EVBUM2307/D - 1947 KB

NCL30082SMRTGEVB
NCL30082 8W Smart LED
Driver Evaluation Board
User's Manual
Overview
This manual covers the specification, theory of operation, testing
and construction of the NCL30082DIMGEVB demonstration board.
The NCL30082 board demonstrates an 8 W SEPIC LED driver with
a 3.3 V aux voltage for power control accessories.
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EVAL BOARD USER’S MANUAL
Table 1. SPECIFICATIONS
Parameter
Input Voltage
(Class 2 Input, No Ground)
Line Frequency
Value
Notes
100–120 V ac
50 Hz/60 Hz
Power Factor (100% Load)
0.6
LED Output Voltage Range
40–80 V dc
LED Output Current
100 mA dc
Aux. Voltage (Available in All Modes)
3.3–3.5 V
Typ.
±5%
Aux. Current
20 mA
Max.
Efficiency
83.5%
Typ.
90 mW
Typ.
(Top View)
Standby Power
120 V 60 Hz
Analog Dimming Voltage
100% Output
VDIM > 2.5 V
0% Output
VDIM < 0.1 V
PWM Dimming Voltage
0–3.3 V
PWM Range (Freq > 200 Hz)
0–100%
Start Up Time (from AC On)
< 600 ms
Start Up Time (from Enable On)
< 1 ms
EMI (Conducted)
Class B
Typ.
FCC/CISPR
Key Features
• Single Mains
• Integrated Auto-Recovery Fault Protection (Can be Latched by
•
•
•
(Bottom View)
Figure 1. NCL30082SMRTGEVB
Evaluation Board
Choice of Options)
♦ Over Temperature on Board (a PCB Mounted NTC)
♦ Over Current
♦ Output and VCC Over Voltage
3.3 V Aux Voltage
♦ Available in All Modes
“Dim to Zero Output”
On/Off Control
© Semiconductor Components Industries, LLC, 2015
August, 2015 − Rev. 0
1
Publication Order Number:
EVBUM2307/D
NCL30082SMRTGEVB
THEORY OF OPERATION
Power Stage
CrM Timing
In the off time, the voltage on the transformer/inductor
forward biases DOUT and D9. When the current in the
magnetic has reached zero, the voltage collapses to zero.
This voltage collapse triggers a comparator on the ZCD pin
to start a new switching cycle. The ZCD pin also counts rings
on the auxiliary winding for higher order valley operation.
A failure of the ZCD pin to reach a certain threshold also
indicates a shorted output condition.
The power stage for the demo board is a non-isolated
coupled SEPIC converter. The controller has a built in
control algorithm that is specific to the flyback transfer
function. Specifically:
V OUT
Duty
+
(1 * Duty)
V IN
(eq. 1)
This is applicable to flyback, buck-boost, and SEPIC
converters. The controller has a built in hardware algorithm
that relates the output current to a reference on the primary
side.
I OUT +
V REF @ N PS
2 @ R SENSE
N PS +
N PRI
N SEC
VCC Power
The auxiliary winding forward biases D9 to provide
power for the controller. This arrangement is called
a “bootstrap”. Initially the CVCC, is charged through
RSTART and RSTART1. When the voltage on CVCC
reaches the startup threshold, the controller starts switching
and providing power to the output circuit and the CVCC.
CVCC discharges as the controller draws current. As the
output voltage rises, the auxiliary winding starts to provide
all the power to the controller. Ideally, this happens before
CVCC discharges to the under voltage threshold where the
controller stops operating to allow CVCC to recharge once
again. The size of the output capacitor will have a large
effect on the rise of the output voltage. Since the LED driver
is a current source, the rise of output voltage is directly
dependent on the size of the output capacitor.
There are tradeoffs in the selection of COUT and CVCC.
A low output ripple will require a large COUT value. This
requires that CVCC be large enough to support VCC power to
the controller while COUT is charging up. A large value of
CVCC requires that RSTART and RSTART1 be lower in
value to allow a fast enough startup time. Smaller values of
RSTART and RSTART1 have higher static power
dissipation which lowers efficiency of the driver.
(eq. 2)
(eq. 3)
Where NPRI = Primary Turns and NSEC = Secondary Turns.
We can now find RSENSE for a given output current.
R SENSE +
V REF @ N PS
2 @ I OUT
(eq. 4)
Line Feedforward
The controller is designed to precisely regulate output
current but variation input line voltage do have an impact.
