150 W High Performance LED Driver Evaluation Board User's Manual
Contents
1. 20 10 0 NCL30030GEVB eT 00 O O O eH LO Min Load 50 Load Max Load 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 Line Voltage V ac Figure 19 Efficiency over Line and Load Y 60 V dc Output PTT Min Load 50 Load Max Load 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 Line Voltage V ac Figure 20 Efficiency over Line and Load 120 V dc Output WWW onsemi com 18 Efficiency Output Current mA dc NCL30030GEVB 100 um KGK OWN Een Ge Ge DE een mm mn en ER E ER GER E 70 60 Min Load 50 50 Load Max Load 40 30 20 10 0 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 Line Voltage V ac Figure 21 Efficiency over Line and Load 210 V dc Output 70 69 68 67 A 65 120V 27 W 64 63 62 61 60 60 75 90 105 120 135 150 165 180 195 210 Output Voltage V dc Figure 22 Minimum Load Regulation over Line www onsemi com 19 NCL30030GEVB 720 718 716 714 712 710 EXA ESA AAA AK EE 708 Output Current mA dc 120V 706 UN 704 702 700 60 75 90 105 120 135 150 165 180 195 210 Output Voltage V dc Figure 23 Maximum Load Regulation over Line Noise Filter Uff TRIS o 2 610ma PALE CLEZIO Figure 24 Ripple Current at 120 V ac Maximum Load www onsemi com 20 NCL30030GEVB T2. A N A NIA NA NIA we mem wmm v v P mm ma raj m Gen na 3 Rs Sem NI Mi EE M NA 27 NIA I N NA M Ni NIA NA NA NIA 12 045mA 18 067 mA HIR B2uA NIA NIA gr0 Z6UA NIA NA NA Low o w P 3 3 ta CH 2 3 34 NA NIA NIA NIA NIA NA A A HA A A A A A D NA A A E Ei m NIA Mi NA 12 045mA 741 BDUA NIA NIA 800 194 NIA NIA 37 i 12 045mA 18 067 mA 842 32uA NA 1 0056mA NIA a A P SUR NIA WA NA WA WA WA Ux NE WA WA WA NA N A NA WA WA MA NA NIA MIA z Figure 32 IEC61000 3 2 Report 277 V 50 Load 60 Hz www onsemi com 25 NCL30030GEVB 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 co
3. TAK Di e lt vi0 R32 C27 Leg les BAT54T1G 2 49k 22pF A UEMISPE R50 L sh T10uF100V E lt K D19 Da L We 3 R23 OvP lt gt pf K Y C30 gt 7 50k 22uF 50V MMSZ5267BT1 UFM15PL e Kee Vec lt gt U11 NZ afet Low Tes m R54 4 AOTF20S60L F C26 OnF Y1 ER WA Ist 220p 1kV R27 j v Ka 2 49k R4 Ka Z gt 1k M Qcsc WW Rsens C36 0 25 100pF 7 Figure 6 Flyback Schematic L3 LED 100uH Iset 700mA Active Preload J2 R52 R14 1 R44 Ofet3 4 7k 1W 604k Se BSS127S 7 lt on off CON3 LED rtn lt S 0 09 V10 lt gt R12 604k R16 R19 Voltage Control Loop ik U6 Ke OVP 210 V 3 32k 3 YA 2 R48 50V out off FB ve so hm R28 Z Se lt gt On ofi FOD817A3SD NCP4328A s R47 63 4k T Sal Current Control Loop 19k R13 C10 8 06k 7v R49 4 7nF R11 10k 100k Ireg C11 lt gt R15 100nF R20 io D14 lt gt V10 tk U7A FET zen Overtemp Foldback R21 NCP43P8A 160k Il C13 an Figure 7 Control Schematic WWW onsemi com 6 NCL30030GEVB V10 lt gt C28 R17 R18 R46 On Off l 1uf U9Ae 100k 100k 110k On Off Open Off lt gt di 2 p V10 lt gt R31 LM358 1k R30 R40 gt 24 9k 5 49k C15 J3 2 2uf V10 lt gt R34 Te 100k UB gt R35 i R33 Bi level AW 100k LM358 GG ik D17 Ireg 4 gt BAS21DW5T1G R36 TERE R37 um 110k 100k V10 lt gt R39 oa Analog or PWM MI mmm va lt gt Open Dimming Line
