User Guide for FEBFL7730_L20L008B Dimmable LED Bulb at Low Line Featured Fairchild Product: FL7730 Direct questions or comments about this evaluation board to: “Worldwide Direct Support” Fairchild Semiconductor.com © 2012 Fairchild Semiconductor Corporation FEBFL7730_L20L008B • Rev.1.1.1 Table of Contents 1. Introduction ............................................................................................................................... 3 1.1. 1.2. 1.3. General Description........................................................................................................ 3 Features .......................................................................................................................... 3 Internal Block Diagram .................................................................................................. 4 2. General Specifications .............................................................................................................. 5 3. Photographs............................................................................................................................... 6 4. Printed Circuit Board ................................................................................................................ 7 5. Schematic .................................................................................................................................. 8 6. Bill of Materials ........................................................................................................................ 9 7. Transformer and Winding Specifications ............................................................................... 11 8. Performance of Evaluation Board ........................................................................................... 12 8.1. 8.2. 8.3. 8.4. 8.5. 8.6. 8.7. 8.8. 8.9. Startup .......................................................................................................................... 12 Operation Waveforms .................................................................................................. 12 Constant Current Regulation ........................................................................................ 13 Open/Short-LED Protections ....................................................................................... 14 Dimming Operation...................................................................................................... 15 System Efficiency ........................................................................................................ 18 Power Factor and Total Harmonic Distortion .............................................................. 19 Operating Temperature ................................................................................................ 21 Electromagnetic Interference (EMI) ............................................................................ 22 9. Revision History ..................................................................................................................... 23 © 2012 Fairchild Semiconductor Corporation 2 FEBFL7730_L20L008B • Rev.1.1.1 This FEBFL7730_L20L008B Evalution Board can be identified by the silkscreen marking FL7730 Low Line on the top side of the pcb. This user guide supports the evaluation board for the FL7730, FEBFL7730_L20L008B. This kit supersedes the FEBFL7730_L20L008A. The revised kit incorporates the next generation FL7730, which is redesigned for improved dimming performance. It should be used in conjunction with the FL7730 datasheet as well as Fairchild’s application notes and technical support team. Please visit Fairchild’s website at www.fairchildsemi.com or the evaluation board page http://www.fairchildsemi.com/products/evaluationboards/. 