Kit Description Rev. 1.01 / June 2013 ZSLS7031 ZSLS7031KIT-D1 Demonstration Kit Description LED Lighting ICs Wise and Efficient ZSLS7031KIT-D1 Demonstration Kit Description Important Notice Restrictions in Use ZMDI’s ZSLS7031KIT-D1 Demonstration Kit hardware is designed for ZSLS7031 evaluation, demonstration, laboratory setup, and module development only. The ZSLS7031KIT-D1 Demonstration Kit hardware must not be used for module production or production test setups. Disclaimer Zentrum Mikroelektronik Dresden AG (ZMD AG) shall not be liable for any damages arising out of defects resulting from (i) delivered hardware and software (ii) non-observance of instructions contained in this manual and in any other documentation provided to user, or (iii) misuse, abuse, use under abnormal conditions or alteration by anyone other than ZMD AG. To the extent permitted by law, ZMD AG hereby expressly disclaims and user expressly waives any and all warranties, whether express, implied, or statutory, including, without limitation, implied warranties of merchantability and of fitness for a particular purpose, statutory warranty of non-infringement and any other warranty that may arise by reason of usage of trade, custom or course of dealing. Important Safety Warning: These procedures can result in high currents, which can cause severe injury or death and/or equipment damage. Only trained professional staff should connect hardware and operate the board. For safety, ensure that these instructions and the ZSLS7031 data sheet have been read by all kit users and remain readily available for reference. ! Any use other than as specified in this document is not allowed and dangerous. Any misuse, abuse, use under abnormal conditions, or noncompliance with the current-related safety restrictions could result in life-threatening situations; e.g., short-circuit, fire, explosion, electric shock. Contents 1 2 3 Kit Contents ................................................................................................................................................... 4 Safety Advice ................................................................................................................................................ 4 Kit Description ............................................................................................................................................... 6 3.1. ZSLS7031 Overview ............................................................................................................................... 6 3.1.1. Recommended Equipment .............................................................................................................. 6 3.1.2. Maximum Ratings ............................................................................................................................ 6 3.2. ZSLS7031PCB-D1 Demonstration Board Schematic and Layout ......................................................... 6 3.3. ZSLS7031PCB-D1 Demonstration Board Components ......................................................................... 8 3.3.1. Transformer Data ............................................................................................................................. 8 3.3.2. Bill of Materials ............................................................................................................................... 10 Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 2 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 4 5 6 7 8 9 ZSLS7031KIT-D1 Operation ....................................................................................................................... 12 Typical Measurement Results ..................................................................................................................... 13 Ordering Information ................................................................................................................................... 14 Related Documents ..................................................................................................................................... 