UM10342 SSL2101 3 W mains dimmable buck board
Contents
1. DO 15 P6KE400A FAI 31 1 V3 Diode DO 41 HER107 MLC 32 1 V4 Diode DO201AD HER307 MLC 33 1 V5 Zener Diode 24V SOT23 BZX84C24 NXP 34 1 X1 Connector MSTB 2 5 1759020 PHC 3 G 5 08 35 1 X2 Connector Socket 6 SIL6_2 54mm 972 8880 36 1 X3 Connector Socket 3 SIL3_2 54mm 972 8880 37 1 X4 Connector header 8 SIL8 8280200 08 02 38 1 X5 Connector header 4 SIL4 8280200 04 02 39 5 X6 X7 X8 Test Point TP X9 X10 Table 4 Bill of materials 120 V AC Part Qty Ref design Part Value Tol Package Type Manuf no 1 1 A1 IC S016 SSL2101T N1 515 NXP 2 1 C1 Capacitor 470 pF 1 kV DEBB33A471 MUR 3 2 C2 C3 Capacitor 470 nF 400 V 10 15 mm 2222 468 28474 VIS 4 1 C4 Capacitor 4 7 uF 63 V 10 7 5mm B32560J475K EPC 5 dl C5 Capacitor 4 7 uF 50 V 10 1210 GRM32ER71H475KA88L MUR 6 1 C6 Capacitor 10 uF 16 V 10 1206 GRM31CR61C106KC31L MUR 7 1 C7 Capacitor 680 pF 50 V 10 0805 C0805C681J5GAC KEM 8 1 C8 Capacitor 100 pF 100 V 5 0805 B37940K1101J60 EPC 9 1 L1 Inductor 2 2 mH 10 RLB9012 222KL BRN UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 11 of 16 NXP Semiconductors UM10342 SSL 2101 3 W buck board Table 4 Bill of materials 120 V AC continued Part Qty Refdesign Part Value Tol Package Type Manuf no 10 1 L2 Ferrite 800 Q at 100 MHz 7427501 SCN 11 L3 Ferrite 50 Qat4MHzto BLO2RN2R1M2B MUR 100 Mhz 12 1 L4 Inductor 310 uH custom 14 1 R2. SSL 2101 3 W buck board Dimming curve Using a resistive divider and low pass filter consisting of R2 R3 R10 R11 and R21 and C6 a DC voltage is created from the rectified mains voltage This DC voltage is used as a reference for the dimming position of the attached dimmer The voltage is connected with the BRIGHTNESS and PWMLIMIT pin of the SSL2101 These pins influence output power by restricting the duty factor of the converter PWMLIMIT and frequency of the converter brightness They are sensitive in the range of 0 4 V to 2 5 V By tuning the divider circuit dimming steepness and lower threshold can be tuned Bear in mind that at upper range both pins should be high enough to obtain full output power if input voltage independent current stabilization is to be achieved ma V AC 250 4 200 4 e Vpwm l Freq Vbright lt lt Comb 150 4 100 4 50 4 Fig 6 BRIGHTNESS pin and sensitivity 8 Board optimization UM10342_1 8 1 You can do the following modifications on the demo board in order to meet specific customer application specifications Change output current Header X5 on the driver board can be used to tune the output current through the LED s Table 2 shows measured current versus number of LEDs NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 8 of 16 NXP Semiconductors U M1 0342 8 2 SSL 2101 3
3. The dimmer unit can be placed on either input lead If a galvanic isolated transformer is used this should be placed in between the AC source and the dimmer demo board e Connect the load to the right side of the driver board using the side connectors Attach a jumper on the connector X5 according to load configuration Remark When the board is placed in a metal enclosure the middle pin of connector K1 can be connected to the metal casing for grounding Remark There should always be one load board with end terminations At open output and with power applied the driver board might be damaged due to an overvoltage on C4 No output overvoltage protection is implemented 4 Specifications Table 1 gives the specifications for the SSL2101 3 W LED buck board Table 1 Specifications Parameter Conditions Comment AC line input