Texas Instruments TPS92520-Q1 User manual

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TPS92520-Q1 LaunchPad-Controlled, ECU
Evaluation Module User's Guide
User's Guide
Literature Number: SLUUC29B
August 2019–Revised October 2019

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Table of Contents
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Contents
1 Trademarks......................................................................................................................... 8
2 Description.......................................................................................................................... 9
2.1 Typical Applications...................................................................................................... 9
2.2 Warnings .................................................................................................................. 9
2.3 Connector Description ................................................................................................. 10
3 REACH Compliance............................................................................................................ 12
4 Performance Specifications................................................................................................. 12
4.1 ECU Current Regulator ................................................................................................ 12
5 Performance Data and Typical Characteristic Curves ............................................................. 13
5.1 Start-up Waveforms .................................................................................................... 13
5.2 PWM Dimming .......................................................................................................... 14
6 Schematic, PCB Layout, and Bill of Materials ........................................................................ 14
6.1 Schematic................................................................................................................ 14
6.2 Layout.................................................................................................................... 17
6.3 Bill of Materials.......................................................................................................... 20
7 GUI Installation, Description, and Use................................................................................... 23
7.1 TPS92520EVM-074 GUI Installer .................................................................................... 23
7.2 Programming the MSP-EXP432E401Y LaunchPad Board ....................................................... 28
8 TPS92520EVM-074 Power UP and Operation.......................................................................... 33
8.1 Launch the GUI (Graphical User Interface)......................................................................... 34
9 Appendix........................................................................................................................... 39
Revision History.......................................................................................................................... 40

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List of Figures
1 TPS92520EVM-074 Block Diagram....................................................................................... 9
2 Component Connections.................................................................................................. 10
3 Jumper Placement for Launch Pad Use ................................................................................ 11
4 Boost Output Voltage Limit Adjustment ................................................................................. 12
5 ECU Metrics, VIN = 12 V, TPS92682 Boost Channel and 2 Channels from 1 x TPS92520 IC .................. 13
6 Start-up Waveforms........................................................................................................ 13
7 PWM Dimming with IADJ Level Adjustment............................................................................ 14
8 TPS92520EVM-074 Schematic .......................................................................................... 15
9 TPS92520EVM-074 Schematic - Page 2 ............................................................................... 16
10 TPS92520EVM-074 Assembly .......................................................................................... 17
11 TPS92520EVM-074 Inner Layer (Ground Plane)...................................................................... 18
12 TPS92520EVM-074 Inner-Layer 1....................................................................................... 18
13 TPS92520EVM-074 Bottom Layer (Bottom View)..................................................................... 19
14 Setup Screen 1............................................................................................................. 23
15 Setup Screen 2............................................................................................................. 24
16 Setup Screen 4............................................................................................................. 24
17 Setup Screen 5............................................................................................................. 25
18 Setup Screen 6............................................................................................................. 25
19 Setup Screen 7............................................................................................................. 26
20 Setup Screen 8............................................................................................................. 26
21 Setup Screen 9............................................................................................................. 27
22 Setup Screen 10............................................................................................................ 27
23 Setup Screen 11............................................................................................................ 27
24 Setup Screen 12............................................................................................................ 28
25 Setup Screen 13............................................................................................................ 28
26 LaunchPad Connection for Programming............................................................................... 29
27 UniFlash Programming, Step 1........................................................................................... 29
28 UniFlash Programming, Step 2........................................................................................... 30
29 UniFlash Programming, Step 4........................................................................................... 30
30 UniFlash Programming, Step 5........................................................................................... 31
31 Debug Probe Update Required on First Flash of Launch Pad....................................................... 31
32 LaunchPad Connection for GUI Operation ............................................................................. 32
33 LaunchPad Connection to the TPS92520EVM-074 ................................................................... 33
34 LaunchPad Connection to the TPS92520EVM-074 and PWR901 Matrix Manager EVM........................ 34
35 GUI Splash Screen with Configuration Information.................................................................... 35
36 GUI, Main Window (Numbered areas are for explanation purposes only) ......................................... 35
37 SPI Command Window.................................................................................................... 38
38 TPS92663EVM6-901 Addressing Outline............................................................................... 39

