UM10460 Low-cost 4 W mains LED driver for the Japanese market
Contents
1. M 1SO9 MO7 09t0 LNN 5 5 dXN NXP Semiconductors UM10460 7 Bill of materials Low cost 4 W mains LED driver using the TEA1523 Table 2 Bill of materials Reference Description Value Manufacturer and Type Farnell number 1 fuse 1 125 Littelfuse 0251001 MAT1L 9921974 R1 power resistor thin film chip 100 Panasonic ERG1SJ100A RV1 not mounted R2 SMD 0603 resistor 10 Yageo RCO603FR 0710KL 9238603 R3 SMD 0603 resistor 270 Yageo RC0603FR 07270KL 9238778 RT1 SMD 0603 resistor 00 Yageo RC0603JR 070RL 9233130 R4 SMD 0805 resistor 30 SR732ATTD3ROOF 1399723 Radj SMD 0603 resistor R5 SMD 0805 resistor 270 Yageo RC0805FR 07220KL 9237917 R6 SMD 0603 resistor 220 kQ Yageo RCO603FR 0722KL 9238646 R7 SMD 0603 resistor 220 kQ Yageo RCO603FR 0722KL 9238646 C1 not mounted 5 2 electrolytic capacitor 6 8 uF Rubycon BXC C3 ceramic capacitor 100 nF MuRata RDER72bE104K3B1C11B C4 not mounted C5 ceramic capacitor 470 nF MuRata RDER72bE474K5B1C13B C6 SMD 0805 ceramic capacitor 1 uF 25 V Yageo CC0805KKX7R8BB105 1458903 C7 SMD 0603 ceramic capacitor 220 pF 50 V Yageo CC0603JRNPO9BN221 430948 C8 SMD 1206 ceramic capacitor 220 pF 200 V Yageo CCO603JRNPO9BN221 1284139 C9 SMD 1206 ceramic capacitor 220 pF 200 V Yageo CCO603JRNPO9BN221 1284139 L1 inductor 390 0 46 A 0 86 Q2. 98 019aab707 n 94 90 86 50 70 90 110 130 150 Vmains Vrms Fig 10 Efficiency of the converter as a function of the 50 Hz mains voltage Table 3 Mains conducted harmonic values Harmonic 120 V AC 50 Hz Harmonic 120 V AC 50Hz 1 100 96 11 29 96 2 12 3 83 96 13 21 96 4 14 5 58 15 9 6 57 16 7 41 17 8 18 9 34 96 19 3 96 10 20 The Total Harmonic Distortion THD is 0 133 96 The value of the parasitic capacitance between drain and ground is calculated using Equation 2 At Coe EI 2 The voltage across the internal MOSFET rises to 133 V during 240 ns The maximum value of the peak current is 0 163 A This results in a parasitic capacitance of 294 pF UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 12 of 16 NXP Semiconductors UM10460 UM10460 Low cost 4 W mains LED driver using the TEA1523 conductors RBW
3. 1 1 The 4 1523 buck converter board is a low cost solution with an excellent price performance ratio Only a minimum number of commercial off the shelf components are needed to build a fully functional LED driver that can be powered directly from the AC mains supply The board can achieve an efficiency greater than 90 Safety warning The board needs to be connected to 100 V mains voltage and it has no galvanic isolation between the mains and the LEDs Touching the demo board during operation must be avoided at all times An isolated housing for the board and the LEDs is mandatory when used in uncontrolled non laboratory environments Therefore the board must be connected to the mains supply via a galvanic isolated variable transformer These devices can be recognized by the symbols shown in Figure 1 019aab173 019aab174 a Isolated b Not isolated Fig 1 Variac isolation symbols Remark This board is for 100 V only do not connect it to 230 V mains 2 Connecting the board UM10460 The board is optimized for a 100 V AC mains supply but it is also possible to operate it from a 120 V supply The target load is a string of 24 LEDs with a total voltage of 68 V and an output current of 60 mA The TEA1523 is supplied from the mains input voltage using a supply removing the need for an auxiliary power supply The board footprint is as small as possible requiring the fuse and the inrush resistor
4. Applications that are described herein for any of these products are for illustrative purposes only NXP Semiconductors makes no representation or warranty that such applications will be suitable for the specified use without further testing or modification Customers are responsible for the design and operation of their applications and products using NXP Semiconductors products and NXP Semiconductors accepts no liability for any assistance with applications or customer product design It is customer s sole responsibility to determine whether the Semiconductors product is suitable and fit for the customer s applications and products planned as well as for the planned application and use of customer s third party customer s Customers should provide appropriate design and operating safeguards to minimize the risks associated with their applications and products UM10460 All information provided in this document is subject to legal disclaimers NXP Semiconductors does not accept any liability related to any default damage costs or problem which is based on any weakness or default in the customer s applications or products or the application or use by customer s third party customer s Customer is responsible for doing all necessary testing for the customer s applications and products using NXP Semiconductors products in order to avoid a default of the applications and the products or of the application or use by customer s thi
