AND8427/D A Constant Current Adjustable 0.7 A to 1.5 A, Up to 55 Vdc Single Stage Power Factor Corrected LED Power Supply http://onsemi.com APPLICATION NOTE Prepared by: Frank Cathell ON Semiconductor Introduction Platinum and Golden Dragon Plus. The use of these type of LEDs reduces the number of LEDs required and eliminates the need for a two stage power architecture where an offline AC−DC conversion stage is followed by multiple strings of DC−DC constant current stages. While this supply has been designed to tightly regulate a fixed current, the supply can also operate in a constant voltage mode as the current and voltage are tightly regulated based on the tightly regulated 2.5 V reference within of the NCS1002. The maximum output voltage can be adjusted via selection of a single resistor (R34 in Figure 2), however, it is compliant enough to handle approximately a 1.5:1 range depending on the summed LED forward voltage drop (Vf max), and the output current. The default current has been set at 1.5 A and can be adjusted in a range from 0.7 A − 1.5 A (R32 in Figure 2) to support the specific application needs of the end product. This application note describes an up to 90 W, off−line, isolated, single conversion stage power supply with active power factor correction (PFC) intended for LED lighting. In addition to LED drivers, the basic design concept could also be applied to constant current applications such as high power battery chargers. The power supply is designed around ON Semiconductor’s NCL30001 single stage, continuous conduction mode (CCM) PFC controller and the NCS1002 secondary side, constant voltage, constant current (CVCC) controller. The specific LED applications in the 40 W − 125 W range that can be addressed by the NCL30001 include end products such as street lights, refrigerator case lightning, low bay lighting, down lights and wall packs. The high current capability of this driver targets LEDs such as the Cree XLamp™ XP−G, Seoul Semiconductor P7, Bridgelux 800 and 1200 lumen LED Arrays, and OSRAM Target Specifications: Universal Input: 90 − 265 Vac / 47−63 Hz Can support 277 Vac (305 Vac max) with minor component value/rating changes Power Factor: > 0.9 (50 − 100% of load) Harmonic Content EN61000−3−2 Class C Compliance Efficiency > 87% at 50−100% of 50 W, Iout = 1.5 A / Vf = 45 Vdc Pout Maximum: 90 W Vout max Range: 28 − 58 V (default − 52 V, resistor adjustable) Constant Current Output Iout Range: 0.7 − 1.5 A (default − 1.5 A, resistor adjustable) CC Vout Compliance 50% to 100% of Vout max. Current Ripple: 20% max p−p (dependent on Cout and Iout) Current Tolerance $3% or better Cold Startup < 500 msec typical to 50% of load Protection: Short Circuit Protection Open Circuit Protection < 60 V peak (within UL Class 2) Over Current Protection − Auto recovery The NCL30001 has a robust suite of protection features. In addition optional protection for latched over temperature and over voltage protection can be implemented. © Semiconductor Components Industries, LLC, 2010 May, 2010 − Rev. 2 1 Publication Order Number: AND8427/D AND8427/D Primary Side Circuitry the exception of the VCC regulator circuit for the NCL30001. Components Q3, Z3, and R4 form a simple 15 V regulator to prevent VCC overvoltage due to the wide