RLFF sets the line feedforward and compensates for power
stage delay times by reducing the current threshold as the
line voltage increases. RLFF is also used by the shorted pin
detection. At start up the controller puts out a current to
check for a shorted pin. If RLFF is zero, the current sense
resistor is too low a value and the controller will not start
because it will detect a shorted pin. So RLFF is required to
make the controller operate properly. In practice, RLFF
should be greater than 250 W.
Output Voltage Sense
The auxiliary winding voltage is proportional to the
output voltage by the turns ratio of the output winding and
the auxiliary winding. The controller has an overvoltage
limit on the VCC pin at about 26 V minimum. Above that
threshold, the controller will stop operation and enter
overvoltage fault mode such as when an open LED string
occurs.
In cases where the output has a lot of ripple current and the
LED has high dynamic resistance, the peak output voltage
can be much higher than the average output voltage.
The auxiliary winding will charge the CVCC to the peak of
the output voltage which may trigger the OVP sooner than
expected so in this case the peak voltage of the LED string
is critical.
Voltage Sense
The voltage sense pin has several functions sets the brown
level and line range selection.
The amplitude of VIN is important for the range detection.
Generally, the voltage on VIN should be 3.5 V peak at the
highest input voltage of interest. Voltage on VIN must not be
greater than 4 V under any operating condition. The voltage
on VIN determines which valley the power stage will operate
in. At low line and maximum load, the power stage operates
in the first valley (standard CrM operation). At the higher
line range, the power stage moves to the second valley to
lower the switching frequency while retaining the advantage
of CrM soft switching.
Auxiliary Winding
The auxiliary winding has 3 functions:
1. CrM Timing
2. VCC Power
3. Output Voltage Sense
SD Pin
The SD pin is a multi-function protection input.
1. Thermal Foldback Protection
2. Programmable OVP
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NCL30082SMRTGEVB
Programmable OVP
While the SD pin has a current source for the OTP, it can
be overcome raising the voltage on the SD pin. At about
2.5 V, the SD pin detects an OVP and shuts down the
controller. Typically, a zener to VCC is used for this. In this
way, the designer can set the OVP to a lower value that the
OVP threshold built into the VCC pin. The zener
programmable OVP is not implemented on this demo board.
Thermal Protection
There is an internal current source from the SD pin.
Placing an NTC from the SD pin to ground will allow the
designer to choose the level of current foldback protection
from over temperature. Below 0.5 V on SD, the controller
stops. Series or parallel resistors on the NTC and shape the
foldback curve. In the event that the pin is left open, there is
a soft voltage clamp at 1.35 V (nominal). Output current is
reduced when the voltage on the SD pin drops below 1 V.
Aux Power Management
Figure 2. Aux Power Management
Circuit Modifications
Output
1. Wire 3 (Red) − LED+
2. Wire 4 (Black) − LED–
Output Current
The output current is set by the value of RSENSE as shown
above. It’s possible to adjust the output current by changing
RSENSE. Since the magnetic is designed for 8 W, it is
possible to increase the current while reducing the
maximum LED forward voltage within limits. Changes of
current of ±10% are within the existing EMI filter design and
magnetic, changes of more than 10% may require further
adjustments to the transformer or EMI filter.
I/O (J7)
1. 3.3 V
2. On/Off
3. Dim
4. NC
5. Common
6. NC
Connections
AC Input
1. Wire 1 (White) − AC Line
2. Wire 2 (White) − AC Neutral
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NCL30082SMRTGEVB
Interface Control Signals
the power on startup time to be longer than 0.5 s since power
on timing is now a one-time event. In this case, RSTART and
RSTART1 are optimized for low power consumption rather
than an optimized startup time. Once the converter is
operating, startup through on/off control is less than 1 ms.
On/Off Control
The on/off control defaults to “on” if left open. Grounding
this pin to signal ground turns the output “off”. In “off”
mode, the output voltage will regulate to ~16 V. This is well
below the level that will cause the LEDs to pass current
resulting in a true off mode. “Off” mode is also the standby
mode. The standby power consumption is greatly affected
by the values of RSTART and RSTART1. The designer may
choose to trade off start up time for standby power
consumption. In a “Smart Bulb” application, the mains
power is left on so the bulb can be controlled remotely. This
designer can choose to optimize standby power by allowing
Dim Control
The dim control input will accept either an analog or
PWM signal. The output has full range from 0% to 100%
output. A 0 V input to the dim connection causes Q4 to
operate in linear mode which maintains the voltage on the
dim pin of the controller at its minimum level. At 0 V on the
dim connection, the output voltage will be ~25 V which is
below the Vf of the LEDs.
