Texas Instruments LM5180-Q1 User manual

1
SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
User's Guide
SNVU592D–July 2018–Revised April 2020
LM5180-Q1 Single-Output EVM User's Guide
With input voltage range and current capability as specified in Table 1, the family of PSR flyback DC/DC
converters from TI provides flexibility, scalability, and optimized solution size for a range of applications.
Using an 8-pin WSON package with 4-mm × 4-mm footprint and 0.8-mm pin pitch, these converters
enable isolated DC/DC solutions with high density and low component count.
Table 1. PSR Flyback DC/DC Converter Family
PSR FLYBACK
CONVERTER INPUT VOLTAGE RANGE PEAK SWITCH CURRENT (TYP) MAXIMUM LOAD CURRENT, VOUT = 12 V, NPS = 1
VIN = 4.5 V VIN = 13.5 V VIN = 24 V
LM5181-Q1 4.5 V to 65 V 0.75 A 90 mA 180 mA 225 mA
LM5180-Q1 4.5 V to 65 V 1.5 A 180 mA 360 mA 450 mA
LM25180-Q1 4.5 V to 42 V 1.5 A 180 mA 360 mA 450 mA
LM25183-Q1 4.5 V to 42 V 2.5 A 300 mA 600 mA 750 mA
LM25184-Q1 4.5 V to 42 V 4.1 A 500 mA 1 A 1.25 A
The LM5180EVM-S05 evaluation module (EVM) is a flyback DC/DC converter that employs primary-side
regulation (PSR) based on sampling of the primary winding voltage of the transformer to achieve high
efficiency in a small footprint. It operates over a wide input voltage range of 10 V to 65 V, providing a
regulated 5-V output using a transformer with 3 : 1 turns ratio. Operating without an optocoupler or
transformer auxiliary winding, the converter delivers an output voltage with ±1.5% regulation.
The EVM design uses the LM5180-Q1 65-V PSR flyback converter. An integrated 100-V, 1.5-A power
MOSFET provides ample margin for line transients and switch (SW) node voltage spikes related to
transformer parasitic leakage inductance. Load regulation errors related to transformer secondary winding
resistance are avoided by virtue of the quasi-resonant boundary conduction mode (BCM) control scheme.
Additional features includes current-mode control with internal compensation, hiccup-mode fault
protection, programmable soft-start, and optional output voltage temperature compensation. Input UVLO
protects the converter at low input voltage conditions, and the EN/UVLO pin supports adjustable UVLO
with user-defined hysteresis for application specific power-up and power-down requirements.
The LM(2)5180 and LM(2)5180-Q1 converters are available in a 8-pin WSON package with 4-mm × 4-mm
footprint and 0.8-mm pin pitch to enable isolated DC/DC solutions with high density and low component
count. Wettable flank pins provide a visual indicator of solderability, which reduces inspection time and
manufacturing costs in high-reliability industrial and automotive applications. See the LM5180 and
LM5180-Q1 data sheets for more information. Use the LM5180-Q1 with WEBENCH®Power Designer to
create a custom regulator design. Furthermore, you can download the LM5180 Quickstart Calculator to
optimize component values and examine predicted efficiency performance across line and load ranges.
Contents
1 High Density EVM Description............................................................................................. 3
1.1 Typical Applications ................................................................................................ 3
1.2 Features and Electrical Performance ............................................................................ 3
2 EVM Performance Characteristics......................................................................................... 4
3 Application Circuit Diagram................................................................................................. 5
4 EVM Photo.................................................................................................................... 5
5 Test Setup and Procedure.................................................................................................. 6
5.1 Test Setup ........................................................................................................... 6
5.2 Test Equipment ..................................................................................................... 7
5.3 Recommended Test Setup........................................................................................ 7

