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CAT4201 350 mA High Efficiency Step Down LED Driver
Description
The CAT4201 is a high efficiency step-down converter optimized to drive high current LEDs. A patented switching control algorithm allows highly efficient and accurate LED current regulation. A single RSET resistor sets the full scale LED string current up to 350 mA from supplies as high as 36 V. The switching architecture of the CAT4201 results in extremely low internal power dissipation allowing the device to be housed in a tiny package without the need for dedicated heat sinking. The device is compatible with switching frequencies of up to 1 MHz, making it ideal for applications requiring small footprint and low value external inductors. Analog dimming and LED shutdown control is provided via a single input pin, CTRL. Additional features include overload current protection and thermal shutdown. The device is available in the low profile 5-lead thin SOT23 package and is ideal for space constrained applications.
Features
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5 1 TSOT-23 TD SUFFIX CASE 419AE
PIN CONNECTIONS
1 CTRL GND RSET (Top View) SW VBAT
* * * * * * * * * *
LED Drive Current up to 350 mA Compatible with 12 V and 24 V Standard Systems Handles Transients up to 40 V Single Pin Control and Dimming Function Power Efficiency up to 94% Drives LED Strings of up to 32 V Open and Short LED Protection Parallel Configuration for Higher Output Current TSOT-23 5-lead Package These Devices are Pb-Free, Halogen Free/BFR Free and are RoHS Compliant 12 V and 24 V Lighting Systems Automotive and Aircraft Lighting General Lighting High Brightness 350 mA LEDs
VBAT 9V C1
MARKING DIAGRAMS
TFYM
TF = Device Code Y = Production Year (Last Digit) M = Production Month: 1-9, A, B, C
ORDERING INFORMATION
Device CAT4201TD-GT3 Package TSOT-23 (Pb-Free) Shipping 3,000/ Tape & Reel
Applications
* * * *
* Plated Finish: NiPdAu Bulb Replacement
4.7 mF VBAT CAT4201 RSET R1 10 kW D: Central Schottky CMDSH05-4 L: Sumida CDRH6D26-220 See Table 4 on page 6 for external component selection.
D
C2 10 mF L
300 mA
CTRL SW GND
22 mH
Figure 1. Typical Application Circuit
(c) Semiconductor Components Industries, LLC, 2010
February, 2010 - Rev. 5
1
Publication Order Number: CAT4201/D
CAT4201
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Table 1. ABSOLUTE MAXIMUM RATINGS
Parameters VBAT, SW, CTRL RSET Switch SW peak current Storage Temperature Range Junction Temperature Range Lead Temperature Ratings -0.3 to +40 -0.3 to +5 1 -65 to +160 -40 to +150 300 Units V V A _C _C _C
Stresses exceeding Maximum Ratings may damage the device. Maximum Ratings are stress ratings only. Functional operation above the Recommended Operating Conditions is not implied. Extended exposure to stresses above the Recommended Operating Conditions may affect device reliability.
Table 2. RECOMMENDED OPERATING CONDITIONS
Parameters VBAT voltage (Notes 1, 2) SW voltage Ambient Temperature Range LED Current Switching Frequency Ratings 6.5 to 36 (Note 1) 0 to 36 -40 to +125 50 to 350 50 to 1000 Units V V _C mA kHz
1. The VBAT pin voltage should be at least 3 V greater than the total sum of the LED forward voltages in order to operate at nominal LED current. 2. During power-up, the slew rate of the input supply should be greater than 1 ms for every 5 V increase of VBAT.
