LED Driver ICs EVAL-LED-ICL 8001 G-Bu lb02 Quasi-Resonant Flyback Converter for Phase Cut Dimming with High Power Factor ICL8001G App lication No te Revision 2.0, 2010-05-05 I ndust rial & Mu l t i mar ke t Edition 2010-05-05 Published by Infineon Technologies AG 81726 Munich, Germany © 2010 Infineon Technologies AG All Rights Reserved. Legal Disclaimer The information given in this document shall in no event be regarded as a guarantee of conditions or characteristics. With respect to any examples or hints given herein, any typical values stated herein and/or any information regarding the application of the device, Infineon Technologies hereby disclaims any and all warranties and liabilities of any kind, including without limitation, warranties of non-infringement of intellectual property rights of any third party. Information For further information on technology, delivery terms and conditions and prices, please contact the nearest Infineon Technologies Office (www.infineon.com). Warnings Due to technical requirements, components may contain dangerous substances. For information on the types in question, please contact the nearest Infineon Technologies Office. Infineon Technologies components may be used in life-support devices or systems only with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered. EVAL-LED-ICL8001G-Bulb02 ICL8001G Revision History: 2010-05-05, Revision 2.0 Previous Version: Version 1.0 Page Subjects (major changes since last revision) [email protected] Application Note 1 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Contents Contents Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 Evaluation Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 List of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 5.1 5.1.1 5.1.2 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Setup and Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input / Output sliding contact description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constant Output Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Output Current Ripple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Current Harmonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7 7.1 7.2 7.3 7.4 Schematic and BOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bill of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Documentation From Infineon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Note 2 4 4 4 4 4 4 5 6 6 7 7 8 10 10 11 12 13 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Content 1 Content The EVAL-LED-ICL8001G-Bulb02 demonstrates the single-stage flyback and PFC controller ICL8001G in an LED Bulb application. Its quasiresonant operation mode, primary side control, integrated PFC and phase-cut dimming control makes it the best in class system solution for dimmable LED bulbs. 2 Evaluation Board Figure 1 EVAL-LED-ICL8001G-Bulb02 Top Side Figure 2 EVAL-LED-ICL8001G-Bulb02 Bottom Side 3 List of Features • • • • • • • • • • High, stable efficiency over wide operating range through quasiresonant operation mode Primary side side flyback control with integrated PFC and phase-cut dimming Energy efficient phase cut dimming Power cell for VCC pre-charging with constant current Built-in digital soft-start Foldback correction and cycle-by-cycle peak current limitation VCC over- and under-voltage lockout Auto restart mode for short circuit protection Adjustable latch-off mode for output overvoltage protection Best in class system BOM for dimmable bulbs Application Note 3 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Technical Specification 4 Technical Specification Table 1 provides a summary of the EVAL-LED-ICL8001G-Bulb02 performance specification. The Input Voltage indications refer to the RMS voltage without modification by means of phase cut dimmer. Output parameter indicated refer to output voltage variation at fixed nominal input voltage. Table 1 Performance Specification Specification Min Typ Max Unit Input Voltage 207 230 253 AC V Output Voltage 23 26 29 V Output Current 380 350 320 mA Output Power 9.0 9.1 9.2 W 5 Setup and Results 5.1 Input / Output sliding contact description 5.1.1 Vin Input sliding contact for AC supply. Please see Table 1for the maximum input voltage. 5.1.2 Vout Output sliding contact for output DC voltage with polarity indication. This output is isolated from the AC input supply. If you connect an additional load via this connector please make sure not to exceed the maximum output voltage- and power ratings as stated in Table 1. 5.2 Setup For non-dimming operation of the board it is suffiecient to connect the sliding contact for Vin directly to the input AC voltage (see Table 1 for input voltage range). For dimming operation the phase cut dimmer shall be connected to the Vin contacts according the dimmer switch instructions of the dimmer manufacturer. Attention: Please be aware that high voltages of appoximately 800 V will be accessable on the board. 