DN05015/D 30 V, 2 A High Efficiency CVCC LED Driver http://onsemi.com DESIGN NOTE Circuit Description manual (EVBUM2039/D) and is essentially identical circuit-wise with the exception of the component changes that are indicated in the BOM. The resonant half-bridge transformer design for this DN was merely ratioed from the secondary winding on the original 55 V transformer design to meet the new voltage and current requirements. The primary winding, required inductances, and overall construction are essentially the same. This Design Note (DN) is an extension to ON Semiconductor’s Evaluation Board User’s Manual EVBUM2039/D and features a 30 V max, 2 A version of the off-line, NCL30051 based constant voltage, constant current (CVCC) high efficiency LED driver. The original document features a 55 V max, constant current, 1.5 A (current settable) LED driver with multiple dimming capabilities and active power factor correction in a two-stage off-line converter utilizing a resonant half-bridge in the main conversion stage. This DN presents a similar version of that design which is suitable for driving LED strings up to 30 V at a max current of up to 3 A. This design is suitable for LED street lighting and wall pack lamp applications. The maximum output voltage and output current can be adjusted via resistors R28 and R26 respectively, shown in the secondary circuit schematic. The detailed circuit operational description can be found in the original mentioned NCL30051 evaluation board user’s Key Features Input EMI Filter for Class A Constant Voltage, Constant Current Output Characteristic for LED Drive Dimming Features Including Pulse Width and Analog Dimming to 10% Over Current, Over Voltage and Over Temperature Capabilities Typical Efficiencies of 90% Table 1. DEVICE DETAILS Device Application Input Voltage Output Power Topology I/O Isolation NCL30051 NCS1002 LED Lighting (Wall Pack/Street Lights) 90−270 Vac 60 W Nominal Boost PFC + Resonant HB Yes − 3 kV Table 2. OTHER SPECIFICATIONS Output Others Unit Output Voltage 30 V max Ripple 250 mA max Nominal Current 2 A Max Current (3) A Min Current 0 A PFC (Yes/No) Yes Minimum Efficiency 88% Inrush Limiting/Fuse NTC Inrush Thermistor + 1.5 A Fuse Operating Temperature Range 0 to +50C Cooling Method/Supply Orientation Convection/NA Signal Level Control Yes (Dimming Controls) PWM, Bi-level and Analog LED Dimming Input Options Semiconductor Components Industries, LLC, 2013 January, 2013 − Rev. 2 1 Publication Order Number: DN05015/D Figure 1. NCL30051 60 W LED Driver 2 0.22 “X” 1. Q2A, Q2B are D−Pak devices 2. L1 is Coilcraft E3492−AL (2.9 mH) 3. Heavy schematic lines are recommended ground plane areas − blue is power ground; black is signal/logic ground; green is drive ground. 4. NCL30051 signal grounds and associated components should be single-point connected to the power and drive ground planes as shown in schematic. 5. L2 and T1 are PQ2020 cores with 14 pin bobbins. 6. Q1 requires small heatsink. 7. C10, C17, and Q7/R40 should be as close to associated U1 pins as possible. TH1 T R1B C2 R13 Open R12 680 kW 0.5 W R11 680 kW 0.5 W 0.22 mF 400 V C3 4 1 3 6 Q1 TO−220 D6 MURS360 Z1A 0.1 F 100 pF C12 Logic/Signal Ground 820 pF C10 MRA4007 4.7 kW, 0.5 W C11 D12 R10 5.6 nF C8 R8 1.2 kW R17 C1 10 W, 0.25 W 0.22 “X” R9 L2, 700 mH 10 kW 560kW x2 NOTES: AC In L1 R2 R1A R7 26.7 kW + R16 1 kW 14 13 12 11 3 4 5 6 8 1nF R5 10 kW Q8 C17 1.8 nF Q3 MMBTA06LTG 0.22 25V C9 C15 C16 0.1 F 330 mF 35 V C14 9 10 15 2 7 16 1 1.2 kW U1 NCL30051 R40 D9 MRA4007 R4 560 kW 0.5 W R3 560 kW 0.5 W MURA160 D10 C13 Z1B 82 mF 400 V C5 82 mF 400 V C4 Q2A