Table 3. ELECTRICAL CHARACTERISTICS
(VIN = 13 V, ambient temperature of 25C (over recommended operating conditions unless otherwise specified)) Symbol IQ ISD VFB ILED Parameter Operating Supply Current on VBAT pin Idle Mode Supply Current on VBAT pin RSET Pin Voltage Programmed LED Current CTRL = GND 2 LEDs with ILED = 300 mA R1 = 33 kW R1 = 10 kW R1 = 8.25 kW 1.15 270 Conditions Min Typ 0.4 90 1.2 100 300 350 2.6 LED enable voltage threshold LED disable voltage threshold VCTRL = 3 V VCTRL = 12 V ISW = 300 mA 0.4 0.9 0.9 40 200 0.9 150 20 Typical Application Circuit 86 80 1.5 1.25 330 3.1 1.2 V V V mA W C C % Max 1 Units mA mA V mA
VCTRL-FULL VCTRL-EN VCTRL-SD ICTRL RSW TSD THYST h
CTRL Voltage for 100% Brightness CTRL Voltage to Enable LEDs CTRL Voltage to Shutdown LEDs CTRL pin input bias Switch "On" Resistance Thermal Shutdown Thermal Hysteresis Efficiency
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TYPICAL OPERATION CHARACTERISTICS
(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C2 = 10 mF, TAMB = 25C unless otherwise specified) 1.0 QUIESCENT CURRENT (mA) 0.8 0.6 0.4 0.2 0 IDLE CURRENT (mA) 8 10 12 14 16 18 20 22 24 200
150
100
50
0
0
4
8
12
16
20
24
INPUT VOLTAGE (V)
INPUT VOLTAGE (V)
Figure 2. Input Operating Supply Current
250 CTRL BIAS CURRENT (mA) 200 150 100 50 0 RSET VOLTAGE (V) 1.30
Figure 3. Idle Mode Supply Current (CTRL = 0 V)
VIN = 13 V 1.25
1.20
1.15
0
2
4
6
8
10
12
1.10 -40
0
40 TEMPERATURE (C)
80
120
CTRL VOLTAGE (V)
Figure 4. CTRL Input Bias Current
1.4 1.2 1.0 0.8 0.6 0.4 0.2 0 0 1 2 CTRL VOLTAGE (V) 3 4 0 5 +25C -40C +85C LED CURRENT (mA) RSET VOLTAGE (V) 300 400
Figure 5. RSET Voltage vs. Temperature
200
100
10
15
20 RSET (kW)
25
30
35
Figure 6. RSET Voltage vs. CTRL Voltage
Figure 7. LED Current vs. RSET
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TYPICAL OPERATION CHARACTERISTICS
(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C2 = 10 mF, TAMB = 25C unless otherwise specified) 500 SWITCHING FREQUENCY (kHz) SWITCHING FREQUENCY (kHz) 400 300 300 mA 200 100 0 150 mA 700 600 150 mA 500 400 300 200 100 0 8 12 16 20 24 28 300 mA
8
12
16
20
24
28
INPUT VOLTAGE (V)
INPUT VOLTAGE (V)
Figure 8. Switching Frequency vs. Input Voltage (1 LED)
500 SWITCHING FREQUENCY (kHz) VIN = 13 V SW RESISTANCE (W) 400 150 mA 1.6 1.2 0.8 0.4 0 2.0
Figure 9. Switching Frequency vs. Input Voltage (2 LEDs)
300 300 mA
200
100 -40
0
40 TEMPERATURE (C)
80
120
8
10
12
14
16
18
20
22
24
INPUT VOLTAGE (V)
Figure 10. Switching Frequency vs. Temperature
100 95 EFFICIENCY (%) EFFICIENCY (%) 90 85 80 75 70 150 mA 300 mA 100 95 90
Figure 11. Switch ON Resistance vs. Input Voltage
150 mA 300 mA
85 80 75 70
8
10
12
14
16
18
20
22
24
8
10
12
14
16
18
20
22
24
INPUT VOLTAGE (V)
INPUT VOLTAGE (V)
Figure 12. Efficiency vs. Input Voltage (1 LED)
Figure 13. Efficiency vs. Input Voltage (2 LEDs)
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TYPICAL OPERATION CHARACTERISTICS
(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C2 = 10 mF, TAMB = 25C unless otherwise specified) 100 95 EFFICIENCY (%) 90 85 80 75 70 1 LED 2 LEDs LED CURRENT VARIATION (%) 10 8 6 4 2 0 -2 -4 -6 -8 -10 -40 VIN = 13 V
100
150
200
250
300
350
0
40 TEMPERATURE (C)
80
120
LED CURRENT (mA)
Figure 14. Efficiency vs. LED Current
350 300 LED CURRENT (mA) 250 200 150 100 50 0 0 4 8 12 16 20 24 28 VF = 3.1 V 150 mA VF = 3.3 V 300 mA LED CURRENT (mA) 350 300 250 200 150 100 50 0 0