1. Introduction This document describes the proposed solution for low-line voltage LED ballast using the FL7730 Primary-Side Regulator (PSR) single-stage controller. The input voltage range is 90VRMS – 140VRMS and there is one DC output with a constant current of 380mA at 22VMAX. This document contains general description of FL7730, the power supply specification, schematic, bill of materials, and the typical operating characteristics. 1.1. General Description The FL7730 is an active Power Factor Correction (PFC) controller using single-stage flyback topology. Dimming control with no flicker is implemented by an analog sensing method. Primary-side regulation and single-stage topology reduce external components such as input bulk capacitor and feedback circuitry and minimize cost. To improve good power factor and Total Harmonic Distortion (THD), constant on-time control is utilized with internal error amplifier and a low-bandwidth compensator. Precise constant-current control regulates accurate output current, independent of input voltage and output voltage. Operating frequency is proportionally changed by output voltage to guarantee DCM operation with higher efficiency. FL7730 provides protections such as open-LED, short-LED, and over-temperature protection. 1.2. Features Compatible with Traditional TRIAC Control Cost-Effective Solution without Input Bulk Capacitor and Feedback Circuitry Power Factor Correction (PFC) Accurate Constant-Current (CC) Control Line Voltage Compensation for CC Control Linear Frequency Control for Better Efficiency and Simpler Design Open-LED Protection Short-LED Protection Cycle-by-Cycle Current Limiting Over-Temperature Protection with Auto Restart Low Startup Current: 20μA Low Operating Current: 5mA VDD Under-Voltage Lockout (UVLO) Gate Output Maximum Voltage Clamped at 18V SOP-8 Package Available © 2012 Fairchild Semiconductor Corporation 3 FEBFL7730_L20L008B • Rev.1.1.1 1.3. Internal Block Diagram Figure 1. © 2012 Fairchild Semiconductor Corporation Internal Block Diagram 4 FEBFL7730_L20L008B • Rev.1.1.1 2. General Specifications All data in Table 1 was measured at an ambient temperature of 25°C. Table 1. Summary of Features and Performance for LED Lighting Bulb Description Input Voltage Input Frequency Output Voltage Current Symbol Value VIN,MIN 90V Minimum Input Voltage VIN,MAX 140V Maximum Input Voltage VIN,NOMINAL 110~120V fIN 50-60Hz VOUT,MIN 10V Minimum Output Voltage VOUT,MAX 28V Maximum Output Voltage VOUT,NOMINAL 22V Nominal Output Voltage IOUT,NOMINAL 380mA Nominal Output Current IOUT,RIPPLE ±65mA Output Current Ripple <±3.9% Line Input Voltage Change:90~140VAC <±2.1% Output Voltage Change:10~28V CC Deviation Comments Nominal Input Voltage Line Frequency Note: No Dimmer Connected Efficiency Eff90VAC 80.7% Efficiency at 90VAC Line Input Voltage Eff110VAC 82.2% Efficiency at 110VAC Line Input Voltage Eff120VAC 82.5% Efficiency at 120VAC Line Input Voltage Eff140VAC 82.9% Efficiency at 140VAC Line Input Voltage Note: No Dimmer Connected PF / THD PF / THD90VAC 0.98 / 7.4% PF / THD at 90VAC Line Input Voltage PF / THD110VAC 0.96 / 9.5% PF / THD at 110VAC Line Input Voltage PF / THD120VAC 0.95 / 10.4% PF / THD at 120VAC Line Input Voltage PF / THD140VAC 0.91 / 12.4% PF / THD at 140 VAC Line Input Voltage Note: Open-Frame Condition (TA=25°C) Temperature © 2012 Fairchild Semiconductor Corporation TFL7730 50ºC FL7730 Temperature TMOSFET 53ºC Primary MOSFET Temperature TDIODE 47ºC Secondary Diode Temperature TTRANSFORMER 52ºC Transformer Temperature TDAMPER 57ºC Active Damper Temperature TSTR.RESISTOR 56ºC Startup Resistor Temperature 5 FEBFL7730_L20L008B • Rev.1.1.1 3. Photographs Figure 2. Top View of Evaluation Board Figure 3. Bottom View of Evaluation Board Dimensions: 62.5mm (L) × 26.8mm (W) × 12.0 (H) Figure 4. Side