Fairchild Reference Design

Transcription

1 Reference Design This reference design supports inclusion of the FL7930C, FAN6300H, FAN7346, FSL138MRT, FAN7382, and FAN3111C devices in the design of an offline, 100 W, CCCV, LED power supply intended for industrial lighting applications. The RD-400 reference design leverages several advanced technologies to offer a complete LED driver solution suitable for wide-range, AC-input voltage, high Power Factor (PF), and high efficiency up to 100 W output power. The overall power architecture consists of an EMI filter stage, a PFC boost converter, a dual-switch flyback converter, and two control options for configuring the output to operate a single LED string or up to four independent LED strings. It should be used in conjunction with the FL7930C, FAN6300H, FAN7346, FSL138MRT, FAN7382, and FAN3111C datasheets as well as s application notes and technical support team. Please visit s website at Application Devices Input Voltage Range Rated Output Power Output Voltage (Rated Current) Industrial LED Lighting FL7930C, FAN6300H, FAN7346, FSL138MRT, FAN7382, FAN3111C V AC 100 W Single-Channel: 30 V - 50 V, (2 A) 4-Channel: 30 V - 62 V, (1.4 A) Key Features Wide Input Voltage Range from 80 V AC <V IN(AC) <310 V AC Wide Range, High Efficiency Inrush Current Limiting Dedicated On-Board Flyback Bias Regulator PFC-Ready (RDY) Function BCM PFC Boost Pre-Regulator Can Operate as Boost Follower Simple 2-Switch QRC Flyback Power Topology Configurable for Single-Channel or 4-Channel LED Operation 4-Channel, 1.5% LED Current Accuracy Supports LED Voltage up to 100 V per Channel 0 V - 10 V, On-Board, Analog Dimming 1% - 100%, On-Board, PWM Dimming Individual Channel Dimming when Operating in 4-Channel Mode Protection Functions: Open LED, Short LED, Error Flag Output, Over-Voltage, Over-Current, and Thermal Shutdown Low 25 mm Cross-Section Profile 2013 Corporation 1 RD-400 Rev

2 1. Schematics Figure 1. PFC, Boost Follower Enable, Inrush Limit; Power Board Schematic 2013 Corporation 2 RD-400 Rev

3 Figure 2. 2-Switch Flyback, PWM Dimmers, 5 V Secondary Bias 2013 Corporation 3 RD-400 Rev

4 Figure 3. High-Voltage, Flyback Bias Regulator Figure 4. Controller Daughter Card Schematic Single Channel, CCCV LED Controller 2013 Corporation 4 RD-400 Rev

5 Figure 5. Controller Daughter Card Schematic 4-Channel, LED Controller 2013 Corporation 5 RD-400 Rev

6 2. Custom Magnetics 2.1. BCM PFC Coupled Inductor (Wurth ) Winding Specification Winding Pins (S F) Wire Layers Turns Main, N (6-1) / 40, Served Litz 2 40 ZCD, N ZCD(9-10) 9 10 # Core: EFD30 (Ae=69 mm 2 ) Bobbin: EFD30, 12 Pin, Horizontal Gap: 1.2 mm 2.3. Electrical Characteristics Pin Specification Remark Inductance µh ±10% 500 khz, 100 mv AC R DC(6-1) 6 1 <120 mω R DC(9-10) 9 10 <80 mω 2013 Corporation 6 RD-400 Rev

7 2.4. Quasi-Resonant Flyback Transformer (EV30 Custom) , , Winding Specification Winding Pins (S F) Wire Layers Turns ½ Primary, N P(2-3) /38, Served Litz 1 36 Secondary, N S(9,10-11,12) 9, 10 11, 12 30/38, Served Litz 1 19 ½ Primary, N P(3-4) /38, Served Litz 1 35 Detect, N DET(6-5) 6 5 2/38, Bifilar 1 4 High-Side, N HS(2-1) 2 1 2/38, Bifilar 1 3 Core: EV30 (Ae=99 mm 2 ) Bobbin: EV30/12-1, 12 Pin, THT, Horizontal Gap: 1.2 mm 2.6. Electrical Characteristics Pin Specification Remark Inductance mh ±10% 500 khz, 100 mv AC Leakage µh ±10% 1, 2, 5, 6, 9, 10, 11, 12 Shorted R DC(2-4) 2 4 <500 mω 465 mω, Typical R DC(9,10-11,12) 9, 10 11, 12 <150 mω 135 mω, Typical 2013 Corporation 7 RD-400 Rev

8 2.7. Flyback Bias Transformer (Wurth ) Winding Specification Winding Pins (S F) Wire Layers Turns ½ Primary, N P(2-3) 2 3 # Secondary Bias, N SBIAS(8-7) 8 7 # ½ Primary, N P(1-2) 1 2 # Primary Bias, N PBIAS(5-4) 5 4 # Core: EE16/7/5 (Ae=18.4 mm 2 ) Bobbin: EE16, 10 Pin, THT, Vertical Gap: 0.57 mm 2.9. Electrical Characteristics Pin Specification Remark Inductance mh ±10% 300 khz, 100 mv AC Leakage µh, Typical 30 µh, Maximum R DC(2-4) 1 3 <1.82 Ω R DC(5-4) 5 4 <420 mω R DC(8-7) 8 7 <325 mω 4, 5, 7, 8 Shorted 2013 Corporation 8 RD-400 Rev