4. programs the peak current and sets the valley selection There is a current source that pulls up the FB pin Consequently the control is setup for secondary side feedback only Connections to the Evaluation Board There are several connections necessary to operate the evaluation board e AC Input J1 3 Pin Connector 1 AC Line 2 nc 3 AC Neutral e ED Output J2 3 Pin Connector 1 LED 2 nc 3 LED e Control J3 7 Pin Connector 1 10 V 1 10 V Dimming 0 5 V Analog or Digital PWM Dimming Lamp TCO Bi level Dimming On Off Common SN NN BW WN Control Connections 10V This connection provides a current limited 10 V source which can be used to power the dimming interface Current is limited to 10 mA through a 1 kQ resistor LED Lamp TCO The LED assembly may have a PTC that opens when the LED assembly exceeds a safe temperature The cold value of the PTC should be approximately 470 62 and the transition resistance should be greater than 5 kQ The action of the TCO folds back the output current to maintain the temperature at a safe level but does not turn the LEDs completely off NOTE Connect the Lamp TCO connection to common if a TCO is not used On Off The driver can be turned off from the secondary side An open on the on off connection defaults to off Connect the on off connection to common to turn on the driver Off mode operates the output in a low voltage 50 V CV mode such
5. that the output voltage is below the LED operational voltage Dimming Control Mode Setup The evaluation board can be configured to support numerous dimming configurations only one type of dimming is supported at a time In addition to a 1 10 V Dimming interface analog digital and bi level options are supported Bi level can be used in conjunction with motion sensors or timers to provide two light output levels depending on the use case www onsemi com 3 NCL30030GEVB Table 2 CONFIGURING THE BOARD FOR DIMMING CONTROL Connection 1 10V 1 10 V Analog Voltage 0 5 V Analog 1 10V 0 5 V Analog O SV Digital Open Open Open O 5 V Digital N A O 5 V Digital Input Open Freq 400 Hz Modifications It is possible for the user to select different operating conditions for the evaluation board such as output current over voltage threshold and over temperature threshold Output Current R9 and R44 set the output current R44 is a trim resistor to make fine adjustments to the current set point The reference voltage for U2 is 62 5 mV Iputput is calculated as follows 62 5 mV x R9 R44 H9 x R44 The low reference voltage makes even the copper PCB trace resistance important in setting the output current There are limitations to setting the current without making major component changes Generally the current can adjusted from 0 5 A 1 0 A output CV Regulation As illustrated in Figure 7 the
6. 0 1 EN60950 1 UL60950 1 CSA60950 1 and AS NZS60950 1 Reinforced insulation for a primary circuit at a working voltage of 450VDC OPERATING TEMPERATURE RANGE 40 C to 125 C including temp rise Wire insulation 8 RoHS status not affected by wire color Wire insulation color may vary depending on availability Unless otherwise specified tolerances are as follows m e Wurth Electronics Midcom Inc Angles 1 Fractions 1 64 a Decimals 005 127mm Footprint 001 03mm expec Watertown SD USA Drawing Title Toll Free 800 643 2661 Fax 605 886 4486 Transformer 750314657 Engineer LJG 05 30 2014 you www onsemi com 12 NCL30030GEVB PFC INDUCTOR SPECIFICATION C ISTOMER VLA te TANS Dh JE CO CUSTOMER TERMINAL LEAD Pb FREE o Sn96 Ag4 AME o W RTH ELEKTRONIK PART MUST INSERT FULLY TO SURFACE A IN RECOMMENDED GRID 028 12 70 147 172 X DOT LOCATES TERM 1 3 75 4 38 1 154 MAX 1 195 MAX get J 1 150 MAX _ 29 20 m L 750314934 LOT CODE amp DATE CODE 9 045 12 1 15 d j PRI 2 100kHz 150 4 3 50 x TERM NO s FOR REF ONLY 299 2 7 60 RECOMMENDED P C PATTERN COMPONENT SIDE ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE Q20 C 2 5 tie 3 4 0 183 Ohms 10 9 10 0 026 Ohms 20 DIELECTRIC RATING 500VAC 1 minute tested by applying 625VAC for 1 second between
