AND9451/D 4 Key Steps to Design a NCL30188‐Controlled LED Driver Description This paper proposes the key steps to rapidly design a NCL30188-driven flyback converter to power an LED string. The process is illustrated by a practical 10 W, universal mains application: • Maximum Output Power: 10 W • Input Voltage Range: 90 to 265 V rms • Output Voltage Range: 12 to 20 V dc • Output Current: 500 mA www.onsemi.com APPLICATION NOTE Introduction • Cycle-by-cycle Peak Current Limit: when the current The NCL30188 is a driver for power-factor corrected flyback, non-isolated buck-boost and SEPIC converters. The current-mode, quasi-resonant architecture optimizes the efficiency by turning on the MOSFET when the drain-source voltage is minimal (valley). At high line, the circuit delays the MOSFET turn on until the second valley is detected to reduce the switching losses. An internal proprietary circuitry controls the input current in such a way that a power factor as high as 0.99 and an output current deviation below ±2% are typically obtained without the need for a secondary-side feedback. The circuit further contains a suite of powerful protections to ensure a robust LED driver design without the need for extra components or overdesign. Among them, one can list: • Over Temperature Thermal Fold-back: connecting a NTC to the SD pin allows for gradual reduction of the LED current down to 50% of its nominal value when the temperature is excessive. If the current reduction does not prevent the temperature from reaching a second level, the controller stops operating (SD_OTP). • Over Voltage Protection (SD_OVP): A Zener diode can further be used on the SD pin to provide an adjustable OVP protection (SD OVP). © Semiconductor Components Industries, LLC, 2016 June, 2016 - Rev. 0 • • • • sense voltage exceeds the internal threshold (VILIM ), the MOSFET immediately turns off (cycle-by-cycle current limitation). Winding and Output Diode Short-circuit Protection (WODSCP): an additional comparator stops the controller if the CS pin voltage exceeds (150% ⋅ VILIM ) for 4 consecutive cycles. This feature can protect the converter if a winding or the output diode is shorted or simply if the transformer saturates. Output Short-circuit Protection (AUXSCP): If the ZCD pin voltage remains low for a 90-ms time interval, the controller stops pulsating until 4 seconds has elapsed. Open LED Protection: if the VCC pin voltage exceeds the OVP threshold, the controller shuts down and waits 4 seconds before restarting switching operation. Floating/Short Pin Detection: the circuit can detect most of these situations which helps pass safety tests. Pin−to−pin compatible to the NCL30088, the NCL30188 provides the same benefits with in addition, an increased resolution of the digital current−control algorithm for a 75% reduction in the LED current quantization ripple. 1 Publication Order Number: AND9451/D AND9451/D PRELIMINARY REMARKS Two NCL30188 Versions There exist two NCL30188 versions. As summarized by Table 1, they differ in their respective protection mode. When the Winding and Output Diode Short Circuit Protection (WOD_SCP) or the Output and Auxiliary Winding Short Circuit Protection (AUX_SCP) triggers, the A version latches-off while the NCL30188B enters the auto-recovery mode. Similarly, the SD over-temperature and over-voltage protections (SD pin OTP and SD pin OVP) are latching-off in the NCL30188A and auto-recovery in the NCL30188B. Table 1. PROTECTION MODES AUX_SCP WOD_SCP SD Pin OTP SD Pin OVP NCL30188A Latching Off Latching Off Latching Off Latching Off NCL30188B Auto-Recovery Auto-Recovery Auto-Recovery Auto-Recovery In the case of a latching-off fault, the circuit stops pulsing until the LED driver is unplugged and VCC drops below VCC(reset) (5 V typically). At that moment, the fault is cleared and the circuit can resume operation. In the auto-recovery case, the circuit cannot generate DRV pulses for the auto-recovery 4-s delay. The circuit recovers operation when this time has elapsed. regulation will then be optimal as long as the lowest line peak voltage is higher than the inductor demagnetization voltage, i.e.,: Duty-Ratio Limitation where (Vin,rms )LL is the lowest-line rms voltage (85 or 90 V rms in general) and (Vf ) is the output diode forward voltage. The NCL30188A/B duty-ratio is internally limited to 50% at the top of the lowest line sinusoid. Output current • If ǒǸ2 @ ǒV • If ǒǸ2 @ ǒV Ǔ Ǔ w V out ) V f with non-isolated converters, Ǔ np w n ǒV out ) V fǓ in flyback applications, in,rms LL in,rms LL Ǔ s Table 2. NCL30188 CONDITIONS OF USING Output Voltage Range for Non-Isolated Converters (Note 1) NCL30188A (Note 2) NCL30188BA Output Voltage Range for Flyback Converters (Note 1) V out ) V f v Ǹ2 @ ǒV in,rmsǓ LL n V out ) V f v n s @ Ǹ2 @ ǒV in,rmsǓ p LL V out ) V f v Ǹ2 @ ǒV in,rmsǓ LL n V out ) V f v n s @ Ǹ2 @ ǒV in,rmsǓ LL p 1. (Vin,rms)LL is the lowest-line rms voltage (e.g., 85 V rms), (Vf), the output diode forward voltage. 