Phase cut dimmable isolated Flyback converter for PAR38 LED lamp with ICL8002G & CoolMOS™ 600V C6 01_00 | Jun 26, 2012 | PDF | 1.37 mb

Phase Cut Dimmable Isolated
Flyback Converter for PAR38 LED Lamp with
ICL8002G & CoolMOS™ 600V C6
Application Note
http://www.infineon.com/ledoffline
Rev. 1.0, 2012 -06 -21
Power Management & Multimarket
Edition June, 2012
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2012 Infineon Technologies AG
All Rights Reserved.
Legal Disclaimer
The information given in this document shall in no event be regarded as a guarantee of conditions or
characteristics. With respect to any examples or hints given herein, any typical values stated herein and/or
any information regarding the application of the device, Infineon Technologies hereby disclaims any and all
warranties and liabilities of any kind, including without limitation, warranties of non-infringement of intellectual
property rights of any third party.
Information
For further information on technology, delivery terms and conditions and prices, please contact the
nearest Infineon Technologies Office ( www.infineon.com).
Warnings
Due to technical requirements, components may contain dangerous substances. For information on the types
in question, please contact the nearest Infineon Technologies Office.
Infineon Technologies components may be used in life-support devices or systems only with the express
written approval of Infineon Technologies, if a failure of such components can reasonably be expected to
cause the failure of that life-support device or system or to affect the safety or effectiveness of that device or
system. Life support devices or systems are intended to be implanted in the human body or to support and/or
maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user
or other persons may be endangered.
Test report
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PAR38 EVAL-LED-ICL8002G
Table of Contents
1
Introduction
4
2
List of Features
4
3
Technical Specification
4
4
Setup
5
4.1
Input Connection
5
4.2
Output Connection
5
5
Schematic
6
6
Test Data and Waveforms
7
6.1
Efficiency
7
6.2
Start-Up
8
6.3
Power Factor & THD
9
6.4
Power MOSFET Waveforms
10
6.5
7
Output
11
6.6
Output Current Regulation
11
6.7
LED Open Load Protection
13
6.8
Output Short Circuit Protection
14
Dimming
15
Board Layout
16
9
Bill of Materials
17
10
Transformer
20
8
11
Related Documentation
Test report
21
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PAR38 EVAL-LED-ICL8002G
Introduction
1
The PAR38 EVAL-LED-ICL8002G is a dimmable single-stage PFC/ Fly-back LED driver designed
for high efficiency, high power factor, low THD and isolation. The ICL G’s quasi-resonant
operation mode, primary side control, cycle-by-cycle current control, integrated PFC and phasecut dimming control makes it an excellent choice for dimmable LED bulbs especially those
requiring very high efficiency.
2
List of Features
•
•
•
•
•
•
•
•
•
•
•
High efficiency > 89%
High Power Factor (>0.97) with low THD (<10%).
High Dimmer compatibility.
Quasi-resonant operation mode with isolated Fly-back.
Primary side control with integrated PFC.
Integrated Start-Up Power cell.
Built-in digital soft-start
Cycle-by-cycle peak current limitation
VCC over- and under-voltage lockout
Auto restart mode for short circuit and thermal protection
Adjustable latch-off mode for output overvoltage protection
3
Technical Specification
Parameter
Input Voltage
Line Frequency
Output Voltage
Output LED Current
Output Power
Power Factor
THD
Efficiency
Table 1
Specification
Test report
Value
108-132
60
32-40
560
22
> 0.97
< 10
> 89
Unit
Vrms
Vdc
mA
W
%
%
4
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PAR38 EVAL-LED-ICL8002G
4
Setup
Attention:
This Evaluation board is not protected against human
touch. Do not touch live board due to dangerous voltages. Do not
leave board unattended when it is powered up.
4.1
Input Connection
AC source is applied at the two terminals near the common mode inductor. Please refer to
Figure 1 for input voltage connection and Table 1 for input voltage range. For dimming
operation, the phase cut dimmer should be connected to the input terminals according to the
dimmer’s instructions provided by the dimmer manufacturer.
