DN06068/D Design Note – DN06068/D 28V, 3.3A Off-Line High PF LED Driver Device Application NCL30001 NCS1002 90 Watt CVCC LED Driver with Dimming • Input Voltage 90 – 265/305* Vac Output Power Topology I/O Isolation 90 Watts Single Stage PFC/Flyback Yes – 3 kV 277 Vac can be supported with a slight BOM change Output Output Voltage Ripple Nominal Current Max Current Min Current 30 Vdc max < 10% 3.3 Amps 3.5 Amps Zero Yes 87% Yes 0 to 50C Convection NA Yes – Dimming functions PFC (Yes/No) Typical Efficiency Inrush Limiting / Fuse Operating Temp. Range Cooling Method / Supply Orientation Signal Level Control Overview This Design Note (DN) is an extension to ON Semiconductor’s Application Note AND8427/D and illustrates how the NCL30001 continuous conduction mode power factor corrected single stage flyback controller can be used to implement a constant current LED driver for area lighting applications such as high bay, tunnel, parking garage and roadway lighting This specific design has been optimized for LEDs that require greater than 3A drive capability such as the Luminus Devices CSM360 and SST90. This design can support up to 8 SST90 devices in series or 2 CSM360. The CSM360 LED has a nominal forward voltage of 12.8 V at a drive current of 3.2A and depending on the color temperature and flux bin can generate 1600-3900 lumens. Circuit Description This circuit design illustrates a 3.3A, and up to 28 volt maximum forward voltage configuration March 2010, Rev. 0 of the off-line, NCL30001 based constant voltage, constant current (CVCC) LED driver. Since this design has comparable power level to the standard NCL30001 evaluation board (50V up to 2A), the principle circuit changes were in the transformer design and the constant current / constant voltage secondary control circuitry based on the NCS1002. The primary stage is illustrated in Figure 1. The secondary side control circuitry is illustrated in Figure 2. In this design, the output voltage is determined by a resistor ratio and the output current is also set based on a resistor ratio. As result only two resistors: R34 which is part of the output voltage divider and R32 which is part of the current setting circuit need to be changed. In addition, since the output voltage is lower and the output current is higher, the output capacitance is increased and the voltage rating of the capacitors are reduced. The flyback transformer for this design was scaled from the secondary winding on the www.onsemi.com 1 DN06068/D original design to meet the new maximum voltage and current requirements. The primary 277 Vac input can be utilized with proper voltage winding, required inductance, and overall rating changes to the EMI input filter “X” and “Y” construction are essentially the same. capacitors. Top Size View of Board March 2010, Rev. 0 www.onsemi.com 2 DN06068/D 1 F1 2.5A C1 C2 0.47 "X" 0.47 "X" MRA4007T 1M 0.5W Z1 C3 0.1uF 600V R7 R6 365K 365K D5 R9 R10 R11 30.1K 332K 365K R2 560K 0.5W MMBTA06LT1G Q3 D6 MURS 160T Z3 C6 C5 100uF MMSZ5245B 220uF 50V 35v R14 C11 4.7uF 25V C12 470pF C13 33nF 0.1 1 11 Q1 SPP11N80C3 R23 4.7 ohm 12 6 11 7 8 10 C14 10nF 6 D7 13 U1 SFH615A-4 U2 R22 10K 9 4 1 3 2 D9 R21 R16 TBD MMSD 4148 100K C10 1nF + 5 C8 16 15 14 NC Z2 10K R13 C29 0.1 2.2K R15 8 220 R17 56K R18 49.9K 20K Q2 7.32K 680pF C9 MMBTA06LT1G R12 30.1K R25 T1 100nF 2 400V MURS 160T R5 NCL30001 C28 1uF C7 2.2K 0.5W R8 2K 1/2W 1 2 3 4 5 R4 D10 C4 22uF 450V R3 36K 3W C15 C16 C17 C18 0.1 0.1 10nF 1nF R19 76.8K R1 MRA4007T AC In D1 - D4 1N5406 x 4 L2 L1 1.5KE440A J1 10 ohm R20 0.10 ohm 0.5W C27 Notes: 1. 2. 3. 4. 5. 6. 