2. Please contact local sales representative for availability. As an example, let’s assume that we must design a 90 to 265 V rms, non-isolated buck-boost converter. For optimal control accuracy, the LED driver output voltage should not exceed: V out,max + Ǹ2 @ ǒV in,rmsǓ LL * Vf ^ ^ Ǹ2 @ 90 * 1 ^ 126 V If the duty-ratio limitation is exceeded by your application, the LED current will be below its nominal value at the lowest line voltage but will meet the target when the input voltage level is sufficient. By the way, a symptom of the duty-ratio limitation effect can be observed as shown by Figure 1 where the input current is clamped by the over-current protection during normal load conditions. (eq. 1) www.onsemi.com 2 AND9451/D V CC I LED The current is MOSFET current clamped to (V / R ILIM sense Figure 1. Current Over-Current Limitation (VILIM is Over-Current Threshold, RSENSE the Current Sense Resistor) Our application of interest is a flyback converter. Note that in this case, turns ratio provides some flexibility which can help meet the condition of using. LED Driver Dimensioning D1 RSTUP Aux . RC RS1 . DC RZCD1 COUT . CC NCL30188 RS2 RZCD2 CZCD CCOMP CSD RTH 1 8 2 7 3 6 4 5 DZ Q1 RLFF C2 Figure 2. Basic Schematic www.onsemi.com 3 C1 CCS RSENSE ) AND9451/D STEP 1: POWER COMPONENTS SELECTION This leads in our case to: Basically, the transformer, the output capacitor and the power silicon devices are dimensioned “as usual”, that is, as done with any other PF corrected, quasi-resonant flyback converter. This chapter does not detail this process, but highlights the major points. n AUX v n S @ 25.5 ^ 1.3 @ n S 20 ) 1 (eq. 4) Practically, we will select (nAUX = nS). In this case, VCC will be in the range of Vout , with some deviations due to the imperfect coupling. Transformer Selection Selecting the Auxiliary Winding Number of Turns An auxiliary winding is necessary for zero current detection and to provide the VCC voltage. The output voltage of a LED driver generally exhibits a large range. The VCC voltage provided by the auxiliary winding will vary in a similar manner. The NCL30188 features a large VCC range to address these variations. Practically, after start-up, the operating range is 9.4 V up to 25.5 V. NOTE: (VCC(OVP) )min = 25.5 V is the threshold minimum value of the VCC over-voltage protection. This safety feature protects the circuit if the LED string happens to be disconnected. Selecting the Secondary Winding Number of Turns In general, NPS , the secondary to primary transformer turns ratio (NPS = nS / nP) [nP designates the primary number of turns, nS , the secondary number of turns] is selected as low as possible so that the input current stress is reduced. NPS cannot be too small however. NPS sets the amount of voltage reflected during the off-time (see Figure 3) and hence, must be high enough to limit the voltage stress across the primary-side MOSFET. Indeed, the voltage to be sustained by the primary-side MOSFET and the output diode are: The auxiliary winding number of turns can be selected so that the auxiliary voltage is slightly below (VCC(OVP))min when the output voltage is at a maximum factoring in impact of the 100/120-Hz ripple. Practically, this criterion turns into: V diode,max + N PS Ǹ2 (V in,rms) max ) V out ) V f ) V D*ov n AUX n S (V out,max ) V f) v (V CC(OVP)) min ) V f V DS,max + Ǹ2 (V in,rms) max ) (V CC(OVP)) min ) V f V out,max ) V f (eq. 5) Where: • NPS is the secondary to primary transformer turns ratio NPS = nS / nP • VQ−ov is the MOSFET overvoltage shown in Figure 3. This overshoot is due to the leakage inductor reset. It is limited by the clamping network consisting of DC , CC and RC of Figure 2. • VD−ov is a similar overshoot that occurs across the output diode when the MOSFET turns on. (eq. 2) Hence: n AUX v n S @ V out ) V f ) V Q*ov N PS (eq. 3) www.onsemi.com 4 AND9451/D The clamping network is often designed so that VQ−ov is between 50% and 100% of the reflected voltage: V Q*ov + k C @ v out ) V f with 0.5 v k c v 1.0 N PS V ds,max + Ǹ2 @ (V in,rms) HL ) N PS (eq. 7) Some derating is generally requested. The typically-applied 15% safety factor implies that the MOSFET voltage does not exceed 85% of its breakdown voltage. Hence: (eq. 6) We can estimate the maximum voltage reached on the drain node, considering Vout(OVP) level as the maximum output voltage: V ds,max + Ǹ2 @ (V in,rms) HL ) (1 ) k c)(V out(OVP) ) V f) (1 ) k c)(V out(OVP) ) V f) N PS Where VDSS is the MOSFET breakdown voltage. v 85%V DSS (eq. 8) 85%V DSS* Ǹ2 @ (V in,rms) HL nP v nS (1 ) k c)(V )V) Finally: out(OVP) (eq. 9) f Figure 3. MOSFET Drain-source Voltage (Yellow Trace) and Current (Blue) In our application, (Vin,rms )HL is 265 V rms and (Vout(OVP) + Vf ) is about 28 V. With a 600 V MOSFET, nP 85% @ 600* Ǹ2 @ 265 ^ 4.8 n S (1 ) k c) v 28 f sw + nP 85% @ 800* Ǹ2 @ 265 ^ 10.9 (eq. 11) n S (1 ) k c) v 28 We select the second option (800 V MOSFET) with nP n S + 6 and (kc = 80%), which meets Eq. 11 requirements n since nP (1 ) k c) + 6 @ 180% + 10.8 v 10.9 . S It can be easily checked that the Table 2 condition of using the A or B version is met. The NCL30188B will be used for this application. ǒ Ǔ Ǔ 2 (eq. 12) The switching frequency is a rising function of the rms line voltage. At a given line magnitude, the switching frequency is yet higher near the line zero crossing and decays as the line voltage rises due to the (nin (t)) term. Note that when high-line conditions are detected (see NOTE), the NCL30188 does not operate in quasi-resonant mode but delays the MOSFET turn on until the 2nd valley is detected (see Figure 4). This reduces the switching frequency upper range and optimizes the high-line efficiency. NOTE: The input voltage is sensed by the VS pin for brown-out protection, feedforward and line range detection. High-line conditions are detected when the VS pin voltage exceeds 2.4 V typically. See data sheet for more details. (eq. 10) With a 800 V MOSFET, ǒ ǒ (V in,rms) 2 V out ) V f @ 2L PP in,avg N PS n in(t) ) V out ) V f Ǔ Selecting the Primary Inductance Assuming a quasi-resonant operation and neglecting the