EVBUM2179 - 10 W Passive PFC Flyback and BuckBoost
Contents
1. Efficiency 85 0 eee e5LED 6 LED 7 LED 84 5 84 0 Line Voltage Vac Figure 33 230 V ac Class C Flyback Line amp Load Efficiency J ower Factor Harmonie Semen caecum om er TI Figure 34 Class C Measured Harmonic Content Vin 230 V ac 50 Hz ENERGY STAR and the ENERGY STAR mark are registered U S Marks Microsoft Excel is a registered trademark of Microsoft Corporation ON Semiconductor and D 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 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 custo2. Fractions 1 64 Decimals 0 005 127 mm This drawing is dual dimensioned Dimensions in brackets are in millimeters http onsemi com 9 NCL30083FLYGEVB NCL30083BB1GEVB FLYBACK ECA PICTURES Output Lead Breakout Figure 11 Flyback Top View Figure 12 Flyback Bottom View hitp onsemi com 10 NCL30083FLYGEVB NCL30083BB1GEVB BUCK BOOST ECA PICTURES A a Output Lead Breakout Figure 13 Buck Boost Top View Figure 14 Buck Boost Bottom View http onsemi com 11 NCL30083FLYGEVB NCL30083BB1GEVB Note location of transformer Flying Leads trim as short as possible Mark the Appropriate Configuration Figure 15 Flyback Lead Breakout Figure 16 Buck Boost Lead Breakout http onsemi com 12 NCL30083FLYGEVB NCL30083BB1GEVB TEST PROCEDURE Equipment Needed Flyback 14 17 V de 5 LED Load 0 500 mA AC Source 100 to 265 V ac 50 60 Hz Minimum 1 A Buck Boost 50 55 V dc 15 LED Load ac capabilities 200 mA AC Wattmeter 30 W Minimum True RMS Input Test Connections Voltage and Current Power Factor 0 2 accuracy or 1 Connect the Unit Under Test UUT per the test set better Ba gt up in Figure 17 DC Voltmeter 100 V de minimum 0 1 accuracy or 2 Set the AC source to 120 1 V ac RMS 60 Hz or better 230 2 V ac RMS 50 Hz DC Ammeter 1 A dc minimum 0 1 accuracy or better NOTE Unless otherwise specified all voltage measurements are L
3. Bottom 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 vvithin 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 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 All un dimensioned holes to be drilled using the NC drill data 11 12 13 14 16 17 18 Surface finish electroless nickel immersion gold 19 20 Size tolerance of plated holes 0 003 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 accordance with IPC SM B40C Type B Class 2 and be green in color Solder mask mis registration 0 004 in max 15 Silkscreen shall be permanent non conductive whi
4. FL2 Ls TURNS RATIO 4 3 1 2 2 5 1 00 1 4 3 FL1 FL2 3 1 00 1 OPERATING TEMPERATURE RANGE 40 C TO 125 C including temp rise Unless otherwise specified tolerances are as follows Angles 1 Fractions This drawing is dual dimensioned Dimensions in brackets are in millimeters http onsemi com 8 1 64 Decimals 0 005 127 mm NCL30083FLYGEVB NCL30083BB1GEVB BUCK BOOST INDUCTOR SPECIFICATION LEAD Pb FREE Yes PART MUST INSERT FULLY TO SURFACE A IN RECOMMENDED GRID iti i DOT LOCATES TERM 1 13 46 020 SQ 4 110 MIN 837 Max 2 79 800 Max 20 32 NO S FOR REF ONLY LOT CODE amp DATE CODE O PRI Q 047 4 120 375 V 1 20 100 kHz O 150 2 AUX 3 81 i 16 V 10 mA m mi RECOMMENDED P C PATTERN COMPONENT SIDE ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE 20 C 1 2 0 450 Q 10 3 4 0 965 Q 10 DIELECTRIC RATING 1 000 VAC 1 minute tested by applying 1 250 VAC for 1 second between pins 1 4 INDUCTANCE 950 uH 10 10 kHz 100 mVAC 0 mADC 3 4 Ls SATURATION CURRENT 1 A saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 25 0 uH max 100 kHz 100 mVAC 3 4 tie 1 2 Ls TURNS RATIO 4 3 1 2 3 1 00 1 OPERATING TEMPERATURE RANGE 40 C TO 125 C including temp rise Unless otherwise specified tolerances are as follows Angles 1