voltage 85 V AC to 276 V AC Board has been optimized for 230 V AC or 120 V AC 10 variation Output voltage LED voltage 3 5 V DC to 60 V DC Board has been optimized for 19 5 V DC Output current LED current 20 mA to 700 mA Board has been optimized for 250 mA Output current accuracy 4 to 4 at Based on 250 mA 6 W 230 V AC 10 Maximum output power 9 W Using 9 x 1 W LED 350 mA LED power Efficiency without dimmer Typically 66 Using 6 x 1 W LED 250 mA Power Factor 230 V AC 0 72 At 6 W output power UM10342_1 NXP B V 2009 All rights reserved User manual R
4. V 10 0805 C0805C681J5GAC KEM 8 1 C8 Capacitor 100 pF 100 V 5 0805 B37940K1101J60 EPC 9 1 L1 Inductor 2 2 mH 10 5 RLB9012 222KL BRN 10 1 L2 Ferrite 800 Q 100 MHz 7 7427501 SCN 11 1 L3 Ferrite 50 Q at 4 Mhz to E BLO2RN2R1M2B MUR 100 Mhz 12 1 L4 Inductor 310 uH custom 14 1 R1 Resistor Fusistor 10 Q a NFR25H0001009JA100 VIS UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 10 of 16 NXP Semiconductors UM10342 SSL 2101 3 W buck board Table 3 Bill of materials 230 V AC continued Part Qty Refdesign Part Value Tol Package Type Manuf no 15 2 R2 R3 Resistor 750 kQ 1 1206 2322 724 67504L PHY 16 2 R4 R5 Resistor 22 kQ 1 W 1 2512 CRCW251222KOFKEG ND VIS 17 2 R6 R7 Resistor 1kQ 1W 1 2512 541 1 00KAFCT ND VIS 18 2 R8 R9 Resistor 33 kQ 1 W 1 2512 CRCW251233KOFKEG ND VIS 19 1 R10 Resistor 15 kQ 1 0805 2322 734 61503L PHY 20 1 R11 Resistor 10 kQ 1 0805 2322 734 61003L PHY 21 1 R12 Resistor 100 KQ 1 0805 2322 734 61004L PHY 22 1 R13 Resistor 5 6 KQ 1 0805 2322 734 65602L PHY 23 2 R14 R15 Resistor 100 QO 1 W 1 2512 541 100AFTR ND VIS 24 1 R16 Resistor 39 kQ 1 0805 2322 734 63903L PHY 25 1 R17 Resistor 2 2 KQ 1 0805 2322 734 62202L PHY 26 2 R18 R19 Resistor 10 1 1206 2322 724 61008L PHY 27 1 R20 Resistor 2 20 1 1206 2322 724 62208L PHY 28 1 R21 Resistor 00 0805 2322 730 91002L PHY 29 1 V1 Bridge DIP4 Long DBL205G TAI Recitfier 30 1 V2 TVS Diode 400 V 600 W
5. boards This will allow tighter margins in optimization and more effective use of available LED power The design gives an example of how to make a drive that is suitable for small form factor applications like retrofit lamps 2 Safety warning The board needs to be connected to mains voltage Touching the board during operation must be avoided at all times An isolated housing is obligatory when used in uncontrolled non laboratory environments so a galvanic isolation of the mains supply using a variable transformer is always recommended These devices can be recognized by the symbols shown in Figure 1 OIC a Isolated b Not Isolated Fig 1 Variac isolation symbols 3 Connecting the board The board can be optimized for either a 230 V AC 50 Hz or a 120 V AC 60 Hz mains source Besides the mains source optimization the board has been designed to work with a several types and configurations of high power LEDs The dimming performance may decrease if the board is used at a different mains voltage UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 3 of 16 NXP Semiconductors U M1 0342 SSL 2101 3 W buck board Driver Board Light Dimmer 5 aCA EEFEREEI D T SS 014aaa924 Fig 2 Board connection diagram e Connect the mains line and the dimmer as shown in Figure 2
6. information 13 2 Disclaimers General 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 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 UM10342_1 Suitability for use NXP Semiconductors products are not designed authorized or warranted to be suitable for use in medical military aircraft space or life support equipment nor in applications where failure or malfunction of a 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 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
