NCL30082 8 W Smart LED Driver Evaluation Board User`s Manual
Contents
1. www onsemi com 5 NCL30082SMRTGEVB d 9 20 01 SWL q031 q31 hk N apo HO Uu A E S apo ANIV Ul A S E S LLASIZSGWIN Pauuoas q wig uoneinBay 9 EJJOA 9121S HO uo u jinejaq x x 1041U09 HO UO TAN 50 r OM 001 OLLMPOSELEMIA m SH 20 JUL 019 DLLMPFOGELANN LO seLssa 6 001 i 19MOd A 9181S HO 10j 4oleInB t A b OLLASIZSAW 7 Oka G OL A V LEPdON 94 E NQOVLS6Ed1 a I JJ tai MY wo ma F DLLI9LISVA x 9125 varus deion Ha i GEW Ju a TJ Toh HAKI IS va on vid QPOW PANDY 104 991N08 1u uino WWI OZ N rav r z AA NIA lt IDA 5 89 LLEWT l q31 8ru sn Figure 5 Interface Schematic www onsemi com NCL30082SMRTGEVB GERBER VIEWS Figure 7 Bottom Side PCB www onsemi com 7 NCL30082SMRTGEVB 38 0mm 14 5mm 6 5mm 20 0mm 17 4mm 28 0mm 20 0mm Figure 8 PCB Outline www onsemi com 8 NCL30082SMRTGEVB All Wire 6 0 5 Strip Ends 0 5 Wire 1 White l 10 2 Wire 3 Red La N yA Wire 4 Black gt m ed Mat Place the Label on Top of T1 NCL30082SMRTGEVB Rev Wire 2 White L2 Mounts Horizontally Figure 9 Assembly Notes Top Bevel Edge of D4 Indicates Polarity Figure 10 Assembly Notes Bottom www onsemi com 9 NCL30082SMRTGEVB CIRCUIT BARD FABRICATION NOTES 1 2 Fabricate per IPC 6011 and IPC6012 Inspect to IPA A 62. The SD pin is a multi function protection input 1 Thermal Foldback Protection 2 Programmable OVP www onsemi com 2 NCL30082SMRTGEVB 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 V 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 Vcc is used for this In this way the designer can set the OVP to a lower value that the OVP threshold built into the Vcc pin The zener programmable OVP is not implemented on this demo board Aux Power Management HVDC c5 Dout il lt ZLED 100nF 250V Rstart1 1 0 Meg 1 0 Meg 4 7uF 100V Rbo CVcc 3 01 Meg a R20 2 56k L a MMBTAO6LT D12 U1 eep Alive Regulator MM5Z15VT1G ifo mE active in off mode C11 I z Qfet Vv F NDD02N60Z Rtco l jini Riff Ja 100k Ohm NTQ 620 NCL30082 R2 b Vcc
3. 51 1k Rsens 10 BASZIDWST1G c13 c15 v Vcc Power On Mode Vcc Power Off Mode 3 3V Power On Mode 3 3V Power Off Mode 4 7uF 4 7uF Figure 2 Aux Power Management 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 Rsense Since the magnetic is designed for 8 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 Connections AC Input 1 Wire 1 White AC Line 2 Wire 2 White AC Neutral Output 1 Wire 3 Red LED 2 Wire 4 Black LED VO J7 1 3 3 V 2 On Off 3 Dim 4 NC 5 Common 6 NC www onsemi com 3 NCL30082SMRTGEVB Interface Control Signals On Off Control The on off control defaults to on if left open Grounding this pin to signal ground turns the output off In off mode the output voltage will regulate to 16 V This is well below the level that will cause the LEDs to pass current resulting in a true off mode Off mode is also the standby mode The standby power consumption is greatly affected by the values of RsrART and RsrARTI The designer may choose to trade off start up time for standby power cons
4. 00 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 for etched features within the PCB outline Material in accordance with IPC 4101 21 FRA Tg 125 C min Layer to layer registration shall not exceed 0 004 External finished copper conductor thickness shall be 0 0026 min i e 2 oz Copper plating thickness for through holes shall be 0 0013 min i e 1 oz All holes sizes are finished hole size Finished PCB thickness 0 031 All un dimensioned holes to be drilled using the NC drill data www onsemi com 11 12 13 14 15 16 17 18 19 20 10 Size tolerance of plated holes 40 0037 non plated holes 0 002 All holes shall be 0 003 of their true position U D S Construction to be SMOBC using liquid photo image LPI solder mask in accordance 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 UL94V0 to be marked on the solder