View in Bulb Case Type 1 Figure 5. Bottom View in Bulb Case Type 1 Bulb Case Type 1 : 32mm (Case Diameter) × 40mm (Case Depth) Figure 6. Side View in Bulb Case Type 2 Figure 7. Bottom View in Bulb Case Type 2 Bulb Case Type 2 : 34mm (Case Diameter) × 44mm (Case Depth) © 2012 Fairchild Semiconductor Corporation 6 FEBFL7730_L20L008B • Rev.1.1.1 4. Printed Circuit Board Figure 8. Figure 9. © 2012 Fairchild Semiconductor Corporation Printed PCB, Top Side Printed PCB, Bottom Side 7 FEBFL7730_L20L008B • Rev.1.1.1 5. Schematic Figure 10. © 2012 Fairchild Semiconductor Corporation Schematic of Evaluation Board 8 FEBFL7730_L20L008B • Rev.1.1.1 6. Bill of Materials Item Part No. Reference Part Number Qty. Description Manufacturer 1 Q1 MB8S 1 Bridge Diode Fairchild Semiconductor 2 Q2 FQN1N50C 1 1A / 500V Active Damper MOSFET Fairchild Semiconductor 3 Q3 FL7730MY_F116 1 Main Controller Fairchild Semiconductor 4 Q4 FQU5N60C 1 5A / 600V Main Switch Fairchild Semiconductor 5 F1 SS-5-1A 1 1A / 250V Fuse Bussmann 6 L1, L2 R06472KT00 2 4.7mH Filter Inductor Bosung 7 D1 ES1J 1 1A / 600V Diode Fairchild Semiconductor 8 D2 1N5241 1 11V Zener Diode Fairchild Semiconductor 9 D3 1N4003 1 1A / 200V Diode Fairchild Semiconductor 10 D4 RS1M 1 1A / 1000V Diode Fairchild Semiconductor 11 D5 ES3D 1 3A / 200V Fast Rectifier Fairchild Semiconductor 12 C1, C2 MPE 400V334K 14S 1 330nF / 400V Film Capacitor Sungho 13 C3 C0805C104K3RACTU 1 100nF / 25V SMD Capacitor 2012 Kemet 14 C4 C1206C335K3PACTU 1 3.3µF / 25V SMD Capacitor 3216 Kemet 15 C5 C0805C100M3GACTU 1 10pF / 25V SMD Capacitor 2012 Kemet 16 C6 C2012Y5V1E225Z 1 2.2µF / 25V SMD Capacitor 2012 TDK 17 C7 KMG 47µF / 35V 1 47µF / 35V Electrolytic Capacitor Samyoung 18 C8 C1206C103KDRACTU 1 10nF / 1kV SMD Capacitor 3216 Kemet 19 C9 SCFz2E472M10BW 1 4.7nF / 250V Y-Capacitor Samwha 20 C10 KMG 330µF / 35V 1 330µF / 35V Electrolytic Capacitor Samyoung 21 C11 RM 1000µF / 35V 1 1000µF / 35V Electrolytic Capacitor Samwha 22 R1 SR03700005600KR500 1 560Ω / 0.5W Metal Resistor Vishay 23 R2 RNF12JTD100R 1 100Ω / 0.5W Metal Resistor Stackpole Electrical 24 R3 RC1206JR-0720KL 1 20kΩ SMD Resistor 3216 Yageo 25 R4 RC1206JR-071ML 1 1MΩ SMD Resistor 3216 Yageo 26 R5 RC0805JR-0775KL 1 75kΩ SMD Resistor 2012 Yageo 27 R6 RC0805JR-0762KL 1 62kΩ SMD Resistor 2012 Yageo 28 R7 RC0805JR-070R0L 1 0Ω SMD Resistor 2012 Yageo 29 R8 RC0805JR-07150KL 1 150kΩ SMD Resistor 2012 Yageo 30 R9 RC0805JR-0720KL 1 20kΩ SMD Resistor 2012 Yageo 31 R10 RNF12GTD100K 1 100kΩ / 0.5W Metal Resistor Stackpole Electrical 32 R11, R12 RC1206JR-07510KL 2 510kΩ SMD Resistor 3216 Yageo 33 R13 RC0805JR-0710RL 1 10Ω SMD Resistor 2012 Yageo © 2012 Fairchild Semiconductor Corporation 9 FEBFL7730_L20L008B • Rev.1.1.1 Bill of Materials Item Part No. Reference (Continued) Part Number Qty. Description Manufacturer RC1206JR-071R2L 1 1.2Ω SMD Resistor 3216 Yageo 34 R14 35 R15 RC1206FR-071RL 1 1.0Ω SMD Resistor 3216 Yageo 36 R16 RC0805JR-07200RL 1 200Ω SMD Resistor 2012 Yageo 37 R17 RC1206JR-0751KL 1 51kΩ SMD Resistor 3216 Yageo © 2012 Fairchild Semiconductor Corporation 10 FEBFL7730_L20L008B • Rev.1.1.1 7. Transformer and Winding Specifications RM6 (PC47) 6 5 3 NP1 NA 2 NS+ NP2 4 NS Figure 11. Transformer Specifications & Construction Figure 12. Table 2. NS- Transformer Winding Structure Winding Specifications No. Winding Pin (S F) Wire Turns Winding Method 1 NP1 53 0.13φ 38 Ts Solenoid Winding 2 Insulation: Polyester Tape t = 0.025mm, 2-Layer 3 NS 4 NS- NS+ 0.3φ (TIW) 24 Ts Solenoid Winding Insulation: Polyester Tape t = 0.025mm, 2-Layer 5 NA 26 NP2 34 6 0.13φ 18 Ts Solenoid Winding Insulation: Polyester Tape t = 0.025mm, 2-Layer 7 8 0.13φ 38 Ts Solenoid Winding Insulation : Polyester Tape t = 0.025mm, 6-Layer Table 3. Electrical Characteristics Pin Specification Remark Inductance 1–2 1mH ±10% 50kHz, 1V Leakage 1–2 8µH 50kHz, 1V Short All Output Pins © 2012 Fairchild Semiconductor Corporation 11 FEBFL7730_L20L008B • Rev.1.1.1 8. Performance of Evaluation Board 8.1. Startup Startup time is 0.8s. There is no overshoot at output current and voltage in startup sequence (refer IOUT and VDD waveform. VDD indicates a reflected output voltage). Figure 13. 