5. 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 Vpuik Then by monitoring the voltage on the CS pin we have an image of the primary current red curve in Figure 4 When the diode conducts the secondary current decreases linearly from Ip px 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 pa VREF 2N sp R sense The output current value is set by choosing the sense resistor eq 1 I out V Rsense eq 2 2N sp I 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 Figure 4 Flyback Currents and Auxiliary Winding Voltage in DCM At this point the Excel sprea
6. 0 260 Line Voltage V ac Figure 25 Buck Boost Efficiency over Line V1 55 V lout 195 mA http onsemi com 17 Output Current A Power Factor 0 210 0 208 0 206 0 204 0 202 0 200 0 198 0 196 NCL30083FLYGEVB NCL30083BB1GEVB 100 120 140 160 180 200 220 240 260 Line Voltage V ac Figure 26 Buck Boost Power Factor over Line V4 55 V lout 195 mA 0 194 ji 0 192 0 190 0 188 0 186 Time ms Figure 27 Buck Boost Output Ripple 120 V ac 60 HZ http onsemi com 18 Output Current A NCL30083FLYGEVB NCL30083BB1GEVB Time ms Figure 28 Buck Boost Output Ripple 230 V ac 50 Hz e RBW 10 kHz VBW 10 kHz Ref 97 0 dBuV e Att 0 dB 1 7653800 MHz 1 7651 MHz 50 0 dByV Start 150 kHz Detector Mode 12 09 12 15 09 SWT 93 ms Trace Max Hold Trig Free Run Detect Sample Figure 29 Conducted EMI Pre compliance 150 kHz 2 MHz http onsemi com 19 NCL30083FLYGEVB NCL30083BB1GEVB amp Ref 97 0 dBuV RBW 10 kHz VBW 10 kHz 1 7638925 MHz 1 7651 MHz 50 1 dByV Start 150 kHz 12 09 12 15 10 SWT 1 49 s Trace Max Hold Trig Free Run Detect Sample Stop 30 MHz Stop ns i mme Freq Offset Figure 30 Conducted EMI Pre compliance 150 kHz 30 MHz APPENDIX IEC61000 3 2 Class C Compliance Compliance to IEC61000 3 2 Class C under 25 W is not possible with the valley fill front end architec
7. 94 492 490 Line Voltage V ac Figure 18 Flyback Line amp Load Regulation 2 0 1 5 1 0 0 5 0 0 0 5 1 0 1 5 2 0 90 115 140 165 190 215 240 265 Line Voltage V ac Figure 19 Flyback Relative Line Regulation http onsemi com 14 Efficiency Power Factor 89 88 87 86 85 84 83 82 90 0 95 0 90 0 85 0 80 0 75 0 70 0 65 NCL30083FLYGEVB NCL30083BB1GEVB 3 ED 4 LED 5LED Ed LED 115 140 165 190 215 240 265 Line Voltage V ac Figure 20 Flyback Line amp Load Efficiency 9 6 V LED Vf 22 1 V LED Vf Line Voltage V ac Figure 21 Flyback Line amp Load Power Factor http onsemi com 15 NCL30083FLYGEVB NCL30083BB1GEVB v 1usund indino Time ms Figure 22 Flyback Output Ripple 120 V ac 60 Hz y uana Indino Time ms Figure 23 Flyback Output Ripple 230 V ac 50 Hz http onsemi com 16 Output Current mA NCL30083FLYGEVB NCL30083BB1GEVB 200 199 198 197 196 195 194 L J L 193 29V LED Vf 192 60 V LED Vf 191 190 100 120 140 160 180 200 220 240 260 Line Voltage Figure 24 Buck Boost Line amp Load Regulation 93 0 92 5 92 0 91 5 Efficiency 91 0 90 5 90 0 100 120 140 160 180 200 220 24