small delay necessary for detecting the MOSFET drain-source valley, the primary inductance dictates the switching frequency as follows: www.onsemi.com 5 AND9451/D Figure 4. Quasi-Resonant Mode in Low Line (Left), Turn On at Valley 2 when in High Line (Right) The primary inductor will be selected with respect to the targeted switching frequency range, keeping in mind that: • High switching frequency levels reduce the size of the storage elements • Conversely, increasing the switching frequency leads to more switching noise and losses. Also, EMI filtering may be tougher because of the EMI generated at the switching frequency and close harmonic levels. Most power supplies have to meet standards which apply to frequencies above 150 kHz. That is why SMPS designers often select FSW = 130 kHz to keep the fundamental component below 150 kHz and then out of the regulation scope. Often, 65 kHz is also chosen to not to have to damp harmonic 2 too. • nominal line voltage when ǒ n in(t) + V in,pkń2 Ǔ Our application is a wide-range one. Let us compute LP so that at 115 V rms, the switching frequency is below fsw,T = 65 kHz: ȡ ȧ ȢN (P in,avg) max (V in,rms) LL (P in,avg) max (I L,pk) max + 2 Ǹ3 (V in,rms) LL LP w ǒ @ 1) Ǹ ǒ Ǹ (I L,rms) max + 2 12 @ @ Ǹ3 90 1) 1) Ǹ2@V in,rms PS 115 2 2 @ 65 @ 10 3 @ 12 @ 2 ǒ ) V out 12 ) 1 Ǹ2@115 6@2 ȣ ȧ ) VȤ (eq. 13) f Ǔ ) 12 ) 1 2 ^ 2 mH (eq. 14) Finally we have to consider the primary current magnitude constraints: 90 6 N PS(V in,rms) LL V out ) V f Ǔ 16 Ǹ2 @ (V in,rms) LL 1) In our application, assuming an efficiency of 84% ((Pin,avg )max = 12 W), Eq. 15 and Eq. 16 lead to: 12 (I L,pk) max + 2 Ǹ2 @ @ 90 V out ) V f Which leads to: in,pk (I L,pk) max + 2 Ǹ2 @ 2 (V in,rms) 2 LP w @ 2f sw,TP in,avg As the rule of thumb, let us select LP as follows: • In wide mains application: choose LP so that the switching frequency is below 65 kHz at the low-line range nominal voltage (typically 115 V rms) over a large part of the sinusoid. Practically, we can select that the frequency target will have to meet starting from (V ń2) that is ǒǸ2 @ 115ń2Ǔ. This arbitrary choice relies on the idea that for below this line voltage level the input current is relatively small and easy to filter. Check that at the high-line nominal voltage (230 V rms typically), the switching frequency stays below 65 kHz thanks to the valley-2 operation. Similarly, in a narrow mains operation case, select LP so that the switching frequency is below 65 kHz at the 3p @ Ǔ 20 ) 1 V out)V N PS f (eq. 15) ) 6p @ (V in,rms) LL 4@ ǒ V out)V N PS ^ 0.65 A 16 Ǹ2 @ 90 6p @ 90 2 ) ^ 350 mA 3p @ 6 @ 21 4 @ (6 @ 21) 2 We selected transformer 750871144 from Wurth Elektronik with the following characteristics: LP = 1.9 mH, nP / nAUX = nP / nS = 6. www.onsemi.com 6 Ǔ 2 2 (eq. 16) f (eq. 17) (eq. 18) AND9451/D Power Switches a circuit requires a diode, a resistor and a capacitor (DC , RC and CC of Figure 2): • The capacitor CC absorbs the leakage inductor energy when the MOSFET turns off. The voltage rating of this capacitor must be equal to the MOSFET breakdown voltage or higher. Note that similarly to the snubber capacitor, the CC negative terminal should preferably be connected to the MOSFET source rather than to ground. • The resistor RC loads CC to ensure that the CC voltage does not drift up but stabilize at a level which ensures a proper MOSFET protection (the MOSFET voltage is clamped to the CC voltage by means of DC ). • The diode DC prevents CC from discharging when the MOSFET turns on. This diode is generally a fast-recovery diode. A low-value resistor (R14 of Figure 9) is inserted to limit the current spike which otherwise occurs when the MOSFET turning off, CC abruptly charges. Do not oversize this series resistor. The leakage current flowing through it creates a voltage drop. The MOSFET voltage is clamped to the CC voltage PLUS the series resistor voltage. In our case, the maximum leakage current is (V ILIMńR sense) that is (1Vń1.5W ^ 667mA). In our design, a 22 W resistor is implemented that results in an overshoot less than (22W @ 0.667 ^ 17V). MOSFET The voltage constraints on the MOSFET have been discussed in the transformer section. Conduction losses depend on the MOSFET rms current which can be computed with the following equation: (P in,avg) max (I Q,rms) max + 2 Ǹ3 (V in,rms) LL Ǹ 1) 8 Ǹ2 @ (V in,rms) LL 3p @ V out)V N f PS (eq. 19) A NDD03N80 MOSFET is selected (DPAK, 800 V, 4.5 W). Output Diode Similarly, the voltage constraints have been discussed in the previous section. Losses are mainly produced by the average current flowing through the diode. This average is simply the LED current (0.5 A in our case). A 200-V, 2-A SMB diode is selected (MURS220). Snubber and Clamping Network A snubber capacitor can be placed across the MOSFET to reduce the dV/dt and lower the switching noise. A 47-pF, 1,000-V capacitor is placed in our application (C2 of Figure 9). Note that for optimal operation, it is recommended to connect the snubber capacitor between the MOSFET drain and source terminals rather than between drain and ground. When the MOSFET turns off, the magnetizing inductor energy is conveyed to the secondary side and charges the output. The leakage inductor current cannot be used by the output. It must be diverted from the MOSFET. If not, the MOSFET drain-source voltage would rise to destructive levels. A clamping network is hence necessary. Such (1)k c )@(V )V ) f out(OVP) N PS ER + @ Eq. 7 gives the maximum voltage (1 ) k c)(V out(OVP) ) V f) Ǹ2 @ (V in,rms) HL ) N PS the MOSFET must