8.2. Startup – VIN [110VAC], C1 [VIN], C2 [VCS] C3 [VDD], C4,[IOUT], (No Dimmer Connected) Operation Waveforms In steady state, line compensation regulates output current regardless of input voltage variations. Output current ripple is ±65mA with a rated output current of 380mA. VIN = 110VAC VIN = 90VAC VIN = 120VAC Figure 14. VIN = 140VAC Operation Waveforms – VO [22V], IO [380mA], C1 [VCS], C3, [VIN], C4 [IOUT] © 2012 Fairchild Semiconductor Corporation 12 FEBFL7730_L20L008B • Rev.1.1.1 8.3. Constant Current Regulation Constant current deviation in the output voltage range from 10V to 28V is less than 2.1% at each line input voltage. Line regulation at the rated output voltage (22V) is less than 3.9%. 35 30 OVP 25 VOUT 20 [V] 90Vac 110Vac 120Vac 15 140Vac 10 5 0 0 100 200 300 400 500 Output Current [mA] Figure 15. Constant Current Regulation – Measured by E-Load [CR Mode] Table 4. Constant Current Regulation by Output Voltage Change (10~28V) Input Voltage Min. Current Max. Current Tolerance 90VAC / 60Hz 352mA 365mA ±1.8% 110VAC / 60Hz 368mA 384mA ±2.1% 120VAC / 60Hz 374mA 388mA ±1.8% 140VAC / 60Hz 381mA 395mA ±1.8% Table 5. Constant Current Regulation by Line Voltage Change (90~140VAC) Output Voltage 90VAC 110VAC 120VAC 140VAC Tolerance 20V 355mA 372mA 377mA 383mA ±3.8% 22V 360mA 372mA 377mA 386mA ±3.5% 24V 357mA 374mA 383mA 386mA ±3.9% © 2012 Fairchild Semiconductor Corporation 13 FEBFL7730_L20L008B • Rev.1.1.1 8.4. Open/Short-LED Protections In short-LED condition, the OCP level is reduced from 0.7V to 0.2V because the FL7730 lowers the OCP level when VS voltage is less than 0.4V during output diode conduction time. The output current in the short-LED condition is less than 1.5A, which doesn’t damage any external components. Figure 16. Short-LED Condition – VIN [110VAC], C1 [VCS], C2 [VDD], C3 [VIN], C4 [IOUT] In open-LED condition, output voltage is limited around 32V by OVP in VDD. The output over-voltage protection level can be controlled by turn ratio of auxiliary and secondary windings. Figure 17. Open-LED Condition – VIN [110VAC], C1 [VCS], C2 [VDD], C3 [VIN] © 2012 Fairchild Semiconductor Corporation 14 FEBFL7730_L20L008B • Rev.1.1.1 8.5. Dimming Operation Dimming operation waveforms are shown in Figure 18 - Figure 20. Active damper, RC bleeder, and dimming control in FL7730 implement flicker-free dimming operation. Spike current at dimmer firing is less than 1.2A. Figure 18. Figure 19. Dimming Operation Waveforms: Max. Dimming Angle, VIN [120VAC], C1 [VIN], C2 [VCS], C4 [IIN] Dimming Operation Waveforms: 90º Dimming Angle, VIN [120VAC] ,C1 [VIN], C2 [VCS], C4 [IIN] © 2012 Fairchild Semiconductor Corporation 15 FEBFL7730_L20L008B • Rev.1.1.1 Figure 20. Dimming Operation Waveforms – Min. Dimming Angle, VIN [120VAC], C1 [VIN], C2 [VCS], C4 [IIN] Output current is controlled by dimming function when rotating dimmer switch as in the dimming curve in Figure 21. The dimming control block in FL7730 smoothly changes regulated output current by detecting dimming angle. Figure 21. Dimming Curve (Effective RMS Input Voltage vs. Output Current) – Line Voltage [120VAC] © 2012 Fairchild Semiconductor Corporation 16 FEBFL7730_L20L008B • Rev.1.1.1 Table 6. TRIAC Dimmer Compatibility Manufacturer Dimmer Condition Maximum Current Minimum Current Flicker LUTRON S-600P-WH 120V / 60Hz 330mA 40mA (12%) No LUTRON CN-600P-WH 120V / 60Hz 328mA 11mA (3%) No LUTRON GL-600H 120V / 60Hz 365mA 8mA (2%) No