www.ti.com
2SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback
Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
5.4 Test Procedure...................................................................................................... 7
6 Test Data and Performance Curves....................................................................................... 8
6.1 Conversion Efficiency .............................................................................................. 8
6.2 Load Regulation..................................................................................................... 9
6.3 Operating Waveforms ............................................................................................ 10
6.4 Enable On.......................................................................................................... 12
6.5 CISPR 25 EMI ..................................................................................................... 13
7 EVM Documentation....................................................................................................... 15
7.1 Schematic .......................................................................................................... 15
7.2 Bill of Materials .................................................................................................... 16
7.3 PCB Layout ........................................................................................................ 17
7.4 Assembly Drawings............................................................................................... 18
8 Device and Documentation Support .................................................................................... 20
8.1 Device Support ................................................................................................... 20
8.2 Documentation Support .......................................................................................... 20
List of Figures
1 LM5180 PSR Flyback Converter Simplified Schematic ................................................................ 5
2 EVM Photo (Top Side), 50 mm × 35 mm................................................................................. 5
3 EVM Test Setup ............................................................................................................. 6
4 Conversion Efficiency (Linear Scale)...................................................................................... 8
5 Conversion Efficiency (Log Scale)......................................................................................... 8
6 Load Regulation (Linear Scale)............................................................................................ 9
7 Load Regulation (Log Scale)............................................................................................... 9
8 SW Node Voltage, VIN = 24 V, IOUT = 1 A................................................................................ 10
9 SW Node Voltage, VIN = 48 V, IOUT = 1 A................................................................................ 10
10 Load Transient Response, VIN = 24 V, 0.1 A to 1 A at 1 A/µs ....................................................... 11
11 Start-Up, VIN = 24 V, IOUT = 1 A Resistive ............................................................................... 11
12 Enable On, VIN = 24 V, IOUT = 1 A ........................................................................................ 12
13 CISPR 25 Class 5 Conducted Emissions Plot, VIN = 12 V, IOUT = 0.85 A, (a) 150 kHz to 30 MHz, (b) 30
MHz to 108 MHz ........................................................................................................... 13
14 CISPR 25 Class 5 Conducted Emissions Plot, VIN = 24 V, IOUT = 0.85 A, (a) 150 kHz to 30 MHz, (b) 30
MHz to 108 MHz ........................................................................................................... 13
15 CISPR 25 Class 5 Radiated Emissions Plot, VIN = 13.5 V, IOUT = 0.5 A............................................. 14
16 PSR Flyback EVM Schematic............................................................................................ 15
17 Top Copper (Top View) ................................................................................................... 17
18 Bottom Copper (Top View)................................................................................................ 17
19 Top Component Drawing.................................................................................................. 18
20 Bottom Component Drawing.............................................................................................. 18
21 Layout Design Tips for a Single-output PSR Flyback Converter .................................................... 19
List of Tables
1 PSR Flyback DC/DC Converter Family................................................................................... 1
2 Electrical Performance Characteristics ................................................................................... 4
3 EVM Connections............................................................................................................ 6
4 Bill of Materials ............................................................................................................. 16
Trademarks
WEBENCH is a registered trademark of Texas Instruments.
All other trademarks are the property of their respective owners.

www.ti.com High Density EVM Description
3
SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
1 High Density EVM Description
The LM5180-Q1 single-output EVM is designed to use a regulated or non-regulated high-voltage input rail
ranging from 10 V to 65 V to produce a tightly-regulated, isolated output voltage of 5 V at load currents of
1 A (or higher depending on VIN). This wide VIN range isolated DC/DC solution offers outsized voltage
rating and operating margin to withstand supply rail voltage transients.
The power-train passive components selected for this EVM, including flyback transformer, flyback
rectifying diode, and ceramic input and output capacitors, are available from multiple component vendors.
Transformers with functional or basic grade isolation are available with isolation voltages of 1.5 kV and
greater.
1.1 Typical Applications
•Automotive HEV/EV powertrain systems
• Sub-AM band automotive body electronics
•Traction inverters: IGBT and SiC gate drivers
•Isolated field transmitters and field actuators
•Building automation HVAC systems
• Isolated bias power rails
1.2 Features and Electrical Performance
• Tightly-regulated, isolated output voltage of 5 V with ±1.5% load regulation from 1% to 100% load
• Wide VIN operating range of 10 V to 65 V
• Rated full load current of 1 A at VIN = 24 V
• Maximum switching frequency of 350 kHz remains below the AM band
• High efficiency across wide load current range
– Full load efficiency of 86% and 85.5% at VIN = 24 V and 48 V, respectively
– 86% efficiency at half-rated load, VIN = 24 V
• 1.3-mA and 1-mA no-load supply current at VIN = 24 V and 48 V, respectively
• Ultra-low conducted and radiated EMI signatures
– Optimized for CISPR 25 Class 5 requirements
– Soft switching avoids diode reverse recovery
– Input π-stage EMI filter with damping from electrolytic capacitor ESR
• BCM control architecture provides fast line and load transient response
– Peak current-mode control
– Quasi-resonant switching for reduced power loss
– Internal loop compensation
• Integrated 100-V flyback power MOSFET
– Provides large margin for input voltage transients
• Cycle-by-cycle overcurrent protection (OCP)
• Monotonic prebias output voltage start-up
• User-adjustable soft-start time using capacitor connected between SS/BIAS and GND
– Option for external bias using auxiliary winding connected to SS/BIAS
• Resistor-programmable input voltage UVLO with customizable hysteresis for applications with wide
turnon and turnoff voltage difference
– Input UVLO set to turn on and off at VIN of 9.5 V and 6.5 V, respectively
• Fully assembled, tested, and proven PCB layout with 50-mm × 35-mm total footprint