sustain. This voltage is the CC maximum voltage. Hence, the energy that RC can consume and re-inject to the input over a switching cycle is given by: ǒ ǒ Ǔ (1)k c )@(V )V ) f out(OVP) N PS Ǔ ) Ǹ2 @ (V in,rms) HL @ T SW (eq. 20) RC C The energy due to the leakage inductor must be handled. V ILIM It is maximal when the primary current exceeds its R sense limit where VILIM is the over-current protection threshold and Rsense , the current sense resistor: ǒ Ǔ ǒ V ILIM EL + 1 L leak leak 2 R sense Ǔ@ 2 (1)k c )@(V )V ) f out(OVP) N PS (1)k c )@(V )V ) (V )V ) f f out(OVP) out(OVP) * N N PS PS + This energy of Eq. 20 must be equal or higher than the leakage inductor energy defined in Eq. 21. From this, we can deduce the following minimum RC value: (V RC v )V ) f out(OVP) N PS @ ǒ (1)k c )@(V 1 2@k )V ) f out(OVP) N PS C L leak ǒ V ILIM R sense Ǔ @ f SW www.onsemi.com 7 ) Ǹ2 @ (V in,rms) HL 2 ǒ 1 ) kC V ILIM L 2 @ k C leak R sense Ǔ 2 (eq. 21) Ǔ (eq. 22) AND9451/D Ǹ Select the CC capacitor so that the time constant (RC ⋅ CC ) is large compared to a switching period, practically, in the range of 1 ms. Since in our application, we have selected (kC = 80%), it comes: RC v 28 @ 6 ǒ(180% @ 28 @ 6) ) Ǹ2 @ 265Ǔ 1 2@80% 2 1 Ǔ 20m ǒ1.5 @ 65k ȡ ȧǒ Ȣ C out,min + ^ 315 kW (180% @ 28 @ 6) 2 ^ 290mW 315k Two 470 kW, 1/2W resistors are placed in parallel for the following effective resistance: (470 k || 470 k = 235 kW). A 4.7 nF/100 V capacitor is implemented for CC that with RC forms a 1.1 ms time constant. This resistor will dissipate The power delivered by PFC converters exhibits a large ac component at twice the line frequency. To some extend, the output capacitor compensates for it but yet, the output current exhibits some ripple inversely proportional to the capacitor value (Cout ). Below equation expresses the current ripple: C out,min + Ǹ S 2 @ (eq. 26) Ǹǒ Ǔ *1 2 2 1 2 @ 100p @ 6 ^ 460 mF (eq. 27) A 470 F/35 V is implemented. Bulk Capacitor Heating: It must also be checked that the ESR is low enough to prevent the rms current that flows through it, from overheating the bulk capacitor. This capacitor rms current can be estimated using the following expression. From Eq. 24, the following minimum value for Cout can be deduced (Eq. 25): P (eq. 25) 4p @ f line,min @ R LED,min In our application the minimum LED dynamic resistance is estimated to be 6 W and the minimum line frequency is 50 Hz. In this case, the minimum output capacitor value is: (eq. 24) ȡ32 Ǹ2 n ȧ 9p @ ǒn Ǔ Ȣ pk*pk I out,nom (DI out) pk*pk +1 I out,nom Output Capacitor (I C,rms) max + 2 DI outǓ Cout must then be large enough to avoid an excessive current ripple which could reduce the LED reliability. The flicker index is commonly specified below 0.15. This requirement corresponds to a 100% peak-to-peak ripple in a PF-corrected LED driver with a sinusoidal output current shape This criterion (100% peak to peak ripple), leads to: (eq. 23) (DI out) pk*pk 2 + I out,nom Ǹ1 ) (4p @ fline @ R LED @ C out)2 2 ȣ ȧ*1 Ȥ (P in,avg) max V in,rms @ 2 V out)V N PS ȡ 9p V ȣȣ ȧ1 ) 16 Ǹ2 @ ȧȧ*I Ȣ ȤȤ 2 f in,rms V out)V f N PS out,nom 2 (eq. 28) It remains wise to check the output capacitor heating in the lab. STEP 2: OUTPUT CURRENT SETTING As explained in the data sheet, the output current is regulated to equal the following Iout,nom nominal output current: V REF I out,nom + 2N PSR sense R sense + V REF 2N PSI out,nom (eq. 30) The power dissipated by Rsense can be computed by the following equation: (eq. 29) ǒ Ǔ ȡȧ P in,avg P Rsense + 4 R sense 3 V in,rms Where: • NPS is the secondary to primary transformer turns ratio NPS = nS / nP • Rsense is the current sense resistor (see Figure 2) • VREF is the output current internal reference. In our application: • NPS = 1/6 • Iout,nom = 500 mA • (Pin,avg )max = 12 W • (Vin,rms )LL = 90 V • Vout,min = 10 V Hence once the transformer is designed, NPS is known and the only current sense resistor dictates the output current level. www.onsemi.com 8 2 1) Ȣ ȣ ȧ (eq. 31) Ȥ 8 Ǹ2 @ V in,rms V out 3p @ N PS AND9451/D Hence: R sense + 10 *3 250 @ + 1.5 W 2 @ 16 @ 500 @ 10 *3 And: ǒ Ǔ P Rsense + 4 1.5 12 90 3 2 ǒ 1) Ǔ 8 Ǹ2 @ 90 10 3p @ 1ń6 R S2 @ Ǹ2 (V in,rms) BOH + V BO(on) R S1 ) R S2 (eq. 32) Where VBO(on) is the internal threshold (1 V typically) the VS pin voltage must exceed to allow circuit operation. In other words, ^ 100 mW R S1 + R S2 (eq. 33) Input Voltage Sensing and Feedforward: A portion of the input voltage must be applied to the VS pin to provide the circuit with the sinusoidal reference necessary for shaping the input current (PFC). The obtained current reference is further modulated so that when averaged over a half-line period, it is equal to the output current reference (VREF ). This averaging process is made by an internal Operational Trans-conductance Amplifier (OTA) and the capacitor connected between the COMP pin (pin3) and ground. The recommended minimum COMP capacitance is 1 mF. R S1 + 47 @ 10 3 @ (eq. 35) ǒ Ǔ Ǹ2 @ 81 *1 [ 5.4 MW 1 (eq. 36) Feedforward The NCL30188 computes the current setpoint (Vcontrol ) for power factor correction and proper regulation of the LED current. Now, the MOSFET cannot turn off at the very moment when the current-sense voltage exceeds Vcontrol . There actually exists a propagation delay tprop (Figure 5) for which the primary current keeps rising. As a result, the primary current does not exactly peak to the expected (Vcontrol / Rsense ) value but to a higher level. The output current is hence also affected. Optimal regulation performance requires the peak current