9 3. Bill of Materials Table 1. Main Power Board BOM Item Qty. Reference Value Part Number Description Manufacturer Package 1 2 C1, C6 470 pf FK26C0G2J471J 2 2 C2, C7 150 nf ECQ-E6154KF 3 2 C nf B32922C3334M Cap, Ceramic, 630 V, 10%, COG, Cap, X Type, 630 V, 10%, Poly Metalized Cap, X Type, 630 V, 10%, Poly TDK Panasonic EPCOS 4 2 C5, C8 330 µf UVR2E331MRD Cap, 250 V, Alum Elect. Nichicon 5 9 C9, C11, C13 C19, C26, C29 C33, C36, C nf 6 1 C10 15 nf 7 3 C12, C20, C µf 8 1 C µf 9 2 C15, C30 10 pf 10 1 C nf 11 6 C17, C27-28 C34-35, C47 10 nf 12 1 C18 1 µf 25 V, X7R 25 V, X7R 25 V, X7R 10 V 25 V, X7R 25 V, X7R 25V, X7R 50 V, X5R 13 2 C µf UPW1J471MHD3 Cap, 63 V, Alum, Elect. Nichicon 14 3 C23-24, C nf 15 1 C31 39 nf 16 1 C pf 17 2 C37, C44 10 µf C3216X7R1E106K160AB 18 1 C38 10 nf ECQ-E6103KF 19 4 C39, C41, C C42 22 nf 22 1 C48 10 µf 47 µf F931C476MNC 23 4 D1-2, D9-10 ES3J 100 V, X7R 25V, X7R 25 V, X7R CAP, SMD, CERAMIC,25 V, X7R CAP, 630 V, 10 nf, 10%, Poly CAP, SMD, TANT, 16 V, 20% 25 V, X7R 50 V, X5R Diode, 600 V, 3 A, Fast Recovery 24 1 D3 GBU6J Diode Bridge, 6 A, 1000V 25 4 D4, D8, D15, D23 MBR D5 5.1 V MMBZ5231B 27 8 D6-7, D N4148WS 28 2 D11, D29 17 V MMSZ5247B Diode, Schottky,40 V, 500 ma Diode, Zener, 10 V, 350 mw Diode, 300 ma, 100 V Std. Rec. Diode, Zener, 17 V, 500 mw STD 1206 STD 1206 Panasonic Nichicon SMC SOD-123 SOT-23 SOD-323F SOD Corporation 9 RD-400 Rev

10 Item Qty. Reference Value Part Number Description Manufacturer Package 29 4 D12-13, D24, D26 RGF1M Diode, Fast, 600 V, 1 A 30 1 D14 EGP30D Diode, 200 V, 3 A 31 1 D16 S1J 32 3 D25, D27-28 S100 Diode, General Purpose 1 A, 600 V Diode, Schottky, 100 V, 1 A 33 1 F1 3 A YXP Fuse, 3 A, 350 VAC Littlefuse 34 8 J1, J3, J5, J8-9 J14, J J J4, J17, J J6-7, J22, J J15-16, J18, J20 OSTTA J19 SS-132-TT J23 SS-132-TT K1 G5CA-1A DC12 SMA Axial SMA SMA Test Pin, Gold, 40 mil, Mill-Max Header, 3 Pin, Spacing Header, 3 Pin, 100 mil Spacing TE Connectivity STD Test Pin, SMD, 1206 Te Connectivity 1206 Header, 2 Pin, 100 mil Spacing, 15 A Connector, Header, 8 Pin, 100 Mil Connector, Header, 10 Pin, 100 Mil RELAY PWR SPST-NO 10 A 12 VDC OST Inc. Samtec inc. Samtec Inc. Omeron Electronics 43 1 L1 175 µh BCM PFC Inductor, EFD30 Wurth 44 1 L2 9 mh L µh Q1 FCP190N60E 47 3 Q2, Q7, Q10 ZXTP25020DFL 48 1 Q3 2N7002K 49 2 Q4-5 MMBT2222A 50 2 Q6, Q9 FDP22N50N 51 2 Q8, Q11 KA431ADTF Common Mode Choke, 9 mh Inductor, Power, 4.7 µh, 0.85 A MOSFET, NCH, SuperFET2, 600 V, 60 A Transistor, PNP, 20 V, 1.5 A MOSFET N-CH 60 V 300 ma Transistor, NPN, 40 V, 1.0 A MOSFET, NCH, UniFET, 500 V, 22 A Adjustable Shunt Regulator Wurth Wurth Zetex SMD TO-220 SOT-23 SOT-23 SOT R1 0 RES, SMD, 1/2 W STD R2 0 RES, SMD, 1/2 W STD R3, R5 604 kω RES, SMD, 1/8 W R4, R16, R21, R24-25, R29, R35, R40, R50, R68 TO-220 SO-8 10 kω RES, SMD, 1/8 W 56 3 R6, R31, R Ω RES, SMD, 1/8W 57 2 R7, R12 33Ω B57237S0330M000 THERMISTOR EPCOS 58 1 R8 590 kω RES, SMD, 1/8 W 59 2 R9, R11 1 kω RES, SMD, 1/8 W 60 1 R Ω RES, SMD, 1/8 W 61 2 R Ω RES, SMD, 1/4 W STD Corporation 10 RD-400 Rev