EVM Performance Characteristics www.ti.com
4SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback
Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
2 EVM Performance Characteristics
(1) The default output voltage of this single-output EVM is 5 V. Efficiency and other performance metrics can change based on
operating input voltage, load current, externally-connected output capacitance, and other parameters.
(2) The maximum output power delivered by the LM5180-Q1 PSR flyback converter increases with input voltage.
(3) The selected flyback transformer provides functional isolation to 1500 V DC.
Table 2. Electrical Performance Characteristics
PARAMETER TEST CONDITIONS MIN TYP MAX UNIT
INPUT CHARACTERISTICS
Input voltage range, VIN Operating 10 24 65
V
Input voltage turnon, VIN-ON Adjusted using EN/UVLO divider resistors 9.5
Input voltage turnoff, VIN-OFF 6.5
Input voltage hysteresis, VIN-HYS 3
Input current, no load, IIN-NL IOUT = 0 A VIN = 24 V 1.3 mA VIN = 48 V 1
VIN = 65 V 1
Input current, disabled, IIN-OFF VEN = 0 V VIN = 24 V 10 µA
OUTPUT CHARACTERISTICS
Output voltage, VOUT(1) 4.95 5.025 5.1 V
Output current, IOUT(2) VIN = 12 V 0.8 AVIN = 24 V 1.2
VIN = 48 V 1.4
Output voltage regulation, ΔVOUT Load regulation, VIN = 24 V IOUT = 10 mA to 1 A 1%
Line regulation, IOUT = 500 mA VIN = 10 V to 65 V 1%
Output voltage ripple, VOUT-AC VIN = 24 V, IOUT = 1 A 50 mVrms
Output overcurrent protection, IOCP VIN = 24 V 1.55 A
VIN = 48 V 1.55
Soft-start time, tSS 8 ms
SYSTEM CHARACTERISTICS
Switching frequency, FSW-NOM VIN = 24 V, IOUT = 0.5 A 350 kHz
Half-load efficiency, ηHALF(1) IOUT = 0.5 A VIN = 12 V 86%
VIN = 24 V 86%
VIN = 48 V 84%
VIN = 65 V 82%
Full load efficiency, ηFULL IOUT = 1 A
VIN = 24 V 86%
VIN = 36 V 86%
VIN = 48 V 85.5%
VIN = 65 V 84.5%
Isolation rating(3) 1500 V
LM5180 junction temperature, TJ–40 150 °C

CAUTION
Caution Hot surface.
Contact may cause burns.
Do not touch.
VOUT = 5 V
SW
FB
VIN
EN/UVLO
TC
GND
SS/BIAS
RSET
LM5180
COUT
CIN
100 F
2.2 F
T1
VIN = 10 V...65 V
3 : 1
DFLY
RSET
12.1 k:
RFB
158 k:
D2
D1
RTC
130 k:
CSS
47 nF
Copyright © 2018, Texas Instruments Incorporated
DOUT
5.6 V
24 V
www.ti.com Application Circuit Diagram
5
SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
3 Application Circuit Diagram
Figure 1 shows the schematic of an LM5180 PSR flyback converter (EMI filter stage not shown). Soft start
(SS), temperature compensation (TC), and UVLO (EN/UVLO) components are shown that are
configurable as required for the specific application.
Figure 1. LM5180 PSR Flyback Converter Simplified Schematic
4 EVM Photo
Figure 2. EVM Photo (Top Side), 50 mm × 35 mm

ACOM
Ammeter 1 Electronic Load
+ -
V
Voltmeter 1
COM V
Voltmeter 2
COM
Oscilloscope
+
-
Power Supply
ACOM
Ammeter 2
Test Setup and Procedure www.ti.com
6SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback
Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
5 Test Setup and Procedure
5.1 Test Setup
Table 3. EVM Connections
LABEL DESCRIPTION
VIN+ Positive input voltage power and sense connection
VIN– Negative input voltage power and sense connection
VOUT+ Positive output voltage power and sense connection
VOUT– Negative output voltage power and sense connection
EN ENABLE input. Tie to GND to disable converter
SW SW node connection
Referencing the EVM connections described in Table 3, the recommended test setup to evaluate the
LM5180EVM-S05 is shown in Figure 3. Working at an ESD-protected workstation, make sure that any
wrist straps, boot straps, or mats are connected and referencing the user to earth ground before power is
applied to the EVM.
Figure 3. EVM Test Setup
SPACER
CAUTION
Refer to the LM5180 data sheet, LM5180 Quickstart Calculator, and
WEBENCH® Power Designer for additional guidance pertaining to component
selection and converter operation.

