UM10386 SSL2102 19 W to 22 W mains dimmable LED driver Rev. 2 — 1 February 2011 User manual Document information Info Content Keywords SSL2102, LED driver, AC/DC conversion, dimmable, driver, mains supply, user manual. Abstract This is a user manual for the SSL2102 mains dimmable 19 W to 22 W LED driver demo board. UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Revision history Rev Date Description v.2 20110201 second issue Modification: • v.1 UM10386 User manual 24-01-2011 Figure 8 - pin names corrected first issue All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 2 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 1. Introduction WARNING Lethal voltage and fire ignition hazard 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 qualified according to local requirements and labor laws to work with non-insulated mains voltages and high-voltage circuits. This product shall never be operated unattended. The SSL2102 19 W to 22 W LED driver is a solution for a professional application with multiple high power LEDs that requires galvanic isolation and a safe output voltage. It is mains dimmable for both forward phase (triac) dimmers, and reverse phase (transistor) dimmers. It can generate up to 22 W output power, which is equal to a 150 W incandescent lamp (at 63 Lumen/W). Examples are shelf lighting, down lighting, LED lighting for bathrooms etc. The design gives an example of how to make a driver that is suitable for small form factor applications such as retrofit lamps. 2. Safety warning The board needs to be connected to mains voltage. Touching the reference board during operation must be avoided at all times. An isolated housing is obligatory when used in uncontrolled, non-laboratory environments. Even though the secondary circuit with LED connection has a galvanic isolation, this isolation is not according to any regulated norm. Galvanic isolation of the mains phase using a variable transformer is always recommended. These devices can be recognized by the symbols shown in Figure 1: 019aaa691 019aaa690 a. Isolated Fig 1. UM10386 User manual b. Not Isolated Variac isolation symbols All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 3 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 3. Connecting the board Remark: All components referred to in the text can be located on Figure 8 “Board schematic diagram” and connectors can be found on Figure 2 “Board connection diagram”. The board can be optimized for a 230 V 50 Hz or a 120 V 60 Hz mains supply. In addition to the mains voltage optimization, the board is designed to work with multiple high power LEDs with a total working voltage of between 9 V and 23 V. The output current can be limited using trimmer R20. A dedicated LED load that is to be connected to K3 can be delivered on request. Connector K2 can be used to attach other LED loads. The output voltage is limited to 25 V. When attaching a LED load to an operational board (hot plugging) an inrush peak current will occur due to the discharge of capacitor C6. After frequent discharges, the LEDs may deteriorate or become damaged. 1 K1; pin 1: L pin 2: Earth pin 3: N 9 mm 9 mm − L K1 K2 N K2; pin 1: LED+ pin 2: LED− + 1 6 6 − K3 + 9 mm Fig 2. 1 K3; pin 1: LED+ pin 2: LED+ pin 3: LED+ pin 4: LED− pin 5: LED− pin 6: LED− 6 J1 1 J2 1 019aaa806 Board connection diagram If a galvanically isolated transformer is used, it should be placed between the AC source and the dimmer/demo board. Connect a user defined LED (string) to connector K2 as shown in Figure 2. Note that the anode of the LED (string) is connected to the bottom side of this connector. Remark: When the board is placed in a metal enclosure, the middle pin of connector K1 should be connected to the metal casing for grounding. UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 4 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 4. Specifications Table 1 shows the specifications for the SSL2102 19 W to 22 W LED driver