increase caused by tprop to be compensated. Input Voltage Sensing A resistors divider (RS1 and RS2 of Figure 2) provides pin 2 with the VS signal. The scale-down factor is computed in accordance with the brown-out protection. If (Vin,rms )BOH is the targeted minimum line rms voltage necessary for entering operation, RS1 and RS2 must comply with: Rsense Ǔ Ǹ2 @ (V in,rms) BOH *1 V BO(on) It is generally recommended not to have a single resistor placed between a high-voltage rail and a low potential node. Instead, two or more resistors are to be placed in series. In our case, we use two 2,700 kW resistors for RS1. COMP Pin Capacitor A 1 mF capacitor is to be placed between COMP pin and ground. Vcontrol ǒ RS2 values in the range of 50 kW generally provide a good tradeoff between losses and noise immunity. In our application, we select 47 kW. Our system being supposed to enter operation when the line voltage exceeds 81 V rms: Two 3 W resistors are placed in parallel. IL (eq. 34) DIL,pkH High Line DIL,pkL Low Line tprop tprop Figure 5. Propagation Delay Effect on Peak Current www.onsemi.com 9 time AND9451/D However, for a first approximation, we can calculate RLFF, using tprop = 200 ns. Then, the offset resistor value can be fine-tuned on the bench so that the output current characteristic is nearly flat over the line voltage range. Using Eq. 39, we can calculate the first value of RLFF for our design: The NCL30188 compensates for the propagation delay by sourcing a current proportional to the VS pin voltage out of the CS pin during the on-time. Placing a resistor RLFF between the CS pin and the sense resistor, the following offset is hence obtained: V CS(offset) + K LFF n S (t)R LFF (eq. 37) Where the VS pin voltage vS (t) equates: n S(t) + R S2 n (t) R S1 ) R S2 in ǒ R LFF + 1 ) (eq. 38) ǒ R S1 R S2 Ǔ t L RK prop P Sense LFF prop P Sense LFF Ǔ + 1 ) 5400 200n 47 1900m Ǔ R LFF + 1 ) Ǔ t L RK ǒ Since the CS pin offset must compensate for R sense @ n in(t) @ t prop R sense @ DI L,pk + , the offset resistor LP value can be computed as follows: ǒ R S1 R S2 + (eq. 40) 1.5 ^ 915W 20m After experiments in the lab, RLFF value was decreased to 820 W. Important Note: As indicated in the NCL30188 data sheet, RLFF must be selected higher than 250 W. If not, the circuit may improperly detect that the CS pin is grounded. (eq. 39) Where: • KLFF is the VS pin voltage to CS pin current conversion ratio. Its typical value is 20 mS. • RS1 and RS2 are the input voltage sensing resistors (see Figure 2). Selecting the CS Pin Capacitor The shape of the current-sense voltage influences the output current regulation. If the CS pin filter (RLFF, CCS ) is too big, the output current setpoint will vary (Iout higher than expected value). Thus, once RLFF has been chosen, it is important to keep the value of CCS as small as possible to have an optimal output current regulation. CCS should be in the range of 10–100 pF. Finally: (see Table 3) Parameter tprop includes the controller internal delay of the controller (about 50 ns) and the MOSFET turning off time. Thus, it varies with respect to the chosen MOSFET and the way it is driven (value of the gate resistors for instance). As a consequence, it is difficult to predict its exact value prior to evaluating the LED driver design. Table 3. RS1 RS2 CCOMP RSENSE RLFF CCS 5400 kW (two 2.7 MW placed in series) 47 kW 1 mF 1.5 W (two 3 W resistors in parallel) 820 W − • The output current value depends on the sense resistor NCL30188 proprietary regulation technique ensures a very precise LED current control. Please note that sources of deviation are however to be considered. They are detailed in [3]. Let’s recall the main points: • The NCL30188 regulates the total current provided by the converter, that are, the LED current plus the VCC current. Hence, the actual output current is: I out,nom + In general, the N N P @ V REF * Aux I CC NS 2 @ N S @ R sense ǒNN Aux S • (eq. 41) (Rsense ). Select a precise resistor and avoid long tracks that lead to an additional series resistance. If Rsense is 1 W and that the circuit additionally senses the voltage across a 20 mW track, the total sensing resistor will be 1.02 W instead of 1 W. Ultimately, the output current will 2% below target. Avoid inductive sense resistor. If not, the output current will be less than the target because of the offset the series inductor causes on the CS pin voltage: l Rsense @ n in(t) where l Rsense is the Rsense parasitic LP inductance. ǒ Ǔ I CC term is small compared to the target LED current and can be ignored. If not, Rsense should be reduced to compensate for the circuit consumption. www.onsemi.com 10 Ǔ AND9451/D STEP 3: SD PIN MANAGEMENT The Thermal Foldback and Shutdown block of the NCL30188 is inherited from the NCL30082 and its functioning and design is detailed in application note AND9131/D ([2]). Only key points will be highlighted here. voltage at a low enough level. This is not the case in our application. No Zener diode is hence implemented. Selecting the Thermistor The resistance of a Negative Coefficient Temperature thermistor (NTC) reduces when its temperature rises. An NTC is to be placed between the SD pin and ground to detect an over-temperature condition. In response to a high temperature, the circuit gradually reduces the LED current down 50% of its nominal value. If despite the current reduction, the temperature still increases, the circuit will eventually stop operation. In general a 50% reduction in current is more than a 50% drop dissipated power as the LED forward voltage