Figure 1
Top Side of PAR38 EVAL-LED-ICL8002G
4.2
Output Connection
The output is functionally isolated from the AC input supply. Connect the load at the electrolytic
capacitors C3 and C4. Please refer to Figure2. Please make sure not to exceed the maximum
output voltage. For the output voltage range (number of LEDs in string) please refer to Table 1.
Output +
Output -
Figure 2
Test report
Bottom Side of PAR38 EVAL-LED-ICL8002G
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PAR38 EVAL-LED-ICL8002G
5
Schematic
Figure 3
Schematic
Test report
6
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PAR38 EVAL-LED-ICL8002G
The ICL8002G is a quasi-resonant PWM controller that can operate in different topologies such as
Buck and Fly-back converters. The PAR38 EVAL-LED-ICL8002G is designed using the Fly-back
topology to provide isolation. Test Data and typical operating waveforms are shown below.
See app note AN-EVALLED-ICL8002G-B2 for details on the non isolated buck topology.
6
6.1
Test data and Waveforms
Efficiency
The Quasi-Resonant operation of this controller o i ed ith I fi eo ’s high perfor a e Coolmos™
HV MOSFETs; results in high conversion efficiency. The chart below is taken at nominal input
voltage of 120VRMS. Efficiency is dependent on output voltage. The ICL8002G IC is designed to
maintain constant output power. If the number of LEDs in the string is reduced (output voltage
is reduced), the LED current increases resulting in increased power loss in the output diode.
This results in slight loss of efficiency which as shown in figure 4.
Figure 4
Test report
Efficiency vs Output Voltage
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PAR38 EVAL-LED-ICL8002G
This output diode is a significant contributor to power loss overall. If additional efficiency is
required, active rectification can be applied to increase efficiency by 1-2%.
Figure 5
Secondary with Synchronous Rectification
On the other hand, if cost is valued over efficiency, components with lower cost can be
substituted for Q3, Q4 and D5. Q4 can be replaced with IPD60R950C6 which results in a 0.1%
drop in efficiency. Q3 can be substituted with a lower VDS and/ or higher Rds-on MOSFET such
as Infineon’s new CE 500V Vds series. Replacing Q3 with IPP60R950C6 (higher Rds-on) drops
efficiency by 0.25%. Additional cost reduction can be achieved by eliminating the active
damper (highlighted in green in schematic above) and substituting a 33- Ω three watt resistor
in series with fuse F1. The substitution of the resistor lowers efficiency by about 3%. Other cost
reductions can also be considered including changing output diode D5 or the transformer to a
lower cost selection. These may also affect efficiency.
6.2
Start Up
The ICL8002G integrates a start-up cell to charge Vcc capacitor (C15) in order to kick-start the
controller into operation. Please refer to schematic. The integrated start-up cell allows for
short start-up times of the system without sacrificing efficiency. The below waveforms were
obtained with C15=10uF. If a shorter Start-up time is required, the value of C15 can be
reduced.
Test report
8
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PAR38 EVAL-LED-ICL8002G
Figure 6
6.3
Start-up waveform: Input voltage (CH1, Blue), Output voltage (CH2, Turquoise), and
output current (CH3, Pink)
Power Factor & THD
The input current and voltage waveforms are shown in Figure 7 below. The input current
waveform shown below is sinusoidal and in phase with the input voltage indicating low THD
(Total Harmonic Distortion) and high PF (Power Factor). Measured PF and THD over the entire
input voltage range are given below.
Figure 7
Test report
Input voltage (CH1, Blue), Input current (CH2, Turquoise).
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PAR38 EVAL-LED-ICL8002G
Figure 8
6.4
Power Factor & THD vs. Input Voltage
Power MOSFET Waveforms
Being a Quasi-Resonant PWM mode controller, the ICL8002G operates at the boundary of
DCM/CCM turning on the power MOSFET (Q4) when the voltage across its Drain to Source is
close to zero. This significantly reduces capacitive switching loss of the power MOSFET during
turn-on. The VDS waveform displayed in Figure 9 shows a Quasi-resonant operation. The
voltage waveform across sense resistors R4, R25 and R26 quantifies the current through
power MOSFET Q4.
Figure 9 VDS waveform of power MOSFET (CH1, Blue), Sense resistors (R4, R25 & R26) voltage (CH2,
Turquoise).