7. Crossed schematic lines are not connected. Heavy lines indicate power traces/planes. Z2/D9 is for optional OVP (not used). L1 is Coilcraft BU10-1012R2B or equivalent. L2 is Coilcraft P3221-AL or equivalent. L3 is Coilcraft RFB0807-3R3L or equivalent. Q1 and D8 will require small heatsinks. NCL30001 CVCC, 90 Watt Power Supply Primary Control Side Schematic Figure 1: Primary Side Schematic 1 © 2010 ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party’s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Frank Cathell, e-mail: [email protected] March 2010, Rev. 0 www.onsemi.com 3 DN06068/D Xfmr + 3,300uF, 35V x 3 7,8 R24 C19 C21 C20 C23 0.1 100V 15, 1/2W 2.2nF 11,12 D8 MBRF20H150CTG MJD243G Q4 R28 2.2K U2 1 R29 C25 43K 0.1 2 D11 7 MMSD4148 Z4 MMSZ5245B C30 1uF C34 Current Sense Sample & Hold 0.1 C33 U3B + R31 2.7K R36 C31 Is 5 R30 43K 1 MMSD4148 Vref + 4 3 U3A internal to U3 To Primary Ground Plane C27 Q5 Q7 MMBTA06LT1G 10K R44 10K R40 10K R41 10 Vcc 2.5V R42 10 C35 C32 0.1 10nF 6 Gnd PWM In 1 kHz 1 kHz PWM Out 5 Vcc In Jumper if DIM Card not used 3 R43 10 J3 R39 2N7002KT1G R34 R33 43K 6.2K R32 20K LED Cathode NTD12N10T4G R38 100 2.7K 1nF NCS1002 2 D12 Q6 Vs 6 30V/3.3A 5.1K 1uF C26 0.1 Z5 J2 R37 Is 8 feedback optocoupler MMSZ5245B 0.10 2W R27 PWM Output Switch 0.1 100V R26 4.7K, 0.5W Vcc = 14V LED Anode C24 C22 Vref In 2 Dimming Control Options Card Analog Dim out R35 3.9K Gnd 1 Common 2.2nF P1 Notes: 1. R32 sets constant output current. 2. R34 sets maximum output voltage. 3. P1 connector should have pins 2 and 3 jumpered if DIM card is not used. 4. External PWM input for 200 Hz to 1 kHz. 5. D8 will require a small heatsink 6. Crossed lines on schematic are not connected. 30Vout LED Driver CVCC Secondary Sensing with PWM Dimming Input & Option Card (Rev 2) Figure 2: Secondary Side Schematic 1 © 2010 ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party’s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Frank Cathell, e-mail: [email protected] March 2010, Rev. 0 www.onsemi.com 4 DN06068/D Test Results: 1) Efficiency with 3.3 A output: LED Forward Voltage (V) 26.0 13.0 120 Vac 230 Vac 86% 82% 87% 84% 2) Power Factor during PWM Dimming (Vf = 26V/Iout = 3.3A PWM Duty Ratio 100% 75% 50% 25% 10% 120 Vac PFC 230 Vac PFC 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.92 0.75 3) Output Ripple at 120 Vac Input and 3.3 Amps Output March 2010, Rev. 0 www.onsemi.com 5 DN06068/D 4) Current Regulation Versus LED Forward Voltage 3.5 3 LED Current (A) 2.5 2 1.5 1 0.5 0 10.0 12.5 15.0 17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 Forward Voltage (V) 1 © 2010 ON Semiconductor. Disclaimer: ON Semiconductor is providing this design note “AS IS” and does not assume any liability arising from its use; nor does ON Semiconductor convey any license to its or any third party’s intellectual property rights. This document is provided only to assist customers in evaluation of the referenced circuit implementation and the recipient assumes all liability and risk associated with its use, including, but not limited to, compliance with all regulatory standards. ON Semiconductor may change any of its products at any time, without notice. Design note created by Frank Cathell, e-mail: [email protected] March 2010, Rev. 0 www.onsemi.com 6 DN06068/D MAGNETICS DESIGN DATA SHEET Project: NCL30001, 90W, 28V CVCC LED driver Part Description: CCM Flyback transformer, 70 kHz, 3.2 A, 30 Vout max Schematic ID: T1 Core Type: PQ3230, 3C94 (Ferroxcube) or P material (Mag Inc.) Core Gap: Gap core for 575 to 625 uH across pins 1 to 2. Inductance: 600 uH nominal measured across primary (pins 1 to 2) Bobbin Type: 12 pin pc mount (Mag Inc PC-B3230-12 or equivalent) Windings (in order): Winding # / type Turns / Material / Gauge / Insulation Data Primary A: (1 - 3) 28 turns of #24HN over one layer (no margins). Self-leads to pins. Insulate for 3 kV to next winding. 28V Secondary (7, 8 - 11, 12) 14 turns of 2 strands of #24HN flat wound (bifilar) over one layer with tape cuffed ends for safety (no margins) Terminate with 1 wire per pin as shown in drawing below. Insulate with tape for 3 kV to next winding. Primary B: (3 - 2) Same as primary A. Insulate for 1.5 kV to Vcc/Aux. Vcc/Aux (5 - 6) 14 turns of #24HN spiral wound and centered with 8 mm end margins. Insulate with tape and terminate self-leads to pins. Hipot: 3 kV from primary/Vcc to 28V secondary windings. Lead Breakout / Pinout Schematic (bottom view) 2 7 8 9 10 11 12 28T Pri B 7 8 3 14T, 2 strands 24 Pri A 28T 1 5 14T Vcc 11 12 6 5 4 3 2 1 Wurth Part #: 750311269 6 March 2010, Rev. 0 www.onsemi.com 7 DN06068/D March 2010, Rev. 0 www.onsemi.com 8