7. 123FL SOD523 SC 88A TO 220 UP SOD123FL SOD123FL SOD123FL 15mm axial Conn 3P Scrmnt Conn 7P Scrmnt HOR 4P 19X10 Rad Ind LS5 Rad Ind LS5 TO 220 3 Vert SOT23 TO92 e O o co Ol co O1 2512 2512 MOV 20mm disc 805 805 805 805 1206 805 1206 805 1206 805 805 805 805 805 805 Substitutions Allowed Yes Yes N Yes Yes Yes z Z o o Z o lt S X X lt x XI gt z z z z dele o o n Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes NCL30030GEVB Table 3 BILL OF MATERIAL Reference Substitutions PCB Footprint Allowed R28 Yaego RCO805FR 0763K4L 805 R30 Yaego RCO805FR 0724k9L 805 R36 R46 Yaego RCO805FR 07110KL 805 R38 R40 R41 Yaego RCO805FR 075K49L 805 R39 Yaego RC0805FR 0747K5L co Ol R42 R43 Yageo RC1206FR 0716K9L 1206 R44 1 5 Yageo RC1206FR 071R5L 1206 10k Yaego RC1206FR 0710KL 1206 4 7k 1W 15MM_Axial Yageo RSF100JB 73 4K7 XFRM LINEAR Wurth 7 5E 08 PQ2625 X12 a XFRM_LINEAR Wurth 750314657 Rev3 ER2817 G NCL30030 ON Semiconductor NCL30030B1DR2G SO16 P2 NCP4328A ON Semiconductor NCP4328A TSOP 5 FOD817A3SD Fairchild FOD817A3SD 4SMD co O LM358 ON Semiconductor LM358DR2G SO8M1 C TLV271SN2T1G ON Semiconductor TLV271SN2T1G SOT23 5 TL431 ON Semiconductor TL431ACLPRAG TO92 NCP5106ADR2G ON Semiconductor NCP5106ADR2G SO8M1 All
8. 35 MAX Me 39 00 1 260 Max U CE 32 00 750314657 r 4 IE L TERM NO s FOR REF ONLY LOT CODE DATE CODE ALTERNATE MARKING DETAIL 9 052 12 1 181 1 32 A 30 00 d SEC TI S9bLEOS 57 ELEL ga zi VI QA PRI 250 450V 100kHz Oa e s 9 210V 500mA 197 10 5 00 30 TAP D Customer to tie terminals 4 5 RECOMMENDED and 9 10 internally on PCB P C PATTERN COMPONENT SIDE oe ee w ELECTRICAL SPECIFICATIONS 25 C unless otherwise noted D C RESISTANCE 20 C 1 2 0 160 Ohms 10 3 6 tie 445 0 170 Ohms 10 8 11 tie 9 10 0 130 Ohms 10 9 11 0 045 Ohms 20 DIELECTRIC RATING 3000VAC 1 minute tested by applying 3750VAC for 1 second between pins 1 11 tie 24344 9 10 500VAC 1 minute tested by applying 625VAC for 1 second between pins 1 6 tie 4 5 INDUCTANCE 425 uH 10 10kHz 100mVAC OmADC 3 6 tie 445 Ls SATURATION CURRENT 3 3A saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 8uH typ 15uH max 100kHz 100mVAC 3 6 tie 445 849410411 Ls TURNS RATIO 6 4 5 3 1 1 00 1 6 3 2 1 3 29 1 00 tie 4 5 11 6 3 9 11 3 29 1 00 tie 4 5 11 6 3 8 11 1 1 00 tie 4 5 9410 11 Designed to comply with the following requirements as defined by IEC6095
9. 80ET3G D15 LA lt gt ROZA lt _ gt Vboost By JE J 33uH VVU VU u m gt lt T gt Vec L 16 9k R6 70nF R43 620k 16 9k Q1 lt gt Vcc Reg Y D11 C21 C23 2N5551G BAS16XV2T1G 68uF ell 68uF 500V Ge AN E i C24 10m T C29 R26 Cvcc I 100V R2 i tut Ver BO HV 1k Vboost z 250V Low Line A Vboost 450V 2 High Line Ofet1 27uF j 10k Qdrv lt _ gt QDRV Pon off GEN Qzcd lt _ gt QZCD PDRV Rgd p 100 D10 x MMSZ18T1 Hu AOTF20S60L Qcs QCS Pcomp FB lt gt QFB Mut U p1 D22 R8 QCTGND Fault K 100k 1 C22 NCL30030 19 MBRO540T1G 220pF C8 32 10nF 00nF 2 C7 T 2 2uF ne T 220pF 1k N N R10 w Rsens1 Y s 20k 25 0 12 gt OVP BAS21DW5T1G C9 Ho 47k NTC R51 1k i d d Figure 5 PFC Schematic www onsemi com 5 NCL30030GEVB Dboot pi MURA160T3G Vboosi lt gt e U12 tut C31 Ofet2 C34 Vec Regs i vcc VB e R53 L AOTF20S60L Odrv lt nH HO CH i x T 220p 1kV R57 nL vs 5 C33 100 mcm toj T1 Dout 1uf NN CP51 O6ADR2G e 1 1 STTH810FP L d i Db gt LED T C35 U Qdrv LO lt gt a D21 3 MURA160T3G 1 L T C14 D13 x 3 4 7uF 250V RZ xL MURA160T3G 2 R25 D20 e LED rtn Qzcd gt wi s ej R58 YA D12 deer i D25 x