Table 1. UM10386 User manual Specifications Parameter Value Comment AC line input voltage 85 V to 276 V board has been optimized for 230 V, 50 Hz or 120 V, 60 Hz ± 10 % variation DC output voltage (LED voltage) 9 V to 23 V - Output voltage protection 25 V (DC) - Output current (LED current) 400 mA to 1050 mA adjustable with trimmer. The 120 V (AC) version is limited to 900 mA. Output voltage /load current dependency < ± 4 % / Volt in regulated range see attached graphs in Section 12 “Appendix A - Load curves” Current ripple ± 50 mA at 500 mA Maximum output power (LED power) 22 W at VO + 21 V. The 120 V (AC) version is limited to 19 W. Efficiency 70 % to 78 % at Tamb = 25 °C see attached graphs in Section 13 “Appendix B - Efficiency curves” graphs Power Factor: 120 V, 60 Hz 0.99 at 19 W output power 230 V, 50 Hz 0.97 at 22 W output power Switching frequency 60 kHz to 75 kHz - Dimming range 100 % to 0 % - Board dimensions 103 mm × 50 mm × 20 mm length × width × height Operating temperature 0 °C to 85 °C - Isolation voltage 1.8 kV between primary and secondary circuit Input voltage / load current dependency +5 % to −6 % in the range of 130 V 60 Hz to 110 V 60 Hz +3 % to −3 % in the range of 250 V 50 Hz to 210 V 50 Hz All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 5 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 5. Board photos 019aaa809 Fig 3. Demo board (top) 019aaa808 Fig 4. Demo board (bottom) UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 6 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 6. Dimmers Several triac based dimmers have been tested by NXP Semiconductors. Because different dimmers have different specifications, the dimming performance of the board may vary. Table 2 provides a list of dimmers that have currently been tested with the board: Table 2. UM10386 User manual Dimmer selection Manufacturer Type Voltage V (AC) Power range (W) Load Min. dimming range (%) Opus 852.390 230 60-400 Ha/Inc 0.6 Opus 852.392 230 20-500 Inc 0.05 Bush-Jaeger 2250U 230 20-600 Ha/Inc 0.03 Bush-Jaeger 2247U 230 20-500 Ha/Inc 0.07 Bush-Jaeger 6519U 230 40-550 Ha/Inc 8.4 Gira 1184 230 60-400 Inc 1 Everflourish EFO700D 230 50-300 Ha/Inc 0.2 Drespa 0817 230 20-315 Ha/Inc 3.4 Ehmann 39 Domus 230 20-500 Ha/Inc 1 Drespa 815 230 20-500 Inc 1.1 Lutron TG-600PH-WH 120 600 Inc 0 (off) Levitron L12-6641-W 120 600 Inc 0 (off) Levitron L02-700-W 120 600 Inc 0 (off) Levitron 6602-IW 120 600 Inc 0 (off) Levitron 6683-W 120 600 Inc 0 (off) Levitron R12-6631-LW 120 600 Inc 0 (off) Cooper 6001 120 600 Inc 0 (off) Lutron MIR-600THW-WH 120 600 Ha/Inc 0.9 All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 7 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 7. Functional description Remark: All components referred to in the text can be located on Figure 8 “Board schematic diagram”. The IC controls and drives the flyback converter part, and ensures proper dimmer operation. Several high voltage switches are integrated in the IC. One of these controls the flyback input power, and is situated between the DRAIN and SOURCE pins. When the switch closes, energy is stored in the transformer TX1. The switch is opened when the duty factor has exceeded the level set by the PWMLIMIT pin, by a maximum of 75 %, or when the voltage on the SOURCE pin exceeds 0.5 V. Following this, the energy stored in the transformer is discharged to D6 and the output capacitors C5 and C6, and finally absorbed by the load. The converter frequency is set with an internal oscillator, the timing of which is controlled by external RC components on pins RC and RC2. By varying the BRIGHTNESS pin voltage, the oscillator frequency can be modulated to an upper and lower value. The ratio between R15 and R16 sets the frequency variation. ISENSE SBLEED WBLEED 12 1 4 BLEEDER VCC 5 20 SUPPLY DRAIN VALLEY 13 GND LOGIC 2, 3, 6, 7, 14, 16, 17, 18, 19 AUX 100 mV Stop RC 10 OSCILLATOR 15 Low freq SOURCE Blank THERMAL SHUTDOWN BRIGHTNESS RC2 POWER - UP RESET 8 9 PROTECTION LOGIC FRC Overcurrent PWMLIMIT 11 0.5 V PWM LIMIT CIRCUIT 1.5 V Short-winding protection 019aab394 Fig 5. Block diagram SSL2102 UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 8 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Two other switches are referred to as the weak bleeder (pin WBLEED) and the strong bleeder (pin SBLEED). When the voltage on these pins is below a certain value (typically 52 V) the SBLEED switch closes, providing a current path that loads the dimmer during zero voltage crossing. This resets the dimmer timer. When the voltage on either of these pins is above 52 V, and the voltage on the ISENSE pin is below −100 mV, the weak bleeder switch closes. This current is boosted using Q3 and it provides a current path that loads the dimmer when the converter draws insufficient current to stabilize the dimmer latching. While the strong bleeder will always switch, the weak-bleeder will not activate until the output power drops below 8 W. This happens when the LEDs are dimmed, or when the maximum LED power is tuned below 8 W. Figure 6 and Figure 7 represent bleeder voltage versus time in dimmed and undimmed position (low voltage = active). VCC linput SBLEED WBLEED 019aaa810 Fig 6. Dimmed bleeder operation VCC linput WBLEED SBLEED 019aaa815 Fig 7. Undimmed bleeder operation This board is optimized to work with a power factor above 0.9. In order to achieve this, the converter operates in constant ton mode. The output power of the converter is buffered by capacitor C6. Due to this configuration, the circuit has a resistive input current behavior during undimmed operation (see input in Figure 7). During dimmed operation however, not only must the dimmer latch and hold current be maintained, but a damper must be added to dampen the inrush current and to dissipate the electric power that was stored in UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 9 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver the LC filter within the dimmer. A serial resistor can be used for this for low power ranges (<10 W) but for higher power ranges a single series resistor is not efficient. This is because the converter supply current will cause significant voltage drop and thus dissipation through this resistor. To improve efficiency, a combination of serial resistance and a parallel damper has been chosen for the demonstration board. The serial resistor is made up of F1, R1, R2 and R12 and the parallel damper comprises C2 and R3. The input circuit of the converter must be equipped with a filter that is partially capacitive. The combination of C1, L1, L2, C3 and C4 makes a filter that blocks most of the disturbance generated by the converter input current. A drawback of this filter is a reduction of power factor, due to the capacitive load. A lower converter power, in relation to the capacitive value of this filter/buffer, will cause a lower power factor. The 230 V (AC) design uses 150 nF capacitors, which attain a power factor of 0.9 for an 11 W output power. The board is equipped with a feedback loop that limits the output current. This feedback loop senses the LED current over sense resistor R18 and a current mirror is used, consisting of Q1 and Q2. The current level can be set using R20. The same feedback loop is also used for overvoltage protection. If the LED voltage exceeds 23 V, a current will flow through R19 and D9. The current through the opto-coupler IC2 will pull down the PWMLIMIT and BRIGHTNESS pin. The on-time is zero at a value below 400 mV. The feedback loop has proportional action only, and the gain is critical because of phase shift caused by the converter and C6. The relationship between PWMLIMIT and output current is quadratic in nature. The resultant output current spread will be acceptable for most LED applications. The dimming range is detected by sensing the average rectified voltage. R4, R5 and R17 comprise a voltage divider, and C9 filters the resultant signal. The converter sets its duty factor and converter frequency accordingly. UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 10 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 8. Board optimization The following modifications must be made in order to meet different customer application requirements: Remark: All components referred to in the text can be located on Figure 8 “Board schematic diagram”. 