Figure 15. LED Current Regulation vs. Temperature
VF = 3.3 V 300 mA
VF = 3.1 V 150 mA
4
8
12
16
20
24
28
INPUT VOLTAGE (V)
INPUT VOLTAGE (V)
Figure 16. LED Current vs. Input Voltage (1 LED)
Figure 17. LED Current vs. Input Voltage (2 LEDs)
SW 5V/div
CTRL 5V/div
Inductor Current 200mA/ div
LED Current 200mA/ div 2 ms/div 40 ms/div
Figure 18. Switching Waveforms
Figure 19. CTRL Power-up
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TYPICAL OPERATION CHARACTERISTICS
(VIN = 13 V, ILED = 300 mA, L = 22 mH, C1 = 4.7 mF, C2 = 10 mF, TAMB = 25C unless otherwise specified)
Figure 20. RSET Transient Response External Component Selection
Figure 21. Line Transient Response (10 V to 13 V)
Table 4 provides the recommended external components L and C2 that offer the best performance relative to the LED current accuracy, LED ripple current, switching frequency and component size.
Table 4. EXTERNAL COMPONENT SELECTION
1 LED LED Current (mA) 150 L Inductor (mH) 10 22 < 150 33 47 NOTE: C2 Capacitor (mF) 2.2 4.7 4.7 10 47 2.2 L Inductor (mH) 22 2 LEDs C2 Capacitor (mF) 4.7
Larger C2 capacitor values allow to reduce further the LED ripple current if needed.
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Table 5. PIN DESCRIPTION
Pin 1 2 3 4 5 Name CTRL GND RSET SW VBAT Analog dimming control and shutdown pin. Ground reference. RSET pin. A resistor connected between the pin and ground sets the average LED current. Interface to the inductor. Supply voltage for the device. Function
Pin Function VBAT is the supply input to the device. Typical current conduction into this pin is less than 1 mA and voltage transients of up to 40 V can be applied. To ensure accurate LED current regulation, the VBAT voltage should be 3 V higher than the total forward voltage of the LED string. A bypass capacitor of 4.7 mF or larger is recommended between VBAT and GND. CTRL is the analog dimming and control input. An internal pull-down current of 20 mA allows the LEDs to shutdown if CTRL is left floating. Voltages of up to 40 V can be safely handled by the CTRL input pin. When the CTRL voltage is less than 0.9 V (typ), the LEDs will shutdown to zero current. When the CTRL voltage is greater than about 2.6 V, full scale brightness is applied to the LED output. At voltages of less than around 2.6 V, the LED current is progressively dimmed until shutdown. For lamp replacement applications, or applications where operation in dropout mode is expected, it is recommended
that the CTRL pin voltage be derived from the LED cathode terminal. GND is the ground reference pin. This pin should be connected directly to the ground plane on the PCB. SW pin is the drain terminal of the internal low resistance high-voltage power MOSFET. The inductor and the Schottky diode anode should be connected to the SW pin. Voltages of up to 40 V can be safely handled on the SW pin. Traces going to the SW pin should be as short as possible with minimum loop area. The device can handle safely "open-LED" or "shorted-LED" fault conditions. RSET pin is regulated at 1.2 V. A resistor connected between the RSET pin and ground sets the LED full-scale brightness current. The external resistance value and the CTRL pin voltage determine the LED current during analog dimming. The RSET pin must not be left floating. The highest recommended resistor value between RSET and ground is 90 kW.