10. Components to be RoHS Compliant www onsemi com 9 NCL30030GEVB GERBER VIEWS Ery m TERI EN d 7 CK Genie Figure 9 Top Side PCB Figure 10 Bottom Side PCB C2 RI see Ti NCL30030GEVB Rev 1 TF X cz Q2 120 277V a R52 UN c18 C30 RoHS OOR LED Un E mu Vout 50 210 V de Current 500mA 1A de AC TI T2A25L x gt z z Bii t i E LED m ug ri E J2 D C6 Di el z i 8 i s J3 j 7 H E O la ee TU SCH esr an Pi n pa om di m sem d Ges T TOT mm S Ei Er 020 o FALI n bn R GER e sz d me CEA LI 2 LJ DN EE e R57 pas poj sa indy di RM R33 R29 R3 RIT RAS Be CJ m nanann r1 me LI LJ LJ U Lj Lj 8 Figure 12 Bottom Silkscreen www onsemi com 10 NCL30030GEVB 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 40 004 in External finished copper conductor
11. Math Clear All Pass Fail UserKey et Frequency E Center Freq 15 075 MHz RBYW 10 000 kHz YEW 10 000 kHz Figure 31 Conducted EMI Pre compliance Peak Data 150 kHz 30 MHz www onsemi com 24 NCL30030GEVB Product NCL30030_04 Serial No 18 Jul 2014 3 27 03PM Description 2 7Vac 50 Load Page 1 of 1 Voltech Pre Compliance IEC61000 3 2 Windows Software Test Date 18th Jul 2014 15 22 56 PM Type of Test IEC61000 3 2 2005 with Interharmonics to EN61000 4 7 2002 Worst Case Table Power Analyzer Voltech PM1000 100008202290 Ver 4 25 AC Source Mains AC Source Notes Overall Result PASS Class Class C 225W Class Multiplier 1 Supply Voltage outside permitted limits Voltage Crest Factor outside permitted limits L1 Reading is below limit 1 lt L2 Reading is below limit 2 x Where Class D test has failed mA W L2 A Reading is below 200 Class A Only N A Harmonic current below 0 6 of rated current or MA whichever is greater Or where the test is not applicable Avg Rag R lt lt L2 Max Rdg lt L2 A PassFail NIA 438 74A NIA Pass 45 413mA NM A M I A SCH SC NIA 5 27 08mA NA NIA NIA A 4 0163mA MIA WIA MIA WA 12 045mA 18 067mA 1 9888m4 N A NIA NA NIA NIA 3 84 13m NIA N NIA 12 045m4 18 067 mA Pass NIA NIA 2 0764mA NIA NIA NIA NIA 12 045mA 18 0G7MA 15153MA HA SAUMA NIA Harm OR LA 6 I N
12. NCL30030GEVB 150 W High Performance LED Driver Evaluation Board Users Manual Overview This manual covers the specification theory of operation testing and construction of the NCL30030GEVB evaluation board The NCL30030 board demonstrates a 150 W high performance LED driver intended for commercial industrial applications The NCL30030 combines a CrM PFC boost converter and a QR flyback converter in a single controller An integrated HV start up is included in the NCL30030 Table 1 SPECIFICATIONS Parameter Value Comment Input voltage Class 2 Input 90 305 V ac no ground Line Freguency 50 Hz 60 Hz Class 1 een Mains Isolated Output Voltage Range Voltage Range Off Mode CV Volt 50 V dc age Omunwb HE 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 including Support for 277 V ac US Commercial Line Voltage Low THD across Line and Load High Power Factor across Wide Line and Load Remote On Off Mains Isolated Integrated Auto recovery Fault Protection can be latched by Choice of Options On Board Over Temperature Shutdown via NCL30030 Fault Input Pin LED Module Over Temperature Foldback Input a remote PTC on LED Array Over Voltage e CC CV Modes e Can be Configured for several Dimming Modes 1 10V dc 0 5 V dc Analog e 0 5 V PWM Bi level Figur
