18 W High Power Factor LED Driver Evaluation Board User`s Manual
Contents
1. SCHEMATIC HVDC R10 L iso 4HVDC iso 5 1k Annn P AC L L 9 1 C4 Ki C5 FUSE T 420nF 450V 420nF 450V AC NI Z Figure 2 Input Circuit HVDC_iso 7 SH LED R14 3 Te 1 Me T 18uF 200V 75k 1 2W Dout US1K TP LED Q1 STU8N80K5 S NCL30088D C11 R3 de o lt 4 gt 100k Ohm NTC NZ RZ 1 00 Figure 3 Main Schematic http onsemi com 4 NCL30088LED1GEVB BILL OF MATERIAL Table 2 BILL OF MATERIAL Substitution Reference PCB Footprint Allowed 6 8 uF TDK C3216X7R1V685K160AC mme Cout 18 uF 200 V Rubycon 200LLE18MEFC10X12 5 NE M 10X12M5 V ERT C4 C5 120 nF 450 V Panasonic ECW FD2W124KQ CAP BOX 12M6X 4M6_ LS10 ON Semiconductor SC 88A sa FUSE Littelfuse 0263 500WRT1L FUSE HAIRPIN L S250 Li L2 Wurth RAD IND L UL Yes Wes o 2 Ek EN ut lt m EH Ium Wire Red 24AWG McMaster Carr 7587K922 UL1569 NA Wire Blk 24AWG McMaster Carr 7587K921 UL1569 12 Wire Wht 24AWG McMaster Carr 7587K924 UL1569 All Components to comply with RoHS 2002 95 EC Construction Options NCL30088D Revision 01 Yes No http onsemi com 5 NCL30088LED1GEVB GERBER VIEWS CJ o Re EI c O sem L2 C4 NCL Rev E LED Figure 4 Top Side PCB a CVCCi SR RoHS Ft 1 _fu i f Figure 5 Bottom Side PCB 65 0mm 17 0mm Figure 6 PCB Outline http onsemi com 6 NCL30088LED1GEVB2. White Wires Here Mark the appropriate Revision Here Black Wire Here 1 Strip and tin lead wires to 6 0 5 4 Places Notch Here Figure 7 Assembly Notes http onsemi com 7 NCL30088LED1GEVB CIRCUIT BOARD FABRICATION NOTES Fabricate per IPC 6011 and IPC6012 Inspect to IPA A 600 Class 2 or updated standard Printed Circuit Board is defined by files listed in fileset Modification to copper within the PCB outline is not allowed without permission except where noted otherwise The manufacturer may make adjustments to compensate for manufacturing process but the final PCB is required to reflect the associated gerber file design 0 001 in for etched features within the PCB outline Material in accordance with IPC 4101 21 FR4 Tg 125 C min Layer to layer registration shall not exceed 0 004 in External finished copper conductor thickness shall be 0 0026 in min ie 20z Copper plating thickness for through holes shall be 0 0013 in min ie loz All holes sizes are finished hole size Finished PCB thickness 0 031 1n All un dimensioned holes to be drilled using the NC drill data 11 12 13 14 15 16 17 18 19 20 Size tolerance of plated holes 40 003 in non plated holes 0 002 in All holes shall be 0 003 in of their true position U D S Construction to be SMOBC using liquid photo image LPI solder mask in acco
3. INDUCTANCE 85uH typ 120uH max 100kHz 100mVAC 6 2 tie 3 5 Ls TURNS RATIO 6 2 3 5 8 1 00 2 OPERATING TEMPERATURE RANGE 40 C to 125 C including temp rise Wire insulation amp RoHS status not affected by wire color Wire insulation color may vary depending on availability Unless otherwise specified tolerances are as follows m a Wurth Electronics Midcom inc Angles 1 Fractions 1 64 n you Decimals 005 127mm Footprint 001 03mm expec Watertown SD USA Drawing Title Toll Free 800 643 2661 Fax 605 886 4486 Inductor 750314731 o pec Sheet 1 of 1 Engineer EJK 04 10 2014 http onsemi com 9 NCL30088LED1GEVB ECA PICTURES Vout 90 180Y B Nn de Figure 8 Top View Figure 9 Bottom View TEST PROCEDURE Equipment Needed e LED Load 10V 30V 01A e AC Source 90 to 305 V ac 50 60 Hz Minimum 500 W capability Test Connections e AC Wattmeter 300 W Minimum True RMS Input 1 Connect the LED Load to the red and black Voltage Current Power Factor and THD 0 2 leads through the ammeter shown in Figure 10 accuracy or better CAUTION Observe the correct polarity or the load may be damaged e DC Voltmeter 300 V dc minimum 0 1 accuracy or l 2 Connect the AC power to the input of the AC better S wattmeter shown in Figure 10 Connect the white e DC Ammeter 1 A de minimum 0 1 accuracy or leads to the output of WA mana better 3 Connect the DC volt