8. ED Load taken at the terminals of the UUT AC Power LED Source Test Load DC Voltmeter Figure 17 Test Set Up Functional Test Procedure Table 4 FLYBACK VERSION NCL30083FLYGEVB Test Limits Test Condition Test Variable Min Pass Fail Vin 100 V ac Output Current 490 mA Vin 120 V ac Output Current 490 mA Vin 265 V ac Output Current 490 mA Vin 265 V ac Power Factor 0 70 Vin 120 V ac Efficiency 82 Vout 14 V Use Actual Measured Data Table 5 BUCK BOOST VERSION NCL30083BB1GEVB Test Condition Test Variable Vin 100 V ac Vin 120 V ac Vin 265 V ac Vin 265 V ac Vin 120 V ac Efficiency Vout 55 V Use Actual Measured Data Efficiency Vour x lour 1 Pin x 100 Step Dimming Test Procedure 4 Interrupting the AC input for 1 2 s will step the NCL30083BB1 GEVB NCL30083FLYG EVB output current down 1 Connect the UUT to the LED load 5 There 6 discrete current levels After the lowest 2 Apply 120 V ac power level the current will return to maximum output 3 Verify that the output current is within the 6 Cycle the input power 6 times validating that the regulation limits as specified in the functional test current steps down at each cycle and returns to procedure maximum http onsemi com 13 Output Current mA Line Regulation NCL30083FLYGEVB NCL30083BB1GEVB TEST DATA 510 508 506 504 502 500 9 6 V LED Vf PNE Po ze A e o A 496 4
9. EDs to be dimmed in 5 discrete steps by toggling the AC line Vin off momentarily Cyccbulk holds up Vcc while Vin toggles low switching to the next lower dim level Since the timing is user controlled by switching on off the light switch the timing window is very wide Toggling the AC input in one second is typical It may take more than 20 seconds of AC off to reset the IC at which time when turned on again it return to the 100 state By removing the Cyccbulk the step dimming function is effectively disabled so the performance of the current control is just like the NCL300082 It is also possible with this board to replace the NCL30083 with an NCL30082 to evaluate the analog dimming control The value of Rsense sets the final output current value in conjunction with Rtrim which is for fine adjustment The nature of the primary side loop control makes the current adjustment somewhat iterative because several circuit parameters affect the output current setting It is relatively easy by changing Rgense to increase the output of the evaluation board as long as the output power limit is considered Vbulk Clamping Network Since the NCL30082 3 has a wide Vcc range this allows one transformer inductor design to a gt 2 1 change in LED string forward voltage If it is desired to reduce the output current the output power is no longer the limit but simply the level of the reflected voltage from the auxiliary winding which is monitored b
10. NCL30083FLYGEVB NCL30083BB1GEVB 10 W Passive PFC Flyback and Buck Boost Dimmable LED Driver Evaluation Board User s Manual Introduction This documentation package covers two NCL30083 LED driver implementations illustrating their use in an E26 E27 based A PAR and BR LED lamps form factor The Electronic Circuit Assembly ECA is designed to support Figure 1 NCL30083FLYGEVB Flyback Table 1 DESIGN PARAMETER Safety Designed to Meet Optimized Output Voltage Range Flyback NCL30083FLYGEVB Buck Boost NCL30083BB1GEVB Output Current Flyback NCL30083FLYGEVB Buck Boost NCL30083BB1GEVB Output Ripple Flyback NCL30083FLYGEVB Buck Boost NCL30083BB1GEVB Efficiency Flyback NCL30083FLYGEVB Buck Boost NCL30083BB1GEVB Start Up Time Semiconductor Components Industries LLC 2013 May 2013 Rev 1 ON Semiconductor http onsemi com EVAL BOARD USER S MANUAL either an isolated flyback or non isolated buck boost configuration The nominal total power is 10 W for either application The selection is controlled through selective component population of the ECA IEC61347 2 13 UL8750 9 6 22 1 V dc 30 60 V de 500 mA dc 195 mA dc 200 mA P P 50 mA P P lt 500 msec Publication Order Number EVBUM2179 D NCL30083FLYGEVB NCL30083BB1GEVB Demo Board Modifications The board as shipped contains the NCL30083 to demonstrate the line step dimming function which allows the L
