UM10693 SSL2109ADB1106 - 230 V/7 W GU10 isolated LED

UM10693
SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver
demo board
Rev. 1 — 9 April 2013
User manual
Document information
Info
Content
Keywords
SSL2109ADB1106, flyback converter, GU10
Abstract
This document describes the operation of a 230 V/7 W non-dimmable
LED driver demo board featuring SSL2109A and using an isolated
flyback topology. The SSL2101ADB1106 demo board is designed for
GU10 form factors used in Solid State Lighting (SSL) applications.
UM10693
NXP Semiconductors
SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
Revision history
Rev
Date
Description
v.1
first issue
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20130409
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
1. Introduction
This user manual describes the operation of the SSL2109ADB1106 demo board
featuring the SSL LED driver SSL2109A in a 230 V/7 W isolated flyback converter
application.
The SSL2109ADB1106 demo board is designed for driving a 3-LED string load.
The PCB dimensions is compatible with GU10 form factors used in SSL applications
The demo board provides a simple and effective solution having a power factor of 0.7
and efficiency up to 85 % for SSL applications.
1.1 Features of the application
• GU10 form factor compatibility
• Open LED and short circuit LED string protection
• OverCurrent protection (OCP) and OverTemperature protection (OTP)
• Power factor = 0.7
• Efficiency up to 85 %
• Compliant with IEC61000-3-2 harmonics standard
The assembled top and bottom board views are shown in Fig 1 with the board
dimensions in Fig 3. The board dimensions allow enough headroom with GU10 lamps.
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
a. Top view
b. Bottom view
Fig 1.
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SSL2109ADB1106 230 V/7 W GU10 demo board
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2. Safety
The board is connected to mains voltage. Avoid touching the demo board while it is
connected to the mains voltage. An isolated housing is obligatory when used in
uncontrolled, non-laboratory environments. Galvanic isolation of the mains phase using a
variable transformer is always recommended.
a. Isolated
Fig 2.
b. Not isolated
Variable transformer isolation symbols
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
3. Specifications
Table 1.
Symbol
Specifications of the SSL2109ADB1106
Parameter
Value
V mains
AC mains supply voltage
230 V; ±10 %
P in
input power
7.4 W at nominal V mains = 230 V
P out
output power
6.2 W
V LED
output voltage (LED voltage) 8 V to 14 V with nominal V LED = 10.8 V
I LED
output current (LED current) 575 mA
I ripple
output ripple current
45 mA (p-p)
∆I LED / ∆V mains
line regulation
1 mA/V
(±3.5 % I LED at ±10 % V mains variation)
∆I LED / ∆V LED
load regulation
η
efficiency
84 %
PF
power factor
0.7
f SW
total harmonic distortion
90 kHz
1.5 mA/V
(±0.2 % I LED at ±10 % V LED variation)
Fig 3.
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SSL2109ADB1106 demo board dimensions
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4. Functional description
4.1 Input filtering
A differential mode π filter is implemented to reduce differential mode noise originating
from the High-frequency (HF) switching currents/voltages in the primary of the converter
from returning to the mains. This noise must be kept to a minimum by:
• Small primary current loop (C2 to pin 5 of T1, pin 3 of T1 to drain of external
MOSFET Q5, ground return from sense resistors R1, R24, R26 to C2 ground)
• Snubber components D3, R17, C8 closely parallel to pins 5 and 3 of T1
• Track length from pin 3 of T1 to drain of external MOSFET to be small in order to
reduce capacitance to surroundings
For this 7 W application, C2 must be chosen sufficiently large to act as a buffer for the HF
current flowing in the primary where a value of 100 nF for C2 is sufficient.
4.2 PF adjustment
PF adjustment is realized with a RC circuit after the rectifier comprising of R14 and C7.
For 7 W, optimum values of C7 = 1 µF, R14 = 510 Ω result in PF = 0.7 and 0.5 W loss. A
diode D5 prevents the voltage across R14 from going negative.