8.1 Changing the output voltage and LED current Compared to other topologies, a flyback converter has the major advantage that it is suitable for driving a broader range of output voltages. Essentially, changing the winding ratio whilst maintaining the value of the primary inductance, will shift the output working voltage accordingly. Part of the efficiency of the driver is linked to the output voltage. A lower output voltage will increase the transformation ratio, and cause higher secondary losses. In practice, a mains dimmable flyback converter will have an efficiency of between 80 % for high output voltages (such as 60 V) down to 50 % for low output voltages (such as 3 V). Synchronous rectification might become advisable to reduce losses at low voltages. The NXP Semiconductors TEA1791 can be used for this purpose. For exact calculations of transformer properties and peak current, refer to application note AN10754, “SSL2101 dimmable mains LED driver”, and the calculation tool that is provided with it. 8.2 Changing the output ripple current The output current ripple is principally determined by the LED voltage, the LED dynamic resistance and the output capacitor. The value of C6 has been chosen to optimize capacitor size with light output. A ripple of ± 25 % will result in an anticipated deterioration of light output of <1 %. The size for the buffer capacitor can be estimated using the following equation: I LED 1 C out = ----------- × -------------------------------------------ΔI 6 × f net × R dynamic (1) Example: For a ripple current of ± 5%, and a mains frequency of 50 Hz, and a dynamic resistance of 0.6 Ω, C6 has to be 20 ÷ (300 × 0.6) = 111 mF. For a ripple current of 25 % and a dynamic resistance of 6 Ω, C6 has to be 4 ÷ (300 × 6) = 2200 μF. Using a series of LEDs, the dynamic resistance of each LED can be added to the total dynamic resistance. 8.3 Adapting to high power reverse phase (transistor) dimmers. Reverse phase (transistor) dimmers differ in two ways that can be beneficial but can also cause problems with dimming detection: • The negative phase-cut (trailing edge) causes no inrush current when the dimmer triggers. When using triac dimmers, there will be a sudden voltage difference over the input leading to a steep charge of the input capacitors. The resultant peak current will lead to higher damper dissipation. Because this steep charge is missing, the input capacitors will have less stress, and the input circuit is less prone to audible noise. UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 11 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Transistor dimmers contain active circuitry that require a load charge during the time that the dimmer is open. The dimensioning of the circuit generating the internal supply voltage inside the dimmer is made critical in order to avoid excessive internal dimmer losses. This means that the remaining voltage drop over the lamp must be low enough to reach this charge. For dimmers such as the Busch-Jaeger 6519U, the minimum lamp load is specified at 40 W which is equivalent to a 1.3 kΩ resistor load at 230 V(AC). Such a load would result in highly inefficient operation at low output power levels, since most energy is wasted in order to drive the dimmer, and not to produce light. The value of the demo board weak bleeder (R6 and R7) is chosen to minimize losses (approximately 2 W to 3 W). The weak bleeder normally only switches on during dimmed operation. The voltage drop with some transistor dimmers is, however, not sufficient to cause full dimming range control (minimum 10 % instead of <1 %), because the average rectified voltage is used to determine the dimming position. To compensate for the reduced voltage difference, voltage detection can be made more sensitive by replacing R4 with a zener diode, such as the BZV85-C200 for 230 V (AC), or the BZV85-C68 for 120 V (AC) applications. Because of increased sensitivity, the dimming curve will also be steeper when using triac dimmers. 