5. 102 5 102 0 101 5 LED Output Current in mA 101 0 0 0 2 0 4 0 6 0 8 0 10 0 12 0 14 0 16 0 18 0 20 0 3 3V Load in mA Figure 17 Cross Regulation Effect of 3 3 Load on Output Current 3 48 3 46 pod gt jil 3 3 Output Voltage 8 3 36 3 30 l T T 0 10 20 30 40 50 60 70 80 90 100 LED Output Current in mA Figure 18 Cross Regulation Effect of Output Current on 43 3 V Output www onsemi com 15 NCL30082SMRTGEVB 120 7 I I I 110 100 60 l Power mW 50 4 1 30 10 85 90 95 100 105 110 115 120 125 130 135 Line Voltage V ac Figure 19 Standby Power Consumption over Line Noise Filter Off 100ms l Figure 20 Start Up with AC Applied 120 V Maximum Load Noise Filter Off PENEN CENNE E lt Figure 21 Start Up with Enable www onsemi com 16 NCL30082SMRTGEVB BILL OF MATERIALS Table 3 NCL30082SMRTGEVB BILL OF MATERIALS Substitution Reference Manufacturer Part Number PCB Footprint Allowed C13 C15 Czig 4 7 uF Taiyo Yuden EMK107ABJ475KA T ETRE Cvc 603 Yes G No D9 D13 BAS21DW5T1G ON Semiconductor BAS21DW5T1G SC 88A Qty 4 1 2 1 2 1 1 2 D10 D12 D15 MM5Z15VT1G ON Semiconductor MM5Z15VT1G SOD523 No D11 BAS116LT1G ON Semiconductor BAS116LT1G SOT23 BAS16XV2T1G ON Semic
6. 39 G3QN3NN0934 NI V IJVANNS OL ATINA 183SNI ISAW LiVd s0F 9S _ g oo 2208 J trez 4 L oor 2131931319 m 3009 3lvd 3009 107 913419313109 es x o _ SONVLONGNI 3SV1iV31 2434 120 x zio JONVLONQNI 3OVWVv31 INIHHNO NOILVHNLVS J le A vesti JONVLILSIS34 IA 334 009 JONVLSIS34 DG SONVLSISSY 9 G f sr 9ret ON IN XVW Orr XVW OSS N _ ie g rs z 3GIS waal S3LVJOT 0S1 001 3ONVIA YaddN NI HOLON ser SPAT r5v 96us 3394 49 av37 SHOH IVNINH43L YSWOLSNO Figure 11 SEPIC Inductor Specification www onsemi com 11 NCL30082SMRTGEVB ECA PICTURES Figure 12 Top View Figure 13 Bottom View www onsemi com 12 NCL30082SMRTGEVB TEST PROCEDURE Equipment Needed e AC Source 90 to 135 V ac 50 60 Hz minimum 500 W capabilitv e AC Wattmeter 300 W minimum true RMS input voltage current power factor and THD 0 2 accuracy or better e DC Voltmeter 300 V dc minimum 0 1 accuracy or better e DC Ammeter 1 A dc minimum 0 1 accuracy or better e LED Load 75 V 0 1 A A constant voltage electronic load is an acceptable substitute for the LEDs as long as it is stable AC Power Source Test Connections 1 Connect the LED load to the red and black leads through the ammeter shown in Figure 14 Caution Observe the correct polarity or the load may be damaged 2 Connect the AC power t
7. NCL30082SMRTGEVB NCL30082 8 W Smart LED Driver Evaluation Board User s Manual Overview This manual covers the specification theory of operation testing and construction of the NCL30082DIMGEVB demonstration board The NCL30082 board demonstrates an 8 W SEPIC LED driver with a 3 3 V aux voltage for power control accessories Table 1 SPECIFICATIONS Parameter Value Notes Input Voltage 100 120 V ac Class 2 Input No Ground Line Frequency 50 Hz 60 Hz Porere one fs m enoue nne me anc age Wale namos sosy x Sma CPi 0 Output Vpims0 1V PWM Dimming Voltage 0 3 3V PWM Range Freq 2 200 Hz 0 100 EMI Conducted Class B FCC CISPR Key Features e Single Mains e Integrated Auto Recovery Fault Protection Can be Latched by Choice of Options Over Temperature on Board a PCB Mounted NTC Over Current Output and Vcc Over Voltage e 3 3 V Aux Voltage Available in All Modes e Dim to Zero Output e On Off Control Semiconductor Components Industries LLC 2015 1 August 2015 Rev 0 ON Semiconductor www onsemi com EVAL BOARD USER S MANUAL Bottom View Figure 1 NCL30082SMRTGEVB Evaluation Board Publication Order Number EVBUM2307 D NCL30082SMRTGEVB THEORV OF OPERATION Power Stage The power stage for the demo board is a non isolated coupled SEPIC converter The controller has a built in control algorithm that is specific to the fl