13. NCP4328A U2 also serves as the CV regulator loop control R12 R13 R14 and R28 set the CV output As built the evaluation board CV point is 210 V dc The reference voltage for the CV loop is 1 25 V R13 and R28 are in parallel Their equivalent resistance is R R13 x R28 R13 x R28 CV regulation is calculated as follows _ R13 Reg R14 d Heq x 1 25 V Open High Current GND Low Current Over Voltage Protection Zener D19 is used to set the primary side over voltage fault protection level As built the CV loop will prevent an OV fault under normal circumstances D19 pulls up the fault pin on UI to trigger a fault The fault shuts down U1 for 4 seconds and then recycles the fault latch A non resetting latch is an option for U1 The set point for the trip point is calculated as follows _ Vd19 SES 30 D19 must be replaced to change the OV threshold Thermal Protection The evaluation board has an onboard thermal shutdown utilizing the NTC R3 connected to the fault pin of U1 As R3 heats the output current will shut off until the NTC cools down R3 can be replaced with a fixed resistor if no thermal protection is desired www onsemi com 4 NCL30030GEVB SCHEMATIC F1 Np e JI i 2A25 Slo cu L2 D1 WOH OWI C4 A lt gt HVDC Rect CON3 ja aa b T cz 9 470nF 6 8mH 470nF 6 8mH GBU8M BP e Figure 4 Input Circuit D18 HVDC Rect MURS4
14. RE 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 For additional information please contact your local Email orderlit onsemi com Phone 81 3 5817 1050 Sales Representative EVBUM2247 D
15. S21DW5T1G NHPJ08S600G MURS480ET3G MMSZ5267BT1G MBRO540T1G BAT54T1G N al TI 2A25 Slo J1 J2 CON3 O CON7 L1 L2 6 8mH r 0 100uH r A no co co al 33uH Qfet1 Qfet2 Qfet AOTF20S60L Qfet3 BSS127S 7 Q1 Q2 2N5551G Q R57 Rgdp Rgdp1 R53 R54 R58 Rsens1 320 V osjo zi N N a gt R2 R20 R25 R47 R48 R49 x O 47k NTC R4 R16 R22 R24 R26 R29 x R31 R33 R45 R51 s 27k R6 R7 620k R8 R11 R17 R18 R34 R35 R37 100k N NJ o 20k R12 R14 604k R13 8 06k R15 165k R19 3 32k R21 160k R23 7 50k R27 R32 2 49k All Components to be RoHS Compliant NCL30030GEVB Yageo Yageo ON Semiconductor Q C Q C ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor ON Semiconductor Littelfuse Wurth On Shore Wurth Wurth Wurth AOS Diodes ON Semiconductor Yaego Yaego Vishay Yaego Epcos Yaego Epcos Yaego Yaego Yageo Yaego Vishay Yaego Yageo Yaego Yaego Yaego Yaego Yaego Yaego CCO805JRNPO9BN102 BSS127S 7 RCO805FR 0710RL WSL2512R2500FEA RL2512FK 070R12L S20K320E2 RCO805FR 0710KL B57431V2473J62 RCO805FR 071KL RC0805FR 077K5L RC0805FR 072K49L www onsemi com 8 PCB Footprint 805 805 Wei gt TO 220 2 vert 4P inline SOD123FL SOD
16. bility AC Wattmeter 300 W Minimum True RMS Input Voltage Current Power Factor and THD 0 2 accuracy or better DC Voltmeter 300 V dc minimum 0 1 accuracy or better DC Ammeter 1 A de minimum 0 1 accuracy or better LED Load 50V 210 V 1A AC Power Source Test Connections 1 Connect the LED Load to J2 through the ammeter shown in Figure 16 WARNING Observe the correct polarity or the load may be damaged 2 Connect the AC power card to J1 and connect the other end to the AC wattmeter shown in Figure 16 3 Connect a Switch between J3 6 and J3 7 This switch will provide on off control 4 Short J3 4 to J3 7 This replaces the external TCO 5 Connect a 100k Potentiometer to J3 as follows high side to J3 1 wiper to J3 2 low side to J3 7 6 Connect the DC voltmeter as shown in Figure 16 LED Test Load NOTE Unless otherwise specified all voltage measurements are taken at the terminals of the UUT Figure 16 Test Set Up WWW onsemi com 15 NCL30030GEVB Functional Test Procedure 3 Set the input power to 120 V 60 Hz 1 Set the potentiometer to about 50 of its rotation WARNING Do not touch the ECA once it is energized NOTE The on off switch should be in the open state because there are hazardous voltages until instructed otherwise present 2 Set the LED Load for 60 V output 4 Close the On off switch LINE AND LOAD REGULATION Table 4 120 V MAX LOAD Set the potentiometer fu