NDD04N60ZT HVIN JMP1 HVOUT R6 D5 1N5406 0.68 mF 0.15 W 0.5 W + MMSZ5248B R14 2.7MW 0.5W R18 2.7MW 0.5W http://onsemi.com R19 26.7 kW Drive Ground D11 + D1−D4 MRA4007 x4 0.1 mF 400 V C7 JMP3 C6 0.1 mF 400 V D13 MMSD 4148B 3 4 PS2561A U2 PS2561A U3 R15 2.7 kW 2 1 R42 5.1 kW 3 4 R41 10 kW Primary Ground Plane MMBT 2907A GND NDD04N60ZT Q2B D8 MURA160 10 W 10 kW R43 D7 MURA160 Q7 MMBTA06LTG F1 1.5 A 2 1 A T1 14 11 10 7 C CVCC Feedback A C PWM Dim C27 5 2 DN05015/D SCHEMATIC − PRIMARY SECTION http://onsemi.com A C27 2.2 nF 2.7 kW R39 Q9 MMBT2907A C26 0.1 F Z2 MMSZ5245B 4 U4A R24 47 kW 1 5 6 Internal to U3 Vref 3 2 NCS1002 C28 0.1 mF 8 U4B 0.22 mF 47 kW 7 C25 R23 IS 0.1 F C30 2.5 V R26 42.2 kW 10 nF C29 C24 1 nF R27 6.2 kW C20 0.1 mF 100 V R25 2.7 kW IS 15 kW, 0.5 W R21 C19 1. D16 requires small heatsink. 2. Heavy schematic lines are recommended ground plane areas. NOTES: C PWM Dim 2.2 kW VCC = 14 V Q4 MJD243G C18 R29 3.9 kW R28 42.2 kW VS GND C23 0.1 F R22 0.10 W 0.5 W VCC R35 10 W R34 10 W R33 10 W Q10 MMUN2212L R31 100 W Q5 2N7002KT1G R32 2.7 kW 1 mF C22 R30 5.1 kW Current Sense Sample & Hold C21 0.1 mF 100 V JMP2 1 2 3 Jumper if DIM 5 Card Not Used 6 Q6 MMBTA06LT1G R37 R20 D14 MMSD4148 To Primary Side Ground Plane D15 MMSD4148 C CVCC Feedback A 11 14 + 3 − 7 10 10 kW 4.7 mF 100 V x 2 + D16 MBRF10H150 − T1 Xfmr P1 R38 10 kW J2 LED Anode GND Common Dimming Control Options Card PWM In 100−200 Hz J3 − LED Cathode Analog Dim Out Vref In VCC In PWM Out R36 10 kW 30 V max 2 A Output + DN05015/D SCHEMATIC − SECONDARY SECTION Figure 2. NCL30051 LED Driver CVCC Secondary Sensing and PWM Dimming Input Option DN05015/D TEST DATA Performance Parameters: Load is two Luminous Devices LED modules in series Table 3. TEST DATA VIN PIN PF %THD IOUT VOUT POUT Efficiency 90 64 0.994 9.1 2.025 27.35 55.38 86.54% 100 63.2 0.995 9.5 2.025 27.34 55.36 87.60% 115 62.9 0.993 10.3 2.026 27.34 55.39 88.06% 180 62.4 0.975 15.9 2.025 27.33 55.34 88.69% 230 62.5 0.95 21.5 2.025 27.33 55.34 88.55% 265 62.6 0.926 26 2.025 27.32 55.32 88.38% MAGNETICS DESIGN DATA SHEET Project/Customer: ON Semiconductor − NCL30051 30 V/2 A CVCC LED driver Part Description: Resonant Half-bridge Transformer − 60 W, 35 kHz, 30 V/2 A output Schematic ID: T1 Core Type: PQ20/20, Ferroxcube 3C95 or equivalent material Primary Inductance: 6 mH minimum Leakage Inductance: 90−110 mH nominal (resonant half-bridge, leakage inductance is Lr) Bobbin Type: PQ20/20 14 pin PC mount bobbin Windings (in order): Winding #/Type Turns/Material/Gauge/Insulation Data Primary Winding (2−5) 96 turns of #28 HN magnet wire over 3 layers, 32 turns per layer approx. Self-leads to pins. Insulate with Mylar tape sufficient for 3 kV Hipot to next winding. Secondary Winding (7, 11−10,14) 11 turns of 2 X #24 magnet wire bifilar wound over 2 or 3 layers. Self-leads to pins per schematic below. Final insulate with Mylar tape. NOTE: The critical parameter is to achieve a leakage inductance of 90−110 mH with a min primary inductance of 6 mH. The overall turns can be increased or decreased to achieve this as long as the turns ratio remains 8.7:1. Vacuum varnish assembly. Hipot: 3,000 V from Primary to Secondary (1 minute) Schematic Lead Breakout/Pinout Bottom View 2 Primary 5 14 7 11 11 Secondary 10 14 10 7 http://onsemi.com 4 1 2 3 4 5 6 DN05015/D ON Semiconductor and are registered trademarks of Semiconductor Components Industries, LLC (SCILLC). SCILLC owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. A listing of SCILLC’s product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent−Marking.pdf. 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