8. The voltage on ViN determines 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 Dour 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 RSTART and RSTARTI When the voltage on Cvcc reaches the startup threshold the controller starts switching and providing power to the output circuit and the Cycc Cvcc 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 wh
9. 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 resal
10. e 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 19521 E 32nd Pkwy Aurora Colorado 80011 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 chief us Fax 303 675 2176 or 800 344 3867 Toll Free USA Canada Japan Customer Focus Center For additional information please contact vour local Email orderlit onsemi com Phone 81 3 5817 1050 Sales Representative EVBUM2307 D
11. ere the controller stops operating to allow Cycc 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 Cour and Cvcc A low output ripple will require a large Cour value This requires that Cvcc be large enough to support Vcc power to the controller while Cour is charging up A large value of Cvcc requires that RSTART and RSTARTI be lower in value to allow a fast enough startup time Smaller values of RSTART and RSTARTI have higher static power dissipation which lowers efficiencv of the driver Output Voltage Sense The auxiliarv winding voltage is proportional to the output voltage bv the turns ratio of the output winding and the auxiliarv winding The controller has an overvoltage limit on the Vcc 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 SD Pin
12. o the input of the AC wattmeter shown in Figure 14 Connect the white leads to the output of the AC wattmeter 3 Connect the DC voltmeter as shown in Figure 14 Functional Test Procedure 1 Set the LED Load for 75 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 LED Test Load present NOTE Unless otherwise specified all voltage measurements are taken at the terminals of the UUT Figure 14 Test Set Up Line and Load Regulation Table 2 120 V MAX LOAD Output Current LED Output 100 mA 3 mA Aux Voltage V Efficiency U OUT 400 IN Output Power Output Voltage Wa EEE E Power Factor 3 3 V Load 0 3 3 V Load 20 mA 3 6 V LED Current Max Po 3 6 V LED Current 0 Dim 0 V 3 6 V On Off Off www onsemi com 13 NCL30082SMRTGEVB TEST DATA 90 70 60 u 8 40 Efficiency 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 Percent of Full Load Figure 15 Efficiencv over Load 150 140 130 120 P o Output Current mA b o o 80 70 60 50 t t t 85 90 95 100 105 110 115 120 125 130 135 Line Voltage V ac Figure 16 Regulation over Line www onsemi com 14 NCL30082SMRTGEVB 103 5 103 0
13. onductor BAS16XV2T1G SOD523 No er es es s o 402 RIFF 620 Q Yaego RC0402FR 07620RL Ye RsTART1 Rstart 1 0 MQ Yaego RCO805FR 071ML 805 Yes R20 Rzco 56 kQ Yaego RCO805FR 0756KL 805 Yes 402 Yes 1 Ye Ye Ye Ye N N N Ye Yi 1 1 1 1 1 2 1 1 1 1 2 i e f e BER BER BEE EEE BER No 1 U4 NCP431A ON Semiconductor NCP431A ON Semiconductor LM317LBDR2G No 6 wi Wire Red 24AWG McMaster Carr 7587K922 UL1569 w2 Wire Blk 24AWG McMaster Carr 7587K921 UL1569 NOTE All components to comply with RoHS 2002 95 EC 1 s ima s s Ea E IE s s 1 2 2 Ee s s s Esa s s 1 1 1 1 1 1 www onsemi com 17 NCL30082SMRTGEVB ON Semiconductor and the D 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
