
Hot surface! Contact can cause burns. Do not touch!
WARNING
High Voltage! Electric shock is possible when connecting board to live wire. Board must be handled
with care by a professional.
For safety, use of isolated test equipment with overvoltage and overcurrent protection is highly
recommended.
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3 Implementation Results
3.1 Performance Data and Results
Figure 3-1 through Figure 3-8 presents typical performance curves for the LM5185EVM-SIO. Because actual
performance data can be affected by measurement techniques and environmental variables, these curves are
presented for reference and the curves can differ from actual field measurements.
3.1.1 Conversion Efficiency
Load Current (A)
Efficiency (%)
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
10
20
30
40
50
60
70
80
90
100
VIN = 20 V
VIN = 30 V
VIN = 40 V
VIN = 50 V
VIN = 60 V
Figure 3-1. EVM Efficiency vs. Load and Input Voltage
3.1.2 Output Voltage Regulation
Load Current (A)
Output Voltage Deviation (%)
0 0.2 0.4 0.6 0.8 1 1.2 1.4
-1%
-0.8%
-0.6%
-0.4%
-0.2%
0
0.2%
0.4%
0.6%
0.8%
1%
VIN = 20 V
VIN = 40 V
VIN = 60 V
Figure 3-2. EVM Output Voltage Regulation vs Load and Input Voltage
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3.1.3 Operating Waveforms
3.1.3.1 Start-up
C1=Vin; C2=Vout; C3=COMP; C4=SW
Figure 3-3. Start-up Under No Load: Vin=24V, Iout=0A
C1=Vin; C2=Vout; C3=COMP; C4=SW
Figure 3-4. Start-up Under Full Load: Vin=24V, Iout=1A
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3.1.3.2 Load Transient Response
C1=Vin; C2=Vout (ac coupled); C3=Vcomp; C4=Iout
Figure 3-5. Load Transient Response: Vin=24V, 0.625A to 1.25A Load Transients
3.1.3.3 Switching
C1=SW; C2=Vsec; C4=Vcomp
Figure 3-6. FFM Operation: VIN=48 V, Iout= 0.1A
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