11. amo MX ves m peso o bose Poe rea m m pes x x ua vamo O romeo m m E RE orok m ra Rjump1 RC0402JR 070RL Rtco_trim RC0402FR 0710KL RC0402FR 0710KL rea M 620 Q RC0402FR 07620RL 0 68 Q RLO603FR 070R68L 0 78 Q RLO603FR 070R78L Rstart1 Rstart 1 0 MQ RC0805FR 071ML Rtco 100 kQ NTC B57331V2104J60 Rtrim Vishay Dale CRCW06037R15FKEA i Stackpole RMCFO603FT5R10 Rzcd Yaego RC0805FR 0756KL Te I pre SIN le ie bo e Poe emo es es PeP PP no re Pe 1 jn poe e 2 Wire Input White UL1430 Alpha Wire 24 AWG Stranded 6 Wire Output Red UL1430 Alpha Wire 24 AWG Stranded 6 je ES E a Ba ac To convert the board to NCL30082 the identified components are changed see NCL30082 configuration table http onsemi com 5 NCL30083FLYGEVB NCL30083BB1GEVB Table 3 NCL30082 CONFIGURATION TABLE Flyback FB NCL30083 Buck Boost BB NCL30083 NCL30082 Remove NCL30082 Replace with Connector Remove xX NCL30082 Replace with Connector Notes Connector Assembly Supplier Part Number Board Connector Molex 22035025 Mating Connector Molex 50375023 Connector Terminal 8701039 GERBER VIEWS Figure 8 Bottom Side PCB http onsemi com 6 Ha NCL30083FLYGEVB NCL30083BB1GEVB m E po LED LE LI VI Figure 9 Top Silkscreen NCL30082 83 10W RoHS T ru ra e FE T ko 90V 265V ac Figure 10
12. dsheet based design guide will help with many of the calculations A trim resistor allows for making fine adjustments to the current limit to set the output current precisely The LFF circuit will create some error on the Cs pin which is adjusted out by proper choice of Rtrim So we will choose Rgense 1 8 Q and use Rtrim for the fine adjustments After setting R4 to 1 1 KQ Riim is 22 Q http onsemi com NCL30083FLYGEVB NCL30083BB1GEVB SCHEMATIC HVDC c4 kelj D3 et Zn ca 200 V c5 00 UFM15PL on 120 nF Ag 400V Do co UFM15PL 18 uF 200 V Figure 5 Input Circuit BB_LED BB LED HVDC TI gt LL LED Rstart 1 0 Meg Cout FB Only 22uF 16V Rstart1 ika 1 0 Meg ee Rjump1 LED as E Dleak ors UFMISPL C14 FB Only 27uF Rzed C13 FB Only 470p 250VAC Y2 Rtco_trim 4000p 630V C15 FB Only 470p 250VAC Y2 Qret R9 FB Only NDDO2N60Z 100 Rtco See BOM NOTE Components labeled FB are only populated for the flyback version and components labeled BB are only required for the Buck boost configuration Figure 6 Main Schematic http onsemi com 4 Table 2 BILL OF MATERIALS Qty Designator NCL30083FLYGEVB NCL30083BB1GEVB os ar cora minaaa remeni pp e ren ECO A ET DS es Le fe pj EE aa O A DE RL EN e rus D M EC EE art ee DE e ie m Lo Po ee m m bei ib ooo NE oz m x x soma v
13. mer 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 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 orde
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15. sal mains solution with a peak charge front end It is possible to convert the Evaluation Board from a valley fill to peak charge front end by deleting changing and shorting selected components hitp onsemi com 20 NCL30083FLYGEVB NCL30083BB1GEVB R Delete D1 D3 amp C2 damp HVDC ACL C4 L1 18 uF D1 220 uH 200 V A UFM15PL C3 C5 120 nF 400V po D3 c2 120 nF 400 V UFM15PL lt UFM15PL 18uF K i 1 i 200 V 1 5 mH Short D2 Figure 31 Peak Charge Conversion for Evaluation Board Table 6 BULK CAPACITOR SELECTION TABLE Minimum Capacitance Maximum Capacitance Voltage Rating 230 V ac 50 Hz 2 2 uF 3 3 uF 400 V de 100 V ac 50 60 Hz 8 2 uF 12 uF 200 V de NOTE Capacitance values based on 10 W output and