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List of Tables
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List of Tables
1 Connector Descriptions.................................................................................................... 11
2 TPS92520EVM-074 ECU EVM Performance Specifications......................................................... 12
3 TPS92520EVM-074 Bill of Materials..................................................................................... 20

WARNING
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General Texas Instruments High Voltage Evaluation (TI HV EMV) User Safety Guidelines
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 those working around you. Contact TI's Product Information Center
http://ti.com/customer support for further information.
Save all warnings and instructions for future reference.
WARNING
Failure to follow warnings and instructions may result in personal injury,
property damage or death due to electrical shock and 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 suitable qualified, you should immediately stop from further
use of the HV EVM.
1. Work Area Safety:
a. Keep work area clean and orderly.
b. Qualified observer(s) must be present anytime circuits are energized.
c. Effective barriers and signage must be present in the area where the TI HV EVM and its interface
electronics are energized, indicating operation of accessible high voltages may be present, for the
purpose of protecting inadvertent access.
d. All interface circuits, power supplies, evaluation modules, instruments, meters, scopes, and other
related apparatus used in a development environment exceeding 50Vrms/75VDC must be
electrically located within a protected Emergency Power Off EPO protected power strip.
e. Use stable and non-conductive work surface.
f. Use adequately insulated clamps and wires to attach measurement probes and instruments. No
freehand testing whenever possible.
2. Electrical Safety:
As a precautionary measure, it is always good engineering practice to assume that the entire EVM
may have fully accessible and active high voltages.
a. De-energize the TI HV EVM and all its inputs, outputs and electrical loads before performing any
electrical or other diagnostic measurements. Revalidate that TI HV EVM power has been safely
de-energized.
b. 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.
c. Once EVM readiness is complete, energize the EVM as intended.

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WARNING
While the EVM is energized, never touch the EVM or its electrical
circuits, as they could be at high voltages capable of causing
electrical shock hazard.
3. Personal Safety
a. Wear personal protective equipment e.g. latex gloves 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.

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TPS92520EVM-074 LaunchPad-Controlled, ECU Evaluation Module
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User's Guide
SLUUC29B–August 2019–Revised October 2019
TPS92520EVM-074 LaunchPad-Controlled, ECU Evaluation
Module
This user's guide describes the specifications, board connection description, operation, and use of the
TPS92520EVM-074. The EVM consists of a CV boost stage, creating a regulated voltage rail that is used
by two TPS92520 ICs. The two TPS92520 ICs then create four current regulated channels for driving
strings of LEDs. The EVM is a representative of a lighting module suitable for automotive applications
creating advanced lighting features.
The TPS92520-Q1 buck current regulator device implements an adjustable constant on-time, valley
detect, current-mode control technique with programmable pseudo-fixed-frequency operation. Additional
features include the following:
• Wide input voltage range (4.5 V to 65 V)
• Analog adjustable output current setting
• Fault reporting
• Internal and external PWM dimming
The TPS92682-Q1 boost controller device implements a fixed-frequency peak-current mode control
technique with programmable switching frequency, slope compensation, and soft-start. Additional features
include the following:
• Wide input voltage range (4.5 V to 65 V)
• Programmable spread spectrum frequency modulation
• Programmable fault handling
• Adjustable output current setting
Optionally, to exercise advanced lighting control features, an accompanying EVM to the TPS92520 ECU
EVM, LMM EVM PWR901, can be used. The TPS92662-Q1 and TPS92663-Q1 (LMM, LED Matrix
Manager) devices include series-connected integrated switches for bypassing individual LEDs. The
individual sub-strings allow the device to accept either single or multiple current sources for bypassing
high current LEDs.
A complete schematic diagram, printed circuit board layouts, and bill of materials are included in this
document.

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1 Trademarks
SimpleLink, LaunchPad are trademarks of Texas Instruments.
All other trademarks are the property of their respective owners.