output compliance voltage that is reflected back to the auxiliary VCC winding. The primary circuitry is composed of the NCL30001 Continuous conduction mode flyback converter and associated control logic, input EMI filter, and Vcc “housekeeping” circuitry (see Figure 1). This circuitry is identical to the primary circuitry shown of AND8397 with L1A MRA4007T C3 0.1uF 600V L1B R7 D5 R2 560K 0.5W R6 365K R10 R11 365K R9 30.1K 332K R8 2K 1/2W 365K 5 MURS 160T Z3 6 C6 C5 100uF MMSZ5245B 220uF D7 1 50V 35v MURS R5 160T 220 11 C10 1nF R13 + C11 4.7uF 25V C12 470pF Z2 C13 33nF D6 2.2K 0.5W C8 0.1 Q1 SPP11N80C3 R23 4.7 ohm 12 11 10 9 R22 10K D9 R16 TBD MMSD 4148 100K C29 0.1 2.2K R15 R14 10K C9 R4 U1 13 6 7 8 20K Q2 7.32K R12 30.1K R25 C14 R17 10nF 56K Notes: 1. Crossed schematic lines are not connected. 2. Heavy lines indicate power traces/planes. 3. Z2/D9 is for optional OVP (not used). 4. L1A/B are Coilcraft PCV−0−224−03L or equivalent. 5. L2 is Coilcraft P3220−AL or equivalent. 6. Q1 and D8 will require small heatsinks. T1 8 16 15 14 NC R18 49.9K C28 1uF C7 100nF 2 400V NCL30001 1 2 3 4 5 Q3 D10 C4 22uF 450V R3 36K 3W MMBTA06LT1G SFH615A−4 U2 4 1 3 2 R21 C15 C16 C17 C18 0.1 0.1 10nF 1nF R19 76.8K Z1 MRA4007T 0.47 ”X” 0.47 ”X” 1M 0.5W D1 − D4 1N5406 x 4 C2 1.5KE440A L2 C1 R1 MMBTA06LT1G AC In F1 2.5A 680pF J1 10 ohm R20 0.10 ohm 0.5W C27 NCL30001 CVCC, 90 Watt Power Supply Primary Control Side Schematic (Rev 2) Figure 1. Primary Side Circuit Schematic http://onsemi.com 2 AND8427/D Secondary Side Control Circuitry The schematic of Figure 2 shows the secondary side circuitry responsible for the CVCC feedback control and associated circuitry. Xfmr + 1000uF, 63V x 3 LED Anode 8 R24 C21 + C22 C24 + C23 1nF 56, 1/2W 11 + C20 + C19 0.1 0.1 100V D8 R26 MUR1640CTG MJD243G R28 U2 feedback C25 R29 1 D11 − 7 Z4 MMSZ5245B C30 1uF C31 Is + Vs R36 6 U3B optocoupler 0.1 R31 2.7K 8 MMSD4148 C34 Is 1uF 20K 2 LED Cathode − 4.7K, 0.5W Vcc = 14V 2.2K 0.10 0.5W R27 Q4 J2 100V 2.7K 1nF 5 NCS1002 C26 0.1 R30 D12 1 MMSD4148 R32 43K 13K − U3A 4 + 2 R33 6.2K R34 82K 2.5V C35 Vref 3 0.1 internal To Primary Ground Plane C27 R35 3.9K C32 to U3 10nF GND 2.2nF LED CVCC Driver Secondary Circuit (Rev1) Figure 2. Secondary Side Control Schematic, Iout = 1.5 A (R32 = 43k) CVCC Feedback and Control Current control is achieved by sensing the output current through R26 and presenting this sense signal to U3B where it is compared to a scaled down value of the 2.5 V internal reference. Because the right hand side of current sense resistor R26 is connected to the secondary logic ground (or common), the sense node on the left hand side of the resistor will go negative with increasing current. The current sense divider network of R31 and R32 is biased up on the low side of R32 by the 2.5 V reference such that when pin 5 of U3B drops to zero, this amplifier becomes dominant and controls the loop (note that the inverting input is grounded via R36.) So the output over−current threshold level is set by adjusting R31 and R32 such that the voltage level presented at pin 5 of U1 at no output load is exactly the voltage drop that will appear across R26 at maximum desired current. In this design example the maximum current is set at 1.5 A, so there must be 150 mV of bias at pin 5 under no