DN05072/D Design Note – DN05072/D 125W Hi-PF Single Stage LED Driver Device Application Input Voltage Output Power Topology I/O Isolation NCL30001 LED Driver 85 – 265 V ac 125W CCM Flyback Yes Output 1 Output Current Ripple Nominal Voltage Max Voltage Min Voltage Typical Power Factor Typical THDi Typical Efficiency Cooling Method / Supply Orientation Single stage power converters offer a cost effective way to provide power for LED applications with high input power factor and low THD. The most common CrM or Critical Conduction Mode solutions are typically limited to about 50 watts due to high peak currents characteristic of this approach. A CCM or Continuous Conduction Mode flyback converter offers higher power with reduced peak current while still providing high power factor and very low THD. This Design Note outlines modifying ON Semiconductor’s NCL30001 CCM solution described in Application Note AND8470 extending the output power up to 125 watts. The standard evaluation board is the basis for this design. Input range: 85 – 265 V ac Output current: 2.5 A Output voltage: 48 V typical Efficiency: 88% Power Factor: >0.98 April 2015, Rev. 0 >0.98 < 6% >88 % Free Air A photo of the modified evaluation board is shown below: Circuit Description The design guidelines for this LED driver are shown below: 2.5 A 560 mA p-p 48 V 55 V 16 V Design The design process begins using the NCL30001 design worksheet found at ON Semiconductor’s website. Directions for using this worksheet are described in the first tab. The design started by entering design guidelines on tab ‘Step1’. Progressing through tabs as directed, the critical changes to the standard evaluation board are noted below and highlighted in the Bill of Materials at the end of this document: www.onsemi.com 1 DN05072/D Multiple resistors will be used to create the proper value. Start with the original value of 0.1 R19 = 39k ohms for R26, and place a second 0.1 ohm R12 = 71.5k surface mount resistor (R26A) across the C20,21,22 = 2200 uF appropriate traces on the bottom of the board. Lastly, change C34 from a capacitor to a 0.2 Increasing the power level requires adjustments ohm resistor resulting in an equivalent resistance outlined above. In particular, the output filter of 0.04 ohms. Note that a filter capacitor like capacitance was increased to reduce ripple due C34 is not always required across low to higher output current. inductance resistors. T1 280 µH R26A = 0.1 ohm ‘C34’ = 0.2 ohm The design worksheet also specified a power transformer with 280 µH inductance and a The PWM dimming function was not required for primary to secondary turns ratio of 2.24. A new this solution and therefore removed. In order to transformer is detailed at the end of this design maintain functionality, Q5 and Q7 should be note meeting the requirements with a larger core bypassed with wire from drain to source. The to process the increased power. The turns ratio changes are highlighted below: was adjusted slightly to optimize fitting the wire in the bobbin. The transformer is available from Z5 = Not Fitted Wurth Electronik as detailed in the BOM. Q5 = Bypassed Q7 = Bypassed F1 = 3.15 Amp Q6 = Not Fitted Current rating of the fuse must be increased to C33 = Not Fitted accommodate higher input current. Heatsinks for R37 = Not Fitted switching MOSFET Q1 and output rectifier D8 R38 = Not Fitted were increased to maintain device temperature R39 = Not Fitted with free-air cooling conditions. D7 voltage rating R40 = Not Fitted should