4. 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 N American Technical Support 800 282 9855 Toll Free ON Semiconductor Website www onsemi com Literature Distribution Center for ON Semiconductor USA Canada P O Box 5163 Denver Colorado 80217 USA Europe Middle East and Africa Technical Support Order Literature http www onsemi com orderlit Phone 303 675 2175 or 800 344 3860 Toll Free USA Canada Phone 421 33 790 2910 Fax 303 675 2176 or 800 344 3867 Toll Free USA Canada Japan Customer Focus Center Fo
5. 00 kHz Stop Freg 30 000 MHz RBW 6dB 4 000 kHz VBW 10 000 kHz SWT 742 51 ms Figure 18 Conducted EMI Pre compliance Peak Data 150 kHz 30 MHz http onsemi com 15 NCL30088LED1GEVB ON Semiconductor and the Dy are registered trademarks of Semiconductor Components Industries LLC SCILLC or its subsidiaries in the United States and or other countries SCILLC owns the rights to a number of patents trademarks copyrights trade secrets and other intellectual property A listing of SCILLC s product patent coverage may be accessed at www onsemi com site pdf Patent Marking pdf 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
6. NCL30088LED1GEVB 18 W High Power Factor LED Driver Evaluation Board Users Manual Overview This manual covers the specification theory of operation testing and construction of the NCL30088LED1GEVB demonstration board The NCL30088 board demonstrates a 18 W high PF buck boost LED driver in a typical T8 outline Table 1 SPECIFICATIONS 100 277 Parameter Input voltage Class 2 Input no ground V ac Line Frequency Power Factor 100 Load THD Load gt 30 oe ER ESCHER ON Semiconductor www onsemi com EVAL BOARD USER S MANUAL Key Features As illustrated the key features of this evaluation board include e Wide Mains e Low THD across Line and Load e High Power Factor across Wide Line and Load e ntegrated Auto Recovery Fault Protection can be latched by Choice of Options Over Temperature on Board a PCB mounted NTC Over Current Output and Vee Over Voltage Figure 1 Evaluation Board Picture Top View Semiconductor Components Industries LLC 2014 November 2014 Rev 0 Publication Order Number EVBUM2285 D NCL30088LED1GEVB THEORY OF OPERATION Power Stage The power stage for the demo board is a non isolated buck boost based The controller has a built in control algorithm that is specific to the flyback transfer function Specifically Vout _ Duty Vin 1 Duty This is applicable to flyback buck boost and SEPIC converters The control is very similar
7. er Line and Load 180V 135V 90V 120 140 160 180 200 220 240 260 280 Line Voltage v ac Figure 14 Regulation over Line http onsemi com 13 NCL30088LED1GEVB Tek p NN MAKAK KARKAR KA KAJA KARA RRR N Ele 200ms 24DV AAU UH gU BU cm sms 133kv LY YN KKD EEEN EEN AEEA NY YN BEEN BEEN GEK L2 ie k 35 33 ENE 10Bms 138kY all ms alika PRET EP ET RD ere R RELIRA b 06 36 36 Figure 16 Start Up with AC Applied 230 V Maximum Load http onsemi com 14 NCL30088LED1GEVB RIGOL 02 50 40 2014 07 29 mi Local TracelPF otatus og Ref 36 00 dBuv Select Trace Pu BE 3 O Feak BB R BW mu 9 9 000 kHz kHz Trace Type Freeze b SWP Cont Avg Times 100 Trace Math Clear All Pass Fail b User ey Set Frequency E s Start Freq 150 00 kHz Stop Freq 1 0000 MHz RBWBdB 4 000 kHz VBW 10 000 kHz SWT 170 00 s Figure 17 Conducted EMI Pre compliance QP Data 150 kHz 1 MHz RIGOL 02 55 19 2014 07 29 Local Trace PF ce Ref 96 00 dBuv Att 20 dB Status 96 Select Trace id 1 NIESIE ie 88 Stop Frequency me 80 000000 MHz Trace Type i Freeze b SWP Cont Avg Times 100 Mi ni doa F Trace Math Hoja ki z i ly Lui di 1 ki pot FU dr A Jl i LO D I y 4 fe MIN Au yn LARA Y LC N m TTE kuk ui Mag PT Clear All Pass Fail Userkey Set Frequency P Start Freg 150