output load. Frequency compensation (bandwidth) of the current amplifier is set by R29 and C25. Voltage and current regulation are achieved by utilizing ON Semiconductor’s NCS1002 secondary side CVCC controller. This chip contains two precision op−amps and an internal 2.5 V reference and is housed in a compact 8 pin SOIC package. The reference is internally connected to the non−inverting input of one of the op amps. Referring to the schematic of Figure 2, this latter op−amp is used for voltage control (U3A). The power supply output is sensed through resistor divider R34 and R35 and presented to the inverting input of this op−amp section. The resistors are selected so as to provide 2.5 V to pin 3 when the output is at the desired maximum voltage (around 55 V in this case). Frequency compensation is provided by R/C network R30 and C26. Since both amplifier outputs are “OR ed” via diodes D11 and D12 to drive the optocoupler U2, the amplifier with the lowest output is dominant; hence CVCC control and mode transitions between CV and CC are smooth with no interaction between the op−amps. http://onsemi.com 3 AND8427/D Secondary VCC Regulator The efficiency was impacted most by the nature of the output rectifier D8. In this case an ultra−fast device showed improved efficiency over the soft−recovery, ultra−fast part due to the lower Vf of the diode. For 120 Vac input only applications, further efficiency improvement can be achieved by the use of a 200 V Schottky diode and optimization of snubber network R24 and C19. Since the VCC to run the secondary side circuitry is derived from the main output capacitors, this voltage can vary due to series LED diode Vf compliance, and with the nominal adjusted level of the output voltage. In order to keep the VCC voltage for U3 and the associated circuitry stable, a simple linear regulator composed of Q4, Z4, and R27. This prevents the secondary VCC from exceeding approximately 15 V. This is well below the maximum 32 V capability of the NCS1002. Power Factor The power factor was highest with 120 Vac input nominal and was 0.98 or higher for any of the 4 current level outputs. At 230 Vac input, the power factor was minimum at 0.93 for the 0.7 A output current level. Plots of the line current envelope with a 1 A Constant Current load are shown in Figures 3 and 4. Test Results and Plots Efficiency: Efficiencies were measured with a normalized output voltage of 45 V using an electronic LED load simulator. Iout (CC) 120 Vac input 230 Vac input 1.50 A 87% 87.5% 1.25 A 87% 87.5% 1.00 A 86% 86.5% 0.70 A 85.5% 86.0% Figure 3. Line Current Envelope; 120 Vac input, 1 A output (PF = 0.98) Figure 4. Line Current Envelope; 230 Vac input, 1 A output (PF = 0.97) Output Current Ripple and 700 mA output, respectively. The ripple amplitude is directly proportional to dc output current and the output capacitance. The 120 Hz output current ripple was highest at 250 mA peak−to−peak (17%) with max rated load (1.5 A). The ripple profiles are shown in Figures 5 and 6 below for 1.5 A output http://onsemi.com 4 AND8427/D Figure 5. Output Current Ripple at 1.5 A CC Load Figure 6. Output Current Ripple at 700 mA CC Load Output Turn−on Profiles control loop is not damped sufficiently. Figures 7 and 8 show the output current turn−on