14. side in silkscreen with date manufactures approved logo and type designation Warp and twist of the PCB shall not exceed 0 0075 per in 100 electrical verification required Surface finish electroless nickel immersion gold ENIG RoHS 2002 95 EC compliance required L dO L 133HS NOILVOISIOAdS LWODPIW UOD SUIJUO ISM MMM rrozreror Lva 00 Aa 040 9Yd Air ONS SJOJSLLIJJILI u Que SJO JEJQ 9GOSLEOSZ UI SUCISUSWIJ PALOISUSWIP JENP SI UIMEJP SIYL finawaovia nounzanoo HIWHO4HSNVUL Aes poyeyulr oz 21 6 31Vd ON LHVd FILL ONIMVHQ suoneoyloeds Buibeyoed ds waa NCL30082SMRTGEVB SEPIC INDUCTOR SPECIFICATION ALF bb LE LL xew Hrl0 SZ AJ HNO GL xew Hrl0 0 AA Hrl0 0Z ove 9687 HUOE L ST AWQOL ZHMOL 7 3ONV1OnGNI 9020 L 8 WOLF SWYO 006 L OLF SWUO 0990 OLF SWUOQOL L MINO LHITI HIANM SM Aiqejrene uo Buipu d p JBA Aew Jojo UOIJRJNSUI 8JIM Jojo asim Aq payoaye Jou SNJEJS SHOM 9 UONEJNSUI JIAA YWOT AOZ XNY VUQOT A08 JIS Ajuo uonelnsui Ieuonoun3a asil dwa UIPNJOLI O SZL o 9 0v JONVU SYNLVYAdWAL DNILVHIHO puoo s OVASZ9 puoo s OVASZ8L g z el ST AWQOL ZH3001 9 n ST AWQOL ZH1001 g n leui LOL YONO 0Z SNOILIGNOD 1S31 aaa PSJOU 9SIMUSYJO Ss lun O Gc W SNOILVOIJIO93dS 1V9318319313 SNOILVOI4ID3dS TWHINID 30IS INZNOdWOD NY3LLVd O d Q3ONIWWODIU vv Z zso s 1
15. umption In a Smart Bulb application the mains power is left on so the bulb can be controlled remotely This designer can choose to optimize standby power by allowing the power on startup time to be longer than 0 5 s since power on timing is now a one time event In this case RsTART and RsTarr are optimized for low power consumption rather than an optimized startup time Once the converter is operating startup through on off control is less than 1 ms Dim Control The dim control input will accept either an analog or PWM signal The output has full range from 0 to 100 output A 0 V input to the dim connection causes Q4 to operate in linear mode which maintains the voltage on the dim pin of the controller at its minimum level At 0 V on the dim connection the output voltage will be 25 V which is below the Vr of the LEDs www onsemi com 4 NCL30082SMRTGEVB SCHEMATIC RDAMP 180 Q CA c3 10 uF a 100 nF 200 V 250 V ACN Figure 3 Input Circuit LLI l 56 kQ MM5Z15VT1G 8 gt gt 4 7 uF 100 V Cour 4 7 uF 100 RD Lo LL G 5 MMETADSLTI 3 2 lt ate os A os gt Q gt Lo LL ow OL gt ede T On bk gt o oO B N lo amp MW Oo ma oog HF Ta lt x gt lt Sa gt Ar a why 4 LLI OFET a NDDO2N60Z un 5 oc LO 3 a N lt m N 09 e sp 1 6 z G a a tt in gt 8 gt gt lt Figure 4 Main Schematic
16. yback transfer function Specifically Vour _ Duty Vu Duly aks This is applicable to flyback buck boost and SEPIC converters The controller has a built in hardware algorithm that relates the output current to a reference on the primary side VRer Nps l eq 2 OUT ZI Reene eq 2 Npni Nps N eq 3 SEC Where Npr Primary Turns and Nsec Secondary Turns We can now find Rsense for a given output current VRer Nps Rsense eq 4 2 lour Line Feedforward The controller is designed to precisely regulate output current but variation input line voltage do have an impact RLFF sets the line feedforward and compensates for power stage delay times by reducing the current threshold as the line voltage increases RLFF is also used by the shorted pin detection At start up the controller puts out a current to check for a shorted pin If RLFF 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 RLFF is required to make the controller operate properly In practice RLFF should be greater than 250 Q Voltage Sense The voltage sense pin has several functions sets the brown level and line range selection The amplitude of Vin is important for the range detection Generallv the voltage on Vin should be 3 5 V peak at the highest input voltage of interest Voltage on Vin must not be greater than 4 V under anv operating condition
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