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Simplified Block Diagram
12 V/24 V
VBAT 30 kW CTRL 7V 20 mA EN PWM Controller 1.2 V Reference ON-Time Control R2 1W OFF-Time Control SW
+ -
EN
1.2 V
RSET
GND
Figure 22. CAT4201 Simplified Block Diagram
Basic Operation The CAT4201 is a high efficiency step-down regulator designed to drive series connected high-power LEDs. LED strings with total forward voltages of up to 32 V can be driven with bias currents of up to 350 mA. During the first switching phase, an integrated high voltage power MOSFET allows the inductor current to charge linearly until the peak maximum level is reached, at which point the MOSFET is switched off and the second phase commences, allowing the inductor current to then flow through the Schottky diode circuit and discharge linearly back to zero current. The switching architecture ensures the device will always operate at the cross-over point between Continuous Conduction Mode (CCM) and Discontinuous Conduction Mode (DCM). This operating mode results in an average LED current which is equal to half of the peak switching current.
LED Pin Current
The LED current is set by the external RSET resistor connected to the regulated output of the RSET pin. An overall current gain ratio of approximately 2.5 A/mA exists between the average LED current and the RSET current, hence the following equation can be used to calculate the LED current.
LED Current (A) ^ 2.5 V RSET (V) R SET (kW)
Table 6 lists the various LED currents and the associated RSET resistors.
Table 6. RSET RESISTOR SELECTION
LED Current (A) 0.10 0.15 0.20 0.25 0.30 0.35 RSET (kW) 33 21 15 12 10 8.25
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APPLICATION INFORMATION
Input Voltage Range
Capacitor Selection
The minimum supply voltage required to maintain adequate regulation is set by the cathode terminal voltage of the LED string (i.e., the VBAT voltage minus the LED string voltage). When the LED cathode terminal falls below 3 V, a loss of regulation occurs. For applications which may occasionally need to experience supply "dropout" conditions, it is recommended that the CTRL input be used to sense the LED cathode voltage. The CTRL pin can either be tied directly to the cathode terminal (for Lamp Replacement) or connected via a pass-transistor for PWM lighting applications. Figure 23 shows the regulation performance obtained in dropout, when the CTRL pin is configured to sense the LED cathode voltage.
400
A 10 mF ceramic capacitor C2 across the LED(s) keeps the LED ripple current within 15% of nominal for most applications. If needed, a larger capacitor can be used to further reduce the LED current ripple. Any resistance in series with the LED (0.5 W or more) contributes to reduce the ripple current. The capacitor voltage rating should be equivalent to the maximum expected supply voltage so as to allow for "Open-LED" fault conditions. The capacitor value is independent of the switching frequency or the overall efficiency. A 4.7 mF ceramic input capacitor C1 is recommended to minimize the input current ripple generated on the supply. Using a larger capacitor value further reduces the ripple noise appearing on the supply rail. If a constant capacitance is needed across temperature and voltage, X5R or X7R dielectric capacitors are recommended.
Schottky Diode
LED CURRENT [mA]
300
300 mA
200 150 mA 100
0
The peak repetitive current rating of the Schottky diode must be greater than the peak current flowing through the inductor. Also the continuous current rating of the Schottky must be greater than the average LED current. The voltage rating of the diode should be greater than the peak supply voltage transient preventing any breakdown or leakage. Central Semiconductor Schottky diode CMDSH05-4 (40 V, 500 mA rated) is recommended. Schottky diodes rated at 400 mA (or higher) continuous current are fine for most applications.
5 6 NOTE: Schottky diodes with extremely low forward voltages (VF) are not recommended, as they may cause an increase in the LED current.
0
1
2
3
4
CTRL VOLTAGE [V]
Figure 23. "Dropout" Configured LED Current
(as shown in Typical Application on page 1)
Dimming Methods
Inductor Selection
For 350 mA LED current drive levels, a 22 mH inductor value is recommended to provide suitable switching frequency across a wide range of input supply values. For LED current of 150 mA or less, a 33 mH or 47 mH inductor is more suitable. The inductor must have a maximum current rating which equals or exceeds twice the programmed LED current. For example, when driving LEDs at 350 mA, an inductor with at least 700 mA current rating must be used. Minor improvements in efficiency can be achieved by selecting inductors with lower series resistance.