14 Glossary ...................................................................................................................................................... 14 Document Revision History ......................................................................................................................... 15 List of Figures Figure 1.1 Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 4.1 ZSLS7031PCB-D1 Demo Board .................................................................................................... 4 Schematic for ZSLS7031PCB-D1 Demonstration Board ................................................................ 7 ZSLS7031PCB-D1 Demonstration Board Layout ............................................................................ 8 PQ16/20 Transformer ...................................................................................................................... 9 Transformer Pin Assignment ......................................................................................................... 10 ZSLS7031PCB-D1 Connection Diagram ....................................................................................... 12 List of Tables Table 3.1 Table 3.2 Table 3.3 Table 5.1 Transformer Components ................................................................................................................ 9 Winding Parameters ........................................................................................................................ 9 Bill of Materials for the ZSLS7031PCB-D1 Demonstration Board ................................................. 10 Typical Measurement Results with a AL250nH Transformer Core ............................................... 13 For more information, contact ZMDI via [email protected]. Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 3 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 1 Kit Contents The ZSLS7031KIT-D1 Demonstration Kit includes the following: ZSLS7031PCB-D1 Demonstration Board – 17W Flyback Converter ZSLS7031ZI1R (MSOP8 3x3mm) 5 IC samples ZSLS7031KIT-D1 Start-Up Information The ZSLS7031KIT-D1 Demonstration Kit is fully assembled and ready for immediate operation. Figure 1.1 2 ZSLS7031PCB-D1 Demo Board Safety Advice Important: The ZSLS7031PCB-D1 Demonstration Board delivered in this kit contains freely accessible parts which might be energized with high electrical voltages during and after operation. Users operating the Demonstration Board could have contact with these parts and must consider this life-threatening hazard if touching the Demonstration Board. Any use of the Demonstration Board requires strict observance of the standards and safety regulations for electrical engineering. Line-power-driven circuits must only be operated by trained staff observing national safety rules. All applicable rules for working with line power must be followed! If the Demonstration Board is operated in Germany, the appropriate VDE rules must be followed, particularly VDE 0100, VDE 0550/0551, VDE 0700, VDE 0711, and VDE 0860. In any other countries, these VDE restrictions must be considered as applicable. Also observe the following safety advice: The Demonstration Board could generate life-threatening high electrical voltage even when operated with low supply voltages (e.g., 24V); therefore also take adequate safety measures even with low supplies. For evaluation purposes, isolating transformers must be used. If there is any evidence that the Demonstration Board is malfunctioning, it must be put out of operation, especially in the case when an optical inspection shows damages (e.g., tape tracks) or if there are loosely or incorrectly mounted components. Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 4 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Operation of the AC/DC converters or DC/DC converters could result in intensely heated parts, so the risk of burn hazards must be considered. Do not leave the Demonstration Board unattended during operation. Important: Before leaving the workplace unattended, disconnect the board from its power supply and ensure that the board cannot be energized unintentionally. When the Demonstration Board is not being used, secure it to prevent unintended use. Do not operate the Demonstration Board in an environment that contains or might contain inflammable gas, explosive vapors, or dust. Repairs must be done only by educated staff observing the relevant safety rules. Broken parts must not be replaced with parts that are not original spare parts. Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 5 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 3 3.1. Kit Description ZSLS7031 Overview The ZSLS7031 LED driver IC is designed to work in buck-boost and fly-back topologies. The circuit operates with peak current detection and in constant frequency mode. The ZSLS7031KIT-D1 application demonstrates the following features: Universal supply voltage range (85VAC to 265VAC can be applied) Active power factor correction to power factor values of typically over 90% High efficiency of typically over 85% Few external components Over-current, over-voltage, and over-temperature protection 15 W constant power output Loads from 9 (about 24V forward voltage) to 19 (52V) LEDs; if operating with 230VAC, loads down to 6 LEDs (17V) can be used Quick start 3.1.1. Recommended Equipment 85VAC to 265VAC / 50Hz to 60Hz power supply (isolating transformer) LED string of about 37V forward voltage and 400mA current capability Emergency main power switch True RMS multimeter Eye protection for all persons exposed to the power LED light from the Demonstration Board during operation 3.1.2. Maximum Ratings If the following maximum ratings are exceeded, the Demonstration Board may be damaged or the output will be limited: Supply voltage 265VAC LED load < 54V forward voltage 3.2. ZSLS7031PCB-D1 Demonstration Board Schematic and Layout Figure 3.1 gives the schematic for the Demonstration Board and Figure 3.2 shows its layout. Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 6 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Schematic for ZSLS7031PCB-D1 Demonstration Board + C4 330u n.p. CY R24 1R C9 5 FB GND R17 240k C8 1u 1n 0.1u R18 13k R9 910k C7 R19 20k 7 6 CS GATE n.c. FSET 4 3 2 R15 1M2 8 VCC 1 VSINE ZSLS7031 U1 R16 68k R11 910k 10u R10 180k 10R R14 47R R12 1n D3 R20 1R21 D2 R21 1R3 D4 Q1 IPP60R950 R23 10k R22 220k C10 6 D5 5 1u 8 10 4 3 1 TR R3 150k C2 R6 180k R7 910k R5 910k C6 3m L1 + Evaluation Kit June 3, 2013 R13 L3 4k7 0.1u 0.1u 1AT N 85VAC to 265VAC J1 L F1 MOV 3m CX2 CX1 L2 3m R2 4k7 - DB1 to DB4 R4 4k7 3n3 PQ20/16 transf ormer + C3 330u R1 D1 n.p. C1 C5 n.p. R8 n.p. LED- LED+ J2 Figure 3.1 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 7 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Figure 3.2 ZSLS7031PCB-D1 Demonstration Board Layout Top of Board Bottom of Board 3.3. 3.3.1. ZSLS7031PCB-D1 Demonstration Board Components Transformer Data The TR transformer included on the Demonstration Board meets the following specifications: Primary inductance LP 650µH @ 10kHz Primary leakage inductance LK < 20µH @ 10kHz Electrical strength 3kV, 50/60Hz, 1 min Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 8 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Figure 3.3 PQ16/20 Transformer Core Halves Table 3.1 Bobbin Bobbin with Winding Complete Transformer Transformer Components ITEM TYPE MANUFACTURER Bobbin CPVPQ20161S14P Ferroxcube Winding PRI & AUX CuL Grade 2 IEC 317-20 MW 79 Elektrisola Winding SEC TEX-E wire Furukawa Isolation Tape CMC 10260/ 3M 1350F, CMC Volz Core (Option 1) PQ20/16-3C95 Ferroxcube AL250 nH Core (Option 2) PQ20/16-3C94 Ferroxcube AL260 nH Core Clamp CLMPPQ2016 Table 3.2 REMARKS Winding Parameters WINDING No. of TURNS No. of PLIES WIRE DATA No. of PLIES TAPE PRI1 25 2 0.3mm-2-UEW 2 0.02mmx4mm SEC 22 2 0.4mm-TEX 3 0.02mmx4mm PRI2 25 2 0.3mm-2-UEW 2 0.02mmx4mm AUX 9 1 0.13mm-2-UEW 3 0.02mmx4mm Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 9 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Figure 3.4 Transformer Pin Assignment PRI1 1 8 SEC 3 PRI2 10 4 5 AUX 6 3.3.2. PIN13 - mechanical support Bill of Materials In the following table, “n.p.” refers to positions that