® RT8458E High Efficiency PWM Buck LED Driver Controller for High Power Factor Applications General Description Features The RT8458E is a PWM controller with an internal high side gate driver. It is used for step down converters by well controlling the external MOSFET and regulating a constant output current. The output duty cycle of the RT8458E can be up to 100% for wider input voltage application, such as E27 and PAR30 off-line LED lighting products. z The RT8458E also features a 47kHz fixed frequency oscillator, an internal −250mV precision reference, and a PWM comparator with latching logic. The accurate output LED current is achieved by an averaging current feedback loop and the LED current dimming can be easily controlled via the ACTL pin. The RT8458E also has multiple features to protect the controller from fault conditions, including Under Voltage Lockout (UVLO), Over Current Protection (OCP) and Over Voltage Protection (OVP). Additionally, to ensure the system reliability, the RT8458E is built with the thermal protection function. z z z z z z z z z z Support High Power Factor Applications Low Cost and Efficient Buck Converter Solution Universal Input Voltage Range with Off-Line Topology Programmable Constant LED Current Dimmable LED Current by ACTL Output LED String Open Protection Output LED String Short Protection Output LED String Over Current Protection Built-in Thermal Protection TSOT-23-6 Package RoHS Compliant and Halogen Free Applications z E27, PAR30, Offline LED Lights Marking Information 00= : Product Code 00=DNN The RT8458E is housed in a TSOT-23-6 package. Thus, the components in the whole LED driver system can be made very compact. DNN : Date Code Simplified Application Circuit VIN CIN RVCC1 RD R1 RVCC2 D3 R2 RT8458E VCC ACTL CVCC RVC CVC1 VC CVC2 D2 C1 GATE Q1 GND SENSE C2 R3 D1 RS L1 LED+ COUT LED- Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 is a registered trademark of Richtek Technology Corporation. www.richtek.com 1 RT8458E Ordering Information Pin Configurations RT8458E (TOP VIEW) Package Type J6 : TSOT-23-6 SENSE VC ACTL Lead Plating System G : Green (Halogen Free and Pb Free) 6 Note : Richtek products are : ` 4 2 3 VCC GND GATE RoHS compliant and compatible with the current requireTSOT-23-6 ments of IPC/JEDEC J-STD-020. ` 5 Suitable for use in SnPb or Pb-free soldering processes. Functional Pin Description Pin No. Pin Name Pin Function 1 VCC Supply Voltage Input of the Chip. For good bypass, a ceramic capacitor near the VCC pin is required. 2 GND Ground of the Chip. 3 GATE 4 ACTL 5 VC Gate Driver Output for External MOSFET Switch. Analog Dimming Control Input. ACTL pin is internally biased around 0.6V. Dimming signal can still be applied to ACTL pin. ACTL dimming signal high is internally clamped around 2V. The sourcing and sinking current should be limited to no more than 20μA. PWM Loop Compensation Node. 6 SENSE LED Current Sense Input. The typical sensing threshold is −250mV between the SENSE and GND pin. Copyright © 2013 Richtek Technology Corporation. All rights reserved. www.richtek.com 2 is a registered trademark of Richtek Technology Corporation. DS8458E-05 October 2013 RT8458E Function Block Diagram + + 17V/8V OVP + VCC 35V VREF Chip Enable 47kHz OSC 12V GATE S 200k R - VREF R CCOMP + - 0.6V VC ACTL Control Circuit GND OTP + OP1 - -250mV Dimming SENSE Operation The RT8458E is a PWM Buck current mode controller with an integrated high side gate driver. The start up voltage of RT8458E is around 17V. Once VCC is above 17V, RT8458E will maintain operation until VCC drops below 8V. The ACTL voltage of RT8458E is internally biased to 0.6V. The adjustment of the regulated sense current threshold (dimming) can be achieved by varying ACTL pin voltage. The typical range of ACTL voltage adjustment is between 0.1V and 2V. The RT8458E's main control loop consists of a 47kHz fixed frequency oscillator, an internal −250mV precision current sense threshold OPAMP (OP1), and a PWM comparator (CCOMP) with latching logic. In normal operation, the GATE turns high when the gate driver is