Table 7. SUMIDA INDUCTORS
Part Number L (mH) I Rated (A) LED Current (A)
Two methods for PWM dimming control on the LEDs are described below. The first method is to PWM on the control pin, the other method is to turn on and off a second resistor connected to the RSET pin and connected in parallel with R1.
PWM on CTRL Pin
A PWM signal from a microprocessor can be used for dimming the LEDs when tied to the CTRL pin. The duty cycle which is the ratio between the On time and the total cycle time sets the dimming factor. The recommended PWM frequency on the CTRL pin is between 100 Hz and 2 kHz.
CDRH6D26-100 CDRH6D26-220 CDRH6D28-330 CDRH6D28-470 CDRH6D28-560
10 22 33 47 56
1.5 1.0 0.92 0.8 0.73
0.35 0.35 0.35 0.35 0.35
Figure 24. PWM at 1 kHz on CTRL Pin http://onsemi.com
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300 250 LED CURRENT [mA] 200 150 100 50 0 100 80 60 40 DUTY CYCLE [%] 20 0
Operation from High Supply Voltage Above 14 V
For operation from a supply voltage above 14 V, it is recommended to have a slew rate of 1 ms or more for every 5 V increase in VBAT supply. When using a high supply voltage of 24 V, a 1 W or 2 W resistor in series with the supply, as shown on Figure 28, is recommended to limit the slew rate of the supply voltage. A 4.7 mF minimum ceramic capacitor is placed between the VBAT pin and ground. The combination of the series resistor R3 and input capacitor C1 acts as a low pass filter limiting the excessive in-rush currents and overvoltage transients which would otherwise occur during "hot-plug" conditions, thereby protecting the CAT4201 driver.
VBAT R3 24 V 1 W C1 4.7 mF VBAT CAT4201 RSET CTRL SW GND R1 1 kW D1 C2 4.7 mF L 33 mH 300 mA
Figure 25. LED Current vs. Duty Cycle
VBAT 12 V C1 VBAT CAT4201 RSET CTRL SW GND D C2 10 mF L 22 mH R2 R4 1 kW R5 47 kW 1 kW Q1 NPN
4.7 mF
R1 10 kW
R1 10 kW
Figure 28. 24 V Application with 5 LEDs Operation from High Supply Voltage of 36 V
5V 0V
PWM control
When powering from a high supply voltage of 36 V, a 2 W resistor in series with the supply is recommended, as shown on Figure 29, to limit the slew rate of the supply voltage.
VBAT R3 36 V 2 W C1 4.7 mF VBAT CAT4201 RSET CTRL SW GND R2 1 kW D1 C2 2.2 mF L 47 mH 300 mA
Figure 26. Circuit for PWM on CTRL PWM on RSET Pin
Another dimming method is to place in parallel to R1 another resistor with a FET in series, as shown on Figure 27. R1 sets the minimum LED current corresponding to 0% duty cycle. The combined resistor of R1 and Rmax sets the maximum LED current corresponding to 100% duty cycle.
VBAT 13 V C1 4.7 mF VBAT CAT4201 RSET R1 CTRL SW GND D C2 10 mF L 22 mH R2 OFF ON 1 kW Q1 NPN
R1 10 kW
Figure 29. 36 V Application with 6 LEDs Parallel Configuration for Driving LEDs Beyond 350 mA
Rmax
PWM control
Figure 27. Circuit for PWM on RSET
A resistor value for R1 of less than 90 kW is recommended to provide better accuracy.
Several CAT4201 devices can be connected in parallel for driving LEDs with current in excess of 350 mA. The CAT4201 driver circuits are connected to the same LED cathode. Figure 30 shows the application schematic for driving 1 A into one LED with three CAT4201 connected in parallel. Each CAT4201 is driving the LED with a current set by its RSET resistor. The resulting LED current is equal to the sum of each driver current.