profiles for 1.5 A and 700 mA CC loads, respectively. Scale is 500 mA per division vertical. Power factor corrector circuits necessarily require low bandwidth feedback loops in order to facilitate high power factor. As such, turn−on overshoot can be problematic if the Figure 8. Turn−on Profile; 700 mA Load Figure 7. Turn−on Profile; 1.5 A Load Current Regulation with Vout Compliance Voltage forward voltage drop can vary depending on number of LEDs in series, LED binning, LED color (die type), nominal operating dc current level, and ambient temperature. As can be seen in the plot, the current regulation is very tight. Figure 9 shows the output current regulation with respect to the output voltage compliance range which simulates different total Vf levels for series strings of LEDs. This total http://onsemi.com 5 AND8427/D 1.1 Output Current (A) 1.0 0.9 0.8 0.7 0.6 R32 = 68k 0.5 30 33 36 39 42 45 48 51 54 57 60 LED Forward Voltage (Vdc) Figure 9. Current Regulation versus Vf Output Compliance Voltage Final Comments components have been sized for 305 Vac operation. The only components that would need to be changed to support 277 Vac (305 Vac max) are the “X” capacitors C1 and C2 in the primary circuitry and secondary side output rectifier D8 changed to a higher PRV rated device such as the MUR1660CTG or the MURH860CTG. This compact single stage power factor corrected constant current LED driver is ideal for general and architectural lighting. With minor changes to resistors (R32 and R34) in the secondary control circuit, the regulated current and voltage can be adjusted to meet the specific applications requirements of the end product. The transformer and power dBuV NCL30001 120 Vac 50 Watt LED Load 100 90 80 EN 55022; Class A Conducted, Quasi−Peak 70 EN 55022; Class A Conducted, Average 60 50 40 30 20 10 Average 0 1 10 5/18/2010 9:53:09 AM (Start = 0.15, Stop = 30.00) MHz Figure 10. Conducted EMI Plot (average) – 50 Watt Load http://onsemi.com 6 AND8427/D BILL OF MATERIALS Designator Qty Description D5, D10 2 D1, D2, D3, D4 Value Tolerance Footprint Manufacturer Manufacturer Part Number Diode SMA ON Semiconductor MRA4007T 4 Diode axial lead ON Semiconductor 1N5406 D6, D7 2 Ultrafast diode SMB ON Semiconductor MURS160 D9, 11, 12, 13 4 Signal diode SOD123 ON Semiconductor MMSD4148A D8 1 UFR diode TO−220AB CT ON Semiconductor MURH860CTG Z1 1 TVS Z3, 4, 5 3 Zener diode 15 V 5% SOD123 ON Semiconductor MMSZ5245B Z2 − Zener diode Not Used 5% SOD123 ON Semiconductor − Q5 1 MOSFET 40 V, 100 mA SOT23 ON Semiconductor 2N7002KT1G Q7 1 MOSFET 100 V, A DPak4 ON Semiconductor NTD12N10T4G Q1 1 MOSFET 11 A, 800 V TO−220 Infineon SPP11N80C3 Q2, Q3, Q6 3 BJT 60 V, 500 mA SOT23 ON Semiconductor MMBTA06LT1G Q4 1 BJT 100 V, 4 A DPak4 ON Semiconductor MJD243G U1 1 PFC controller SOIC16 ON Semiconductor NCL30001 U2 1 Optocoupler 4 pin SMD Vishay H11A817 or SFH6156A−4 U3 1 Dual amp + zener SOIC−8 ON Semiconductor NCS1002 C1, C2 2 X caps 0.47 mF, 277 V 10% LS=15mm Evox Rifa/Kemet or EPCOS PHE840MB6470MB16R17 or B32922C3474M C27 1 Y2 cap 2.2 nF, 1 kV 10% LS=10mm Evox Rifa/Kemet PME271Y422M or P271HE222M250A C3 1 Polyprop. Film 0.22mF (630V) 10% LS=24mm Vishay 2222 383 20224 C7 1 Disc cap 68 to 100 nF, 400V 10% LS=10mm TDK FK22X7R2J104K C8, 15, 16, 