set by the oscillator (OSC). The lower the average of the sensed current is below the loop-regulated −250mV threshold, the higher the VC pin voltage (OP1 output) will go high. Higher the VC voltage means longer the GATE turn-on period. The GATE of RT8458E can turn on up to 100% duty. The GATE turns low until the current comparator (CCOMP) resets the gate driver. The GATE will be set high again by OSC and the next switching cycle repeats. The RT8458E is equipped with protection from several fault conditions, including input Under Voltage Lockout (UVLO), Over Current Protection (OCP) and VIN/VOUT Over Voltage Protection (OVP). Additionally, to ensure the system reliability, the RT8458E is built with internal thermal protection function. Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 is a registered trademark of Richtek Technology Corporation. www.richtek.com 3 RT8458E Absolute Maximum Ratings z z z z z z z z z z z (Note 1) Supply Input Voltage, VCC ---------------------------------------------------------------------------------------------GATE Voltage (Note 7) ------------------------------------------------------------------------------------------------ACTL Voltage --------------------------------------------------------------------------------------------------------------VC Voltage -----------------------------------------------------------------------------------------------------------------SENSE Voltage -----------------------------------------------------------------------------------------------------------Power Dissipation, PD @ TA = 25°C TSOT-23-6 ------------------------------------------------------------------------------------------------------------------Package Thermal Resistance (Note 2) TSOT-23-6, θJA ------------------------------------------------------------------------------------------------------------TSOT-23-6, θJC ------------------------------------------------------------------------------------------------------------Junction Temperature ----------------------------------------------------------------------------------------------------Lead Temperature (Soldering, 10 sec.) ------------------------------------------------------------------------------Storage Temperature Range -------------------------------------------------------------------------------------------ESD Susceptibility (Note 3) HBM (Human Body Model) ---------------------------------------------------------------------------------------------MM (Machine Model) ----------------------------------------------------------------------------------------------------- Recommended Operating Conditions z z −0.3V to 40V −0.3V to 16V −0.3V to 8V −0.3V to 6V −1V to 0.3V 0.392W 255°C/W 135°C/W 150°C 260°C −65°C to 150°C 2kV 200V (Note 4) Supply Input Voltage, VCC ---------------------------------------------------------------------------------------------- 17V to 31V Junction Temperature Range -------------------------------------------------------------------------------------------- −40°C to 125°C Electrical Characteristics (VCC = 24V, TA = 25°C, unless otherwise specified) Parameter Symbol Test Conditions Min Typ Max Unit Input Start-Up Voltage VCC_ST -- 17 19 V Minimum Operation Voltage After Start-Up VCC_(MIN) -- 8 9 V Maximum Startup Current in VCC Hiccup Operation IST(MAX) Maximum ICC to cause VCC stop hiccup at low end of VCC hysteresis level -- 250 300 μA Input Supply Current ICC After Start-Up, VCC = 24V -- 2 5 mA Input Quiescent Current IQC Before Start-Up, VCC = 5V -- 1 20 μA 38 47 56 kHz -- -- 100 % -- 97 -- % Oscillator Switching Frequency fSW Maximum Duty in Transient Operation DMAX(TR) Maximum Duty in Steady State Operation DMAX Blanking Time tBLANK (Note 6) -- 300 -- ns Minimum Off Time tOff(MIN) (Note 6) -- 600 -- ns VC = 3V Copyright © 2013 Richtek Technology Corporation. All rights reserved. www.richtek.com 4 is a registered trademark of Richtek Technology Corporation. DS8458E-05 October 2013 RT8458E Parameter Symbol Test Conditions Min Typ Max Unit −241 −250 −259 mV -- 11 -- μA Current Sense Amplifier Current Sense