8.4 Changing the load curve The load curve can be divided into two regions: one where the control loop limits the duty cycle of the converter, and where the output current is regulated, and another where the duty factor feedback is no longer dominant. This last part occurs at output voltages below 13 V. In this area, constant output power becomes the dominant control mechanism. Changing the turns ratio of the transformer to match the output load will also change the load curve. 8.5 Multiple driver support It is possible to attach multiple converters to a single dimmer. When using triac dimmers the inrush current will rise, although not in proportion to the number of converters used. Transistor dimmers are more suitable for use with multiple converters because the dimming range will increase due to the added bleeder action, and there is no inrush current. UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 12 of 24 xxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxx x xxxxxxxxxxxxxx xxxxxxxxxx xxx xxxxxx xxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxx xxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxx xxxxxxxxxxxxxx xxxxxx xx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxx xxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxx xxxxx x x R1 to LED'S R3 K2 D1 EARTH C1 D3 D6 L2 L1 C2 TX1 C4 LED1..n R6 R8 R5 R7 R9 C6 R18 LED− C10 IC1 Q3 R26 SBLEED R25 WBLEED VCC WBLEED VCC GND/TC BRIGHTNESS RC2 PWMLIMIT RC R16 1 16 2 15 DRAIN GND 3 R11 GND 14 GND 4 SSL2101 13 GND SOURCE SO16 5 12 BRIGHTNESS AUX 6 11 RC2 ISENSE 7 10 RC PWMLIMIT 8 9 GND R23 GND/TC K3 D7 R19 R20 D9 R24 R21 LED+ SOURCE R10 AUX VCC PWMLIMIT Q2 PWMLIMIT LED− ISENSE PWMLIMIT Q1 D10 R13 SBLEED C9 R17 C8 R15 TC TC 1 20 2 19 3 18 DRAIN ISO2 TC TC TC 4 17 TC 5 SSL2102 16 GND SOURCE SO20-W 6 15 GND TC 7 14 BRIGHTNESS AUX 8 13 RC2 ISENSE 9 12 RC PWMLIMIT 10 11 R14 C11 C7 D8 R22 R12 WBLEED VCC Board schematic diagram 019aaa807 UM10386 13 of 24 © NXP B.V. 2011. All rights reserved. Fig 8. RGND SSL2102 19 W to 22 W mains dimmable LED driver Rev. 1 — 1 February 2011 All information provided in this document is subject to legal disclaimers. R4 C5 D5 D2 to MAINS LED+ D4 C3 R2 N L3 RGND NXP Semiconductors F1 Fuse 9. Board schematic UM10386 User manual K1 L1 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 10. Bill Of Materials (BOM) Table 3. Bill of materials 230 V (AC) Part No. Ref. Part Value or part no. Power (W) Tol. (%) Volt (V) Package Type Manufacturer 1 K1 Conn 3 pin 2 m - - - - SL 5.08/3/90 Weidmuller 2 K1' Conn 3 pin 2 f - - - - BL 5.08/3 Weidmuller 3 K3 Conn 6 pin 1 f - - - - BL 3.36Z Fischer 4 K2 Conn 2 pin 2 m - - - - SL 5.08/2/90 Weidmuller 5 K2' Conn 2 pin 2 f - - - - BL 5.08/2 Weidmuller 6 F1 Fusistor 6.8 Ω 1 10 - Free - - 7 R1 Resistor 39 Ω 1 5 - Free - - 8 R2 Resistor 39 Ω 1 5 - Free - - 9 R3 Resistor 1 kΩ 2 5 - Free - - 10 R4 Resistor 470 kΩ 0.25 1 - Free - - 11 R5 Resistor 470 kΩ 0.25 1 - Free - - 12 R6 Resistor 10 kΩ 1 5 200 Free - - 13 R7 Resistor 10 kΩ 1 5 200 Free - - 14 R8 Resistor 2.2 kΩ 1 5 200 Free - - 15 R9 Resistor 2.2 kΩ 1 5 200 Free - - 16 R10 Resistor 0.4 Ω 1 1 - Free - - 17 R11 Resistor 33 kΩ 0.25 5 200 Free - - 18 R12 Resistor 15 Ω 1 5 200 Free - - 19 R13 Resistor 100 kΩ 0.1 1 200 Free - - 20 R14 Resistor 22 kΩ 0.1 1 - Free - - 21 R15 Resistor 470 kΩ 0.1 1 - Free - - 22 R16 Resistor 4.7 kΩ 0.1 1 - Free - - 23 R17 Resistor 12 kΩ 0.1 1 - Free - - 24 R18 Resistor 0.3 Ω 1 1 - Free - - 25 R19 Resistor 10 kΩ 0.1 5 - Free - - 26 