5.3 Power Up The ICL8001G integrates a start-up cell. This allows for short start-up times of the system without sacrificing the efficiency. Figure 3 demonstrates a startup time from mains voltage switch on to light out of about 120ms for a VCC capacitance of C15 = 10uF. Application Note 4 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Setup and Results 2010-01-14 Copyright © Infineon Technologies 2010. All rights reserved. Page 2 Figure 3 Startup: Rectified mains input voltage (green), Controller VCC (dark blue), output voltage (blue), and output current (red) 5.4 Operation The ICL8001G is a quasiresonant flyback controller. Figure 4 shows typical switching waveforms at the MOSFET Q1 on the primary side. 2010-01-14 Figure 4 Copyright © Infineon Technologies 2010. All rights reserved. Page 2 Typical switching waveforms at 230 Vac mains voltage: Gate Drive voltage Vgs, shunt signal VCS and Drain Source Voltage VDS showing quasi resonant on-switching at the first valley approaching zero-voltage Application Note 5 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Setup and Results 5.5 Constant Output Power Control The ICL8001G allows for regulation of the approximate constant output power at fixed phase cut dimming position or fixed input AC voltage. See Figure 5 for the measured output regulation characteristic at output voltage variation. At LED forward voltage decrease the driver power is lowered. Figure 5 Approximate constant output power characteristics 5.6 Output Current Ripple The output capacitor (C25 = 220uF ) is sized for an output current ripple which exhibits no visible light modulation. If a smaller LED current ripple is required, a larger capacitance (C25) up to 470uF can be placed on the board. Figure 6 2010 01 14 C i ht © I fi T h l i 2010 All i ht d P Typical Waveforms: Output voltage ( blue ) and output current ( red ) Application Note 6 4 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Setup and Results 5.7 Input Current Harmonics The input current harmonics amplitudes fulfill the requirements of EN 61000-3-2 standard for input power range Pin < 25W as well as Pin > 25W. The power factor can be adjusted to PF > 99% . but the optimization for phase cut dimming especially leading edge dimmer switches may lead to lower values. Vin Iin Vcs Figure 7 Input voltage Vin, Input current Iin and shunt voltage Vcs 5.8 Driver Efficiency The driver efficiency curve exhibits high efficiency also for low dimming levels. LED Driver Efficiency vs AC Input Voltage 90 88 Efficiency [ % ] 86 84 82 80 78 76 74 50 100 150 200 250 Input Voltage [ Vac ] Figure 8 LED Driver efficiency at variable input voltage Application Note 7 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Setup and Results 5.9 Protection The ICL8001G provides a full set of protection features as detailed in Table 2. Table 2 Protection Features VCC Overvoltage Auto Restart VCC Undervoltage Auto Restart Over Temperature Auto Restart Output Overvoltage Latch Off Output Short Circuit Latch Off Application Note 8 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Board Layout 6 Board Layout Figure 9 EVAL-LED-ICL8001G-Bulb02 - Top Layer Figure 10 EVAL-LED-ICL8001G-Bulb02 - Bottom Layer Application Note 9 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Schematic and BOM 7 Schematic and BOM 7.1 Schematic Figure 11 EVAL-LED-ICL8001G-Bulb02 Schematic Application Note 10 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Schematic and BOM 7.2 Bill of Material Figure 12 Bill Of Material Application Note 11 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Schematic and BOM 7.3 Transformer 750815141 3 PRI 280-380V 85kHz 4 6 5 SEC 27V - 350mA 8 1 AUX 19V - 20mA 2 ELECTRICAL SPECIFICATIONS @ 25°C unless otherwise noted: D.C. RESISTANCE (@20°C): 1-2 , 0.320 Ohms ±10%. 3-5 , 5.05 Ohms ±10%. 6-8 , 0.079 Ohms ±20%. DIELECTRIC RATING: 4500VAC, 1 minute tested by applying 4500VAC for 1 second between pins 1-8(tie2+4). 500VAC, 1 minute tested by applying 625VAC for 1 second between pins 1-4. INDUCTANCE: 6.3 mH ±10%, 10kHz, 100mVAC, 0mADC, 3-5, Ls. SATURATION CURRENT: 200mA saturating current that causes 20% rolloff from initial inductance. LEAKAGE INDUCTANCE: 35µH typ., 50µH max., 100kHz, 100mVAC, 3-5(tie 1+2, 6+8), Ls. TURNS RATIO: ( 4-5 ):( 3-4 ), ( 1 ):( 1 ), ±1%. ( 3-5 ):( 1-2 ), ( 19 ):( 1 ), ±1%. ( 3-5 ):( 6-8 ), ( 13.57 ):( 1 ), ±1%. Designed to comply with the following requirements as defined by IEC61558-2-17: - Reinforced insulation for a primary circuit at a working voltage of 400VDC. OPERATING TEMPERATURE RANGE: -40°C to 125°C including temp. rise. T_0_5280 WE-Midcom, Inc. Watertown, SD USA Toll Free: 800-643-2661 Fax: 605-886-4486 This drawing is dual dimensioned. Dimensions is brackets are in millimeters Unless otherwise specified, tolerances are as follows: Angles: ±1° Fractions: ±1/64 Decimals:±.005(.127mm) Drawing Title Transformer Revisions: See Sheet 1 Engineer:APS Figure 13 WE-Midcom, Inc. Drawing Number Rev. 750815141 00 Scale ---- Sheet 2 of 5 10/28/2009 EVAL-LED-ICL8001G-Bulb02 Trafo Design Application Note 12 Revision 2.0, 2010-05-05 EVAL-LED-ICL8001G-Bulb02 Schematic and BOM 7.4 Related Documentation From Infineon ICL8001G Datasheet at www.infineon.com Quasi-Resonant Controller Application Note at www.infineon.com Quasi-Resonant Controller Design Tips at www.infineon.com Application Note 13 Revision 2.0, 2010-05-05 www.infineon.com Published by Infineon Technologies AG