Test report
10
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PAR38 EVAL-LED-ICL8002G
6.5
Output
Since the PAR38 EVAL-LED-ICL8002G is a single stage design, it produces a ripple at twice the
input voltage frequency. If a smaller LED current ripple is required, larger output capacitance
can be used. The output capacitance in this demo board (C3 & C4) is sized for an output
current ripple which exhibits no visible light modulation.
Figure 10
Output voltage waveform (CH1, Blue), Output Current (CH2, Turquoise)
If the users target specification requires a different combination of output voltage and current
then the existing demo board supports, minor modifications will be needed. The flyback
topology can support a wide range of operation voltages and currents with changes to the
transformer build and value changes for sense resistors R4, R25 and R26. I fi eo ’s Lightdesk
tool can help with these changes. Please go to www.Infineon.com/Lightdesk and select AC/DC
dimmable designs. Note: You will need to modify the auxiliary output voltage on the
transformer to allow the use of the Vcc regulator that is included in this design. Lightdesk’s
design results use a default auxiliary voltage of approximately 19V so the number of turns
on the au iliar i di g ill ha e to e i reased appro i atel . ti es Lightdesk’s
calculated value to provide the target 30V auxiliary voltage output at full load.
6.6
Output Current Regulation
PAR38 EVAL-LED-ICL8002G mimics an incandescent light bulb with its output current changing
in proportion to the input voltage variation. The output voltage and current shown below in
figure 11 is for a 39V LED load.
Test report
11
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PAR38 EVAL-LED-ICL8002G
Figure 11
Output Current vs. Input Voltage variations
The demo board is capable of driving an output LED string with a voltage range between 32 to
40V across the output. The effect on the output current over this range of output voltages is
shown in figure 12.
Figure 12
Output Current vs. Output Voltage variations
If the performance shown in figure 11 and 12 is not acceptable for your end application; the
feed-forward circuit of figure 13 can be implemented to improve output current regulation due
to output voltage and input voltage variations. The below circuit could provide a line and load
regulation of less than 5% over the conditions shown in figure 11 and 12 above
Test report
12
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
+ Vin Rectified
10K
1.1M
510K
10K
VCC
750K
BC857S
300K
75K
1uF
Connect right
to Aux winding
2K
3.3V
0.1uF/
50V
Q4
Pin3 of IC
CS
1.5K
Rsense
R4//R25//R26
Figure 13 Feed-forward Circuit for Output Current Regulation due to LED Vf and Line
Variations.
6.7
LED Open Load Protection
The ICL8002G provides protection against open loads via pin ZCV. When open load occurs
(output current drops to zero), the output voltage will rise. The auxiliary bias voltage (C13) is
coupled to the secondary. When the voltage at pin ZCV reaches the OVP threshold
(Vzcovp=3.7V) the IC will stop switching and latches off. Power recycling of the input is required
to restart the LED driver.
Test report
13
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PAR38 EVAL-LED-ICL8002G
Figure 14
6.8
Output voltage (CH1, Blue), Gate of Q4 (CH2, Turquoise), Output Current (CH3, Pink)
Output Short Circuit Protection
In case of a short circuit at the output, the voltage at Vcc pin will drop below the under voltage
threshold activating the Auto Restart mode.
Figure 15
Test report
Output voltage (CH1, Blue), Gate of Q4 (CH2, Turquoise), Output Current (CH3, Pink)
14
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PAR38 EVAL-LED-ICL8002G
7
Dimming
The ICL8002 delivers a smooth dimming curve that transitions from full light output
to minimum dimming as shown in Figure 16.
Figure 16
Output current vs Dimmer Phase angle
We have tested this evaluation board for dimming performance resulting in the list of dimmers
below that exhibit no flicker or shimmer. This list of dimmers does not represent the complete
list of supported dimmers; but rather a selection of commonly used and available dimmers in
the North American market. Active damping, Vcc regulation, and an active bleeder (see
schematic) were used in the design of the PAR38 to maximize dimming performance. If a small
fixed list of dimmers, or a non dimming solution is required; then these blocks can be deleted
and the passive circuits tuned to maximize the fixed dimmer list. This will result in a
significantly reduced BOM count and lower cost.