Voltage VSENSE VACTL = 0.6V (Note 5) Sense Input Current I SENSE (Note 6) VC Sourcing Current I VC_Source VSENSE = −150mV (Note 6) -- 20 -- μA VC Sinking Current I VC_Sink VSENSE = −250mV (Note 6) -- 180 -- μA VC Threshold for PWM Switch Off VVC 1.15 1.25 1.35 V No Load at GATE Pin -- 12.6 16 V IGATE = −50mA -- 12.1 -- IGATE = −100μA -- 12.5 -- IGATE = 50mA -- 0.75 -- IGATE = 100μA 0.5 -- 60 150 ns GATE Driver Output GATE Pin Maxim um Voltage VGATE GATE Voltage High VGATE_H GATE Voltage Low VGATE_L V V GATE Drive Rise Time 1nF Load at GATE --- GATE Driver Fall Time 1nF Load at GATE -- 30 100 ns GATE Drive Source Peak Current 1nF Load at GATE -- 0.25 0.5 A GATE Driver Sink Peak Current 1nF Load at GATE -- 0.5 0.8 A VACTL = 0.6V -- 1 20 μA -- 0.6 -- V LED Current On Threshold at ACTL VACTL_On -- 1.8 2 V LED Current Off Threshold at ACTL VACTL_Off 0.01 0.1 0.2 V 32 35 38 V -- 150 -- °C LED Dimming ACTL Pin Input Current I ACTL ACTL Internal Bias VACTL_ Bias OVP Over Voltage Protection VOVP VCC Pin Thermal Protection Thermal Shutdown Temperature T SD Note 1. Stresses beyond those listed “Absolute Maximum Ratings” may cause permanent damage to the device. These are stress ratings only, and functional operation of the device at these or any other conditions beyond those indicated in the operational sections of the specifications is not implied. Exposure to absolute maximum rating conditions may affect device reliability. Note 2. θJA is measured at TA = 25°C on a low effective thermal conductivity single-layer test board per JEDEC 51-3. θJC is measured at the exposed pad of the package. Note 3. Devices are ESD sensitive. Handling precaution is recommended. Note 4. The device is not guaranteed to function outside its operating conditions. Note 5. The RT8458E achieves precise LED average current with a current feedback loop to sense the average LED current, in the deep discontinuous mode operation especially when a small inductor is used, small current offset might occur due to current waveform distortion of the nature of the discontinuous operation. This offset current is consistent over production. Note 6. Guaranteed by design, not subjected to production test. Note 7. The GATE voltage is internally clamped and varies with operating conditions. Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 is a registered trademark of Richtek Technology Corporation. www.richtek.com 5 RT8458E Typical Application Circuit VIN VMAIN CIN 0.1µF /500V CVCC 4.7µF/50V RVCC1 1M RD 1M R1 1M RVCC2 511k D3 FR107 R2 1M C1 RT8458E 100nF/50V 1 VCC ACTL 4 RVC 10k CVC1 1nF D2 ES1J RB 10 5 VC CVC2 3.3nF 2 GATE 3 GND SENSE 6 VIN_AC : 85V to 264V VOUT : 30V RG 0R Optional Q1 FTA02N60C R3 C2 4.7nF 24k RS 0.7 D1 ES2J ZD1 Optional 5.1V L1 680µH COUT 330µF/50V IOUT : 350mA Copyright © 2013 Richtek Technology Corporation. All rights reserved. www.richtek.com 6 LED+ ZD2 39V Optional LED- is a registered trademark of Richtek Technology Corporation. DS8458E-05 October 2013 RT8458E Typical Operating Characteristics Output Current vs. Input Voltage 400 95 380 Output Current (mA) Efficiency (%) Efficiency vs. Input Voltage 100 90 85 80 145 175 205 235 320 300 75 115 340 VIN_AC = 85V to 264V, IOUT = 350mA, LED 10PCS, L = 0.68mH VIN_AC = 85V to 264V, IOUT = 350mA, LED 10PCS, L = 0.68mH 85 360 85 265 105 125 145 Input Voltage (V) 260 267 258 264 261 258 255 252 249 246 VIN_AC = 85V to 264V, IOUT = 350mA, LED 10PCS, L = 0.68mH SENSE Threshold (mV) SENSE Threshold (mV) 205 225 245 265 SENSE Threshold vs. Temperature SENSE Threshold vs. Input Voltage 256 254 252 250 248 246 244 VIN_AC = 85V to 264V, IOUT = 350mA, LED 10PCS, L = 0.68mH 242 240 240 85 105 125 145 165 185 205 225 245 265 -50 -25 0 25 50 75 100 125 Temperature (°C) Input Voltage (V) Switching Frequency vs. Temperature Switching Frequency vs. VCC 55 Switching Frequency (kHz)1 55 Switching Frequency (kHz)1 185 Input Voltage (V) 270 243 165 51 47 43 39 51 47 43 39 35 35 0 4 8 12 16 20 24 28 32 VCC (V) Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 36 -50 -25 0 25 50 75 100 125 Temperature (°C) is a