4.3 RCD clamp
Leakage inductance of the transformer is in series with primary inductance and the drain
of MOSFET Q5. This leakage inductance together with the parasitic capacitance across
the drain source of Q5 causes HF ringing when Q5 switches off. If the leakage is not
minimized the voltage at the drain reaches high voltages levels which can damage Q5 if
voltage levels exceed the maximum allowable level.
An RCD clamp (R17, C8 and D3) prevents the voltage on the drain of Q5 exceeding the
maximum drain voltage when Q5 switches off.
4.4 Supply voltage
The supply voltage of the SSL2109A is achieved using an auxiliary winding. As further
advantages, the auxiliary winding provides, via a resistor R25 on its underwinding, both a
simple solution for improved load regulation using R12 and open-circuit protection (OCP)
via the NTC pin using R13.
4.4.1 Open circuit protection
If no LED string is connected to the converter output, the voltage can quickly exceed the
maximum rating of the output capacitor C3.
The underwinding of the auxiliary is connected to resistor R25 to prevent this. The
voltage across R25 decreases as the output voltage increases. Consequently, the
voltage at the NTC pin decreases once the current through R13 exceeds the internal
current of the NTC pin. When the NTC voltage drops below 0.35 V then the SSL2109A
switches off.
An external 18 V Zener diode is included at the VCC pin to prevent that the voltage
exceeds 20 V at the VCC pin for this no LED string situation.
4.4.2 Short circuit
When the LED terminals are shorted, the SSL2109A defaults to its maximum
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
demagnetization time of 36 µs. This prevents that the inductor current ramps up to an
excessively large value while the input power is limited and the SSL2109A enters OPS
protection (latched) mode.
Remark:
Do not try to short-circuit the LED output while the circuit is powered or without
discharging C3. The short-circuit protection is intended for zero-hour short circuit
protection (so a short circuit during first assembly before power is applied).
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
5. Demo board connections
The SSL2109ADB1106 demo board is supplied with a 230 V, 50 Hz mains supply where
the board connection is shown in Fig 4.
Table 2.
Input and output connections
Connector
Function
Remark
L
AC MainsL
line wire solder connection on
small board
N
AC MainsN
neutral wire solder connection
on small board
+
LED anode
positive LED wire solder
connection on small board
-
LED cathode
negative LED wire solder
connection on small board
X5
AC mains input
AC mains in terminal block
X6
LED load output
LED connector 6-way female
for NXP LED load
Remarks:
Make all connections with the input mains supply switched off.
Use a protective shield over application and never touch the board when measuring or
testing.
Connections and testing:
• Connect 3-LED string load to the SSL2109ADB1106 together with power meters at
both inputs and outputs.
• Connect V mains (230 V (AC)/50 Hz) using an isolating transformer (initially set to 0 V)
to the input connection points of the flyback converter. Alternatively, use an AC
power supply with limited output current capability (for example 200 mA).
• Increase V mains to 230 V (AC) and measure the different parameters as shown in
Table 3.
Table 3.
Input /output parameters SSL2109ADB1106
V mains (V)
I in (mA)
PF
P in (W)
V LED (V)
230
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47
0.7
7.4
10.8
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I LED (mA)
P out (W)
η
575
6.2
0.84
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
N
230V
L
3 LEDs
Fig 4.
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Board connection for SSL2109ADB1106 with 3-string LED load
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6. Performance data SSL2109ADB1106
6.1 Efficiency
Fig 5.
Efficiency as a function of mains voltage
6.2 Power factor
Fig 6.
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Power factor as a function of mains voltage
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6.3 Line regulation
Fig 7.
Line regulation
6.4 Load regulation
Fig 8.
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Load regulation
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6.5 ElectroMagnetic Interference (EMI)
Fig 9.