are not populated on the Demonstration Board. Table 3.3 Bill of Materials for the ZSLS7031PCB-D1 Demonstration Board Reference Qty. Component U1 1 LED driver IC ZSLS7031 MSOP8 ZMDI ZSLS7031ZI1R Q1 1 nFET IPP60R950C6 TO220 Infineon IPP60R950C6 DB1,2,3,4 4 Diode 1A, 600V SMA Vishay SF4007 D1 1 Diode 2A, 200V, Ultrafast SMA Diodes ES2D D2 1 Diode 1A, 600V, Ultrafast SMA Diodes ES1J D3, 4, 5 3 Diode 150mA, 100V SOD-80 Vishay LL4148 CX1, 2 2 Film cap, X2 0.1µF, 275VAC 13mmx6mm radial grid 10mm Kemet R46KF310000P1M C1 n.p. C2 1 MLCC 1nF, 1000V, X7R 1206 AVX 1206AC102K C3, 4 2 e-cap 330µF, 63V d10mmx20mm radial grid 5mm Nichicon UVZ1J331MPD C5 n.p. MLCC C6 1 Film cap 100nF, 400V 13mmx5mm radial grid 10mm Kemet MMK10104K400A3LTR C7 1 MLCC 1nF, 16V, X7R 0603 Kemet C0603C102K5R C8 1 MLCC 1µF, 50V, X7R 0805 TaiyoYuden UMK212B7105KG-T C9 1 MLCC 10µF, 25V, X7R 1206 TaiyoYuden TMK316B7106KL-TD C10 1 MLCC 1.0µF, 50V, 1206 TaiyoYuden TMK316B7105KL-T Evaluation Kit June 3, 2013 Type/Value Footprint Manufacturer Order Code 8mmx3mm radial grid 5mm Film cap 1206 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 10 of 15 ZSLS7031KIT-D1 Demonstration Kit Description Reference Qty. Component Type/Value Footprint Manufacturer Order Code X7R CY 1 Film cap, Y2 3.3nF, 250VAC 13.5mmx4mm radial grid 10mm TR 1 Transformer custom wound PQ20/16 L1, 2, 3 3 Inductor 3mH, 300mA sat d8mmx10mm radial grid 5mm R1 n.p. Resistor R2, 4, 13 3 Chip resistor 4.7kΩ 5% R3 2 Chip resistor R5, 7, 9, 11 4 R6, 10 WIMA MP3Y23300/250/20 see section 11 for details Wurth 744772332 0805 KOA RK73B2ATTD472J 150kΩ 5% 1206 KOA RK73H2BTTD1503F Chip resistor 910kΩ 1% 1206 KOA HV732BTTD9103F 2 Chip resistor 180kΩ 5% 1206 KOA RK73H2BTTD1803F R8 n.p. Chip resistor R12 1 Chip resistor 47Ω 5% 0603 KOA RK73H1JTTD47R0F R14 1 Chip resistor 10Ω 5% 0603 KOA RK73H1JTTD10R0F R15 1 Chip resistor 1.2MΩ 1% 0603 KOA RK73H1JTTD1204F R16 1 Chip resistor 68kΩ 1% 0603 KOA RK73H1JTTD6802F R17 1 Chip resistor 240kΩ 1% 0603 KOA RK73H1JTTD2403F R18 1 Chip resistor 13kΩ 1% 0805 KOA RK73H1JTTD1302F R19 1 Chip resistor 20kΩ 1% 0603 KOA RK73H1JTTD2002F R20 1 Chip resistor 1.21Ω 1% 1206 KOA RK73H2BTTD1R21F R21 1 Chip resistor 1.3Ω 1% 1206 KOA RK73H2BTTDD1R30F R22 1 Chip resistor 220kΩ 1% 0603 KOA RK73H1JTTD2203F R23 1 Chip resistor 10kΩ 1% 0603 KOA RK73H1JTTD1002F R24 1 Chip resistor 1Ω 1% 1206 KOA RK73H2BTTD1R00F F1 1 Fuse 1A, 250VAC d3.6mmx10mm axial MOV 1 MOV 7D471K d7mm radial grid 5mm 1 PCB Evaluation Kit June 3, 2013 0207 axial 1206 0875001.MXEP Bourns MOV-07D471K 98mmx28mm © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 11 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 4 ZSLS7031KIT-D1 Operation Always follow the safety advice in section 2. The complete setup must be placed on an isolating work space. Select an appropriate LED string. Connect the positive (anode) terminal of the LED string to the LED+ terminal of the board. Connect the negative (cathode) terminal of the LED string to the LED- terminal of the board. Connect the power supply via main power switch to the supply terminals L and N of the board. Important: Before applying power, ensure that everyone in the vicinity of the Development Board has adequate eye protection from the light of the power LEDs. ! Turn on the power supply. Figure 4.1 ZSLS7031PCB-D1 Connection Diagram Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 12 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 5 Typical Measurement Results The following typical measurement results have been taken on a ZSLS7031PCB-D1 board based on a AL250nH transformer core connected to various LED loads. Table 5.1 Typical Measurement Results with a AL250nH Transformer Core No. of LEDs VACin (V) VLED (V) ILED (mA) Pin (W) Pout (W) Eff (%) PF 9 85 25.5 558 17.1 14.2 83% 99.97% 9 110 25.5 571 17 14.5 85% 99.87% 9 127 25.4 575 16.9 14.6 86% 99.75% 9 230 25.3 556 16.2 14.1 87% 96.50% 9 265 25.3 594 17.5 15.1 86% 94.75% 10 85 28.2 520 17.4 14.6 84% 99.98% 10 110 28.1 531 17.4 14.9 86% 99.88% 10 127 28.1 526 16.9 14.8 87% 99.75% 10 230 28.0 515 16.5 14.4 87% 96.53% 10 265 28.0 542 17.5 15.2 87% 94.79% 14 85 39.0 