will decrease as the current is folded back. More specifically, as shown by Figure 6, Rth designating the NTC resistance: • The circuit starts to gradually reduce the output current when Rth drops below RTF(start) and continues diminishing it until Rth goes below RTF(stop). • At that moment, it maintains the output current at 50% of its nominal level as long as Rth is between RTF(stop) and ROTP(off). If on the contrary, a temperature decay leads Rth to rise above RTF(stop), the current increases according the precedent characteristics. If Rth exceeds RTF(start), full current capability is recovered. • The LED driver totally stops operating if Rth drops below ROTP(off) and stays off until the temperature having reduced, Rth exceeds ROTP(on). At that moment, the circuit resumes (NCL30188B only – the A version latches off) and delivers 50% of the nominal current. • If Rth further rises, the current regulation grows as well until Rth reaches RTF(start). At that moment, the LED driver provides the full current. Selecting the SD Over-voltage Zener Diode A Zener diode can be placed between the VCC and the SD pins. The circuit detects an OVP fault if the SD pin voltage exceeds 2.5 V. Note that the NCL30188 ensures that a 700 mA minimum current flows through the Zener diode in this case (see [1]) so that it can be operated far from its knee region. The SD OVP threshold on VCC is: (V CC) SD,OVP + V Z ) V OVP (eq. 42) Where VOVP is the 2.5-V SD OVP threshold. An SD OVP fault is detected if VCC exceeds (VCC )SD,OVP. For instance, if you applied a Zener diode exhibiting an 18 V Zener breakdown voltage (when biased by a 700 mA current), the SD_OVP protection will trip when VCC exceeds (18.0 + 2.5) volts, that is, 20.5 V. In this case, the NCL30188B stops operating for the auto-recovery 4 s delay. At the end of this time, the circuit attempts to resume operation. If the fault is still present, the circuit again detects an SD OVP fault and stops for 4 s. Finally, the NCL30188B enters a safe, very low duty-ratio burst mode. An SD OVP fault leads the NCL30188A to latch off until the LED driver is unplugged and VCC drops below VCC(reset). At that moment, the fault is cleared and the circuit can resume operation. Such a programmable protection feature is useful if the fixed VCC OVP protection which trips when VCC exceeds VCC(OVP) (26.8 V typically) does not clamp the output Figure 6. Thermal Foldback Characteristics and Over-temperature Protection www.onsemi.com 11 AND9451/D capacitor must not exceed 4.7 nF so that it can charge to its nominal level before the OTP blanking time has elapsed. NOTE: At start-up, the controller blanks the SD function until a delay of 250 ms minimum (OTP blanking time), has elapsed, to provide CSD with enough time to properly charge above the 0.5 V over-temperature threshold. If not, the low SD pin voltage will be considered as caused by the low-resistance of an NTC in excessive temperature conditions. As an example, if thermistor NB12P00104JBB from AVX is implemented: • The circuit starts to reduce the output current at about 82°C ambient temperature. • The circuit stops operation at about 104°C ambient temperature. • The circuit recovers operating at about 90°C ambient temperature. Selecting the SD Pin Capacitor A small capacitor can be placed between the SD pin and ground to prevent the pin from picking up possible surrounding noise. Please note that the value of this Finally: (see Table 4) Table 4. DZ Rth CSD N/A NB12P00104JBB (AVX) 1 nF STEP 4: AUXILIARY WINDING AND VCC MANAGEMENT VCC Capacitor Refueling VCC Capacitor Value and Startup Circuitry In nominal operation, the auxiliary winding provides the VCC voltage as shown by Figure 2. The auxiliary winding number of turns (naux ) is computed in the transformer section of the “Step 1” paragraph. Note that during the on-time, diode DAUX of Figure 2 rectifies the auxiliary voltage to provide VCC . Hence, neglecting the turn on spike, DAUX must be able to sustain: VD AUX + V CC ) ǒnn AUX P @ Ǹ2 @ (V in,rms) HL Ǔ When off (that is until VCC has reached the 18-V start-up level), the NCL30188 consumes a very low current (13 mA typically, 30 mA maximum). Thus, high-impedance, low dissipation, resistors can be used to charge the VCC capacitor at start-up. Note however, that faults like a VCC over-voltage condition lead the LED driver to stop operation and refrain from attempting to recover until a 4 s delay is elapsed. A low duty-ratio burst mode of operation is hence obtained as long as the fault is present. VCC cycles up and down in such a case. For this time, the (off-mode) consumption is slightly higher (75 mA max.). It is hence recommended to have the startup current (Istartup in Figure 7) above 75 mA. If not, VCC may collapse and the circuit reset before the 4 s delay has elapsed. As detailed in application note AND9131/D [2], the startup resistor Rstartup can either be connected to the bulk rail or to half-wave (Figure 7). Connecting the startup resistor to the half-wave allows decreasing the power dissipated in the startup resistor. (eq. 43) The VCC highest value is the maximum voltage the VCC(OVP) threshold can take (28.5 V). Therefore: VD AUX + (V CC(OVP)) max ) ǒnn AUX P @ Ǹ2 @ (V in,rms) HL Ǔ (eq. 44) In our case: VD AUX + (V CC(OVP)) max ) ǒ ǒnn AUX P Ǔ Ǔ @ Ǹ2 @ (V in,rms) HL ^ ^ 28.5 ) 1 @ Ǹ2 @ 265 ^ 91 V 6 (eq. 45) Due to the turn on spike, some significant headroom is necessary. Selecting a diode exhibiting at least twice the computed VRRM value seems a good practice. A 250 V/0.2 A BAV21 diode is