7. 1 Resistor Fusistor 10 Q NFR25H0001009JA100 VIS 15 2 R2 R3 Resistor 360 KQ 1 1206 2322 724 63604L PHY 16 2 R4 R5 Resistor 22 kQ 1 W 1 2512 CRCW251222KOFKEG ND VIS 17 2 R6 R7 Resistor 1kQ 1 W 1 2512 541 1 00KAFCT ND VIS 18 1 R8 Resistor 33 kQ 1 W 1 2512 CRCW251233KOFKEG ND VIS 19 1 R9 Resistor oQ 1 2512 20 1 R10 Resistor 15 kQ 1 0805 2322 734 61503L PHY 21 1 R11 Resistor 10 kQ 1 0805 2322 734 61003L PHY 22 1 R12 Resistor 100 kQ 1 0805 2322 734 61004L PHY 23 1 R13 Resistor 56 kQ 1 0805 2322 734 65602L PHY 24 2 R14 R15 Resistor 100 9 1 W 1 2512 541 100AFTR ND VIS 25 1 R16 Resistor 39 kQ 1 0805 2322 734 63903L PHY 26 1 R17 Resistor 2 2 kQ 1 0805 2322 734 62202L PHY 27 2 R18 R19 Resistor 1 00 1 1206 2322 724 61008L PHY 28 1 R20 Resistor 2 20 1 1206 2322 724 62208L PHY 29 1 R21 Resistor 15 kQ 1 0805 2322 734 61503L PHY 30 1 V1 Bridge DIP4 Long DBL205G TAI Recitfier 31 1 V2 TVS Diode 400 V 600 W DO 15 P6KE400A FAI 32 1 V3 Diode DO 41 HER107 MLC 33 1 V4 Diode DO201AD HER307 MLC 34 1 V5 Zener Diode 24V SOT23 BZX84C24 NXP 35 1 X1 Connector MSTB 1759020 PHC 2 5 3 G 5 08 36 1 X2 Connector Socket 6 SIL6_2 54 mm 972 8880 37 1 X3 Connector Socket 3 SIL3_2 54mm 972 8880 38 1 X4 Connector header 8 SIL8 8280200 08 02 39 1 X5 Connector header 4 SIL4 8280200 04 02 40 5 X6 X7 X8 Test Point X9 X10 UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 12 of 16 N
8. UM10342 SSL2101 3 W mains dimmable buck board Rev 01 28 September 2009 User manual Document information Info Content Keywords SSL2101 LED driver AC DC conversion dimmable mains supply driver user manual Abstract This is a user manual for the SSL2101 3 W mains dimmable buck driver demo boards founded by Philips NXP Semiconductors U M1 0342 SSL 2101 3 W buck board Revision history Rev Date Description 01 20090928 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 UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 2 of 16 NXP Semiconductors U M1 0342 SSL 2101 3 W buck board 1 Introduction The next advance in LED illumination technology requires the optimum use of the maximum potential LED lumen output enabled at an optimum energy efficiency and form factor The NXP AC DC converter dimmable board supports triac and transistor based dimmers Deep dimming has been included to increase dimming ratio up to 1 350 Also a combination of steering methods reduces audible transformer noise and creates a logarithmic dimming curve The curve approaches the natural dimming curve in brightness as experienced with incandescent lamps To provide a cost and size effective thermal design temperature feedback is incorporated in the
9. W buck board Table 2 LED current configuration Jumper position 9 x 1 W mA 6 x 1 W mA 3 x 1 W mA None 85 120 220 1 to 2 150 215 390 2to3 125 185 340 3 to 4 250 360 640 1 to 2 and 3 to 4 32011 46511 8101 1 The coil L4 starts to saturate due to high peak current Changing oscillator frequency The dimming range of the demo board is partly determined by the oscillation circuit made up of C7 R12 and R13 The frequency ratio can be calculated with the min and max oscillator frequencies as follows fin SEG x x 1 Imax 3X R13x C7 min max Frequency range fmax is limited to 200 kHz C7 is limited to a maximum of 1 nF 9 Thermal lumen management UM10342_1 The demo board provides an extra connector for thermal lumen