DN05016/D Design Note – DN05016/D 100V, 450mA Off-Line LED Driver with High PF Device Application NCL30001 NCS1002 High PF CVCC LED Driver with Dimming Input Voltage 85 – 266 Vac Output Power Topology I/O Isolation 35 to 60 Watts Single Stage PFC/Flyback Yes – 3 kV Output 1 Output Voltage Ripple Nominal Current Max Current Min Current 100 Vdc max 100 mA max 450 mA (adjustable) 600 mA 350 mA Yes 86% Yes 0 to +40 °C Convection NA Yes – Dimming functions PFC (Yes/No) Typical Efficiency Inrush Limiting / Fuse Operating Temp. Range Cooling Method / Supply Orientation Signal Level Control Others PWM dimming to 3% with external digital input signal Circuit Description This Design Note (DN) is an extension to ON Semiconductor’s Application Note AND8470/D and features a 100 volt max, 0.45 amp version of the off-line, NCL30001 based constant voltage, constant current (CVCC) LED driver with inherent PFC described in that app note. The original app note features a 50 volt max, constant current, 1 to 2 amp (current settable) LED driver with multiple dimming capabilities and active power factor correction in a single continuous conduction mode (CCM) flyback converter stage. This DN presents a similar version that is suitable for driving series LED strings up to 100 volts at a max current of up to about 600 millamps. This design is suitable for LED strip lighting and fluorescent lamp replacements. The maximum voltage and output current can be adjusted via resistors R34 and R32 respectively. The detailed circuit operational description can be found in the original mentioned app note (AND8470/D) and September 2011, Rev. 0 is essentially identical circuit-wise with the exception of the component changes that are indicated in the BOM. The flyback transformer design for this DN was merely ratioed from the secondary winding on the original design to meet the new maximum voltage and current requirements. The primary winding, required inductance, and overall construction are essentially the same. Key Features Single stage, isolated PFC converter for strip lighting and fluorescent tube replacements. Constant voltage, constant current output characteristic for LED drive Dimming features including pulse width dimming to 3% Over current, over voltage and over temperature capabilities Typical efficiencies above 86% www.onsemi.com 1 DN05016/D Primary Side Schematic1 F1 1.5A L1A 3.9mH 470 uH D1 - D4 MRA4007 x 4 L2 C1 C2 0.22 "X" 0.22 "X" MRA4007T 1M 0.5W Z1 C3 0.1uF 600V L1B D5 D10 C4 22uF 450V 470uH R7 R6 365K 365K R9 R10 R11 30.1K 332K 365K R2 560K 0.5W R8 2K 1/2W MMBTA06LT1G Q3 2K 0.5W MURS 160T Z3 C6 MMSZ5248B 100uF 35V 100uF 35v R5 20K C11 4.7uF 25V C12 470pF 1 11 5 6 D7 MURS 160T 0.1 Q1 SPP08N80C3 R23 4.7 ohm 12 6 11 7 8 10 C14 10nF 8 13 U1 SFH615A-4 U2 R22 10K 9 4 1 3 2 D9 R21 R16 TBD MMSD 4148 C13 33nF 2 C8 16 15 14 NC Z2 100K C10 1nF + 10K R14 R13 C28 0.1 7.32K 680pF C9 2.2K R15 T1 10nF 630V 220 R17 56K R18 49.9K R12 30.1K R25 D6 C7 MBR0530 C5 NCL30001 1 2 3 4 5 R4 D13 R3 47K 1/2W C15 C16 C17 C18 0.1 0.1 10nF 1nF R19 76.8K R1 MRA4007T AC In 1.5KE440A J1 10 ohm R20 0.22 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). L1A/B are Coilcraft RFB1010-471AL or equivalent (470 uH). L2 is Coilcraft E3491AL or equivalent (3.9 mH). Q1 will require a small heatsink. Q3 is omitted. 1 NCL30001 CVCC, 100V, 50 Watt Power Supply Primary Control Side Schematic (Rev 3) © 2011 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] September 2011, Rev. 0 www.onsemi.com 2 DN05016/D Secondary Side Schematic Xfmr J2 330uF, 100V x 3 + 8 R24 100, 1/2W 11 C21 C20 C19 C23 47nF 200V D8 Q4 R28 MJD47G 1 2 R29 C25 43K 0.1 D11 7 MMSD4148 Z4 MMSZ5245B C34 PWM Output Switch 47nF 200V MMSZ5245B Current Sense Sample & Hold 0.1 Is Z5 - Q6 + Vs R36 6 C31 Is 5 - Q7 R37 C33 R31 2.7K LED Cathode NTD12N10T4G 5.1K 1uF U3B C30 1uF 0.22 1/2W 39K 8 feedback optocoupler R26 R27 Vcc = 14V 2.2K U2 C22 390 pF MUR480E LED Anode C24 Q5 R39 R38 100 10K R40 10K 2.7K 1nF MMBTA06LT1G J3 + - PWM In 200Hz -1 kHz 2N7002KT1G NCS1002 C26 0.1 D12 R30 43K 1 MMSD4148 U3A 4 - 2 + Vref To Primary Ground Plane R34 R33 143K 6.2K 2.5V 3 internal to U3 C27 R32 76.8K C32 10nF R35 3.9K Gnd 2.2nF 100V/0.45A LED Driver CVCC Secondary Sensing with PWM Dimming Input (Rev 3) Maximum output voltage adjust resistor: R34 Output current adjust resistor: R32 See ON Semiconductor AND8470/D for original NCL30001 CVCC driver app note details. September 2011, Rev. 0 www.onsemi.com 3 DN05016/D 2 MAGNETICS DESIGN DATA SHEET Project: NCL30001, 40 W, 100 Vout, isolated, single stage CVCC PFC LED driver Part Description: CCM Flyback transformer, 50-70 kHz, 100 Vout, 450 mA Schematic ID: T1 Core Type: PQ3230, 3C94 (Ferroxcube) or P material (Mag Inc.) Core Gap: Gap core for 900 to 1,100 uH across pins 1 to 2. Inductance: 1000 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. 100V Secondary (8 - 11) 50 turns of #30HN close wound over one layer and centered with 1.5 mm end margins. 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) 13 turns of #24HN spiral wound and centered with 8 mm end margins. Insulate with tape and terminate self-leads to pins. Safety margins not necessary as long as specified Hipot below can be met. Hipot: 3 kV from primary/Vcc to 100V secondary winding. Lead Breakout / Pinout Schematic (bottom view) 2 7 8 9 10 11 12 28T Pri B 3 8 50T Pri A 100V sec 28T 11 1 6 5 4 3 2 1 5 13T Vcc Wurth Electronics - Part # 750312294 6 2 September 2011, Rev. 0 www.onsemi.com 4