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EMI performance
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7. Schematic diagram
L2
3.3mH
D1
V8P10-M3/86A
LED+
+
MainsL
X5
R
10 Ω
1W
+
BD1
B6S-G
D11
TVS 400V
L
C7
1 µF
400 V
-
D6
BZX384-C18
N
T1
RM6
5
FL2
3
FL1
VCC
D5
S1JL
C5
100 nF
25 V
C4
100 nF
25 V
NTC
SOURCE
8
1
2
7
3
6
4
5
SSL2109A
DRAIN
R22
220 kΩ
LED-
GND
Q5
SPU02N60C3
DVDT
C9
2.2 nF
4 kV
DRIVER
R23
33 Ω
R8
4.7 kΩ
R26
33 Ω
R24
3.9 Ω
R1
4.7 Ω
D2
BAS21J
R13
300 kΩ
R12
470 kΩ
R2
10 Ω
6
C6
4.7 µF
50 V
2
Conn. F. R/A 6P
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R25
2.2 kΩ
Fig 10. SSL2109ADB1106 schematic
C3
470 µF
16 V
SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
Rev. 1 — 9 April 2013
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U1
HV
R14
510 Ω
1.5 W
X6
D3
ES1J
MainsN
C12
100 nF
450 V
C8
10 nF
250V
R17
220 kΩ
R19
10 kΩ
230 V (AC)
MKDS
3/2-5.08
C2
100 nF
450V
C1
100 nF
450 V
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
8. PCB component assembly and layout
8.1 PCB component assembly
a. Top assembly
b. Bottom assembly
Fig 11. PCB component assembly
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8.2 PCB layout
a. Component side
b. Solder side
Fig 12. PCB layout
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SSL2109ADB1106 - 230 V/7 W GU10 isolated LED driver demo board
9. Bill Of Material (BOM) SSL2109ADB1106
Table 4.
Reference Description and values
Part number
Manufacturer
BD1
bridge rectifier; 600 V; 0.8 A
B6S-G
Comchip Technology
C1
capacitor; 100 nF; 450 V ; 10 %; metal film; radial
CL21-450V-0.1u F/K
Guang Da
C2
capacitor; 100 nF; 450 V ; 10 %; metal film; radial
CL21-450V-0.1u F/K
Guang Da
C3
capacitor; 470 µF; 50 V; 20 %; electrolytic; radial
16ZLH470MEFC8X11.5
Rubycon
C4
capacitor; 100 nF; 25 V; 10 %; X7R ceramic; 0603
GRM188R71E104KA01D
Murata
C5
capacitor; 100 nF; 25 V; 10 %; X7R ceramic; 0603
GRM188R71E104KA01D
Murata
C6
capacitor; 4.7 µF; 50 V; 10 %; 1206
UMK316AB7475KL-T
Taiyo Yuden
C7
capacitor; 1 µF; 400 V; 10 %; electrolytic; radial
400AX10M10X12.5
Rubycon
C8
capacitor; 10 nF; 250 V; 20%; polyester; radial
ECQE2103JF
Panasonic
C9
C12
capacitor; 2.2 nF; 4 kV; 20 %; radial
DE1E3KX222MA5B
capacitor; 100 nF; 450 V; 10 %; 1210
Murata
GR332DD72W104KW01L Murata
D1
Schottky diode; 100 V, 8 A; TO-277A
V8P10-M3/86A
Vishay
D2
switching diode; BAS21J; 300 V; 0.25 A; SOD323F
BAS21J
NXP Semiconductors
D3
fast diode; ES1J; 600 V; 1 A; DO-214AC; SMA
ES1J
Fairchild
D5
high-voltage diode; 600 V; 1.5 A; DO-219-AB; SMF
S1JL
Taiwan Semiconductors
D6
Zener diode; 18 V; 200 mA; SOD323F
BZX384-C18
NXP
D11
TVS diode; 400V; DO-41
BZW04-342
Multicomp
FL1
solder hole for flying lead of transformer T1 (A)
-
-
FL2
solder hole for flying lead of transformer T1 (B)
-
L2
inductor; 3.3 mH; 100 mA; 10 Ω; radial
22R335C
Murata
L
solder pin for MainsL
-
-
N
solder pin for MainsN
-
-
Q5
transistor; N channel MOSFET; 650 V; 3 Ω
SPU02N60C3
Infineon
R
resistor; 10 Ω; 1 W; 5 %; Axial
MFP1-10R JI
Welwyn
R1
resistor; 4.7 Ω; 0.25 W; 1 %; 1206
RC1206FR-074R7L
Yageo
R2
resistor; 10 Ω; 0.1 W; 5 %; 0603
ERJ3GEYJ100V
Panasonic
R8
resistor; 4.7 kΩ; 0.1 W; 1 %; 0603
CRCW06034K70FKEA
Vishay
R12
resistor; 470 kΩ; 0.1 W; 1 %; 0603
CRCW0603470KFKEA
Vishay
R13
resistor; 300 kΩ; 0.1 W; 1 %; 0603
CRCW0603300KFKEA
Vishay
R14
resistor; 510 Ω; 500V; 1.5 W; 1 %; 2512
MCPWR12FTEA5100
Multicomp
R17
resistor; 220 kΩ; 0.25 W; 5 %; 1206
RC1206JR-07220KL
Yageo
R19