Test report
15
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
Manufacturer
LEVITON
LEVITON
LEVITON
LEVITON
LEVITON
LEVITON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
LUTRON
GE
COOPER
Table 2
Dimmer P/N
CAT. NO. 6683
CAT. NO. 6684
CAT. NO. 6161
CAT. NO. IPI06-1LX
CAT. NO. IPI06
6631-LW
CN-600 PHW
DV603PG-WH
D-600P-WH
LG-600PH-WH
LX-600PL-WH
LXLV-600PL-WH
MAW-600H-WH
MCU04
NF-603P-WH
S-600-WH
S-600P-WH
S-603PG-WH
TG-600 PH-WH
TGLV-600PR-WH
4YPH5
5PWL6
AY-600 PNL
GE 0723
COOPER 47Y
Dimmer List
The transformer auxiliary ratios must be changed if this board is used with a load that is less
than 32V at full rated current. If less than 32V of LED load is applied without changing the
auxiliary winding the solution may flicker due to loss of Vcc supply voltage. Vcc voltage is
proportional to the output voltage. Please see the comments in section 6.5 regarding how to
change the design to deliver different output voltages and currents.
8
Board Layout
A two layer PCB with 37.4mm x 87.2mm dimensions and a thickness of 1.5mm is used for the
PAR38 EVAL-LED-ICL8002G. There is sufficient creepage between primary and secondary
circuits to meet class 2 insulation requirements.
Test report
16
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
Figure 17
Top Side
Figure 18
Bottom Side
9
Bill of Materials
Component
Value
Manufacturer
F1
MOV1
Fuse, FUSE 1.6A T-LAG IEC
VARISTOR 150VRMS 10mm
RADIAL
CAP 0.33uF 250V METAL
BELL FUSE
EPCOS
C1
Test report
17
EPCOS
Manufacturer
Part Number
RST 1.6AMMO
S10K150
B32521C3334J
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
C2
C3, C4
C5
C6
C7
C8
C9
C11
C12
POLY
2.2nF 630V METAL POLY
CAP 220uF 50V ELECT
RADIAL
Y CAP CER 1500pF 1KVDC
RAD
CAP CER 47nF 25V X7R 20%
0603
X2 cap 33nF 305VAC
X2 cap 10nF 305VAC
CAP CER 47pF 50V COG
0603
CAP 0.1uF 305VAC
CAP CER 1000pF 50V COG
0402
EPCOS
SUNCON
VISHAY
MURATA
EPCOS
EPCOS
MURATA
EPCOS
MURATA
C13, C14
CAP CER 10uF X7S 50V 1210
TDK Corporation
CAP CER 1uF 50V X7R 0805
CAP CER 220pF 50V X7R
0402
CAP CER 1000pF 50V 5%
COG 0603
COMMON MODE INDUCTOR
6mH
1.5mH
MURATA
C15, C17
C16
C18
L1
T1
R1, R2
R3
R4
R5, R27
R6
R7
R8-R11
R13
R14
R15
R16
Test report
RES 4.7KΩ 1/4W 5% 1206
SMD
RES 3.01KΩ 1% 0402 SMD
RES 3.01Ω 1% 0805 SMD
RES 220Ω 1W 5% 2512 SMD
RES 26.7KΩ 1% 0603 SMD
RES 10Ω 1/8W 5% 0805 SMD
RES 750KΩ, 1/8W 5% 0805
SMD
RES 2MΩ 1/4W 5% 1206 SMD
RES 100KΩ 1/10W 5% 0603
SMD
RES 10.0KΩ 1/10W 1% 0603
SMD
RES 402KΩ 1/10W 1% 0603
SMD
18
MURATA
MURATA
WURTH
ELECTRONICS
WURTH
ELECTRONICS
B32529C8222J
50ME220CA
VY1152M41Y5UQ
63V0
GRM188R71E473
KA01D
B32921C3333M
B32921C3103M
GRM39COG470J
50
B32922C3104M
GRM1555C1H102
JA01D
C3225X7S1H106
M
GRM31CR71E106
KA12
GRM155R71H221
KA01D
GRM1885C1H102
JA01