375 17.2 14.6 85% 99.98% 14 110 39.0 388 17.4 15.1 87% 99.88% 14 127 39.0 387 17.1 15.1 88% 99.75% 14 230 38.8 375 16.5 14.6 88% 96.58% 14 265 38.9 400 17.7 15.6 88% 94.84% 15 85 42.0 352 17.3 14.8 85% 99.98% 15 110 42.0 362 17.4 15.2 87% 99.88% 15 127 41.9 360 17.1 15.1 88% 99.75% 15 230 41.8 353 16.7 14.8 88% 96.66% 15 265 41.9 372 17.7 15.6 88% 94.84% 16 85 44.4 334 17.3 14.8 86% 99.98% 16 110 44.4 344 17.4 15.3 88% 99.88% 16 127 44.4 342 17.2 15.2 88% 99.75% 16 230 44.3 335 16.7 14.8 89% 96.67% 16 265 44.3 353 17.7 15.6 88% 94.85% 18 85 49.9 297 17.3 14.8 86% 99.97% 18 110 49.9 306 17.4 15.3 88% 99.88% 18 127 49.9 305 17.2 15.2 88% 99.75% Evaluation Kit June 3, 2013 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 13 of 15 ZSLS7031KIT-D1 Demonstration Kit Description No. of LEDs VACin (V) VLED (V) ILED (mA) Pin (W) Pout (W) Eff (%) PF 18 230 49.8 298 16.7 14.8 89% 96.69% 18 265 49.9 314 17.7 15.7 89% 94.87% 6 Ordering Information Ordering Code Description Package ZSLS7031KIT-D1 ZSLS7031PCB-D1 Demonstration Board, 5 ZSLS7031 ICs Kit 7 Related Documents Note “Rev_X.x” refers to the latest version of the document. Document File Name ZSLS7031 Datasheet ZSLS7031_Data_Sheet_Rev_X.x.pdf Visit ZMDI’s website www.zmdi.com or contact your nearest sales office for the latest version of these documents. 8 Glossary Term Description LED Light Emitted Diode PCB Printed Circuit Board MSOP8 8-Pin Mini Small-Outline Package Evaluation Kit © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. June 3, 2013 14 of 15 ZSLS7031KIT-D1 Demonstration Kit Description 9 Document Revision History Revision Date 1.00 May 20, 2013 First release. 1.01 June 3, 2013 Minor update for kit contents list. Description Sales and Further Information www.zmdi.com [email protected] Zentrum Mikroelektronik Dresden AG Global Headquarters Grenzstrasse 28 01109 Dresden, Germany ZMD America, Inc. 1525 McCarthy Blvd., #212 Milpitas, CA 95035-7453 USA Central Office: Phone +49.351.8822.0 Fax +49.351.8822.600 USA Phone +855.275.9634 Phone +408.883.6310 Fax +408.883.6358 European Technical Support Phone +49.351.8822.7.772 Fax +49.351.8822.87.772 DISCLAIMER: This information applies to a product under development. Its characteristics and specifications are subject to change without notice. Zentrum Mikroelektronik Dresden AG (ZMD AG) assumes no obligation regarding future manufacture unless otherwise agreed to in writing. The information furnished hereby is believed to be true and accurate. However, under no circumstances shall ZMD AG be liable to any customer, licensee, or any other third party for any special, indirect, incidental, or consequential damages of any kind or nature whatsoever arising out of or in any way related to the furnishing, performance, or use of this technical data. ZMD AG hereby expressly disclaims any liability of ZMD AG to any customer, licensee or any other third party, and any such customer, licensee and any other third party hereby waives any liability of ZMD AG for any damages in connection with or arising out of the furnishing, performance or use of this technical data, whether based on contract, warranty, tort (including negligence), strict liability, or otherwise. European Sales (Stuttgart) Phone +49.711.674517.55 Fax +49.711.674517.87955 Evaluation Kit June 3, 2013 Zentrum Mikroelektronik Dresden AG, Japan Office 2nd Floor, Shinbashi Tokyu Bldg. 4-21-3, Shinbashi, Minato-ku Tokyo, 105-0004 Japan ZMD FAR EAST, Ltd. 3F, No. 51, Sec. 2, Keelung Road 11052 Taipei Taiwan Phone +81.3.6895.7410 Fax +81.3.6895.7301 Phone +886.2.2377.8189 Fax +886.2.2377.8199 Zentrum Mikroelektronik Dresden AG, Korea Office U-space 1 Building 11th Floor, Unit JA-1102 670 Sampyeong-dong Bundang-gu, Seongnam-si Gyeonggi-do, 463-400 Korea Phone +82.31.950.7679 Fax +82.504.841.3026 © 2013 Zentrum Mikroelektronik Dresden AG — Rev. 1.01 All rights reserved. The material contained herein may not be reproduced, adapted, merged, translated, stored, or used without the prior written consent of the copyright owner. The information furnished in this publication is subject to changes without notice. 15 of 15