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4
5
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t°
4
Figure 4. Main Schematic
Com
NCL30082
VCC
GDrv
CS
VIN
5
6
7
8
RIFF
620 W
Dim
QFET
NDD02N60Z
RSENSE
1.0 W
C13
4.7 mF
VCC
VCC_Lin
C4
10 mF
200 V
C15
4.7 mF
D13
BAS21DW5T1G
Keep Alive
Regulator
(Active in Off Mode)
D12
MM5Z15VT1G
R2
51.1 kW
C11
1 nF
3
Dim
Q3
MMBTA06LT1G
ZCD
R20
56 kW
2
U1
−
SD
AC2
1
L2
1.5 mH
T1
+
RZCD
56 kW
D9
BAS21DW5T1G
AC1
CVCC
4.7 mF
RSTART1
1 MW
LED+
FUSE
RBO
3.01 MW
RSTART
1 MW
DOUT
UFM15PL
AC_N
+HVDC
AC_L
1
C5
100 nF
250 V
NCL30082SMRTGEVB
SCHEMATIC
RDAMP
180 W
F1
D4
+HVDC
L1
1.5 mH
C3
100 nF
250 V
1
ABS10
Figure 3. Input Circuit
COUT 4.7 mF 100 V
6
Dim
LED+
VCC_Lin
VCC
Figure 5. Interface Schematic
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ADJ
VIN
VOUT
2
R18
62 W
Error
Vo_Tap
FB
IN
OUT
Com
6th_Dn
SENSE
4
3
2
1
CZIG
4.7 mF
D14
BAS16XV2T1G
R8
100 kW
R9
100 kW
R7
470 W
Q1
MMBT3904WT1G
3.3 V Regulator (for Off State 3.3 V Power)
LP2951ACDM−3.3
5
6
7
8
U2
20 mA Current Source (for Active Mode)
1
3
Off State Voltage Regulation
D10
MM5Z15VT1G
1
2
C10
1 nF
R6
10 kW
R19
100 kW
R11
12 kW
R10
10 kW
3.5 V in Active Mode
3.3 V in Off Mode
D15
MM5Z15VT1G
Dim Disconnect
Q4
BSS138
R15
100 kW
R16
40.2 kW
Q2
MMBT3904WT1G
On/Off Control
(Default in On)
U4
NCP431A
D11
BAS116LT1G
LED+
1
2
U5
LM317
1
2
3
4
5
6
J7
LED−
LED+
TMS−103−02−G−D
1
1
NCL30082SMRTGEVB
R21
3.32 kW
NCL30082SMRTGEVB
GERBER VIEWS
Figure 6. Top Side PCB
Figure 7. Bottom Side PCB
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NCL30082SMRTGEVB
Figure 8. PCB Outline
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NCL30082SMRTGEVB
All Wire 6″ ±0.5″. Strip Ends 0.5″
Wire 3 Red
Wire 1 White
Wire 4 Black
Place the Label
on Top of T1
“NCL30082SMRTGEVB”
“Rev( )”
Wire 2 White
L2 Mounts Horizontally
Figure 9. Assembly Notes Top
Bevel Edge of D4 Indicates Polarity
J7 on the Solder Side
Figure 10. Assembly Notes Bottom
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NCL30082SMRTGEVB
CIRCUIT BARD FABRICATION NOTES
11. Size tolerance of plated holes: ±0.003″: non-plated
holes ±0.002″.
12. All holes shall be ±0.003″ of their true position
U.D.S.
13. Construction to be SMOBC, using liquid photo
image (LPI) solder mask in accordance with
IPC−SM−B40C, Type B, Class 2, and be green in
color.
14. Solder mask mis-registration ±0.004 in. max.
15. Silkscreen shall be permanent non-conductive
white ink.
16. The fabrication process shall be UL approved and
the PCB shall have a flammability rating of
UL94V0 to be marked on the solder side in
silkscreen with date, manufactures approved logo,
and type designation.
17. Warp and twist of the PCB shall not exceed
0.0075″ per in.
18. 100% electrical verification required.