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2 Description
The TPS92520EVM-074 solution provides four current-regulated channels, providing up to 49.5 V, 1.6 A
for each channel (expandable voltage range with board modification), from a 12 V (nom) input. The four
TPS92520 channels and one dual-phase TPS92682 CV (constant voltage) channel are all configurable via
serial peripheral interface (SPI). The maximum output voltage of the TPS92682 CV boost can be
physically adjusted by modifying R34 (see Table 1). The EVM is designed to operate with an input voltage
in the range of 6 V to 40 V and provides a maximum total output power of 100 W (maximum of 50 W per
channel). For example, if one channel is operated at 50 W, the total power of the other three channels
must not exceed 50 W. The TPS92520EVM-074 provides a unique high-efficiency, SPI-programmable
solution with fault handling and reporting. It also includes standard ECU features: CAN (physical layer)
interface and reverse battery protection.
The EVM is operated via a standard TI LaunchPad (MSP-EXP432E401Y) and does not function if the
launchpad and GUI are not installed. It is possible to use your own or a different SPI controller after
reviewing the documentation for all parts in detail.
Figure 1 shows the block diagram of the system.
Figure 1. TPS92520EVM-074 Block Diagram
2.1 Typical Applications
This document outlines the operation and implementation of the TPS92520-Q1 as a four-channel LED
current regulator. Table 2 lists the specifications. For applications with a different input voltage range or
different ILED range, refer to the TPS92520-Q1 1.5-A Dual Synchronous Buck LED Driver Data Sheet. The
MSP-EXP432E401Y SimpleLink™ Ethernet MSP432E401Y MCU LaunchPad™ Development Kit controls
the TPS92520EVM-074 evaluation board. The MSP-EXP432E401Y is available on ti.com. Ensure that the
LaunchPad board from TI has been programmed using the UNIFLASH application before running the GUI.
Section 7 provides the programming instructions.
2.2 Warnings
Observe the following precaution when using the TPS92520EVM-074 evaluation module. Do not leave the
EVM powered when unattended.

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CAUTION
Do not touch. This is a hot surface and contact can cause burns.
CAUTION
Do not stare at the operation LED: (Risk Group 2 (RG2) at a distance <0.9m),
(Risk Group 1 (RG1) at a distance > 0.9m(, (Risk Group Exempt (RGE) at a
distance > 1.8 m). The LED may be hardmful to the eyes. See IEC62471:2008
("photo biological safety of lamps and lamp systems") for risk group definitions.
2.3 Connector Description
Table 1 describes the connectors on the EVM and how to properly connect, set up, and use the
TPS92520EVM-074.
Figure 2 shows the connection diagram and the jumper locations of the TPS92520EVM-074.
Figure 2. Component Connections

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Table 1. Connector Descriptions
CONNECTOR TOPIC DESCRIPTION
J1 Remote SPI
Auxiliary SPI port connection. Use this port to monitor SPI BUS communications to
TPS92520 device U1 and U4.
J2 Auxiliary SPI port connection. Use this port to monitor SPI BUS communications to
TPS92520 device U2 and U3.
J3 5 V Control J3 controls the 5 V enable line. Select position 1–2 for launchpad interface.
J4 Vin Input Voltage Connector
J5 Spare Jumper >> Transfer to Launch
Pad
Spare LaunchPad Jumper – remove from EVM and transfer to the LaunchPad at JP1 as
shown in Figure 3.
Figure 3. Jumper Placement for Launch Pad Use
J6, J7 Expansion Port These ports can be ignored. This port provides a connection port for EVM use with the PWR879 microcontroller board (interface board used with TPS92518). This port also
provides a port to connect an additional TPS92520 EVM.
J8, J10, J12 Expansion Port Provides connection point for additional SSN (slave select n) signals when using additional TPS92520 EVM connections via the J7 port. Leave the port open for normal operation with
the launchpad.
J9 LMM Matrix Manager Connection. Port and GUI are compatible with the TPS92663EVM6-901. Note that current sources are in parallel with 520-BxCx output pins. It is not recommended to
use both at the same time.
J11 Channel Selector The TPS92663EVM6-901 has six inputs and the TPS92520-074 EVM provides four outputs.
J11 allows the user to power five of the six LED strings. Set J11 to route 520-B1C2 to either
the top string of LED controlled via Address 1 OR the bottom string of LEDs controlled by
Address 2.
J13, J14, J15,
J16 Launch Pad Port LaunchPad connection ports. Ensure the launchpad is aligned before applying power or it can result in the launchpad getting damaged.
5VDC 5 V Monitor 5 V output of the U6 controlled LMR16006Y-Q1, fixed 5 V switching regulator
520-B1C1,
520-B1C2,
520-B2C1,
520-B2C2 Output Pins Positive outputs of the four buck regulators
VBOOST Boost Output TPS92682 Dual-Phase VC Boost Output. Adjust R34 to set the maximum boost output
voltage.
GND Ground Ground test points