LUTRON TG-603PGH-WH 120V / 60Hz 252mA 12mA (5%) No LUTRON TG-600PH-WH 120V / 60Hz 333mA 14mA (4%) No LUTRON LG-600P 120V / 60Hz 327mA 3mA (1%) No LUTRON CTCL-153PD 120V / 60Hz 320mA 58mA (18%) No LUTRON S-600-WH 120V / 60Hz 324mA 0mA (0%) No LUTRON DV-600P-WH 120V / 60Hz 323mA 0mA (0%) No LUTRON DV-603PG-WH 120V / 60Hz 260mA 3mA (1%) No LUTRON DV-10P 120V / 60Hz 334mA 28mA (8%) No LUTRON DVLV-600P 120V / 60Hz 316mA 4mA (1%) No LUTRON AY-600P-WH 120V / 60Hz 329mA 8mA (2%) No LUTRON D-600PH-DK 120V / 60Hz 309mA 0mA (0%) No LUTRON Q-600P-WH 120V / 60Hz 333mA 21mA (6%) No LUTRON SLV-600P 120V / 60Hz 330mA 7mA (2%) No LUTRON GLT05 120V / 60Hz 316mA 22mA (7%) No LEVITON 6633-PL 120V / 60Hz 383mA 11mA (3%) No LEVITON 6683 120V / 60Hz 384mA 0mA (0%) No LEVITON IP106 120V / 60Hz 380mA 36mA (9.5%) No LEVITON 1C4005 120V / 60Hz 344mA 0mA (0%) No LEVITON 6631-LW 120V / 60Hz 340mA 0mA (0%) No Legrand F 165H 120V / 60Hz 344mA 3mA (0.9%) No The FL7703 Low-Line Evaluation Board demonstrates good dimmer compatibility without flicker. Minimum LED current is less than 5% for most dimmers. © 2012 Fairchild Semiconductor Corporation 17 FEBFL7730_L20L008B • Rev.1.1.1 8.6. System Efficiency Power efficiency is 80.7 ~ 82.9% in 90 ~ 140VAC input voltage range. 90 88 86 84 Eff. [%] 82 80 78 76 74 72 70 90Vac 110Vac 120Vac 140Vac Input Voltage Figure 22. Power Efficiency (Input Voltage vs. Efficiency) Table 7. System Efficiency Input Input Power Voltage Output Current Output Voltage Output Power Efficiency 90VAC 9.68W 360mA 21.70V 7.81W 80.7% 110VAC 9.96W 376mA 21.77V 8.19W 82.2% 120VAC 10.02W 380mA 21.77V 8.27W 82.5% 140VAC 10.15W 386mA 21.79V 8.41W 82.9% © 2012 Fairchild Semiconductor Corporation 18 FEBFL7730_L20L008B • Rev.1.1.1 8.7. Power Factor and Total Harmonic Distortion FL7730 shows excellent power factor and THD performance. Power factor is very high with enough margins from 0.9. THD is much less than 30% specification. PF THD Input Voltage Figure 23. Power Factor & Total Harmonic Distortion (50Hz) PF THD Input Voltage Figure 24. © 2012 Fairchild Semiconductor Corporation Power Factor & Total Harmonic Distortion (60Hz) 19 FEBFL7730_L20L008B • Rev.1.1.1 Table 8. Power Factor and Total Harmonic Distortion Input Voltage Output Current Output Voltage 90VAC 360mA 21.70V 110VAC 376mA 21.77V 120VAC 380mA 21.77V 140VAC 386mA 21.79V © 2012 Fairchild Semiconductor Corporation 20 Frequency PF THD 50Hz 0.99 7.1% 60Hz 0.98 7.4% 50Hz 0.97 9.4% 60Hz 0.96 9.5% 50Hz 0.96 10.2% 60Hz 0.95 10.4% 50Hz 0.92 12.1% 60Hz 0.91 12.4% FEBFL7730_L20L008B • Rev.1.1.1 8.8. Operating Temperature Temperature of all the components on this board is less than 60ºC. Figure 25. Board Temperature - Top View, VIN [120VAC], IO [380mA] Figure 26. Board Temperature - Bottom View, VIN [120VAC], IO [380mA] © 2012 Fairchild Semiconductor Corporation 21 FEBFL7730_L20L008B • Rev.1.1.1 8.9. Electromagnetic Interference (EMI) The all measurement was conducted in observance of CISPR22 criteria. Figure 27. © 2012 Fairchild Semiconductor Corporation EMI Results – VIN [110V], VOUT [22V], IOUT [380mA] 22 FEBFL7730_L20L008B • Rev.1.1.1 9. Revision History Rev. Date Description 1.0.0. Oct. 2011. Initial Release 1.1.0 Jul. 2012. Manufacturer & Part number are added in BOM FL7730 is changed to FL7730MY_F116 (no frequency hopping) Dimmer compatibility table is updated PF/THD at 50Hz is added EMI test result is updated 1.1.1 Aug. 2012. Updating to match new naming conventions WARNING AND DISCLAIMER Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Users’ Guide. Contact an authorized Fairchild representative with any questions. This board is intended to be used by certified professionals, in a lab environment, following proper safety procedures. Use at your own risk. 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