8. es which valley the power stage will operate in At low line and maximum load the power stage operates in the first valley standard CrM operation At the higher line range the power stage moves to the second valley to lower the switching frequency while retaining the advantage of CrM soft switching Auxiliary Winding The auxiliary winding has 3 functions 1 CrM timing 2 Vcc Power 3 Output voltage sense CrM Timing In the off time the voltage on the transformer inductor forward biases Dout and D9 When the current in the magnetic has reached zero the voltage collapses to zero This voltage collapse triggers a comparator on the ZCD pin to start a new switching cycle The ZCD pin also counts rings on the auxiliary winding for higher order valley operation A failure of the ZCD pin to reach a certain threshold also indicates a shorted output condition Vcc Power The auxiliary winding forward biases D9 to provide power for the controller This arrangement is called a bootstrap Initially the Cvcc is charged through R4 and R5 When the voltage on Cvcc reaches the startup threshold the controller starts switching and providing power to the output circuit and the Cvcc Cvee discharges as the controller draws current As the output voltage rises the auxiliary winding starts to provide all the power to the controller Ideally this happens before Cvcc discharges to the under voltage threshold where the controller stops operating
9. meter as shown in Figure 10 AC Power Source NOTE Unless otherwise specified all voltage measurements are taken at the terminals of the UUT Figure 10 Test Set Up http onsemi com 10 NCL30088LED1GEVB Functional Test Procedure 1 Set the LED Load for 26 V output 2 Set the input power to 120 V 60 Hz CAUTION Do not touch the ECA once it is energized because there are hazardous voltages present LINE AND LOAD REGULATION Table 3 120 V MAX LOAD Output Current 100 mA 3 mA Output Power Power Factor THD lt 20 Table 4 230 V MAX LOAD Vout X lout x 100 Pin Efficiency http onsemi com 11 Power Factor NCL30088LED1GEVB TEST DATA 1 00 0 98 0 96 0 94 0 92 0 90 0 88 0 86 0 84 180V 135V 0 82 90V 0 80 100 120 140 160 180 200 220 240 260 280 Line Voltage V ac Figure 11 Power Factor over Line and Load 32 28 24 180V na 135V 90V D 16 12 8 4 I 0 100 120 140 160 180 200 220 240 260 280 Line Voltage V ac Figure 12 THD over Line and Load http onsemi com 12 Output Current mA 95 94 93 92 91 90 Efficiency 89 88 87 86 85 100 115 113 111 109 107 105 M w 95 93 91 89 87 85 100 NCL30088LED1GEVB 180V 135V 90V 120 140 160 180 200 220 240 260 280 Line Voltage V ac Figure 13 Efficiency ov
10. n is a multi function protection input 1 Thermal Foldback Protection 2 Programmable OVP Thermal Protection There is an internal current source from the SD pin Placing an NTC from the SD pin to ground will allow the designer to choose the level of current foldback protection from over temperature Below 0 5 volts on SD the controller stops Series or parallel resistors on the NTC and shape the foldback curve In the event that the pin is left open there is a soft voltage clamp at 1 35 V nominal Output current is reduced when the voltage on the SD pin drops below 1 V Programmable OVP While the SD pin has a current source for the OTP it can be overcome raising the voltage on the SD pin At about 2 5 V the SD pin detects an OVP and shuts down the controller Typically a zener to Vee is used for this In this way the designer can set the OVP to a lower value that the OVP threshold built into the Vec pin Circuit Modifications Output Current The output current is set by the value of Rsense as shown above It s possible to adjust the output current by changing R7 Since the magnetic is designed for 18 W it is possible to increase the current while reducing the maximum LED forward voltage within limits Changes of current of 10 are within the existing EMI filter design and magnetic changes of more than 10 may require further adjustments to the transformer or EMI filter http onsemi com 3 NCL30088LED1GEVB
11. r additional information please contact your local Email orderlit onsemi com Phone 81 3 5817 1050 Sales Representative EVBUM2285 D