19. Surface finish: electroless nickel immersion gold
(ENIG).
20. RoHS 2002/95/EC compliance required.
1. Fabricate per IPC−6011 and IPC6012. Inspect to
IPA−A−600 Class 2 or updated standard.
2. Printed Circuit Board is defined by files listed in
fileset.
3. Modification to copper within the PCB outline is
not allowed without permission, except where
noted otherwise. The manufacturer may make
adjustments to compensate for manufacturing
process, but the final PCB is required to reflect the
associated gerber file design ±0.001″ for etched
features within the PCB outline.
4. Material in accordance with IPC−4101/21, FR4,
Tg 125°C min.
5. Layer to layer registration shall not exceed
±0.004″.
6. External finished copper conductor thickness shall
be 0.0026″ min. (i.e. 2 oz).
7. Copper plating thickness for through holes shall be
0.0013″ min. (i.e. 1 oz).
8. All holes sizes are finished hole size.
9. Finished PCB thickness 0.031″.
10. All un-dimensioned holes to be drilled using the
NC drill data.
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NCL30082SMRTGEVB
SEPIC INDUCTOR SPECIFICATION
Figure 11. SEPIC Inductor Specification
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NCL30082SMRTGEVB
ECA PICTURES
Figure 12. Top View
Figure 13. Bottom View
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NCL30082SMRTGEVB
TEST PROCEDURE
Equipment Needed
Test Connections
• AC Source – 90 to 135 V ac 50/60 Hz minimum 500 W
•
•
•
•
1. Connect the LED load to the red(+) and black(−)
leads through the ammeter shown in Figure 14.
Caution: Observe the correct polarity or the load
may be damaged.
2. Connect the AC power to the input of the AC
wattmeter shown in Figure 14. Connect the white
leads to the output of the AC wattmeter.
3. Connect the DC voltmeter as shown in Figure 14.
capability
AC Wattmeter – 300W minimum, true RMS input
voltage, current, power factor, and THD 0.2% accuracy
or better
DC Voltmeter – 300 V dc minimum 0.1% accuracy or
better
DC Ammeter – 1 A dc minimum 0.1% accuracy or
better
LED Load – 75 V @ 0.1 A. A constant voltage
electronic load is an acceptable substitute for the LEDs
as long as it is stable
Functional Test Procedure
1. Set the LED Load for 75 V output.
2. Set the input power to 120 V 60 Hz.
Caution: Do not touch the ECA once it is
energized because there are hazardous voltages
present.
DC Ammeter
AC Power
Source
NOTE:
AC
Wattmeter
UUT
DC Voltmeter
LED
Test Load
Unless otherwise specified, all voltage measurements are taken at the terminals of the UUT.
Figure 14. Test Set Up
Line and Load Regulation
Table 2. 120 V/MAX LOAD
LED Output
Output Current
100 mA + 3 mA
Output Power
Power Factor
75 V
3.3 V Load = 0
75 V
3.3 V Load = 20 mA
Output Voltage
Aux Voltage
Min
3.3 V
3.0 V
3.6 V
LED Current = Max
3.3 V
3.0 V
3.6 V
LED Current = 0 (Dim = 0 V)
3.3 V
3.0 V
3.6 V
On/Off = Off
Efficiency +
V OUT @ I OUT
P IN
Measured
@ 100%
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13
Max
NCL30082SMRTGEVB
TEST DATA
Figure 15. Efficiency over Load
Figure 16. Regulation over Line
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14
NCL30082SMRTGEVB
Figure 17. Cross Regulation Effect of +3.3 Load on Output Current
Figure 18. Cross Regulation Effect of Output Current on +3.3 V Output
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15
NCL30082SMRTGEVB
Figure 19. Standby Power Consumption over Line
Figure 20. Start Up with AC Applied 120 V Maximum Load
Figure 21. Start Up with Enable
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NCL30082SMRTGEVB
BILL OF MATERIALS
Table 3. NCL30082SMRTGEVB BILL OF MATERIALS
Qty.
