EVBUM2175 - 3.6 W Flyback 3 LED Step Dimmable Driver
Contents
1. Figure 3 Flyback Currents and Auxiliary Winding Voltage in DCM At this point the Excel spreadsheet based design guide circuit will create some error on the CS pin which is adjusted will help with many of the calculations out by proper choice of A trim resistor allows for making fine adjustments to the current limit to set the output current precisely The LFF SPECIFICATIONS Table 1 SPECIFICATIONS i mam o _ ET _ LUE eee Om Oust orage mange osve Outpace med om om Sume hm http onsemi com 3 NCL30081LEDGEVB SCHEMATIC Start HVDC AC_N ES D4 C2 C3 47uF 1kQ 100 nF A 400 V 400 V AC L Rruse MB6S FUSE Figure 4 Input Circuit Dout HVDC UFM12PL HE Start CN NEED Dclamp 7 Restart BZX100A 7 E 1 0 MQ Rstart1 D9 Rbo OU BAS21DW5T1G 3 01 MQ BE I 420 pF 250 VAC Y2 leak 27 ud UFM15PL C15 470 250 2 R2 CV 180 51 1 NCL30081 Dd DE V I Rtrim Rsens 11Q 180 Figure 5 Main Schematic http onsemi com 4 NCL30081LEDGEVB Table 2 BILL OF MATERIALS Can be Reference PCB Footprint PE 7 088 TayoYuden TayoYuden EMK1 EMK107ABJ475KA T T iT om wm oen ee ewn st aen wm CE ws ew an D AE Sear eno Tu om mws _ re onen n ener iT omm me ou wn m2. 800 1 200 nF W because the nominal main is 100 V ac rather than 230 V ac The recommended capacitance values are line specific So there is no universal mains solution with a peak charge front end It is possible to convert the Evaluation Board to IEC61000 3 2 Class C compliance by of the fundamental current shall not exceed 8646 and changing C2 the fifth shall not exceed 61 moreover the waveform of the input current shall be such that it begins to flow before or at 60 has its last peak if there are several peaks per half period before or at 65 and does not stop flowing before 90 where the zero crossing of the fundamental supply voltage is assumed to be at 0 Table 3 C2 Capacitor Selection Minimum Capacitance Maximum Capacitance Voltage Rating 230 V ac 50 Hz 0 82 uF 1 2 uF 400 V de 100 V ac 50 60 Hz 3 6 uF 200 V dc Microsoft Excel is a registered trademark of Microsoft Corporation ON Semiconductor and ON are registered trademarks of Semiconductor Components Industries LLC SCILLC 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 purp
3. FREE Update views to show flying leads and lead length dimension Sn 96 Ag 4 Leads are 2 from outside bobbin rail and 1 8 tinned 500 676 TERM NO s FOR REF ONLY i 57 77 a 750313306 Le DOT LOCATES TERM 1 LOT CODE amp DATE CODE 621 MAX 15 77 a 050 D e 1 nd PRI 180 265 V B 100 kHz FL1 030 16 76 SEC 10 360 mA ce 042 REF 16 _ di 07 13 FL2 RS 45 067 14 _ o Customer to tie terminals 1 70 AUX 11 12 internally on PCB z 074 REF 16 REFERENCE LAND SIZE 1 88 6 CUSTOMER DETERMINE LAND LAYOUT ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE 20 C 10 13 tie 11 12 2 50 Q 10 15 16 1 28 Q 10 FL1 FL2 0 115 20 DIELECTRICRATING 4 000 VAC 1 minute tested by applying 4 000 VAC for 1 second between pins 10 FL1 tie 12 13 15 500 VAC 1 minute tested by applying 625 VAC for 1 second between pins 10 16 INDUCTANCE 1 50 mH 10 10 kHz 100 mVAC 0 mADC 10 13 11 12 Ls SATURATION CURRENT 420 mA saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 7 uH typ 15 uH max 100 kHz 100 mVAC 10 13 tie 11412 15 16 FL1 FL2 Ls TURNS RATIO 10 12 11 13 1 1 00 1 10 13 15 16 2 5 1 00 tie 11412 1 10 13 FL1 FL2 5 1 00 tie 11 12 196 OPERATING TEMPERATURE RANG
4. 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 American Technical Support 800 282 9855 Toll Free Semiconductor Website www onsemi com USA Canada Europe Middle East and Africa Technical Support Phone 421 33 790 2910 Japan Customer Focus Center Phone 81 3 5817 1050 Order Literature http www onsemi com orderlit For additional information please contact your local Sales Representative EVBUM2175 D
5. E 40 C TO 125 C including temp rise Unless otherwise specified tolerances are as follows Angles 1 Fractions 1 64 Decimals 0 005 127 mm This drawing is dual dimensioned Dimensions in brackets are in millimeters http onsemi com 8 NCL30081LEDGEVB ECA PICTURES CVccbulk Detected for a Non dimming Version Trim Transformer Flying Leads to Shortest Possible Length zd Flying Leads are Solder Strippable Flagged FL1 gt Figure 12 Transformer and Output Terminations http onsemi com 9 NCL30081LEDGEVB TEST PROCEDURE Equipment Needed Test Connections AC Source 1 Connect the Unit Under Test UUT per the test set 90 265 V ac 50 60 Hz Minimum 1 A ac capability up in Figure 13 e AC Wattmeter 2 Set the AC source per the test procedure NOTE Unless otherwise specified all voltage measurements are Power Factor 0 2 accuracy or better kenst ine enn ls oe UUT DC Voltmeter 100 V dc minimum 0 1 accuracy or better DC Ammeter dc minimum 0 1 accuracy or better LED Load 9 10 5 dc 3 LED Load 360 mA DCAmmeter Ammeter AC Power AC LED Source Wattmeter Test Load DC Voltmeter Voltmeter Figure 13 Test Set Up Functional Test Procedure Test Limits Test Condition Test Variable Mn Pass Fail Vin 90 V ac Output Current 350 mA 370 mA 77 4 Vin 120 V ac Output Current 350 mA 370