R20 Resistor 50 kΩ Lin 0.1 5 - Horizontal - Bourns 27 R21 Resistor 22 kΩ 0.1 1 - Free - - 28 R22 Resistor 330 Ω 0.1 1 - Free - - 29 R23 Resistor 470 Ω 0.25 5 Free - - 30 R24 Resistor 3.9 kΩ 0.1 5 Free - - 31 R25 Resistor 470 kΩ 0.25 5 Free - - 32 R26 Resistor 10 kΩ 0.1 5 Free - - 33 C1 Capacitor 470 pF - 10 1k Cer DEBB33A471KC1B Murata 34 C2 Capacitor 150 nF - 10 400 Poly NRM-S154K400F NIC 35 C3 Capacitor 150 nF - 10 400 Poly NRM-S154K400F NIC 36 C4 Capacitor 150 nF - 10 400 Poly NRM-S154K400F NIC 37 C5 Capacitor 4.7 μF - 10 63 Poly B32560J475K Epcos 38 C6 Capacitor 2200 μF 105° 10 25 Free 2222 021 16222 Vishay UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 14 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Table 3. Bill of materials 230 V (AC) …continued Part No. Ref. Part Value or part no. Power (W) Tol. (%) Volt (V) Package Type Manufacturer 39 C7 Capacitor 4.7 μF 105° 10 25 Free - - 40 C8 Capacitor 330 pF Y1 type 5 - Cer, Free - - 41 C9 Capacitor 10 μF 105° 10 25 Free - - 42 C10 Capacitor 2.2 nF - 10 4k Cer DECE33J222ZC4B Murata 43 C11 Capacitor 10 nF - 10 25 Cer, Free - - 44 L1 Inductor 680 μH - - - - 744776268 Wurth 45 L2 Inductor 330 μH - - - - 744776233 Wurth 46 L3 Inductor 100 μH - - - - 74477120 Wurth 47 TX1 Transformer N87/3F3 - - - EFD25 750340505 Wurth 48 D1 Rect. Bridge 2A - - - SO-4 DBLS205G Taiwan semi 49 D2 TVS diode - 600 - 400 - P6KE400A Fairchild 50 D3 Diode 1A - - 800 - HER107 Taiwan semi 51 D4 Zener - 3 - 220 - BZT03-C220 Vishay 52 D5 Diode 1A - - 800 - HER107 Taiwan semi 53 D6 Diode 3A - - 100 - SK310A Taiwan semi 54 D7 Diode 1A - - 800 - HER107 Taiwan semi 55 D8 Zener - - 5 30 - BZV55-C30 NXP 56 D9 Zener - - 5 20 - BZV55-C20 NXP 57 D10 Diode - - - 75 - 1N4148 NXP 58 Q1 Transistor NPN - - - - BC847B NXP 59 Q2 Transistor NPN - - - - BC847B NXP 60 Q3 Transistor PNP - - - - ZTX758 Zetex 61 ISO2 Opto-coupler - - - - - CNY17-1 Fairchild 62 U1 IC - - - - SO-20W SSL2102T NXP UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 15 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Table 4. Part No. Bill of materials 120 V (AC) Ref. Part Value or part no. Power (W) Tole. Volt (%) (V) Package Type Manufacturer 1 K1 Conn 3 pin 2 m - - - 2 K1' Conn 3 pin 2 f - - - - SL 5.08/3/90 Weidmuller - BL 5.08/3 Weidmuller 3 K3 Conn 6 pin 1 f - - - - BL3.36Z Fischer 4 K2 Conn 2 pin 2 m - - - - SL 5.08/2/90 Weidmuller 5 K2' Conn 2 pin 2 f - - - 6 F1 Fusistor 6.8 Ω 1 10 - - BL 5.08/2 Weidmuller Free - - 7 R1 Resistor 27 Ω 1 5 - Free - - 8 R2 Resistor 27 Ω 1 5 - Free - - 9 R3 Resistor 2.7 kΩ 1 5 - Free - - 10 R4 Resistor 470 kΩ 0.25 1 - Free - - 11 R5 Resistor 0Ω 0.25 5 - Free - - 12 R6 Resistor 2.7 kΩ 1 5 200 Free - - 13 R7 Resistor 2.7 kΩ 1 5 200 Free - - 14 R8 Resistor 1 kΩ 1 5 200 Free - - 15 R9 Resistor 1 kΩ 1 5 200 Free - - 16 R10 Resistor 0.4 Ω 1 1 - Free - - 17 R11 Resistor 33 kΩ 0.25 5 200 Free - - 18 R12 Resistor 10 Ω 1 5 200 Free - - 19 R13 Resistor 100 kΩ 0.1 1 200 Free - - 20 R14 Resistor 15 kΩ 0.1 1 - Free - - 21 R15 Resistor 470 kΩ 0.1 1 - Free - - 22 R16 Resistor 10 kΩ 0.1 1 - Free - - 23 R17 Resistor 12 kΩ 0.1 1 - Free - - 24 R18 Resistor 0.3 Ω 1 1 - Free - - 25 R19 Resistor 10 kΩ 0.1 5 - Free - - 26 R20 Resistor 50 kΩ Lin 0.1 5 - Horizontal - Bourns 27 R21 Resistor 22 kΩ 0.1 1 - Free - - 28 R22 Resistor 330 Ω 0.1 1 - Free - - 29 R23 Resistor 3.9 kΩ 0.25 5 - Free - - 30 R24 Resistor 3.9 kΩ 0.1 5 - Free - - 31 R25 Resistor 100 kΩ 0.25 5 - Free - - 32 R26 Resistor NP - - - Free - - 33 C1 Capacitor 470 pF - 10 1k Cer DEBB33A471KC1B Murata 34 C2 Capacitor 100 nF - 10 400 Poly NRM-S104K400F NIC 35 C3 Capacitor 330 nF - 10 400 Poly NRM-S334K400F NIC 36 C4 Capacitor 330 nF - 10 400 Poly NRM-S334K400F NIC 37 C5 Capacitor 4.7 μF - 10 63 Poly B32560J475K Epcos 38 C6 Capacitor 2200 μF 105° 10 25 - 2222 021 16222 Vishay 39 C7 Capacitor 4.7 μF 105° 10 25 Free - - 40 C8 Capacitor 330 pF - 5 Cer, Free - - UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 16 