resistor; 10 kΩ; 0.125 W; 5 %; 0805
CRCW080510K0FKEA
Vishay
R22
resistor; 220 kΩ; 0.25 W; 5 %; 1206
RC1206JR-07220KL
Yageo
R23
resistor; 33 Ω; 0.1 W; 5 %; 0603
RC0603JR-0733RL
Yageo
R24
resistor; 3.9 Ω; 0.25 W; 1 %; 1206
RC1206FR-073R9L
Yageo
R25
resistor; 2.2 kΩ; 0.1 W; 5 %; 0603
CRCW06032K20FKEA
Vishay
resistor; 33 Ω; 0.5 W; 1 %; 1206
flyback transformer ; RM6
CRCW120633R0FKEAHP Vishay
750313738 Rev01
Würth
IC; SSL2109A; SO8
SSL2109A
R26
T1
U1
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Reference Description and values
Part number
Manufacturer
X5
mains connector terminal block
MKDSN2,5-5.08
Phoenix Contact
X6
LED connector terminal block
BL3.36Z
Fischer Elektronik
X6
LED connector terminal block (alternative)
SSW-106-02-G-S-RA
Samtec
+
solder pin for LED+
-
-
-
solder pin for LED-
-
-
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10. Inductor specification
A RM6 transformer with reinforced isolation is used with flying leads.
Fig 13. Inductor specification
Table 5.
Electrical specification
All values are specified at 25 °C unless otherwise specified. All values without tolerance are typical
values. Reinforced insulation for a primary circuit at a working voltage of 250 V (RMS)
Parameter
Value
Comment
UM10693
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DCR (5-3)
1.5 Ω; ±10 %
DCR (FL1-FL2)
130 mΩ; ±10 %
dc resistance (2-6)
685 mΩ; ±10 %
primary inductance (5-3)
1.5 mH; ±10 %
100 mV; 10 kHz
leakage inductance (5-3)
maximum 7.5 µH
short-circuit 2 to 6 and FL1 to FL2
primary saturation current
440mA
turns ratio (5-3):(FL1-FL2)
5:1; ±1 %
turns ratio (5-3):(2-6)
1.5:1; ±1 %
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11. Legal information
the product. NXP Semiconductors does not accept any liability in this
respect.
11.1 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 information.
11.2 Disclaimers
Limited warranty and liability — 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.
In no event shall NXP Semiconductors be liable for any indirect, incidental,
punitive, special or consequential damages (including - without limitation lost profits, lost savings, business interruption, costs related to the removal
or replacement of any products or rework charges) whether or not such
damages are based on tort (including negligence), warranty, breach of
contract or any other legal theory.
Notwithstanding any damages that customer might incur for any reason
whatsoever, NXP Semiconductors’ aggregate and cumulative liability
towards customer for the products described herein shall be limited in
accordance with the Terms and conditions of commercial sale of NXP
Semiconductors.
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.
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 the
specified use without further testing or modification.
NXP Semiconductors does not accept any liability related to any default,
damage, costs or problem which is based on a weakness or default in the
customer application/use or the application/use of customer’s third party
customer(s) (hereinafter both referred to as “Application”). It is customer’s
sole responsibility to check whether the NXP Semiconductors product is
suitable and fit for the Application planned. Customer has to do all necessary
testing for the Application in order to avoid a default of the Application and
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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.