be increased as well. R41 = Not Fitted R44 = Not Fitted The output current is measured by a sense resistor and used by U3B to establish the current Additionally, the primary Over Voltage Protection regulation feedback point. The formula for output circuit was not used. Changes shown below: current is shown below: Iout = (Vref * R31) / (R32 * Rsense) This can be rearranged to solve for Rsense: Rsense = (Vref * R31) / (R32 * Iout) Summary Noting that Vref = 2.5 V as supplied by U3 pin 3 and R31 = 2.7k, R32 = 68k, and the desired output current is 2.5 A: Rsense = (2.5 * 2.7k) / (68k * 2.5) = 0.0397 ohm April 2015, Rev. 0 C8 = Not Fitted R5 = Not Fitted D9 = Not Fitted Z2 = Not Fitted After modifications, the NCL30001 evaluation board met all of the design goals. Detailed performance is outlined on the following pages along with a schematic and Bill of Materials. www.onsemi.com 2 DN05072/D Performance 3 91% 2.5 90% 2 89% 1.5 88% Current 1 87% Efficiency 0.5 Efficicney (Percent) Output Current (Amps) Output current regulation and efficiency across the input voltage range of 85 to 265 V ac is shown below. Typical current was 2.43 amps with a variation of less than 0.1%. Efficiency is above the 88% target. 86% 0 85% 85 105 125 145 165 185 205 225 245 265 Input Voltage (V ac) 1.00 10 0.99 9 0.98 8 0.97 7 Power Factor 60Hz PF 0.96 6 50Hz PF 60Hz THDi 0.95 5 50Hz THDi 0.94 4 0.93 3 0.92 2 0.91 1 THDi (Percent) Shown below are Power Factor and input current THD over the input voltage range for 50 and 60 Hz. 0 0.90 85 April 2015, Rev. 0 105 125 145 165 185 Input Voltage (V ac) 205 www.onsemi.com 225 245 265 3 3.0 90% 2.5 88% 2.0 86% 84% 1.5 Iout Efficiency Iout (Amps) DN05072/D The converter provides constant current output over a wide range of output operating voltage. Efficiency is above 86% for loads greater than 50 watts. Performance is shown below. Efficiency 1.0 82% 0.5 80% 78% 0.0 15 20 25 30 35 40 Vout (Volts) 45 50 55 60 IEC 61000-3-2 Class C data is shown below for 100 V ac 50 Hz input and 2.43 A at 48 V load. The driver is well below the maximum allowed limits: 30 Harmonic Current Percentage of Fundametal (%) 25 20 15 10 Limit (%) Measured (%) 5 0 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic April 2015, Rev. 0 www.onsemi.com 4 DN05072/D Primary Schematic1 April 2015, Rev. 0 www.onsemi.com 5 DN05072/D Secondary Schematic2 April 2015, Rev. 0 www.onsemi.com 6 DN05072/D 3 MAGNETICS DESIGN DATA SHEET Project / Customer: NCL30001 Demo Part Description: 125 Watt 50V 2.5A LED Driver Inductance: 280uH Bobbin Type: 12 pin vertical Core Type: PQ3535Core Gap: Gap for 280uH, ~0.028 inches Winding Number / Type Step Winding Start 1 ½Primary 1 2 Insulate 3 Secondary 7,8 4 5 6 7 8 Insulate ½Primary Insulate Pri Bias Insulate Finish 3 11,12 3 2 5 6 Turns / Material / Gauge / Insulation Data Turns Material Notes 14 •• #26 TEX-E Wind bifilar in one layer 2 Mylar Tape 13 •• #24 Wind bifilar in one layer, terminate one wire per pin 2 Mylar Tape 14 •• #26 TEX-E Wind bifilar in one layer 1 Mylar Tape 7 #26 TEX-E Spread evenly in one layer 3 Mylar Tape Hipot: 3KV from primary to secondary for 1 minute. April 2015, Rev. 0 www.onsemi.com 7 DN05072/D 4 Bill of Materials Designator Description Manufacturer Manufacturer Part Number D5, D10 D1, D2, D3, D4 D6 D7 D9 D11, 12, 13 D8 Diode ON Semiconductor MRA4007T Diode Ultrafast diode Ultrafast diode Signal diode Signal diode UFR diode ON Semiconductor ON Semiconductor Micro Commercial ON Semiconductor ON Semiconductor 