750 311 895
750312496
ANY
ANY
ANY
VISHAY/DALE
ANY
ANY
VISHAY/DALE
ANY
CRCW2512820RJ
NEG
CRCW0805750KJ
NEA
ANY
VISHAY/DALE
VISHAY/DALE
CRCW060310K0F
KEA
CRCW06032M10
FKEA
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
R17
R18
R19
R20
R21
R22
R25
R26
U1
BR1
D1
D2, D3
D4
D5
ZD1
ZD2
ZD3
Q1
Q2
Q3
Q4
Q5
Q6, Q7
Table 3
Test report
RES 22Ω 1/10W 5% 0603
SMD
RES 3.92KΩ, 1/10W 1% 0603
SMD
RES 240KΩ 1/8W 1% 0805
SMD
RES 604KΩ 1/10W 1% 0603
SMD
RES 100KΩ 5% 0402 SMD
RES 3.6KΩ 1W 5% 2512 SMD
RES 0.91Ω 1/8W 1% 0805
SMD
RES 6.81Ω 1% 0805 SMD
ICL8002G, P-DSO-8
RECT BRIDGE GPP 400V
0.8A MBS-1, 4-SOIC
DIODE GP 200V 250mA
MINIMELF
DIODE SWITCH SW 75V .5A
MINIMELF
DIODE SUPER FAST 1A 600V
SMA
DIODE SCHOTTKY 100V 10A,
SMPC
DIODE ZENER 18V 150mW
SOD-323
DIODE ZENER 12V 350mW
SOT23-3
DIODE ZENER 6.8V 150mW
SOD-323
TRANS PNP BIPOLAR 65V
SOT23-BEC
TRANS PNP BIPOLAR 300V
SOT23-3
MOSFET N type, 600V ,
190mΩ
600mΩ 600VOLT MOSFET,
DPAK
45Ω 600VOLT MOSFET,
SOT89
TRANS NPN BIPOLAR 65V
SOT323
ANY
VISHAY/DALE
CRCW06033K92F
KEA
ANY
ANY
ANY
VISHAY/DALE
ANY
ANY
Infineon
Comchip
Technology
Micro Commercial
Co
Micro Commercial
Co
MICRO
COMMERCIAL
VISHAY
CRCW25123K60J
NEG
ICL8002G
B4S-G
BAV102-TP
DL4151-TP
ES1J-LTP
V10P10
Diodes Inc
DDZ9705S
Diodes Inc
BZX84C12-7-F
Diodes Inc
DDZ9692S-7
Diodes Inc
BC856B-7-F
Diodes Inc
MMBTA92-7-F
INFINEON
INFINEON
IPI60R190C6
IPD60R600C6
INFINEON
BSS225
Diodes Inc.
BC846BW-7-F
Bill of Materials
19
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
10
Transformer
Figure 19:
Test report
Transformer
20
Revision 1.0 June, 2012
PAR38 EVAL-LED-ICL8002G
The PCB layout is designed for Class 2 insulation. However, this transformer used on this
evaluation board is not designed for Class 2 isolation. If class2 insulation is required please
contact a custom magnetic supplier for assistance in this design or use our design tool at
www.Infineon.com/lightdesk. Many options are available for core and bobbins to provide Class
2 isolation. For example, the pin-out of the PQ20/16 is very similar to the RM8 and provides
better form factor with more creepage for class2 insulation than the RM8 bobbin.
11
Related Documentation at Infineon
ICL8002G Datasheet:
http://www.infineon.com/cms/en/product/channel.html?channel=db3a3043266237920126b
71e3a221e91
Design Guidelines ICL8001G/ ICLS8082:
http://www.infineon.com/dgdl?folderId=db3a304314dca389011561889ef01fe7&fileId=db3a
30432a7fedfc012a8e9ff4d40493
Infineon Light Desk Design Tool: www.Infineon.com/Lightdesk
Infineon CoolMOS™ High oltage mosfets: www.infineon.com/coolmos
Infineon OptiMOS™ Mid / low voltage Mosfets: www.infineon.com/optimos
Demo board Order code: SP000993130
www.i nfineon. com
Published by Infineon Technologies AG
PAR38