17. e 1 Evaluation Board Picture Top View Semiconductor Components Industries LLC 2014 October 2014 Rev 1 Publication Order Number EVBUM2247 D NCL30030GEVB THEORY OF OPERATION PFC control rather than on time control or average current The boost topology is the most common converter type for control CrM boost converters typically have fidelity issues high performance power factor correction Since this boost near the zero crossing of the AC line This is a natural converter operates in CrM the peak to average input current conseguence of parasitics in the power stage See a typical is always a 2 1 ratio The converter operates in peak current CrM inductor current in Figure 2 I L3 S Note that the current starts below 0 0 0ms 0 8ms 1 6ms 2 4ms 3 2ms 4 0ms 4 8ms 5 6ms 6 4ms 7 2ms 8 0ms 8 8ms Figure 2 Inductor Current across a Line Cycle Near the zero crossings the current starts below zero the output capacitor The conseguence for on time current This is a real effect of energy stored in the controllers is that the target peak current is never reached in capacitance of the FET drain that does not get transferred to the on time which results in distortion at the zero crossing L3 Target Peak Current On Time Error 250 mA i i 8 058ms 8 059ms 8 060ms 8 061ms 8 062ms 8 063ms 8 064ms 8 065ms 8 066ms 8 067ms 8 068ms 8 069ms 8 070ms 8 071ms 8 072ms 8 073ms Figure 3 One Switching Cycle of Boos
18. ek KK na NR WW O 14 26 58 O TNE ESCH Figure 25 Ripple Current at 277 V ac Maximum Load se i bu I mTEERESERNERRSAWEESESNNEENENNNM 100 us SOU Ree uk VI ae WH DNH IN Ji I IR GI PLA PL TE ZLITJE JU TI MURANO UU IAEA l8Bms 130v UU PETE PRR LA ESI e BD VM CET EM Figure 26 Start Up with AC Applied 120 V Maximum Load 21 NCL30030GEVB lek Bee y sis Filter Off A rr Figure 27 Start Up with On Off 120 V Maximum Load 12UMA MERE Tek ye 100 us 40 0 v il 158ms 600V 2155ms ality 350 Y rs Er 59 3372 Hz Figure 28 Start Up with AC Applied 277 V Maximum Load 22 NCL30030GEVB Tek gt ONE TE 344m4 Figure 29 Start Up with AC Applied 277 V Maximum Load 02 27 25 2014 07 18 Status op Ref 96 00 dBu input Attention 4 Start Freq RBWWwi GdB 150 00 kHz H ODO kHz 1 000 MHz 170 00 s Stop Fred VE ST 10 000 kHz Figure 30 Conducted EMI Pre compliance GP Data 150 kHz 1 MHz 23 L Siete re pene EE Naise Filter OI lt 10Hz 1411814 Trace PF Select Trace 41 BENE Trace Type Freeze p Avg Times 100 Trace Math gt Clear All Pass Fail NCL30030GEVB 02 21 29 2014 07 18 GER Trace PF Status op Ref 96 00 dBuv im Select Trace 2113 Reference Level Di 96 00 dBuV Trace Type Freeze Avg Times 100 Trace