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver Table 4. Bill of materials 120 V (AC) …continued Part No. Ref. Part Value or part no. Power (W) Tole. Volt (%) (V) Package Type Manufacturer 41 C9 Capacitor 10 μF 105° 10 25 Free - - 42 C10 Capacitor 2.2 nF Y1 type 10 4k Cer DECE33J222ZC4B Murata 43 C11 Capacitor 10 nF - 10 25 Cer, Free 44 L1 Inductor 680 μH - - - - 744776268 Wurth 45 L2 Inductor 330 μH - - - - 744776233 Wurth 46 L3 Inductor 100 μH - - - - 74477120 Wurth 47 TX1 Transformer N87/3F3 - 5 - EFD25 750340505 Wurth 48 D1 Rect Bridge 2A - - - SO-4 DBLS205G Taiwan semi 49 D2 TVS diode - 600 - 270 - P6KE270A Fairchild 50 D3 Diode 1A - - 800 - HER107 Taiwan semi 51 D4 Zener - 3 - 220 - BZT03-C220 Vishay 52 D5 Diode 1A - - 800 - HER107 Taiwan semi 53 D6 Diode 3A - - 100 - SK310A Taiwan semi 54 D7 Diode 1A - - 800 - HER107 Taiwan semi 55 D8 Zener - - 5 30 - BZV55-C30 NXP 56 D9 Zener - - 5 20 - BZV55-C20 NXP 57 D10 Diode - - - 75 - 1N4148 NXP 58 Q1 Transistor NPN - - - - BC847B NXP 59 Q2 Transistor NPN - - - - BC847B NXP 60 Q3 Transistor PNP - - - - MPSA92 NXP 61 ISO2 Opto-coupler - - - - - CNY17-1 Fairchild 62 U1 IC - - - - SO-20W SSL2102T NXP UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 17 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 11. Transformer specification Figure 9 shows the transformer schematic: 2 N1 3 1 5 N2 4 9 N3 6 019aab066 Fig 9. Transformer schematic 11.1 Turns ratio • (1 -2) : (4 - 5) = 1 : 0.494 ± 2 % • (1 -2) : (6 - 9) = 1 : 0.247 ± 2 % 11.2 Electrical characteristics Table 5. Inductance Section Inductance N1 1.08 mH ± 7 %, at 1.6 A N2 70 μH N3 270 μH • Nominal frequency = 100 kHz 11.3 Core and bobbin1 x • Core: EFD25, 3F3/N87, air gap center 1100 μm • Bobbin: CSH-EFD25-1S-10P 11.4 Physical dimensions 18 − 0.2 13.1 − 0.2 18 − 0.2 11.78 + 0.1 12.55 12 max −0.2 5.53 +0.1 16.4 min 6.9 −0.1 1.3 ±0.15 3.6 10 ∅ 0.8 20 22.5 25.2 max 26.2 max Dimensions in mm 5 019aaa813 Fig 10. Transformer dimensions UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 18 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 12. Appendix A - Load curves 019aaa800 1500 Iout (mA) 1300 1100 900 8 12 16 20 24 Vout (V) Fig 11. 120 V (AC) load curve 019aaa801 1500 Iout (mA) 1300 1100 900 8 12 16 20 24 Vout (V) Fig 12. 230 V (AC) load curve UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 19 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 13. Appendix B - Efficiency curves 019aaa802 80 efficiency (%) 75 70 65 60 55 8 12 16 20 24 Vout (V) Fig 13. 120 V (AC) efficiency curve 019aaa803 81 efficiency (%) 77 73 69 65 8 12 16 20 24 Vout (V) Fig 14. 230 V (AC) efficiency curve UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 20 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 14. Appendix C - Input voltage dependency 019aaa804 1250 019aaa805 1200 Iout (mA) Iout (mA) 1160 1050 1120 1080 850 1040 650 100 105 110 115 120 125 130 135 Vin (V) a. 120 V (AC) 1000 210 220 230 240 250 Vin (V) b. 230 V (AC) Fig 15. Input voltage/output current dependency UM10386 User manual All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 21 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 15. Appendix D - Mains conducted harmonics Table 6. Mains conducted harmonic values Harmonic 230 V (AC) 50 Hz amplitude (%) 120 V (AC) 60 Hz amplitude (%) PF 0.97 0.99 1 100 100 2 0 0 3 13.6 10.7 4 0 0 5 5.5 3.7 6 0 0 7 1.6 0.9 8 0.2 0 9 2.5 1.9 10 0 0 11 1.1 0.6 12 0 0 13 2.5 1.7 14 0 0 15 1.7 1.1 16 0 0 17 0.9 0.2 18 0 0.1 19 2.9 0.8 20 0 0 16. References UM10386 User manual [1] AN10831 — SSL2102 30 W flyback TRIAC dimmable LED driver [2] AN10754 — SSL2101 and SSL2102 dimmable mains LED driver All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 22 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 17. Legal information 17.1 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. 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. 