5. 9 kHz 10 17 11 1 ms Att 10 dB PREAMP OFF ioo 100 kHz 1 MHz 10 MHz Jass H90 SGL EXP 2 AV TDF CLRWR 1o bavp Feet 6DB H20 Lio 9 9 kHz 30 MHz 019aab708 a Phase line tors RBW 9 kHz MT 1 ms Att 10 dB PREAMP OFF Tico 100 kHz 1 MHz 10 MHz IIMIT Pass 90 SGL EX TDF CLRWR 70 FcEipav 60 25 Spit 6DB Hao 30 ai Nl al 20 NA 10 0 9 kHz 30 MHz 019aab709 b Neutral line Fig 11 Emission measurements All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 13 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 9 Optimization TEA1523 demo board When operated at 100 V mains a 100 Hz or 120 Hz in case of 60 Hz mains ripple on the LED current can be seen because at lower bus voltages the maximum value of the peak current Ipeak 15 not reached This can be solved by making the ripple voltage on the bus voltage smaller by increasing the value of the bus electrolytic capacitor The penalty for this is that THD performance decreases Another solution is to increase the value of R2 from 10 kQ to 12 kQ for example This shifts the maximum operating frequency to a lower value and the maximum peak current is reached at a lower bus voltage The bus voltage level at which t
6. to be mounted outside the board The LED string can be directly connected to the board All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 3 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 J3 J1 J2 J4 019aab698 1 J1 and J2 100 V AC 2 J3 LED 3 J4 LED Fig 2 Board connection diagram 3 Power supply specification Table 1 Output specification Description Value Comment AC line input voltage 100 V 10 output current LED current 60 mA see Figure 8 output LED voltage 68 V LED current ripple 38 42 see Figure 9 This ripple current has 100 Hz component and a 100 kHz component Maximum switching frequency 110 kHz efficiency gt 90 10 UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 4 of 16 NXP Semiconductors UM10460 4 Board photographs Low cost 4 W mains LED driver using the TEA1523 UM10460 b Bottom view Fig 3 Demo board views 019aab700 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 5 of 16 NXP Semiconductors U M1
7. 019aab702 1 CH2 Vous 2 ligp 3 V mains 100 V RMS Fig 5 Vbus and ILED at 100 V RMS At higher bus voltages gt 150 V the converter starts to work in Discontinuous Conduction Mode DCM and the LED current starts to drop 019aab703 70 ILED mA 50 30 10 80 120 160 200 Vbus V Fig 6 Average LED current as a function of bus voltage Figure 6 shows the average LED current as a function of the bus voltage The bus voltage was supplied from a DC source for this measurement so there is no 100 Hz ripple All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 7 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 Figure 7 shows the circuit diagram based on the fundamental circuit shown in Figure 4 The input voltage is rectified and buffered in electrolytic capacitor C2 The larger the value of this capacitor the larger the higher mains harmonics are The combination of L1 and C2 prevents drawing high frequency currents from the mains The TEA1523 is supplied by dVdt supply that consists of C8 and double diode D3 The drain voltage is sensed via C9 R5 and R6 and supplied to the AUX input This detects when the flux in inductor L2 reaches 0 The maximum switching frequency is set with C7 and R2 The pea
8. 0460 Low cost 4 W mains LED driver using the TEA1523 5 Functional description UM10460 Although the TEA1523 is often promoted as a flyback controller itis possible to use itas a non isolated down converter Ref 1 Figure 4 shows the fundamental circuit of the buck converter The buck converter that is described in this user manual is in the nominal operating range of 90 V to 110 V working in boundary conduction mode BCM i 02 D VLED Vbus i COD 019aab701 Fig 4 Fundamental circuit The maximum value of the peak current is fixed in the design and the value of the LED current is calculated using Equation 1 TL ED AV 2 1 At higher bus voltages gt 113 V the peak current is fixed by the design at VsoURCE max RsouRcE 0 5V 3 167 mA At lower bus voltages this peak current is not reached in time making the LED current dependent on the bus voltage This is shown in Figure 6 and Figure 7 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 60116 NXP Semiconductors U M1 0460 UM10460 Low cost 4 W mains LED driver using the TEA1523 2010 12 03 12 01 32 ________ Norma 1 YOKOGAWR 8 500kS s 2nsAiv ims CB 61 1399 GHZ 10 1 cHe 168 i Edge Line 50 0 U diu 20 0ma diu Auto DC Full DC Full