19. ignals that the current has gone to zero and starts a new switch cycle Flyback The flyback converter isolates the output from the mains and provides power for the secondary side control For this specific design given the high output voltage of the PFC Bus rail and the high voltage range of the output a two switch flyback configuration was selected The two switch operation for the flyback optimizes efficiency because the leakage energy is recycled back to the primary energy storage One limitation of the two switch flyback is that the reflected output voltage must be less than the input voltage otherwise all of the stored energy in the transformer will be returned to the input energy storage Since the turns ratio is 1 1 and the maximum output voltage is 210 V that condition is satisfied The converter operates in quasi resonant mode At heavy loads the turn on edge is timed to the first valley like CrM mode At progressively lighter loads the controller moves the turn on edge to progressively higher order valleys The voltage on the control determines the valley of operation There are several important benefits of this technique 1 The frequency is more stable over the load range 2 The peak current remains higher across load as the switching frequency is reduced This keeps the signal to noise ratio high on the CS pin Feedback Control The NCL30030 has no internal error amplifier for the flyback control The feedback pin directly
20. lly CW i e maximum output Output Current 710 mA 14 mA Output Power Power Factor THD lt 20 oy E Ca AAA HA zo IS E E z 223 Table 5 120 V MIN LOAD Set the potentiometer fully CCW i e minimum output Output Current 70 mA Max Output Power Power Factor ONA NN NN ma o POZA g 210 o o O ZL o Zv v v EA Table 6 277 V MAX LOAD Set the potentiometer fully CW i e maximum output Output Current 710 mA 14 mA Output Power Power Factor THD lt 20 rE eee eee eee eee Table 7 277 V MIN LOAD Set the potentiometer fully CCW i e minimum output Vout X lout x 100 Pin Efficiency www onsemi com 16 NCL30030GEVB TEST DATA 1 00 0 90 0 80 0 70 0 60 0 50 Power Factor 0 40 2 100 15 20 30 50 7596 0 30 0 20 0 10 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 Line Voltage V ac Figure 17 Power Factor over Line and Load 30 15 PFC Skip Mode 25 az 30 50 N ie CON 20 75 PX f 100 V 15 ke 10 3 0 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 Line Voltage V ac Figure 18 THD over Line and Load www onsemi com 17 Efficiency Efficiency 100 90 80 70 60 50 40 30 20 10 0 100 90 80 70 60 50 40 30
21. nseguential 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 resale in any manner PUBLICATION ORDERING INFORMATION LITERATU
22. pins 2 10 tie3 4 INDUCTANCE 350uH 10 10kHz 100mVAC OmADC 2 5 3 4 Ls SATURATION CURRENT 8 4A saturating current that causes 20 rolloff from initial inductance LEAKAGE INDUCTANCE 35uH max 100kHz 100mVAC 2 5 tie 344 9410 Ls TURNS RATIO 5 3 4 2 2 33 1 00 1 5 2 10 9 15 1 00 tie 344 1 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 more Wurth Electronics Midcom Inc Angles 1 Fractions 1 64 a Decimals 005 127mm Footprint 001 03mm expec Watertown SD USA Drawing Title Toll Free 800 643 2661 Fax 605 886 4486 Inductor 750314934 EI This drawing is dual dimensioned a Revisions See Sheet 1 Scale Spec Sheet 1 of 1 n you Engineer LJG 07 17 2014 www onsemi com 13 NCL30030GEVB ECA PICTURES Y Mi1114023890 cC A is PLECATE Figure 14 Bottom View 14 NCL30030GEVB Material 6063 61 Al Break sharp edges ze 167 50 mm _ m 155 00 mm P m 133 00 mm a 110 00 mm 85 00 mm R l 20 00 mm y em _ 32 25 mm25 40 mm i 5 00 15 00 00 mm Drill 3 3mm 9 Ples 00 mm a 4 50 mm 70 00 mm a 54 50 mm 3 00 mm B 142 50 mm _ Figure 15 NCL30030 Heatspreader TEST PROCEDURE Equipment Needed AC Source 90 to 305 V ac 50 60 Hz Minimum 500 W capa