6. NCL30081LEDGEVB 3 6 W Flyback 3 LED Step Dimmable Driver Evaluation Board User s Manual Overview This documentation package covers an NCL30081 LED driver for use in a GU10 based LED lamp The output is mains isolated by double insulation Maximum input power is 5 W The ECA Electronic Circuit Assembly supports 2 versions one step dimming and one non dimming version The version is controlled through minor bill of material changes The LED current dims in 5 discrete levels sequentially by detecting the interruption of the AC mains briefly about 1 5 to step the LED current down one level until it cycles back to full current Modifications The value of Ririm sets the final output current value along With Rgense Rtrim 15 for fine adjustment The nature of the open loop control makes the current adjustment somewhat iterative based on available standard resistor values and because of the circuit parameters that affect the output current setting ON Semiconductor http onsemi com EVAL BOARD USER S MANUAL Line regulation is optimized by the selection of Rif A line dependent current source creates a line dependent offset on the CS pin to account for propagation delay errors in the peak primary current Changing the FET or gate driver resistor will also have some effect on the output current Since the input power is lt 5 W maximum this falls below the level where power factor or harmonic current requirements are a
7. a ee nn rn Te mse on nam Tm on 0 mm wm lm we on en moon cd X3 2 24 MEE GEN XFRM LINEAR _LINEAR EP13 EP13 SMD 16PIN MOD1 16PIN MOD1 NE NENNEN EN NN a ON Semiconductor 22 NCL30080 es Wire 6 Input White Alpha Wire 24 AWG Stranded oe gt Wire 6 Output Red EN 430 Alpha Wire 24 AWG Stranded Wire 6 Output Black UL1430 Alpha Wire 24 AWG Stranded o o Ms o o o a o o o http onsemi com 5 NCL30081LEDGEVB GERBER VIEWS eects __ Figure 6 Component Side PCB FET CVCCBULK 2 90V 265V ac 1 NCL30080 81 Figure 7 Component Side Silkscreen Figure 8 Solder Side PCB http onsemi com 6 Oo 11 12 13 NCL30081LEDGEVB GERBER VIEWS CONTINUED RSTART R4 CVCC U1 DLEAK Of RTRMIRSENS 05 LED COUT cs RoHS DOUT Figure 9 Solder Side Silkscreen 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
8. ample 2 2866594 MHz 2 2863 MHz 475 dBuV LU ULL AM gM IPIE PI TL EL Pw mip LL LL LLL Ll _ di 1 M emna otart 150 kHz stop 30 MHz Marker Type Marker Marker Function Figure 23 Conducted EMI Pre compliance 150 kHz 30 MHz http onsemi com 15 NCL30081LEDGEVB APPENDIX IEC61000 3 2 Class Compliance Compliance to IEC61000 3 2 Class C under 25 W is not possible with the universal front end architecture since input current does not comply with Class D requirements or the waveform definition requirements as stated in this excerpt Active Input Power 25 Discharge lighting equipment having an active input power smaller than or equal to 25 W shall comply with one of the following two sets of requirements The harmonic currents shall not exceed the power related limits of Table 3 column 2 or The third harmonic current expressed as a percentage If the discharge lighting equipment has a built in dimming device measurement is made only in the full load condition It is possible to comply with the special waveform and harmonic requirements of the third paragraph with a standard peak charge front end if the bulk capacitance is properly sized The bulk capacitor must be in the range of 200 300 nF W for a 230 V ac line for Europe Japan has a similar requirement however the bulk capacitance must be
9. er Line Voltage http onsemi com 12 Drain Voltage V dc Drain Voltage V dc 250 200 150 100 50 500 400 300 200 100 NCL30081LEDGEVB TEST DATA CONTINUED 10 15 20 25 30 as 40 Time psec Figure 18 Drain Voltage 90 V ac P 10 15 20 25 30 35 40 Time usec Figure 19 Drain Voltage 265 V http onsemi com 13 Output Current Output Current A 0 45 0 40 0 35 0 30 0 25 0 20 0 15 0 10 0 05 0 00 0 45 0 40 0 35 0 30 0 25 0 20 0 15 0 10 0 05 0 00 NCL30081LEDGEVB TEST DATA CONTINUED 10 15 20 25 30 35 40 Time ps Figure 20 Output Ripple 90 V ac 50 Hz 10 15 20 25 30 35 40 Time us Figure 21 Output Ripple 265 V ac 50 Hz http onsemi com 14 NCL30081LEDGEVB TEST DATA CONTINUED 12 09 12 15 18 Ref 97 0 dBuV RBW 10kHz SWT 93 ms Trace Max Hold Att 0 dB VBW 10 kHz Trig Free Run Detect Sample 2 2856459 MHz 2 2863 MHz otart 150 kHz otop 2 MHz TETUER Freq Stepsize Freq Offset Mode Figure 22 Conducted EMI Pre compliance 150 kHz 2 MHz 12 09 12 15 17 Ref 97 0 dBuV RBW 10kHz SWT 1 49 5 Trace Hold Att 0 dB VBW 10 kHz Trig Free Run Detect S