17.2 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 life support, life-critical or safety-critical systems or equipment, nor in applications where failure or malfunction of an 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. Customers are responsible for the design and operation of their applications and products using NXP Semiconductors products, and NXP Semiconductors accepts no liability for any assistance with applications or customer product design. It is customer’s sole responsibility to determine whether the NXP Semiconductors product is suitable and fit for the customer’s applications and products planned, as well as for the planned application and use of customer’s third party customer(s). Customers should provide appropriate design and operating safeguards to minimize the risks associated with their applications and products. UM10386 User manual NXP Semiconductors does not accept any liability related to any default, damage, costs or problem which is based on any weakness or default in the customer’s applications or products, or the application or use by customer’s third party customer(s). Customer is responsible for doing all necessary testing for the customer’s applications and products using NXP Semiconductors products in order to avoid a default of the applications and the products or of the application or use by customer’s third party customer(s). NXP does not accept any liability in this respect. 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 non-infringement, 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 non-insulated 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. 17.3 Trademarks Notice: All referenced brands, product names, service names and trademarks are the property of their respective owners. All information provided in this document is subject to legal disclaimers. Rev. 1 — 1 February 2011 © NXP B.V. 2011. All rights reserved. 23 of 24 UM10386 NXP Semiconductors SSL2102 19 W to 22 W mains dimmable LED driver 18. Contents 1 2 3 4 5 6 7 8 8.1 8.2 8.3 8.4 8.5 9 10 11 11.1 11.2 11.3 11.4 12 13 14 15 16 17 17.1 17.2 17.3 18 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety warning . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting the board . . . . . . . . . . . . . . . . . . . . 4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Board photos . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimmers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Functional description . . . . . . . . . . . . . . . . . . . 8 Board optimization . . . . . . . . . . . . . . . . . . . . . 11 Changing the output voltage and LED current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Changing the output ripple current . . . . . . . . . 11 Adapting to high power reverse phase (transistor) dimmers.. . . . . . . . . . . . . . . . . . . . 11 Changing the load curve. . . . . . . . . . . . . . . . . 12 Multiple driver support . . . . . . . . . . . . . . . . . . 12 Board schematic . . . . . . . . . . . . . . . . . . . . . . . 13 Bill Of Materials (BOM) . . . . . . . . . . . . . . . . . . 14 Transformer specification . . . . . . . . . . . . . . . . 18 Turns ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical characteristics . . . . . . . . . . . . . . . . . 18 Core and bobbin1 x . . . . . . . . . . . . . . . . . . . . 18 Physical dimensions . . . . . . . . . . . . . . . . . . . . 18 Appendix A - Load curves. . . . . . . . . . . . . . . . 19 Appendix B - Efficiency curves . . . . . . . . . . . 20 Appendix C - Input voltage dependency . . . . 21 Appendix D - Mains conducted harmonics . . 22 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Legal information. . . . . . . . . . . . . . . . . . . . . . . 23 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Please be aware that important notices concerning this document and the product(s) described herein, have been included in section ‘Legal information’. © NXP B.V. 2011. 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: 1 February 2011 Document identifier: UM10386