1N5406 MURS160 ES1M-TP MMSD4148A MURH860CTG Z1 Z4 Z5 Z3 Z2 Q5 Q7 Q1 Q2, Q3 Q6 Q4 U1 U2 U3 TVS Zener diode Zener diode Zener diode Zener diode Jumper Jumper Mosfet BJT BJT BJT PFC controller Optocoupler Dual amp + zener ON Semiconductor ON Semiconductor Infineon ON Semiconductor ON Semiconductor ON Semiconductor Vishay ON Semiconductor 1.5KE440A MMSZ5245B MMSZ5248B SPP11N80C3 MMBTA06LT1G MJD243G NCL30001 H11A817 or SFH6156A-4 NCS1002 C1, C2 C27 C3 X caps Y2 cap Polyprop. Film C7 Disc cap 0.47 uF, 277 Vac 2.2 nF, 1kV 0.22uF (630V) 68 to 100 nF, 400V Evox Rifa/Kemet or EPCOS Evox Rifa/Kemet Vishay PHE840MB6470MB16R17 or B32922C3474M PME271Y422M or P271HE222M250A 2222 383 20224 TDK FK22X7R2J104K C15, 16, 25, C26, C29 C8, C33 C23, C24 C28, C30 C19 C12 C9 C10, C18, C31 C14, C17, C32 C13 C5 C11 C6 C20, 21, 22 C4 C35 ceramic cap 0.1 uF, 50V TDK C3216X7R2A104K ceramic cap ceramic cap ceramic cap ceramic disc cap ceramic cap ceramic cap Not Fitted 0.1 uF, 100V 1.0 uF, 25V 1 nF, 1 kV 470 pF, 50V 680 pF, 50V TDK TDK TDK Vishay Kemet C3216X7R2A104K C3216X7R1H105K CK45-B3AD102KYNN VJ1206A471JXACW1BC C1206C681K5GACTU ceramic cap 1 nF, 100V Kemet C1206C102K1RACTU ceramic cap ceramic cap electrolytic cap electrolytic cap electrolytic cap electrolytic cap electrolytic cap ceramic cap 10 nF, 50V 33 nF, 50V 100 uF, 35V 4.7 uF, 25V 220 uF, 50V 2200 uF, 63V 22 uF, 450V 0.1 uF, 50V TDK TDK UCC UCC UCC Nichicon Nichicon TDK C3216COG2A103J C3216COG1H333J ESMG350ELL101MF11D ESMG250ELL4R7ME11D ESMG500ELL221MJC5S UPW1J222MHD 647-UVY2W220MHD C3216X7R2A104K 0.25W resistor 0.5W resistor 0.5W resistor 0.2 ohms 2.2K 1M, 0.5W Rohm Semiconductor Vishay Vishay MCR18EZHFLR200 NFR25H0002201JR500 CMF601M0000FHEK C34 R4 R1 April 2015, Rev. 0 Value Not Fitted Input transient option 15V Not Fitted 18V Not Fitted #26 bus wire #20 bus wire 11A, 800V 60V, 500 mA Not Fitted 100V, 4A www.onsemi.com 8 DN05072/D R8 R2 R27 R24 R20, R26 R26A R3 R23 R5 R38 R21, 42, 43 R41 R15, R28 R31, R36 R29,R30 R25 R32 R33 R37 R34 R35 R14, 22 R39, 40, 44 R13 R9 R12 R17 R18 R19 R16 R10 R6, 7, 11 F1 L1A/B L2 0.5W resistor 0.5W resistor 0.5W resistor 0.5W resistor 0.5W resistor 1W resistor 3 or 5W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor 0.25W resistor Fuse EMI inductor EMI inductor T1 J1, J2, J3 (for Q1, D8) Flyback xfmr I/O connectors Heatsink Q1, D8 HD1 Header JMP1 Shorting Jumper 2K, 0.5W 560K 4.7K 100 ohms 0.1 ohms 0.1 ohms 36K to 39K 4.7 ohms Not Fitted Not Fitted 10 ohms Not Fitted 2.2K 2.7K 43.2K 20K 68K 6.2K Not Fitted 82K 3.9K 10K Not Fitted 7.32K 30.1K 71.5K Not Fitted 49.9K 39.2K 100K 332K 365K 3.15A, 250Vac 220uH, 2A 50V, 125W CCM CONN HEADER 2POS 0.1" Two Position Shorting Jumper Vishay Vishay Vishay Vishay Ohmite Vishay/Dale Ohmite Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Vishay/Dale Littlefuse Coilcraft Coilcraft WE-Midcom (Wurth Electronics) Weidmuller Ohmite CMF552K0000FHEB HVR3700005603JR500 CRCW12104K70JNEA CMF50100R00FHEB WNCR10FET WSL2512R1000FEA PR03000203602JAC00 CRCW12064R75F CRCW120610R0F CRCW12062211F CRCW12062741F Molex 90120-0122 Sullins Connector Solutions SPC02SYAN CRCW12062002F CRCW12066812F CRCW12066191F CRCW12068252F CRCW12063921F CRCW12061002F CRCW12064322F CRCW12063012F CRCW12067152F CRCW12064992F CRCW12063922F CRCW12061003F CRCW12063323F CRCW12063653F 37213150001 PCV-0-224-03L P3220-AL 750314494, REV 00 1716020000 EA-T220-64E 1 © 2015 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 Jim Young, e-mail: [email protected] April 2015, Rev. 0 www.onsemi.com 9