10. gulate the output current we need to take into account the leakage inductor current This is accomplished by sensing the clamping network current Practically a node of the clamp capacitor is connected to Rsense instead of the bulk voltage Voulk Then by reading the voltage on the CS pin we have an image of the primary current red curve in Figure 3 Ip pk When the diode conducts the secondary current decreases linearly from Ip pk to zero When the diode current has turned off the drain voltage begins to oscillate because of the resonating network formed by the inductors Lp Lieux and the lump capacitor This voltage is reflected on the auxiliary winding wired in fly back mode Thus by looking at the auxiliary winding voltage we can detect the end of the conduction time of secondary diode The constant current control block picks up the leakage inductor current the end of conduction of the output rectifier and controls the drain current to maintain the output current constant We have 2 R sense The output current value 15 set by choosing the sense resistor eq 1 lout V ref 2N 5 out From eq 1 the first key point is that the output current is independent of the inductor value Moreover the leakage inductance does not influence the output current value as the reset time is taken into account by the controller eq 2 R sense http onsemi com 2 NCL30081LEDGEVB
11. mA Vin 265 Output Current 350 mA 370 mA mm Vin 120 V ac Efficiency 80 Vout 10 5 V dc use actual measured data Efficiency 100 x Vout x Ioyr Pin http onsemi com 10 Output Current mA Efficiency NCL30081LEDGEVB TEST DATA 370 365 360 355 350 9V Out 345 8 10 5V Out 340 90 115 140 165 190 215 240 84 83 82 81 80 79 78 77 76 75 74 Line Voltage V ac Figure 14 Regulation over Line Voltage 9V Out m 10 5V Out 115 140 165 190 215 240 265 Line Voltage V ac Figure 15 Efficiency over Line Voltage http onsemi com 11 265 Power Factor Output Current mA 0 6 0 5 0 4 0 3 0 2 0 1 400 350 300 250 200 150 100 50 0 NCL30081LEDGEVB TEST DATA CONTINUED 9V Out 10 5V Out 90 115 140 165 190 215 240 265 Line Voltage V ac Figure 16 Power Factor over Line Voltage 4 E Level1 Level2 Level3 Level4 Level 5 d 34 Hh Hh TL 3 3 E HR H HH Vy mm ir 90 115 140 165 190 215 240 265 Line Voltage V ac Figure 17 Dimming ov
12. ose 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
13. pplicable in many countries e g US In the EU the harmonic current requirements for IEC61000 3 2 Class C are applicable even at this low power level Compliance to the Class C requirements is simple with a change of the input capacitor from 4 7 uF to 1 uF This change limits the input voltage operation to 200 265 V ac because there is insufficient energy storage for the full universal line range Figure 1 NCL30081LEDG Evaluation Board Semiconductor Components Industries LLC 2013 March 2013 Rev 0 Publication Order Number EVBUM2175 D NCL30081LEDGEVB THEORY OF OPERATION Figure 3 portrays the primary and secondary current of a fly back converter in discontinuous conduction mode Clamping Network DCM Figure 2 shows the basic circuit of a fly back converter Transformer Vout Ciump Rsense Figure 2 Basic Fly back Converter Schematic During the on time of the MOSFET the bulk voltage Vp is applied to the magnetizing and leakage inductors L and Lieak The current ramps up When the MOSFET is turned off the inductor current first charges Crump The output diode is off until the voltage across Lp reverses and reaches Vou Vj The output diode current increase is limited by the leakage inductor As a consequence the secondary peak current 15 reduced L pk No The diode current reaches its peak when the leakage inductor 15 reset Thus in order to accurately re
14. 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 0013 in min Copper plating thickness for through holes shall be 0 0007 in min All holes sizes are finished hole size Finished PCB thickness 0 031 in 10 un dimensioned holes to be drilled using the NC drill data Size tolerance of plated holes 0 003 in non plated holes 0 002 in 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 accordance with IPC SM BAOC Type B Class 2 and be green in color 14 15 16 L7 18 19 20 http onsemi com 7 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 compliance required NCL30081LEDGEVB FLYBACK TRANSFORMER SPECIFICATION CUSTOMER TERMINAL LEAD Pb
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