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Table 1. Connector Descriptions (continued)
CONNECTOR TOPIC DESCRIPTION
R34 VBOOST_Max
The maximum boost output voltage can be adjusted to match your LED string requirements.
For safety requirements, the voltage has been limited to <50 V (49.5 V) by setting R34 to 5.1
kΩ. The voltage can be adjusted to a maximum of 65 V by changing the value of R34: R34 =
(2.39 × 100 k) / (VBOOST_Max - 2.39).
WARNING
Once R34 is changed, the maximum
slider position corresponds to the new
programmed value. A voltage greater
than 50 V can require special handing
precautions at your location. Consult
your local lab manager and safety
codes before making any changes to
the EVM.
Figure 4. Boost Output Voltage Limit Adjustment
3 REACH Compliance
In compliance with the Article 33 provision of the EU REACH regulation, TI is notifying you that this EVM
includes component or components that contain at least one substance of very high concern (SVHC)
above 0.1%. These uses from Texas Instruments do not exceed one ton per year. The SVHC
specifications are:
COMPONENT
MANUFACTURER COMPONENT PART NUMBER SVHC SUBSTANCE SVHC CAS (WHEN AVAILABLE)
PHOENIX CONTACT GmbH &
Co. KG 1715721 and 1715747 Lead (Pb) 7439-92-1
4 Performance Specifications
This section provides the performance specifications and requirements for the dual-phase CV TPS926682
boost and TPS92520 buck current regulators.
4.1 ECU Current Regulator
Table 2 provides the EVM electrical performance specifications for the lighting ECU.
Table 2. TPS92520EVM-074 ECU EVM Performance Specifications
PARAMETER TEST CONDITIONS MIN TYP MAX UNITS
INPUT CHARACTERISTICS
Voltage, VIN 6 12 40 V

CHxIADJ
Output Current (A)
System Efficiency OR Output Power (W)
TPS92682 Boost and 1 x TPS92520 IC (2 Buck Channels)
Total Efficiency
0 150 300 450 600 750 900 1050
0 0
0.1 8
0.2 16
0.3 24
0.4 32
0.5 40
0.6 48
0.7 56
0.8 64
0.9 72
1 80
1.1 88
1.2 96
1.3 104
1.4 112
1.5 120
1.6 128
1.7 136
1.8 144
1.9 152
2 160
effi
ILEDx (A)
System Efficiency
Output Power
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Table 2. TPS92520EVM-074 ECU EVM Performance Specifications (continued)
PARAMETER TEST CONDITIONS MIN TYP MAX UNITS
Maximum Output Power, POUT 100 W
Maximum Input Current, IIN Note: derating of 100 W maximum is
necessary below 10 V 10 A
OUTPUT CHARACTERISTICS
Total LED forward voltage, V(LED) 49.5 V
Output voltage VOUT Maximum voltage on 520-CxBx terminal 65 V
Maximum output current, ILED 1.6 A
Maximum Channel Output Power, POUT 50 W
SYSTEMS CHARACTERISTICS
TPS92520 Switching frequency FSW Target for this EVM design (On Time = 7) 400 kHz
5 Performance Data and Typical Characteristic Curves
Figure 5 shows the efficiency results for the system versus CHxIADJ. The results shown have used eight
LED in series. It is important to note that the efficiency results include the all EVM power losses, including
the input reverse battery protection circuitry.
Figure 5. ECU Metrics, VIN = 12 V, TPS92682 Boost Channel and 2 Channels from 1 x TPS92520 IC
5.1 Start-up Waveforms
Figure 6 shows the start-up waveforms, VLED , COMP, and the switch-node voltage (SWN). In this setup, a
string of 7×LEDs are connected to the buck output and the boost is set to 47 V.