Reference
Part
Manufacturer
Manufacturer Part Number
PCB Footprint
Substitution
Allowed
4
C13, C15, CZIG,
CVCC
4.7 mF
Taiyo Yuden
EMK107ABJ475KA-T
603
Yes
1
COUT
4.7 mF, 100 V
AVX
12061Z475KAT2A
1206
Yes
2
C3, C5
100 nF, 250 V
Epcos
B32559-C3104-+***
CAP-BOX-LS5-3M5X7M2
Yes
1
C4
10 mF, 200 V
Rubycon
200LLE10MEFC8X11.5
CAP-ALEL-8X12-HOR
Yes
2
C10, C11
1 nF
Kemet
C0402C102K3GACTU
402
Yes
1
DOUT
UFM15PL
MCC
UFM15PL
SOD123FL
Yes
1
D4
ABS10
Comchip
ABS10
ABS10
Yes
2
D9, D13
BAS21DW5T1G
ON Semiconductor
BAS21DW5T1G
SC-88A
No
3
D10, D12, D15
MM5Z15VT1G
ON Semiconductor
MM5Z15VT1G
SOD523
No
1
D11
BAS116LT1G
ON Semiconductor
BAS116LT1G
SOT23
No
1
D14
BAS16XV2T1G
ON Semiconductor
BAS16XV2T1G
SOD523
No
1
F1
FUSE
Littelfuse
0263.500WRT1L
FUSE-AXIAL-LS450
Yes
1
J7
TMS−103−02−G−D
Samtec
TMS-103-02-G-D
Conn_Samtec_2X3
Yes
1
L1
1.5 mH
Wurth
7447462152
IND-UPRIGHT-LS25
Yes
1
L2
1.5 mH
Wurth
7447462152
IND-HOR-LS25
Yes
1
QFET
NDD02N60Z
ON Semiconductor
NDD02N60Z
IPAK
No
2
Q1, Q2
MMBT3904WT1G
ON Semiconductor
MMBT2904WT1G
SOT323
No
1
Q3
MMBTA06LT1G
ON Semiconductor
MMBTA06LT1G
SOT23
No
1
Q4
BSS138
ON Semiconductor
BSS138
SOT23
No
1
RBO
3.01 MW
Yaego
RC0805FR-073M01L
805
Yes
1
RDAMP
180 W
Yaego
RC0805JR-07180RL
805
Yes
1
RIFF
620 W
Yaego
RC0402FR-07620RL
402
Yes
1
RSENSE
1W
Yaego
RC1206FR-071RL
1206
Yes
2
RSTART1, RSTART
1.0 MW
Yaego
RC0805FR-071ML
805
Yes
1
RTCO
100 kW NTC
Epcos
B57331V2104J60
603
Yes
2
R20, RZCD
56 kW
Yaego
RC0805FR-0756KL
805
Yes
1
R2
51.1 kW
Yaego
RC0402FR-0751K1L
402
Yes
2
R6, R10
10 kW
Yaego
RC0402FR-0710KL
402
Yes
1
R7
470 W
Yaego
RC0402FR-07470RL
402
Yes
4
R8, R9, R15, R19
100 kW
Yaego
RC0402FR-07100KL
402
Yes
1
R11
12 kW
Yaego
RC0402FR-0712KL
402
Yes
1
R16
40.2 kW
Yaego
RC0402FR-0740K2L
402
Yes
1
R18
62 W
Yaego
RC0402FR-0762RL
402
Yes
1
R21
3.32 kW
Yaego
RC0402FR-073K32L
402
Yes
1
T1
XFRM_LINEAR
Wurth
750315096
RM5_8P_TH
Yes
1
U1
NCL30082B
ON Semiconductor
NCL30082B
MICRO8
No
1
U2
LP2951ACDM−3.3
ON Semiconductor
LP2951ACDM-3.3
MICRO8
No
1
U4
NCP431A
ON Semiconductor
NCP431A
SOT23
No
1
U5
LM317
ON Semiconductor
LM317LBDR2G
TO92
No
6″
W1
Wire, Red, 24AWG
McMaster Carr
7587K922
UL1569
Yes
6″
W2
Wire, Blk, 24AWG
McMaster Carr
7587K921
UL1569
Yes
12″
W3, W4
Wire, Wht, 24AWG
McMaster Carr
7587K924
UL1569
Yes
NOTE:
All components to comply with RoHS 2002/95/EC.
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17
NCL30082SMRTGEVB
ON Semiconductor and the
are registered trademarks of Semiconductor Components Industries, LLC (SCILLC) or its subsidiaries in the United States and/or other countries.
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. 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. This literature is subject to all applicable
copyright laws and is not for resale in any manner.
PUBLICATION ORDERING INFORMATION
LITERATURE FULFILLMENT:
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EVBUM2307/D