25, C26, C29, C33 7 ceramic cap 0.1 mF, 50 V 10% 1206 TDK C3216X7R2A104K C23, C24 2 ceramic cap 0.1 mF, 100 V 10% 1206/1210 TDK C3216X7R2A104K C28, C30 2 ceramic cap 1.0 mF, 25 V 10% 1206 TDK C3216X7R1H105K C19 1 ceramic disc cap 1 nF, 1 kV 10% LS = 8 mm TDK CK45−B3AD102KYNN C12 1 ceramic cap 470 pF, 50 V 10% 1206 Vishay VJ1206A471JXACW1BC Input transient option axial lead 1.5KE440A C9 1 ceramic cap 680 pF, 50 V 10% 1206 Kemet C1206C681K5GACTU C10, C18, C31 3 ceramic cap 1 nF, 100 V 10% 1206 Kemet C1206C102K1RACTU C14, C17, C32 3 ceramic cap 10 nF, 50 V 10% 1206 TDK C3216COG2A103J C13 1 ceramic cap 33 nF, 50 V 10% 1206 TDK C3216COG1H333J C5 1 electrolytic cap 100 mF, 35 V 10% LS=2.5mm UCC ESMG350ELL101MF11D C11 1 electrolytic cap 4.7 mF, 25 V 10% LS=2.5mm UCC ESMG250ELL4R7ME11D C6 1 electrolytic cap 220 mF, 50 V 10% LS = 5mm UCC ESMG500ELL221MJC5S C20, 21, 22 3 electrolytic cap 1000 mF, 63 V 10% LS = 8 mm Nichicon 647−UVR1J102MHD C4 1 electrolytic cap 22 mF, 450 V 10% LS = 5 mm Nichicon 647−UVY2W220MHD C34,C35 2 ceramic cap 0.1 mF, 50 V 0.1 1206 TDK C3216X7R2A104K R4 1 0.5W resistor 2.2K 10% axial lead Vishay NFR25H0002201JR500 R1 1 0.5W resistor 1M, 0.5W 10% axial lead Vishay CMF601M0000FHEK http://onsemi.com 7 AND8427/D Designator Qty Description Value Tolerance Footprint Manufacturer Manufacturer Part Number R8 1 0.5W resistor 2K, 0.5W 10% axial lead Vishay CMF552K0000FHEB R2 1 0.5W resistor 560K 10% axial lead Vishay HVR3700005603JR500 R27 1 0.5W resistor 4.7K − 5.0K 5% 1210 Vishay CRCW12104K70JNEA R24 1 0.5W resistor 100 ohms 10% axial lead Vishay CMF50100R00FHEB R20, R26 2 0.5W resistor 0.1 ohms 5% LS = 18 mm Ohmite WNCR10FET R3 1 3 or 5W resistor 36K to 39K 10% LS = 30 mm Ohmite PR03000203602JAC00 R23 1 0.25W resistor 4.7 ohms 5% 1206 Vishay/Dale CRCW12064R75F R5 1 0.25W resistor 220 ohms 5% 1206 Vishay/Dale CRCW1206220RF R38 1 0.25W resistor 100 ohms 5% 1206 Vishay/Dale CRCW1206100RF R21, 41, 42, 43 4 0.25W resistor 10 ohms 5% 1206 Vishay/Dale CRCW120610R0F R15, R28 2 0.25W resistor 2.2K 5% 1206 Vishay/Dale CRCW12062211F R31, R36 2 0.25W resistor 2.7K 5% 1206 Vishay/Dale CRCW12062741F R29,R30 2 0.25W resistor 43.2K 0.01 1206 Vishay/Dale R25 1 0.25W resistor 20K 1% 1206 Vishay/Dale CRCW12062002F R32 1 0.25W resistor 68K 1% 1206 Vishay/Dale CRCW12066812F R33 1 0.25W resistor 6.2K 1% 1206 Vishay/Dale CRCW12066191F R37 1 0.25W resistor 5.1K 1% 1206 Vishay/Dale CRCW12065111F R34 1 0.25W resistor 82K 1% 1206 Vishay/Dale CRCW12068252F R35 1 0.25W resistor 3.9K 1% 1206 Vishay/Dale CRCW12063921F R14, 22, 39, 40 4 0.25W resistor 10K 1% 1206 Vishay/Dale CRCW12061002F R13 1 0.25W resistor 7.32K 1% 1206 Vishay/Dale CRCW12064322F R9, R12 2 0.25W resistor 30.1K 1% 1206 Vishay/Dale CRCW12063012F R17 1 0.25W resistor 56K 1% 1206 Vishay/Dale CRCW12065622F R18 1 0.25W resistor 49.9K 1% 1206 Vishay/Dale CRCW12064992F R19 1 0.25W resistor 76.8K 1% 1206 Vishay/Dale CRCW12067682F R16 1 0.25W resistor 100K 1% 1206 Vishay/Dale CRCW12061003F R10 1 0.25W resistor 332K 1% 1206 Vishay/Dale CRCW12063323F R6, 7, 11 3 0.25W resistor 365K 1% F1 1 Fuse 2.5A, 250Vac L1A/B 2 L2 1206 Vishay/Dale CRCW12063653F TR−5 Littlefuse 37212500411 EMI inductor Slug core Coilcraft PCV−0224−03L 1 EMI inductor Toroid Coilcraft P3220−AL T1 1 Flyback xfmr custom WE−Midcom (Wurth