management For instance a Negative Temperature Coefficient NTC resistor thermistor mounted in proximity of the LEDs can be used as sensor Then using a current mirror the value is compared with reference resistor and at threshold the PWMLIMIT pin is pulled to GND By variation of the resister value the temperature at which stabilization occurs can be set A lower value will cause higher threshold Because of thermal resistance versus required galvanic isolation a temperature difference will occur If the board is used in free air conditions this will lead to relative higher LED temperatures In an enclosed housing this difference will be smaller NXP B V 2009 Al
10. XP Semiconductors U M1 0342 SSL 2101 3 W buck board 12 Inductor specification Figure 8 shows the inductor schematic Fig 8 Inductor schematic 12 1 Winding specification Table 5 Winding specification No Section Wire Layers Turns Pin Begin End 1 N1 1 x 0 4 3 30 2 5 2 ISO 0 2 12 2 Electrical characteristics Table 6 Inductance Section Inductance N1 310 uH 5 at1 A 12 3 Core and bobbin e Core RM6 4 pin air gap adjust on value N1 310 uH B65807 JR87 e Bobbin B65808K N1004 D1 e Clip B65808A 2203X UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 13 of 16 NXP Semiconductors UM10342 UM10342_1 SSL 2101 3 W buck board 12 4 Physical dimensions Fig 9 4 pins 5 6pins 8 65 0 1 Transformer dimensions NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 14 of 16 NXP Semiconductors UM10342 13 Legal information SSL 2101 3 W buck board 13 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
11. e DCM mode and BCM mode have the advantage over CCM that the switch losses at turn on are minimal because no current is running Also the inductive material is used over the available BH curve because no permanent field is present Connector X5 pin 1 can be used to monitor inductor and switch current The peak current is limited using a sense resistor connected to the source pin The OCP limit is reached when the voltage at the source pin reaches 0 5 Volt Three time slots can be distinguished e t1 This is the time required to build up the magnetic field in the inductor NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 6 of 16 UM10342 NXP Semiconductors SSL 2101 3 W buck board e t2 This is the time required to reduce the magnetic field in the inductor e t3 This is the time that no current flows through the inductor t x Vprim L I t x Vsec Va L Ip f t Vorim L aie t1 12 t8 T 1 Fig 5 Converter operation Because t2 depends on LED voltage t3 will change at fixed frequency and fixed voltage The demo board is optimized for a load board with 6 LEDs To achieve maximum power output at BCM or to avoid CCM mode at low VLep C7 can be tuned up or down leading to a change in base oscillator frequency NXP B V 2009 All rights reserved UM10342_1 User manual Rev 01 28 September 2009 7 of 16 NXP Semiconductors U M1 0342 7 2
12. ev 01 28 September 2009 4 of 16 NXP Semiconductors UM10342 Table 1 Specifications continued SSL 2101 3 W buck board Parameter Conditions Comment Switching frequency 37 kHz Can be adjusted see Section 7 1 Dimming range 0 3 to 100 Board dimensions 75 mm x 50 mm x 20 mm LxBxH Operating temperature 0 C to 85 C 5 Board photos Fig 3 Driver board top UM10342_1 NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 5 of 16 NXP Semiconductors U M1 0342 SSL 2101 3 W buck board Fig 4 Driver board bottom z SCO Mat p pa pal a m Je MNL U ee g i mm rs oF a 6 Dimmers Several triac based dimmers have been tested by NXP