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VIN R5 1W C1 4.7 F U1 VBAT CAT4201 RSET CTRL SW GND D1 C4 10 F 1A L1 22 H R4 1 k
R1
8.3 k
C2 4.7 F U2 VBAT CAT4201 RSET CTRL SW GND D2
Figure 31. Open LED Mode Board Layout
R2
8.3 k
L2 22 H
C3 4.7 F U3 VBAT CAT4201 RSET CTRL SW GND D3
R3 8.3 k
L3 22 H
In order to minimize EMI and switching noise, the Schottky diode, the inductor and the output capacitor C2 should all be located close to the driver IC. The input capacitor C1 should be located close to the VBAT pin and the Schottky diode cathode. The CAT4201 ground pin should be connected directly to the ground plane on the PCB. A recommended PCB layout with component location is shown on Figure 32. The LEDs are connected by two wires tied to both sides of the output capacitor C2. The LEDs can be located away from the driver if needed.
Figure 30. Three CAT4201 in Parallel for 1 A LED Open LED Behavior
If the LEDs are not connected, the CAT4201 stops switching and draws very little current. At power-up with no load connected, the capacitor C2 is charged-up by the CAT4201. As soon as the bottom side of the capacitor (C2-) reaches 0 volt, as shown on Figure 31, the CAT4201 stops switching and remains in the idle mode only drawing about 0.4 mA current from the supply.
Figure 32. Recommended PCB Layout
In order to further reduce the ripple on the supply rail, an optional Pi style filter (C-L-C) can be used. A 10 mH inductor rated to the maximum supply current can be used.
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PACKAGE DIMENSIONS
TSOT-23, 5 LEAD CASE 419AE-01 ISSUE O SYMBOL
A A1 A2 b c D E1 E E E1 e L L1 L2 0.30 0.01 0.80 0.30 0.12 0.15 2.90 BSC 2.80 BSC 1.60 BSC 0.95 TYP 0.40 0.60 REF 0.25 BSC 0.50 0.05 0.87
D e
MIN
NOM
MAX
1.00 0.10 0.90 0.45 0.20
TOP VIEW
0
8
A2 A
q
b
A1 L1
L
c
L2
SIDE VIEW Notes: (1) All dimensions are in millimeters. Angles in degrees. (2) Complies with JEDEC MO-193.
END VIEW
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Example of Ordering Information (Note 5)
Prefix CAT Device # 4201 Suffix TD -G T3
Company ID (Optional)
Product Number 4201
Package TD: TSOT
Plated Finish G: NiPdAu
Tape & Reel (Note 7) T: Tape & Reel 3: 3,000 / Reel
3. 4. 5. 6. 7.
All packages are RoHS-compliant (Lead-free, Halogen-free). The standard plated finish is NiPdAu on all pins. The device used in the above example is a CAT4201TD-GT3 (TSOT-23, NiPdAu, Tape & Reel, 3,000 / Reel). For additional package and temperature options, please contact your nearest ON Semiconductor Sales office. For information on tape and reel specifications, including part orientation and tape sizes, please refer to our Tape and Reel Packaging Specifications Brochure, BRD8011/D.
ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages. "Typical" parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including "Typicals" must be validated for each customer application by customer's technical experts. SCILLC does not convey any license under its patent rights nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part. SCILLC is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner.
PUBLICATION ORDERING INFORMATION
LITERATURE FULFILLMENT: Literature Distribution Center for ON Semiconductor P.O. Box 5163, Denver, Colorado 80217 USA Phone: 303-675-2175 or 800-344-3860 Toll Free USA/Canada Fax: 303-675-2176 or 800-344-3867 Toll Free USA/Canada Email: orderlit@onsemi.com N. American Technical Support: 800-282-9855 Toll Free USA/Canada Europe, Middle East and Africa Technical Support: Phone: 421 33 790 2910 Japan Customer Focus Center Phone: 81-3-5773-3850 ON Semiconductor Website: www.onsemi.com Order Literature: http://www.onsemi.com/orderlit For additional information, please contact your local Sales Representative
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