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Figure 6. Start-up Waveforms
5.2 PWM Dimming
Figure 7 shows PWM dimming of a buck channel of the TPS92520EVM-074 EVM. An additional feature of
the waveform is that the ILED is programmed to a different value during 300Hz PWM dimming.
VIN = 12 V
Figure 7. PWM Dimming with IADJ Level Adjustment
6 Schematic, PCB Layout, and Bill of Materials
This section contains TPS92520EVM-074 schematics, PCB layouts, and bill of materials (BOM).
6.1 Schematic
Figure 9 illustrates the TPS92520EVM-074 schematic.

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Figure 8. TPS92520EVM-074 Schematic

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Figure 9. TPS92520EVM-074 Schematic - Page 2

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6.2 Layout
The TPS92520EVM-074 is a four-layer board. Figure 10 through Figure 13 illustrate the following
TPS92520EVM-074 PCB layout layers:
• Assembly
• Top
• Inner layer 1
• Inner layer 2
• Bottom
One layer is a ground plane and there is no routing on this layer.
Figure 10. TPS92520EVM-074 Assembly

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Figure 11. TPS92520EVM-074 Inner Layer (Ground Plane)
Figure 12. TPS92520EVM-074 Inner-Layer 1

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Figure 13. TPS92520EVM-074 Bottom Layer (Bottom View)