9. Panasonic ELCO9D391F 8094926 L2 inductor with coil 1 5 mH 0 43 2 40 TSL1112S 152JR38 PF D1 bridge rectifier 12 0 6 A 600 V Shindengen 512860 D2 SMT diode 2 A 600 V ST STTH2L06A D3 dual diode NXP Semiconductors BAV99 1081211 202 Zener diode SMT SOD323F 24V NXP Semiconductors PZU24B UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 10 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 8 Measurements UM10460 8 1 Transformer schematic diagram Figure 8 to Figure 11 show measurements that were performed on the board 019aab705 70 ILED mA 50 30 10 50 70 90 110 130 150 Vmains V Fig 8 LED current as a function of the 50 Hz mains voltage 019aab706 70 ILED ripple p p mA 50 30 10 50 70 90 110 130 150 Vmains V Fig 9 Peak to peak ripple LED current as a function of the 50 Hz mains voltage All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 11 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523
10. UM10460 Low cost 4 W mains LED driver for the Japanese market using the TEA1523 Rev 1 16 June 2011 User manual Document information Info Content Keywords TEA1523 SSL low cost LED driver AC DC conversion buck converter driver mains supply user manual Abstract This is the user manual for the TEA1523 4 W LED driver demo board NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 Revision history Rev Date Description v 1 20110616 first issue Contact information For more information please visit http www nxp com For sales office addresses please send an email to salesaddresses nxp com UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 2 of 16 NXP Semiconductors U M1 0460 Low cost 4 W mains LED driver using the TEA1523 1 Introduction WARNING Lethal voltage and fire ignition hazard The non insulated high voltages that are present when operating this product constitute a risk of electric shock personal injury death and or ignition of fire This product is intended for evaluation purposes only It shall be operated in a designated test area by personnel qualified according to local requirements and labor laws to work with non insulated mains voltages and high voltage circuits This product shall never be operated unattended
11. arranties of non infringement merchantability and fitness for a particular purpose The entire risk as to the quality or arising out of the use or performance of this product remains with customer In no event shall NXP Semiconductors its affiliates or their suppliers be liable to customer for any special indirect consequential punitive or incidental damages including without limitation damages for loss of business business interruption loss of use loss of data or information and the like arising out the use of or inability to use the product whether or not based on tort including negligence strict liability breach of contract breach of warranty or any other theory even if advised of the possibility of such damages Notwithstanding any damages that customer might incur for any reason whatsoever including without limitation all damages referenced above and all direct or general damages the entire liability of NXP Semiconductors its affiliates and their suppliers and customer s exclusive remedy for all of the foregoing shall be limited to actual damages incurred by customer based on reasonable reliance up to the greater of the amount actually paid by customer for the product or five dollars US 5 00 The foregoing limitations exclusions and disclaimers shall apply to the maximum extent permitted by applicable law even if any remedy fails of its essential purpose 11 3 Trademarks Notice referenced brands product nam
12. es service names and trademarks are the property of their respective owners NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 15 of 16 NXP Semiconductors UM10460 12 Contents Low cost 4 W mains LED driver using the TEA1523 zu TA 11 1 11 2 11 3 12 Introduction 3 Safety warning 3 Connecting the board 3 Power supply specification 4 Board photographs 5 Functional description 6 Schematic TEA1523 demo board 9 Bill of materials 10 11 Transformer schematic diagram 11 Optimization TEA1523 demo board 14 14 Legal information 15 5 15 5 15 15 Contents A ERG up 16 Please be aware that important notices concerning this document and the product s described herein have been included in section Legal information NXP B V 2011 All rights reserved For more information please visit http Awww nxp com For sales office addresses please send an email to salesaddres