Electronics) 750311267, Rev 01 J1, J2, J3 3 I/O connectors LS = 5 mm Weidmuller 1716020000 (for Q1, D8) 2 Heatsink Q1, D8 LS = 25.4 mm Aavid 531102B02500G (or similar) HD1 1 Header CONN HEADER 2POS 0.100” Molex 90120−0122 JMP1 1 Shorting Jumper 0.1” Two Position Shorting Jumper 0.100” Sullins Connector Solutions SPC02SYAN 55V, 90W CCM http://onsemi.com 8 AND8427/D Designator Qty Description Value Tolerance Footprint Manufacturer Manufacturer Part Number SOD123 ON Semiconductor MMSD4148A Optional DIM Daughter Card BOM D1, D2, D3 3 Signal diode Q1 1 BJT 400mA, 40V SOT23 ON Semiconductor MMBT2222A Q2 1 Mosfet 40V, 100 mA SOT23 ON Semiconductor 2N7002KT1G U1 1 Timer IC _ SOIC8 ON Semiconductor MC1455D U2 1 Quad Opamp _ SOIC14 ON Semiconductor LM324DG C4 1 ceramic cap 1.0 mF, 25V 10% 1206 TDK C3216X7R1H105K C1 1 ceramic cap 68 nF, 50V 10% 1206 Vishay VJ1206Y683KXAA C2, 3, 7, 9 4 ceramic cap 0.1 mF, 50V 10% 1206 TDK C3216X7R2A104K C6, C8 2 ceramic cap 10 nF, 50V 10% 1206 TDK C3216COG2A103J C5 1 ceramic cap 1 nF, 100V 10% 1206 Kemet C1206C102K1RACTU R1 1 potentiometer 20K, 15 Turn Thru hole Vishay T18203KT10 R9 1 potentiometer 100K, 15 turn Thru hole Vishay T18104KT10 R4, 11, 13, 16 4 0.25W resistor 10K 5% 1206 Vishay/Dale CRCW12061002F R2 1 0.25W resistor 150K 1% 1206 Vishay/Dale CRCW12061503F R3 1 0.25W resistor 20K 1% 1206 Vishay/Dale CRCW12062002F R5 1 0.25W resistor 4.3K 1% 1206 Vishay/Dale CRCW12064321F R6 1 0.25W resistor 5K 1% 1206 Vishay/Dale CRCW12064991F R7 1 0.25W resistor 1.0K 1% 1206 Vishay/Dale CRCW12061001F R8 1 0.25W resistor 15K 1% 1206 Vishay/Dale CRCW12061502F R10 1 0.25W resistor 11K 1% 1206 Vishay/Dale CRCW12061102F R12 1 0.25W resistor 30K 1% 1206 Vishay/Dale CRCW12063012F R15 1 0.25W resistor 10 ohms 1% 1206 Vishay/Dale CRCW120610R0F 1% 1206 Vishay/Dale CRCW12060000Z Molex or Tyco Rt angle 6 pin connector, 0.1” pitch R14 1 0.25W resistor Zero ohms TH1 1 PTC Thermistor Not Used Thru hole CON 1 1 right angle pins 0.1” 6 position Thru hole http://onsemi.com 9 AND8427/D REFERENCES ON Semiconductor Application Note AND8397 ON Semiconductor Data Sheet for NCL30001 ON Semiconductor Data Sheet for NCS1002 XLamp is a trademark of Cree, Inc. ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC reserves the right to make changes without further notice to any products herein. SCILLC makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does SCILLC assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages. “Typical” parameters which may be provided in SCILLC data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including “Typicals” must be validated for each customer application by customer’s technical experts. SCILLC does not convey any license under its patent rights nor the rights of others. SCILLC products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the SCILLC product could create a situation where personal injury or death may occur. Should Buyer purchase or use SCILLC products for any such unintended or unauthorized application, Buyer shall indemnify and hold SCILLC and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that SCILLC was negligent regarding the design or manufacture of the part. SCILLC is an Equal Opportunity/Affirmative Action Employer. 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