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6.3 Bill of Materials
Table 3 lists the TPS92520EVM-074 bill of materials.
Table 3. TPS92520EVM-074 Bill of Materials
DESIGNATOR QUANTITY VALUE DESCRIPTION PACKAGE PART NUMBER MANUFACTURER
C1, C4, C33, C34, C67, C68,
C71 7 0.1 µF CAP, CERM, 0.1 µF, 100 V, ±10%, X7S, AEC-Q200 Grade 1, 0603 0603 CGA3E3X7S2A104K080AB TDK
C2, C3, C30, C32 4 2200 pF CAP, CERM, 2200 pF, 50 V, ±10%, X7R, AEC-Q200 Grade 1, 0402 0402 CGA2B2X7R1H222K050BA TDK
C5, C28 2 0.047 µF CAP, CERM, 0.047 µF, 100 V, ±10%, X7S, AEC-Q200 Grade 1, 0603 0603 CGA3E3X7S2A473K080AB TDK
C6, C10, C25, C29 4 0.47 µF CAP, CERM, 0.47 µF, 25 V, ±10%, X7R, AEC-Q200 Grade 1, 0603 0603 CGA3E3X7R1E474K080AB TDK
C7, C31 2 1000 pF CAP, CERM, 1000 pF, 16 V, ±10%, X7R, 0603 0603 885012206034 Wurth
C8, C9, C11, C12, C23, C24,
C26, C27 8 2.2 µF CAP, CERM, 2.2 µF, 100 V, ±20%, X7S, AEC-Q200 Grade 1, 1206_190 1206_190 CGA5L3X7S2A225M160AB TDK
C13, C16, C18, C21, C59,
C60 6 4.7 µF CAP, CERM, 4.7 µF, 16 V,±10%, X7R, AEC-Q200 Grade 1, 0805 0805 CGA4J3X7R1C475K125AE TDK
C14, C15, C17, C19, C20,
C22, C54, C76, C79, C82,
C83, C86, C87, C91, C92,
C95, C96, C99, C100, C103,
C104, C107, C108
23 0.1 µF CAP, CERM, 0.1 µF, 50 V, ±20%, X7R, AEC-Q200 Grade 1, 0402 0402 CGA2B3X7R1H104M050BB TDK
C35, C36, C37, C48, C49,
C50, C55, C70, C72, C73,
C74, C75
12 10 µF CAP, CERM, 10 µF, 50 V, ±10%, X7S, AEC-Q200 Grade 1, 1210 1210 CGA6P3X7S1H106K250AB TDK
C38 1 0.033 µF CAP, CERM, 0.033 µF, 50 V, ±5%, X7R, 0603 0603 06035C333JAT2A AVX
C39 1 33 µF CAP, AL, 33 µF, 80 V, ±20%, 1.3 Ω, AEC-Q200 Grade 2, SMD SMT Radial F EEE-FK1K330P Panasonic
C40, C41, C42, C51, C52,
C53 6 4.7 µF CAP, CERM, 4.7 µF, 100 V, ±10%, X7S, 1210 1210 C3225X7S2A475K200AB TDK
C43, C63 2 10 pF CAP, CERM, 10 pF, 50 V, ±5%, C0G/NP0, 0603 0603 CGA3E2NP01H100D080AA TDK
C44, C56, C80 3 1 µF CAP, CERM, 1 µF, 50 V, ±10%, X7R, AEC-Q200 Grade 1, 1206 1206 CGA5L3X7R1H105K160AB TDK
C45, C57 2 470 pF CAP, CERM, 470 pF, 100 V, ±10%, X7R, 0603 0603 06031C471KAT2A AVX
C46, C61 2 1000 pF CAP, CERM, 1000 pF, 50 V, ±10%, X7R, AEC-Q200 Grade 1, 0402 0402 CGA2B2X7R1H102K050 TDK
C47 1 100 pF CAP, CERM, 100 pF, 50 V, ±5%, C0G/NP0, AEC-Q200 Grade 0, 0603 0603 CGA3E2NP01H101J080 TDK
C58, C62 2 2.2 µF CAP, CERM, 2.2 µF, 16 V, ±20%, X7S, AEC-Q200 Grade 1, 0603 0603 CGA3E1X7S1C225M08 TDK
C64 1 100 µF CAP, AL, 100 µF, 35 V, ±20%, 0.34 Ω, AEC-Q200 Grade 2, SMD SMT Radial D8 EEE-FK1V101XP Panasonic
C65, C66, C69 3 4.7 µF CAP, CERM, 4.7 µF, 50 V, ±10%, X7R, 1206 1206 C3216X7R1H475K160A TDK
C77 1 4700 pF CAP, CERM, 4700 pF, 50 V, ±10%, X7R, 0805 0805 C0805C472K5RACTU Kemet
C78 1 0.22 µF CAP, CERM, 0.22 µF, 25 V, ±10%, X8R, AEC-Q200 Grade 0, 0603 0603 CGA3E3X8R1E224K080 TDK
C81, C84, C85, C88, C90,
C93, C94, C97, C98, C101,
C102, C105, C106, C109
14 1 µF CAP, CERM, 1 µF, 16 V, ±10%, X5R, 0603 0603 C0603C105K4PACTU Kemet
C89 1 0.01 µF CAP, CERM, 0.01 µF, 16 V, ±10%, X7R, 0603 0603 C0603C103K4RACTU Kemet
D1, D2 2 100 V Diode, Schottky, 100 V, 3 A, AEC-Q101, PowerDI5 PowerDI5 PDS3100Q-13 Diodes Inc.
D3, D5, D7, D8 4 60 V Diode, Schottky, 60 V, 1 A, AEC-Q101, SOD-123 SOD-123 PMEG6010CEGWJ Nexperia
D4 1 26 V Diode, TVS, Bi, 26 V, 42.1 Vc, AEC-Q101, SMA SMA SMAJ26CAHE3/61 Vishay-Semiconductor
D6 1 10 V Diode, Zener, 10 V, 500 mW, AEC-Q101, SOD-123 SOD-123 MMSZ4697-HE3-08 Vishay-Semiconductor
H5 1 HEAT SINK HEATSINK ATS-TI1OP-1304-C2-R0 Advanced Thermal
Solutions Inc