Evaluation products — This product is provided on an “as is” and “with all
faults” basis for evaluation purposes only. NXP Semiconductors, its affiliates
and their suppliers expressly disclaim all warranties, whether express,
implied or statutory, including but not limited to the implied warranties of noninfringement, merchantability and fitness for a particular purpose. The entire
risk as to the quality, or arising out of the use or performance, of this product
remains with customer.
In no event shall NXP Semiconductors, its affiliates or their suppliers be
liable to customer for any special, indirect, consequential, punitive or
incidental damages (including without limitation damages for loss of
business, business interruption, loss of use, loss of data or information, and
the like) arising out the use of or inability to use the product, whether or not
based on tort (including negligence), strict liability, breach of contract, breach
of warranty or any other theory, even if advised of the possibility of such
damages.
Notwithstanding any damages that customer might incur for any reason
whatsoever (including without limitation, all damages referenced above and
all direct or general damages), the entire liability of NXP Semiconductors, its
affiliates and their suppliers and customer’s exclusive remedy for all of the
foregoing shall be limited to actual damages incurred by customer based on
reasonable reliance up to the greater of the amount actually paid by
customer for the product or five dollars (US$5.00). The foregoing limitations,
exclusions and disclaimers shall apply to the maximum extent permitted by
applicable law, even if any remedy fails of its essential purpose.
Safety of high-voltage evaluation products — The non-insulated high
voltages that are present when operating this product, constitute a risk of
electric shock, personal injury, death and/or ignition of fire. This product is
intended for evaluation purposes only. It shall be operated in a designated
test area by personnel that is qualified according to local requirements and
labor laws to work with non-insulated mains voltages and high-voltage
circuits.
The product does not comply with IEC 60950 based national or regional
safety standards. NXP Semiconductors does not accept any liability for
damages incurred due to inappropriate use of this product or related to noninsulated high voltages. Any use of this product is at customer’s own risk and
liability. The customer shall fully indemnify and hold harmless NXP
Semiconductors from any liability, damages and claims resulting from the
use of the product.
Translations — A non-English (translated) version of a document is for
reference only. The English version shall prevail in case of any discrepancy
between the translated and English versions.
11.3 Trademarks
Notice: All referenced brands, product names, service names and
trademarks are property of their respective owners.
All information provided in this document is subject to legal disclaimers.
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12. Contents
1.
1.1
2.
3.
4.
4.1
4.2
4.3
4.4
4.4.1
4.4.2
5.
6.
6.1
6.2
6.3
6.4
6.5
7.
8.
8.1
8.2
9.
10.
11.
11.1
11.2
11.3
12.
Introduction ......................................................... 3
Features of the application ................................. 3
Safety ................................................................... 5
Specifications ...................................................... 6
Functional description ........................................ 7
Input filtering....................................................... 7
PF adjustment .................................................... 7
RCD clamp ......................................................... 7
Supply voltage.................................................... 7
Open circuit protection ....................................... 7
Short circuit ........................................................ 7
Demo board connections ................................... 9
Performance data SSL2109ADB1106 .............. 11
Efficiency .......................................................... 11
Power factor ..................................................... 11
Line regulation.................................................. 12
Load regulation ................................................ 12
ElectroMagnetic Interference (EMI) .................. 13
Schematic diagram ........................................... 14
PCB component assembly and layout ............ 15
PCB component assembly ............................... 15
PCB layout ....................................................... 16
Bill Of Material (BOM) SSL2109ADB1106 ........ 17
Inductor specification ....................................... 19
Legal information .............................................. 20
Definitions ........................................................ 20
Disclaimers....................................................... 20
Trademarks ...................................................... 20
Contents ............................................................. 21
Please be aware that important notices concerning this document and the product(s)
described herein, have been included in the section 'Legal information'.
© NXP B.V. 2013.
All rights reserved.
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
Date of release: 9 April 2013
Document identifier: UM10693