implemented in our application. www.onsemi.com 12 AND9451/D Figure 7. The Startup Resistor can be Connected to the Bulk Rail or to the Half Wave Calculating the VCC Capacitor output capacitor (no current flows through the LED string). treg lasts until the output voltage reaches the level at which VCC starts to be charged. In general, we try to minimize the CVcc capacitor by allowing a nearly maximal VCC capacitor discharge, that is, down to a value close to the UVLO level. At that moment, the output voltage will nearly be n V out + (V CC(off)) max n s and treg can then computed as aux follows: The VCC capacitor value (CVcc ) must be large enough to feed the controller until the auxiliary winding voltage Vaux is sufficiently large to supply the controller. The time duration where the controller is supplied by the only CVcc capacitor is noted treg (Figure 8). The circuit enters operation when the VCC capacitor is charged to the VCC(on) startup level. For the treg duration, the VCC capacitor must be able to maintain the VCC voltage above the UVLO level (VCC(off)) while providing the current consumed by the circuit (ICC2 specified in the data sheet) and the current necessary to drive the MOSFET. We can estimate treg by considering that for this period of time, all the LED driver output current is absorbed by the C Vcc w ǒ Ǔ t reg ^ ǒ C out n (V CC(off)) max n s aux I out Ǔ (eq. 46) Now, using the minimum value of the UVLO hysteresis (minimum value of VCC(on) − VCC(off)), the minimum VCC capacitor value comes: (I CC2 ) Q gf sw)t reg ) Q qf sw) (V CC(off)) max (I ns @ C ^ n out @ CC2 @ aux I out (V CC(HYS)) min (V CC(HYS)) min (eq. 47) • Qg is the MOSFET total gate charge • (VCC(HYS) )min is the UVLO hysteresis minimum value Where: • ICC2 is the NCL30188 consumption at 65 kHz when the DRV pin is unloaded (4 mA max) (8 V) Figure 8. VCC Waveform during Startup Once the VCC capacitor value is known, the start-up current needed to charge CVcc can be computed as a function of the maximum acceptable start-up time if specified. Recall anyway that this startup current should not be less than www.onsemi.com 13 AND9451/D 75 mA so that as explained at the beginning of this section, the circuit does not reset in fault mode. Hence: I startup + (V CC(on)) max C Vcc (V CC(on)) max C Vcc ) (I CC(start)) max if ) (I CC(start)) max w 75 mA t startup t startup (eq. 48) I startup + 75 mA otherwise Where: • (VCC(on) )max is the VCC startup threshold maximum value • (ICC(start) )max is the maximum value of the NCL30188 startup consumption (30 mA) • tstartup is the targeted startup time t reg ^ Ǔ (eq. 49) C Vcc w (I CC2 ) Q gf sw)t reg (4m ) 19n 65k)9m ^ ^ 6 mF 8 (V CC(HYS)) min (eq. 50) In our case, assuming a 19-nC gate charge MOSFET, a 65-kHz operation and a 0.5-s target for the startup time, it comes: (Eq. 49 and Eq. 50) I startup + ǒ 470 mF C out n (V CC(off)) max n s + (9.4 @ 1) ^ 9 ms aux I out 500 mA We will select a 10 mF/35 V capacitor. Hence: (V CC(on)) max C Vcc 20 @ 10m ) (I CC(start)) max ^ ) 30m + 430 mA w 75 mA t startup 0.5 Startup Resistor Calculation P startup + Bulk Connection For start-up time, the bulk rail sees the line peak voltage (the input voltage becomes a rectified sinusoid when the LED driver starts to operate), the following formula gives the Rstartup value: Ǹ2 @ (V in,rms) LL R startup + I startup ǒǸ2 @ (Vin,rms) HL*VCCǓ 2 v R startup (eq. 51) 2 @ (V in,rms) HL R startup 2 (eq. 53) Where (Vin,rms )HL is the highest line rms voltage. Half-wave Connection If the resistor is connected to the half-wave: (eq. 52) Ǹ2@(V in,rms) LL R startup1ń2 + Where: • Istartup is the startup current • (Vin,rms )LL is the lowest line rms voltage p I Cvcc ) I CC(start) + R startup p (eq. 54) The maximum power dissipated by the startup resistor connected to the half-wave is thus: The maximum power dissipated by the startup resistor connected to the bulk rail is: P startup1ń2 + ǒ Ǹ2@(V ) in,rms HL *V CC p Ǔ 2 R startup1ń2 R startup1ń2 + p I startup + 90Ǹ2 p 430m 2 (eq. 55) p In Our Application: We selected the half-wave configuration. Since we have computed that the startup current had to be 430 mA or more, we can deduce: (V in,rms) LL Ǹ2 2 (V in,rms) HL (V in,rms) HL v 22 R +2 p R startup p startup P startup1ń2 v ǒ (V Ǹ2 ) in,rms HL p R startup1ń2 Ǔ 2 + ǒ 265Ǹ2 p 94 Ǔ 2 k ^ 151 mW (eq. 57) Three 33-kW, 1/4 W resistors are placed in series. ^ 94 kW (eq. 56) The power dissipated for the startup resistor at maximum input voltage is: www.onsemi.com 14 AND9451/D ZCD Network I ZCD,dmg + RZCD1 of Figure 2 limits: • The current injected into the ZCD pin during the demagnetization time. As indicated in the data sheet, this current must remain below 5 mA. • The current extracted from the ZCD pin during the on-time. This current must not exceed 2 mA. R ZCD1 v 5mA (eq. 59) Where VCC(OVP)max is the VCC maximum value for VCC OVP protection tripping (28.5 V). For optimal output current regulation, it is recommended to keep the ZCD pin voltage below 5 V. This is the goal of RZCD2 of Figure 2. R ZCD2 (V CC,max ) V f) v 5V R ZCD1 ) R ZCD2 During the on-time, the ZCD pin current is maximal at the highest line voltage: Ǹ2 @ (V n in,rms) HL I ZCD,on + naux v 2mA R ZCD1 P V CC(OVP)max ) V f (eq. 60) Where VCC,max is the maximal VCC voltage in normal operation (20 V in our application). Finally, this resistor together with the CZCD capacitor delays the zero-voltage crossing event and helps to tune the turn-on instant when the drain voltage is in the valley. Finally: (see Table 5) (eq. 58) During the demagnetization