12. rdance with IPC SM B40C Type B Class 2 and be green in color Solder mask mis registration 0 004 in max Silkscreen shall be permanent non conductive white ink The fabrication process shall be UL approved and the PCB shall have a flammability rating of UL94VO to be marked on the solder side in silkscreen with date manufactures approved logo and type designation Warp and twist of the PCB shall not exceed 0 0075 in per in 100 electrical verification required Surface finish electroless nickel immersion gold ENIG RoHS 2002 95 EC compliance required http onsemi com 8 NCL30088LED1GEVB BUCK BOOST INDUCTOR SPECIFICATION _ 012 x 030 REF 2 NOTCH IN UPPER FLANGE 30 x 76 X LOCATES TERM 1 SIDE WURTH ELEKTRONIK 100 MIN L l 2 54 520 MAX 655 MAX 13 21 N 16 64 695 MAX TERM NO s FOR REF ONLY Z 9 020 4 50 PART MUST INSERT FULLY TO SURFACE A IN RECOMMENDED GRID PRI 75 100kHz _ 2 9 043 4 Wa bag RECOMMENDED P C PATTERN COMPONENT SIDE ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE 20 C 6 2 1 35 Ohms 10 3 5 0 425 Ohms 10 DIELECTRIC RATING 500VAC 1 minute tested by applying 625VAC for 1 second between pins 6 3 INDUCTANCE 1 25mH 8 100kHz 100mVAC OmADC 6 2 Ls SATURATION CURRENT gt 1 0ADC saturating current that causes 20 rolloff from initial inductance LEAKAGE
13. to allow Cvcc to recharge once again The size of the output capacitor will have a large effect on the rise of the output voltage Since the LED driver is a current source the rise of output voltage is directly dependent on the size of the output capacitor There are tradeoffs in the selection of Cout and Cvcc A low output ripple will require a large Cout value This requires that Cvcc be large enough to support Vcc power to the controller while Cout is charging up A large value of Cvcc requires that R4 and RS be lower in value to allow a fast enough startup time Smaller values of R4 and R5 have higher static power dissipation which lowers efficiency of the driver Output Voltage Sense The auxiliary winding voltage is proportional to the output voltage by the turns ratio of the output winding and the auxiliary winding The controller has an overvoltage limit on the Vec pin at about 26 V minimum Above that threshold the controller will stop operation and enter overvoltage fault mode such as when an open LED string occurs In cases where the output has a lot of ripple current and the LED has high dynamic resistance the peak output voltage can be much higher than the average output voltage The auxiliary winding will charge the Cvcc to the peak of the output voltage which may trigger the OVP sooner than expected so in this case the peak voltage of the LED string is critical http onsemi com 2 NCL30088LED1GEVB SD Pin The SD pi
14. to the control of the NCL30080 83 with the addition of a power factor correction control loop The controller has a built in hardware algorithm that relates the output current to a reference on the primary side lout Vref x Nps 2 x Rsense _ Nori APE Nsec Where Npri Primary Turns and Nsec Secondary Turns We can now find Rsense for a given output current RAE Vref x Nps 2 x lout Line Feedforward The controller is designed to precisely regulate output current but variation input line voltage do have an impact R3 sets the line feedforward and compensates for power stage delay times by reducing the current threshold as the line voltage increases R3 is also used by the shorted pin detection At start up the controller puts out a current to check for a shorted pin If R3 is zero the current sense resistor is too low a value and the controller will not start because it will detect a shorted pin So R3 is required to make the controller operate properly In practice R3 should be greater than 250 Q Voltage Sense The voltage sense pin has several functions 1 Basis for the reference of the PFC control loop 2 Line Range detection The reference scaling is automatically controller inside the controller While the voltage on Vs is not critical for the PFC loop control it is important for the range detection Generally the voltage on Vs should be 3 5 V peak at the highest input voltage of interest The voltage on Vs determin
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