registered trademark of Richtek Technology Corporation. www.richtek.com 7 RT8458E Power Factor vs. Input Voltage Input and Output Current 1.00 Power Factor 0.95 VMAIN (200V/Div) I IN (1A/Div) 0.90 0.85 0.80 0.75 VIN_AC = 85V to 264V, IOUT = 350mA, LED 10PCS, L = 0.68mH VOUT (50V/Div) IOUT (1A/Div) 0.70 85 105 125 145 165 185 205 225 245 265 VIN_AC = 264V, IOUT = 350mA, LED 10 pcs, L = 0.68mH Time (2.5ms/Div) Input Voltage (V) Power On Power Off VIN (400V/Div) VIN (400V/Div) VOUT (20V/Div) VOUT (20V/Div) IOUT (500mA/Div) VIN_AC = 264V, IOUT = 350mA, LED 10 pcs, L = 0.68mH Time (100ms/Div) Copyright © 2013 Richtek Technology Corporation. All rights reserved. www.richtek.com 8 IOUT (500mA/Div) VIN_AC = 264V, IOUT = 350mA, LED 10 pcs, L = 0.68mH Time (100ms/Div) is a registered trademark of Richtek Technology Corporation. DS8458E-05 October 2013 RT8458E Application Information The RT8458E is a high efficiency PWM Buck LED driver controller for high brightness LED application. Its high side gate driver is used to control the Buck converter via an external MOSFET and regulate the constant output current. The RT8458E can achieve high accuracy LED output current via the average current feedback loop control. The internal sense voltage (−250mV typ.) is used to set the average output current. The oscillator’s frequency is fixed at 47kHz to get better switching performance. Once the average current is set by the external resistor, RS. High Power Factor Application The ACTL pin is biased at 0.6V level. The input sine-wave is then AC coupled onto this bias voltage. The amplitude of the modulation voltage is determined by R1, R2 and R3. In this way, the average level of ACTL will hardly change when input voltage is varied. High PF is achieved in RT8458E by changing IOUT current of ACTL (dimming) pin voltage modulation following the line voltage SIN waveform. When IOUT follows line voltage SIN waveform, the line input current follows the line voltage SIN waveform. The compensation network is pretty much fixed for standard offline input condition. The value shown in the data sheet is the optimized value. RT8458E Buck controller ACTL pin directly controls the output current level. By adding sine-wave shaped modulation to this pin, the Buck converter output current will follow the same sine shaped modulation. When using an input rectifier circuit with very small buffer capacitor, the current in the mains leads will start to resemble sine wave current as well which is in phase with the mains voltage. This will improve the Power Factor. The circuit can be designed in such a way that mains voltage variations have little influence on the average output current. Under Voltage Lockout (UVLO) Setting Average Output Current The output current that flows through the LED string is set by an external resistor, RS, which is connected between the GND and SENSE terminal. The relationship between output current, IOUT, and RS is shown below : IOUT = 0.25 RS (A) Component Selection For component selection, an example is shown below for a typical RT8458E application, where VIN = 85 to 264VAC/ 60Hz, LED output voltage = 30V, and output current = 350mA. The user can follow this procedure to design applications with wider AC voltage input and DC output voltage as well. Start-up Resistor Start-up resistor should be chosen not to exceed the maximum start-up current. Otherwise, the RT8458E may latch low and will never start. Start-up current = 130V/R1 for 110VAC regions, 260V/R1 for 220VAC regions. The typical start-up current is 250μA. Input Diode Bridge Rectifier Selection The current rating of the input bridge rectifier is dependent on the VOUT /VIN transformation ratio. The voltage rating of the input bridge rectifier, VBR, on the other hand, is only dependent on the input voltage. Thus, the VBR rating is calculated as below : VBR = 1.2 × ( 2 × VAC(MAX) ) where VAC,Max is the maximum input voltage (RMS) and the parameter 1.2 is used for safety margin. For this example : VBR = 1.2 × ( 2 × VAC(MAX) ) = (1.2 × 2 × 264) = 448V If the input source is universal, VBR will reach 448V. In this case, a 600V, 0.5A bridge rectifier can be chosen. The RT8458E includes a UVLO feature with 9V hysteresis. The GATE terminal turns on when VIN rises over 17V (typ.). The GATE terminal turns off when VIN falls below 8V (typ.) Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 is a registered trademark of Richtek Technology Corporation. www.richtek.com 9 RT8458E Input Capacitor Selection For High Power Factor application, the input Capacitor CIN should use a small value capacitance to achieve line voltage sine-wave. The voltage rating of the input filter capacitor, VCIN, should be large enough to handle the input voltage. VCIN ≥ (1.2 × 2 × VAC(MAX) ) = (1.2 × 2 × 264) = 448V Thus, a 0.1μF / 500V film capacitor can be chosen in this case. Inductor Selection For high power factor application, the RT8458E operates the Buck converter in BCM (Boundary-Condition Mode) at VIN = 85VAC. To guarantee that the ripple current stays below the specified value, the inductor value should be chosen according to the following equation : L= VOUT × TS × (1− D) 3.66 × IOUT 30 × 21.28μs × (1− 0.2496) = = 0.374mH 3.66 × 0.35 where D is the duty cycle and TS is the switching period. The largest ripple current will occur at the highest VIN. The inductor saturation current must estimate probable value. When VIN is 85VAC, the saturation current can design around double output current. When VIN is 264VAC, the saturation current can design around 5 times output current. Forward Diode Selection When the power switch turns off, the path for the current is through the diode connected between the switch output and ground. This forward biased diode must have minimum voltage drop and recovery time. The reverse voltage rating of the diode should be greater than the maximum input voltage and the current rating should be greater than the maximum load current. In reality, the peak current through the diode is more than the maximum output current. This component current rating should be estimated seriously. When VIN is 85VAC, the current rating of diode can design around double output current. When VIN is 264VAC, the current rating can design around 5 times output current. The forward diode reverse Copyright © 2013 Richtek Technology Corporation. All rights reserved. www.richtek.com 10 voltage rating should be greater than 1.2 times the maximum input voltage. The peak voltage stress of diode is : VD = 1.2 × ( 2 × VAC(MAX) ) = 1.2 × ( 2 × 264) = 448V The input source is universal (VIN = 85V to 264V), VD will reach 448V. A 600V, 2A ultra-fast diode can be used in this example. MOSFET Selection The peak current through this MOSFET will be over the maximum output current. This component current rating should be greater than 1.2 times the maximum load current and the reverse voltage rating of the MOSFET should be greater than 1.2 times the maximum input voltage, assuming a ± 20% output current ripple. The peak voltage rating of the MOSFET is : VQ = 1.2 × ( 2 × VAC(MAX) ) = 1.2 × ( 2 × 264) = 448V The largest peak current will occur at the highest VIN. The current rating of MOSFET must estimate probable value. When VIN is 85VAC, the current rating can design around double output current. When VIN is 264VAC, the current rating can design around 5 times output current. The input source is universal (VIN = 90V to 264V), VQ will reach 448V. A 600V, 2A N-MOSFET can be chosen for this example. Output Capacitor Selection The selection of COUT is determined by the required ESR to minimize output voltage ripple. Moreover, the amount of bulk capacitance is also a key for COUT selection to ensure that the control loop is stable. Loop stability can be checked by viewing the load transient response. The output voltage ripple, ΔVOUT, is determined by : ⎡ ⎤ 1 ΔVOUT ≤ ΔIL ⎢ESR + ⎥ 8fOSCCOUT ⎦ ⎣ where fOSC is the switching frequency and ΔIL is the inductor ripple current. The output voltage ripple will be the highest at the maximum input voltage since ΔIL increases with input voltage. Multiple capacitors placed in parallel may be needed to meet the