selected to the nearest standard value To illustrate Class C performance an Typical harmonic content is illustrated in Figure 34 For NCL30083FLYGEVB was modified and the input valley applications with 4 LEDs or less the input capacitor value fill configuration was modified and the input bulk capacitor should be reduced to meet Class C harmonic content was changed to 2 2 uF this is the typical performance data requirements 1 5 Relative Current Regulation o 0 5 1 0 Line Voltage V ac Figure 32 230 V ac Class C Flyback Relative Current Regulation http onsemi com 21 NCL30083FLYGEVB NCL30083BB1GEVB 87 0 86 5 86 0 85 5
16. te 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 ENIG RoHS compliance required http onsemi com 7 NCL30083FLYGEVB NCL30083BB1GEVB FLYBACK TRANSFORMER SPECIFICATION LEAD Pb FREE Yes PART MUST INSERT FULLY TO SURFACE A IN RECOMMENDED GRID 020 SQ 4 110 MIN 2 79 NO S FOR REF ONLY 800 Max DOT LOCATES TERM 1 837 Max 20 32 FL2 047 4 O O 1 20 PRI SEC 120 375 V 14 V 7 V 100 kHz 700 m 200 1 5 08 3 FLI a 150 2 O 3 81 AUX jE _1 16 V 10 mA SS RECOMMENDED P C PATTERN COMPONENT SIDE ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE O 20 C 1 2 1 25 Q 10 3 4 0 695 Q 10 FL1 FL2 0 090 Q 20 DIELECTRIC RATING 3 000 VAC 1 minute tested by applying 3 750 VAC for 1 second between pins 4 FL1 tie 2 3 500 VAC 1 minute tested by applying 625 VAC for 1 second between pins 1 4 INDUCTANCE 700 uH 10 10 kHz 100 mVAC 0 mADC 3 4 Ls SATURATION CURRENT 1 A saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 5 0 uH max 100 kHz 100 mVAC 1 2 tie FL1 FL2 Ls 15 0 uH max 100 kHz 100 mVAC 3 4 tie FL1
17. ture since input current does not comply with Class D requirements or the waveform definition requirements as stated in this excerpt Active Input Power lt 25 W 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 6 column 2 or The third harmonic current expressed as a percentage of the fundamental current shall not exceed 86 and 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 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 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 univer
18. y the built in overvoltage protection of the Vcc pin If a higher output voltage at lower current is required the auxiliary winding turns ratio would have to be modified The input capacitor network uses a valley fill PFC to achieve a power factor of gt 0 8 to easily meet ENERGY STAR input power factor requirements If compliance with EN61000 3 2 Class C is required the input capacitor network can be easily modified and simplified to one capacitor this is discussed in the appendix Constant Current Control Architecture Introduction Figure 4 portrays the primary and secondary current of a fly back converter in discontinuous conduction mode DCM Figure 3 shows the basic circuit of a fly back converter Transformer Vout Clump Rsense Figure 3 Basic Flyback Converter Schematic During the on time of the MOSFET the bulk voltage Vbujk 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 Cump The output diode is off until the voltage across L reverses and reaches Nsp Vou Vo The output diode current increase is limited by the leakage inductor As a consequence the secondary peak current is reduced http onsemi com 2 NCL30083FLYGEVB NCL30083BB1GEVB IL pk lp pk lt Nsp The diode current reaches its peak when the leakage inductor is reset Thus in order to accurately regulate the output current we
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