www.ti.com Test Setup and Procedure
7
SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
5.2 Test Equipment
Voltage Source: The input voltage source VIN must be a 0–65-V variable DC source capable of supplying
0.5 A.
Multimeters:
•Voltmeter 1: Input voltage at VIN+ to VIN–. Set the voltmeter to an input impedance of 100 MΩ.
•Voltmeter 2: Output voltage at VOUT+ to VOUT–. Set the voltmeter to an input impedance of 100 MΩ.
•Ammeter 1: Input current. Set the ammeter to 1-second aperture time.
•Ammeter 2: Output current. Set the ammeter to 1-second aperture time.
Electronic Load: The load must be an electronic constant-resistance (CR) or constant-current (CC) mode
load capable of 0 Adc to 1 Adc at 5 V. For a no-load input current measurement, disconnect the electronic
load as it can draw a small residual current.
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.
Safety: Always use caution when touching any circuits that may be live or energized.
5.3 Recommended Test Setup
5.3.1 Input Connections
• Prior to connecting the DC input source, set the current limit of the input supply to 0.1 A maximum.
Ensure the input source is initially set to 0 V and connected to the VIN+ and VIN– connection points as
shown in Figure 3. 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.
5.3.2 Output Connections
• Connect an electronic load to VOUT+ and VOUT– connections. 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 to measure the output current.
5.4 Test Procedure
5.4.1 Line and Load Regulation, Efficiency
• 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 24 V; use voltmeter 1 to measure the input voltage.
• Increase the current limit of the input supply to 0.5 A.
• Using voltmeter 2 to measure the output voltage, VOUT, vary the load current from 10 mA to 1 A DC;
VOUT should remain within the load regulation specification.
• Set the load current to 0.5 A (50% rated load) and vary the input source voltage from 10 V to 65 V;
VOUT must remain within the line regulation specification.
• Decrease load to 0 A. Decrease input source voltage to 0 V.

Output Current (A)
Efficiency (%)
0.001 0.01 0.1 1 2
30
40
50
60
70
80
90
100
VIN = 12V
VIN = 24V
VIN = 36V
VIN = 48V
VIN = 65V
Output Current (A)
Efficiency (%)
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
60
65
70
75
80
85
90
VIN = 12V
VIN = 24V
VIN = 36V
VIN = 48V
VIN = 65V
Test Data and Performance Curves www.ti.com
8SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback
Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
6 Test Data and Performance Curves
Figure 4 through Figure 11 present typical performance curves for the LM5180EVM-S05. Because actual
performance data can be affected by measurement techniques and environmental variables, these curves
are presented for reference and may differ from actual field measurements.
6.1 Conversion Efficiency
Figure 4. Conversion Efficiency (Linear Scale)
Figure 5. Conversion Efficiency (Log Scale)

Output Current (A)
Output Voltage (V)
0.001 0.01 0.1 1 2
4.8
4.9
5
5.1
5.2
VIN = 12V
VIN = 24V
VIN = 36V
VIN = 48V
VIN = 65V
Output Current (A)
Output Voltage (V)
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
4.8
4.85
4.9
4.95
5
5.05
5.1
5.15
5.2
VIN = 12V
VIN = 24V
VIN = 36V
VIN = 48V
VIN = 65V
www.ti.com Test Data and Performance Curves
9
SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
6.2 Load Regulation
Figure 6. Load Regulation (Linear Scale)
Figure 7. Load Regulation (Log Scale)

1 Ps/DIV
SW 20V/DIV
1 Ps/DIV
SW 20V/DIV
Test Data and Performance Curves www.ti.com
10 SNVU592D–July 2018–Revised April 2020
Submit Documentation Feedback
Copyright © 2018–2020, Texas Instruments Incorporated
LM5180-Q1 Single-Output EVM User's Guide
6.3 Operating Waveforms
6.3.1 Switching
Figure 8. SW Node Voltage, VIN = 24 V, IOUT =1A
Figure 9. SW Node Voltage, VIN = 48 V, IOUT =1A