ESR and RMS current handling requirement. Dry tantalum, special polymer, is a registered trademark of Richtek Technology Corporation. DS8458E-05 October 2013 RT8458E Thermal Protection A thermal protection feature is included to protect the RT8458E from excessive heat damage. When the junction temperature exceeds a threshold of 150°C, the thermal protection will turn off the GATE terminal. Soldering Process of Pb-free Package Plating PC La e y-rB ng S li To meet the current RoHS requirements, pure tin is selected to provide forward and backward compatibility with both the current industry standard SnPb-based soldering processes and higher temperature Pb-free processes. In the whole Pb-free soldering processes pure tin is required with a maximum 260°C (<10s) for proper soldering on board, referring to J-STD-020 for more information. Thermal Considerations For recommended operating condition specifications, the maximum junction temperature is 125°C. The junction to ambient thermal resistance, θJA, is layout dependent. For TSOT-23-6 package, the thermal resistance, θJA, is 255°C/ W on a standard JEDEC 51-3 single-layer thermal test board. The maximum power dissipation at TA = 25°C can be calculated by the following formula : PD(MAX) = (125°C − 25°C) / (255°C/W) = 0.392W for TSOT-23-6 package The maximum power dissipation depends on the operating ambient temperature for fixed T J(MAX) and thermal resistance, θJA. The derating curve in Figure 1 allows the designer to see the effect of rising ambient temperature on the maximum power dissipation. Maximum Power Dissipation (W)1 aluminum electrolytic and ceramic capacitors are all common selections and available in surface mount packages. Tantalum capacitors have the highest capacitance density, but it is important to only use ones that pass the surge test for use in switching power supplies. Special polymer capacitors offer very low ESR value, but with the trade-off of lower capacitance density. Aluminum electrolytic capacitors have significantly higher ESR, but still can be used in cost-sensitive applications for ripple current rating and long term reliability considerations. 0.45 0.40 0.35 0.30 0.25 0.20 0.15 0.10 0.05 0.00 0 25 50 75 100 125 Ambient Temperature (°C) Figure 1. Derating Curve of Maximum Power Dissipation For continuous operation, do not exceed absolute maximum junction temperature. The maximum power dissipation depends on the thermal resistance of the IC package, PCB layout, rate of surrounding airflow, and difference between junction and ambient temperature. The maximum power dissipation can be calculated by the following formula : PD(MAX) = (TJ(MAX) − TA) / θJA where TJ(MAX) is the maximum junction temperature, TA is the ambient temperature, and θJA is the junction to ambient thermal resistance. Copyright © 2013 Richtek Technology Corporation. All rights reserved. DS8458E-05 October 2013 is a registered trademark of Richtek Technology Corporation. www.richtek.com 11 tion e as AIN R1 CIN R2 Power GND C1 C2 RG R3 VCC RB D2 Q1 L1 RS LED+ SENSE D1 COUT LED- ow trace to avoid witching noise. Place the output capacitor COUT as close as possible to LED terminal. 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Tel: (8863)5526789 Richtek products are sold by description only. Richtek reserves the right to change the circuitry and/or specifications without notice at any time. Customers should obtain the latest relevant information and data sheets before placing orders and should verify that such information is current and complete. Richtek cannot assume responsibility for use of any circuitry other than circuitry entirely embodied in a Richtek product. Information furnished by Richtek is believed to be accurate and reliable. However, no responsibility is assumed by Richtek or its subsidiaries for its use; nor for any infringements of patents or other rights of third parties which may result from its use. No license is granted by implication or otherwise under any patent or patent rights of Richtek or its subsidiaries. DS8458E-05 October 2013 www.richtek.com 13