23. s Minimum Output TLV271SN2T1G R38 R41 R29 5 49k 5 49k TCO ik lt gt C16 Laine F Figure 8 Dimming Interface BILL OF MATERIAL Table 3 BILL OF MATERIAL Substitutions Reference PCB Footprint Allowed Cvcc 27uF Panasonic EEU FC1E270 CAP AL 5X11 C1 C2 C4 C6 470nF Epcos B32923C3474K CAP BOX LS22M5 26MX7M CCO805JRNPO9BN221 805 C7 C22 C37 220pF Yageo O Co 10nF gt lt X O805YA103JAT2A 805 O C9 C16 C25 47nF Yageo CC0805KRX7R9BB473 805 no C10 C13 4 7nF Yageo CC0805KRX7R9BB472 805 C11 C12 C19 100nF Yageo CC0805KRX7R9BB104 805 ru 4 7uF 250V Panasonic ECO E2475KB CAP BOX LS175 8M5X18 Cap disc 20mm C15 2 2uf Taiyo Yuden UMK212BB7225KG T C17 10nF Y1 Vishay 440LS10 R C18 C24 10uF 100V Rubycon 100PK10MEFC5X11 CAP AL 5X11 no C21 68uF 500V Nichicon UCY2H680MHD CAP ALEL 18X42 HOR REV C23 68uF 500V Nichicon UCY2H680MHD CAP ALEL 18X42 HOR C26 C34 220p 1kV Kemet R76QD0220SE00J CAP BOX LS5 3M5X7M2 no C27 22pF CCO805JRNPO9BN220 co CI Yageo CC0805KKX7R8BB105 co O1 C28 C29 1uf Yageo C31 C33 A C30 22uF 50V Rubycon 50YXM22MEFC5X11 CAP AL 5X11 C32 2 2uF Yageo CC0805KKX7R6BB225 805 co O1 All Components to be RoHS Compliant WWW onsemi com 7 Table 3 BILL OF MATERIAL Qty Reference 1nF 100pF 3 D13 D21 Dboot MURA160T3G Dout STTH810FP GBU8M BP D4 D12 D20 UFM15PL D10 MMSZ18T1 O O1 D11 BAS16XV2T1G D14 D16 D17 BA
24. t Inductor Current simulated Peak current control corrects the on time error because the multiplier output needs to be filtered to recover the scaled on time is dependent on the peak current This will naturally current threshold signal The value of the filter capacitor 1s increase on time at the zero crossing which reduces total critical to obtain good THD over the entire line range The harmonic distortion THD filter capacitor must be large enough to filter the PWM The error amplifier adjusts the gain of a PWM multiplier carrier frequency but not so large as to cause excess phase to set the peak current threshold in the controller The lag which will degrade the THD www onsemi com 2 NCL30030GEVB Bi Level Boost Follower The HV pin provides start up current for the controller and sense the HVDC voltage The boost output reference for the control loop is adjusted based on the input voltage There are 3 options for this 2 1 1 77 1 and 1 1 i e fixed output voltage This allows the boost converter to operate most efficiently over a broad range of input voltages Current Sense and ZCD The current sense and ZCD are combined on one pin as illustrated in Figure 5 During the switch on time the peak current is sensed through R24 D11 blocks the negative voltage from the sense winding from affecting the current sense During the off time D11 forward biases and pull the pin high through R26 Collapsing voltage on the boost inductor s
25. thickness shall be 0 0026 in min ie 20z Copper plating thickness for through holes shall be 0 0013 in min ie 10z All holes sizes are finished hole size Finished PCB thickness 0 062 in 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 accordance with IPC SM B40C Type B Class 2 and be green in color Solder mask mis registration 40 004 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 www onsemi com 11 NCL30030GEVB FLYBACK TRANSFORMER SPECIFICATION CUSTOMER TERMINAL RoHS LEAD Pb FREE za ZM o Sn96 Ag4 Yes Yes AME E QU EEG PART MUST INSERT FULLY TO W RTH ELEKTRONIK SURFACE A IN RECOMMENDED GRID 9 031 12 80 118 157 m DOT LOCATES TERM 1 3 00 4 00 A 1 5
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