Semiconductors As different dimmers have different specifications the dimming performance of the board might vary Dimming performance optimization can be achieved by tuning components see Section 8 Dimmer compatibility is reached through a combination of sensing and control logic in combination with internal switches and external resistors 7 Functional description 7 1 Converter operation UM10342_1 On the buck demo board a non isolated buck converter is used to drive the LEDs The SSL2101 can be used in two modes DCM Discontinuous Conduction Mode and BCM Boundary Conduction Mode It is not suitable for CCM Continuous Conduction Mod
13. l rights reserved User manual Rev 01 28 September 2009 9 of 16 NXP Semiconductors U M1 0342 SSL 2101 3 W buck board 10 Driver board schematic To DIMMER Vrectmains Jii To LEDS mu E E poet I Fusistor 10 Q Vi HERIOT 2 2mH 800 Q at I I I l DBL205G 100 MHz l I l MANS LED j 2tGND RGND DE Gone ORE Tt ot Mateo l c1 a ie POKERA 400V 400V K L a 5 l i li Te avi aa J T ee BaN Eo i Y LED 3l i Io a I I x1 3 R5 R7 I Se fine 72 r pe V a A Ch TOR ofi fee j go L ea ve er LED i i PWMLIMIT l Ji i i BRIGHTNESS H x2 DRAIN x8 aie 21 l wmm SOURCE Vcc i oa I tics SSL2101T io l R10 10 F BRIGHTNESS I BE m me Rcz lee li mai 100 kQ 5 6 kQ pican Sipi i 2 E F uF tes RC RC2 i i 4 x3 ar x5 i 680 pF 1002 100 Q 50V Fig 7 Driver board schematic 11 Bill Of Materials BOM Table 3 Bill of materials 230 V AC Part Qty Refdesign Part Value Tol Package Type Manuf no 1 1 Al IC S016 SSL2101T NXP 2 1 C1 Capacitor 470 pF 1 kV 7 F DEBB33A471 MUR 3 2 C2 C3 Capacitor 470 nF 400 V 10 15 mm 2222 468 28474 VIS 4 1 C4 Capacitor 4 7 uF 63 V 10 7 5mm B32560J475K EPC 5 1 C5 Capacitor 4 7 uF 50 V 10 1210 GRM32ER71H475KA88L MUR 6 1 C6 Capacitor 10 uF 16 V 10 1206 GRM31CR61C106KC31L MUR 7 1 C7 Capacitor 680 pF 50
14. nsions 14 13 Legal information 00eeee eens 15 13 1 Definitions n a nanana aanne 15 13 2 Disclaimer Seceani kenia eaa a e E a 15 13 3 Trademarks 00 0 00 cee eee eee 15 14 Contents naire aiia oaa ens 16 Please be aware that important notices concerning this document and the product s described herein have been included in section Legal information founded by NXP B V 2009 All rights reserved For more information please visit http www nxp com For sales office addresses please send an email to salesaddresses nxp com Date of release 28 September 2009 Document identifier UM10342_1
15. the specified use without further testing or modification 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 13 3 Trademarks Notice All referenced brands product names service names and trademarks are the property of their respective owners NXP B V 2009 All rights reserved User manual Rev 01 28 September 2009 15 of 16 NXP Semiconductors U M1 0342 SSL 2101 3 W buck board 14 Contents 1 Introduction 2 06 cee eee eee 3 2 Safety warning 0c e cece eee 3 3 Connecting the board 5 5 3 4 Specifications 0 cece eee eee 4 5 Board photoS 002e eee eee eee 5 6 Dimmers sirasi e ee eee eee 6 7 Functional description 00008 6 7 1 Converter operation 0 0005 6 7 2 Dimming curve 00s eee ee eee 8 8 Board optimization 220 20005 8 8 1 Change output current 0 8 8 2 Changing oscillator frequency 9 9 Thermal lumen management 9 10 Driver board schematic 0005 10 11 Bill Of Materials BOM 5 11 12 Inductor specification 00 00es 13 12 1 Winding specification 13 12 2 Electrical characteristics 13 12 3 Core and bobbin a n aaan aaan nnan 13 12 4 Physical dime
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