13. he converter switches from BCM to DCM also shifts to a lower value The LED voltage range is limited the converter works efficiently when the LED voltage is about half the bus voltage 10 References 1 AN00055 STARplug Efficient Low Power supply with the TEA152x UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 14 of 16 NXP Semiconductors UM10460 11 Legal information Low cost 4 W mains LED driver using the TEA1523 11 1 Definitions Draft The document is a draft version only The content is still under internal review and subject to formal approval which may result in modifications or additions NXP Semiconductors does not give any representations or warranties as to the accuracy or completeness of information included herein and shall have no liability for the consequences of use of such information 11 2 Disclaimers Limited warranty and liability Information in this document is believed to be accurate and reliable However NXP Semiconductors does not give any representations or warranties expressed or implied as to the accuracy or completeness of such information and shall have no liability for the consequences of use of such information In no event shall NXP Semiconductors be liable for any indirect incidental punitive special or consequential damages including without limitati
14. k current is set with R4 and Radj The optional R3 and RT1 circuitry enables the implementation of an overtemperature protection In this case the REG pin is supplied with a fixed voltage that drops when the temperature of the circuit rises An Negative Temperature Coefficient NTC resistor should be mounted at position RT1 UM10460 All information provided in this document is subject to legal disclaimers NXP B V 2011 All rights reserved User manual Rev 1 16 June 2011 8of 16 jenuew 1955 eunf 91 8eH oj joefqns si 511 uoneuuojul 91106 siufu LLOZ dXN O Fig 7 L1 1 J3 oomo e GLEDE 300 uH D2 STTH2L06A c5 D1 220 pF 512860 J14 RI 1 D3 BAV99 100 C1 RV1 n m n m 2 14 LED 1 5 mH J21 F1 71 _ C6 B IN2 PZU24B T 1 pF 1 5A C9 Lc2 _ oor TJ 6 8uF T 100nF Tnm P SOURCE R5 T 220 kQ R7 R2 R3 siu C7 10kQ T 220pF 270 RES ters R6 22 RT1 R4 Ragj _ shortout 30 2 019aab704 Schematic TEA1523 demo board 9 2291 v3 EZSLWAL eui
15. on lost profits lost savings business interruption costs related to the removal or replacement of any products or rework charges whether or not such damages are based on tort including negligence warranty breach of contract or any other legal theory Notwithstanding any damages that customer might incur for any reason whatsoever NXP Semiconductors aggregate and cumulative liability towards customer for the products described herein shall be limited in accordance with the Terms and conditions of commercial sale of NXP Semiconductors Right to make changes NXP Semiconductors reserves the right to make changes to information published in this document including without limitation specifications and product descriptions at any time and without notice This document supersedes and replaces all information supplied prior to the publication hereof Suitability for use NXP Semiconductors products are not designed authorized or warranted to be suitable for use in life support life critical or safety critical systems or equipment nor in applications where failure or malfunction of an NXP Semiconductors product can reasonably be expected to result in personal injury death or severe property or environmental damage NXP Semiconductors accepts no liability for inclusion and or use of NXP Semiconductors products in such equipment or applications and therefore such inclusion and or use is at the customer s own risk Applications
16. rd party customer s NXP does not accept any liability in this respect Safety of high voltage evaluation products The non insulated high voltages that are present when operating this product constitute a risk of electric shock personal injury death and or ignition of fire This product is intended for evaluation purposes only It shall be operated in a designated test area by personnel that is qualified according to local requirements and labor laws to work with non insulated mains voltages and high voltage circuits The product does not comply with IEC 60950 based national or regional safety standards NXP Semiconductors does not accept any liability for damages incurred due to inappropriate use of this product or related to non insulated high voltages Any use of this product is at customer s own risk and liability The customer shall fully indemnify and hold harmless NXP Semiconductors from any liability damages and claims resulting from the use of the product Export control This document as well as the item s described herein may be subject to export control regulations Export might require a prior authorization from national authorities Evaluation products This product is provided on an as is and with all faults basis for evaluation purposes only NXP Semiconductors its affiliates and their suppliers expressly disclaim all warranties whether express implied or statutory including but not limited to the implied w
17. ses nxp com Date of release 16 June 2011 Document identifier UM10460
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