time, the auxiliary winding voltage is maximal when VCC is at its maximum value, that is, the OVP level. Hence: Table 5. CVCC Rstartup1/2 Rstartup DAUX RZCD1 / RZCD2 CZCD 10 mF / 35 V three 33 kW, 1/4 W resistors in series N/A BAV21 33 kW / 10 kW 22 pF DETAILED SCHEMATIC FOR OUR 10 W, UNIVERSAL MAINS LED DRIVER NCL30188 Figure 9. Application Schematic www.onsemi.com 15 AND9451/D EXPERIMENTAL DATA Output Current Regulation Figure 10 shows the output current as a percentage of its nominal value. We can see that its characteristic is very flat with respect to the temperature. Thermal Foldback starts at about 80°C. As a result, the output current linearly decays to reach 50% of its nominal value at nearly 92°C. The circuit stops operating (SD pin Over Temperature Protection) at approximately 105°C and resumes operation when the temperature drops down to about 90°C. These temperature thresholds depend on the thermistor connected to the SD pin. Below characteristics were obtained with a NB12P00104JBB thermistor manufactured by AVX. 110 100 90 Iout / Iout,nom (%) 80 Start of Thermal Foldback 70 60 50 40 30 SD pin OTP activation 115 Vrms 230 Vrms 20 10 0 −40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 TEMPERATURE (°C) Figure 10. LED Current Characteristics over the Temperature Range Power Factor Figure 11 shows the power factor measured at two different line magnitudes (115 V rms and 230 V rms). The power factor is extremely stable over the considered temperature range from −40°C to 80°C. Above 80°C, the performance is affected by the thermal foldback which reduces the output current. 1.05 1.00 0.95 PF (−) 0.90 0.85 0.80 0.75 Thermal Foldback and SD pin OTP 0.70 0.65 115 Vrms 230 Vrms 0.60 0.55 0.50 −40 −30 −20 −10 0 10 20 30 40 50 60 70 80 90 100 110 TEMPERATURE (°C) Figure 11. Power Factor Performance over the Temperature Range www.onsemi.com 16 AND9451/D application discussed in this document), illustrate the circuit capability to address shorted/open situations of the LED string or an output diode failure. Application note AND9204/D discusses in details the NCL30088 behavior under safety tests [4]. The NCL30188 only differs from the NCL30088 in an increased resolution of the digital current−control algorithm. Thus, this application note also highlights the NCL30188 protection functions that help pass the safety tests. VCC VRsense Iline (100 mA/div) Open LED String Situation The LED string being disconnected, the VCC voltage rises and the VCC(OVP) protection trips when VCC exceeds 26.8 V (typically). At that moment, the circuit stops operating for the 4-s auto-recovery delay. The LED driver recovers normal operation when the LEDs are again connected. Figure 12. Current Waveform at 115 V rms Fault Situations The NCL30188 incorporates a large suite of protections. Next figures (obtained using the NCL30088B in the VCC The LED string is disconnected Iout (0.5 A/DIV) Figure 13. The System Enters a Safe Low Duty-ratio Burst Mode when the LED String is Disconnected (the LED Driver is Unloaded for about 15 s for this Test) LED String Short Situation In the case of Figure 13, the only VCC(OVP) protection is in play. Note that a Zener diode could have been placed between the VCC and SD pins to select a lower VCC threshold for fault detection (see the SD pin OVP function in the NCL30188 data sheet). Further note that if the VCC(OVP) protection is auto-recovery in all NCL30188 versions, the SD pin OVP can be a latching-off (NCL30188A) or an auto-recovery (NCL30188B) protection. As illustrated by Figure 14, if the output is shorted, the AUX_SCP protection makes the LED driver enters a safe, low duty-ratio burst mode. Normal operation is recovered when the short is removed. Note that the NCL30188A latches off when an output short is detected. No recovery is hence possible with these versions until the LED driver is unplugged and VCC drops below VCC(reset) . At that moment, the fault is cleared and the circuit can resume operation. www.onsemi.com 17 AND9451/D VCC Iout (0.5 A/DIV) The output is shorted Figure 14. The System Enters a Safe Low Duty-ratio Burst Mode when the Output is Shorted (the LED Driver Output is Shorted for about 10 s for this Test) Output Diode Short The LED driver stops operation as soon as 4 faulty DRV pulses are detected (see Figure 16). In this situation, the NCL30188B attempts to resume operation when the 4-s auto-recovery delay is elapsed. The NCL30188A remains latched off until the system is reset. Iout (500 mA/div) VCC VDS Rsense voltage Figure 15. NCL30188B Operation when the Output Diode is Shorted www.onsemi.com 18 AND9451/D Iout (500 mA/div) VCC VDS Rsense Voltage Figure 16. The Winding or Output Diode Short Circuit Protection (WODSCP) Trips as soon as 4 Consecutive Faulty DRV Pulses are Detected REFERENCES [3] Stéphanie Cannenterre, Understanding sources of LED current deviations… [4] Joel Turchi, “NCL30188 and NCL30085 Safety Tests Consideration”, Application Note http://www.onsemi.com/pub_link/Collateral/ AND9204−D.PDF [1] NCL30188 Data Sheet, http://www.onsemi.com/pub_link/Collateral/ NCL30188−D.PDF [2] Stéphanie Cannenterre, Application Note AND9131/D, Designing a LED Driver with the NCL30080/81/82/83, http://www.onsemi.com/pub_link/Collateral/ AND9131−D.PDF ON Semiconductor and are trademarks of Semiconductor Components Industries, LLC dba ON Semiconductor or its subsidiaries in the United States and/or other countries. ON Semiconductor owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. 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