11 Item Qty. Reference Value Part Number Description Manufacturer Package 62 1 R kω RES, SMD, 1/8 W 63 3 R17, R32, R38 DNP RES, SMD, 1/8 W 64 2 R18, R kω RES, SMD, 1/8 W 65 1 R kω RES, SMD, 1/8 W 66 1 R kω RES, SMD, 1/8 W 67 1 R23 34Ω RES, SMD, 1/8 W 68 1 R kω RES, SMD, 1/8 W 69 3 R27, R42, R kω RES, SMD, 1/8 W 70 1 R kω RES, SMD, 1/8 W 71 2 R30, R36 12Ω RES, SMD, 1/8 W 72 1 R33 590Ω RES, SMD, 1/8 W 73 1 R kω RES, SMD, 1/8 W 74 1 R39 0.4Ω RES, SMD, 1/2 W STD R41, R43, R47, R kω RES, SMD, 1/8 W 76 7 R44, R52-54 R58, R RES, SMD, 1/8 W 77 2 R45, R kω 63M-T Potentiometer, 1 - Turn Murata 78 1 R kω RES, SMD, 1/8 W 79 1 R51 100Ω RES, SMD, 1/8 W 80 1 R kω 2W RES BODY:340 CENTERS:1000 STD Thru-hole 81 4 R57, R59, R61, R67 20 kω RES, SMD, 1/8 W 82 1 R64 499Ω RES, SMD, 1/8 W 83 1 R65 12 kω RES, SMD, 1/8 W 84 1 R kω RES, SMD, 1/8 W 85 1 R kω RES, SMD, 1/8 W 86 1 T1 Custom XFMR, Flyback, EV30 EPCOS 87 1 T XFMR, Flyback, Bias Wurth 88 1 U1 LM393M 89 1 U2 FL7930C 90 1 U3 FAN3111C 91 1 U4 FAN7382 Dual, Differential Comparator FL7930 PFC LED Controller Gate Driver, Low-Side, Single, 1 A High-and Low-Side Gate Driver 92 2 U5-6 LM555 Timer, U7 FAN6300H Quasi-Resonant, Current Mode PWM Controller 94 2 U8, U10 FOD817A Opto-Isolator 95 1 U9 FSL138MRT PWM Controller, High Input Voltage SOIC-8 SOIC-8 SOT-23-5 SOIC-8 SOIC-8 SOIC-8 SMD To-220F- 6L 2013 Corporation 11 RD-400 Rev

12 Table 2. Multi-Channel, LED Controller, BOM Item Qty. Reference Value Part Number Description Manufacturer Package 1 6 C101, C , C108, C nf 25 V, X7R 2 1 C102 DNP 25 V, X7R 3 1 C nf 25 V, X7R 4 1 C107 1 µf 50 V, X5R 5 1 C µf 25 V, X7R 6 1 D100 LTST- C170KRKT LED, Red, SMD, 20 ma, 2 V Lite-On J Connector, 8-Pin, Header, 100 mil TE Connectivity 8 5 J Connector, Header, 100 mil TE Connectivity 9 1 J Q FDT86256 Connector, 10-Pin, Header, 100 mil MOSFET,N Ch, Power Trench, 150V, 1.2 A TE Connectivity SOT R1 20 kω 3266W-1-203LF Potentiometer, 12turn precision Murata 12 1 R kω RES, SMD, 1/8 W 13 2 R3, R kω RES, SMD, 1/8 W 14 4 R101, R Ω RES, SMD, 1/8 W 15 4 R Ω RES, SMD, 1/8 W 16 1 R kω RES, SMD, 1/8 W 17 4 R Ω RES, SMD, 1/4W STD R kω RES, SMD, 1/8 W 19 1 R kω RES, SMD, 1/8 W 20 4 R Ω RES, SMD, 1/4 W STD R122 2 kω RES, SMD, 1/8 W 22 4 R kω RES, SMD, 1/8 W 23 1 U100 FAN7346 Table 3. Single-Channel, CCCV LED Controller, BOM 4-Channel LED Current Balance Controller SOIC-28 Item Qty Reference Value Part Number Description Manufacturer Package 1 2 C200, C nf 25 V, X7R 2 2 C201, C nf 25 V, X7R 3 2 D N4148WS Diode, 300 ma, 100 V Std. Rec. SOD-323F 4 1 J Connector, 8-Pin, Header, 100 mil TE Connectivity 5 1 J Header, 3-Pin, 100 mil TE Connectivity 6 1 J Connector, 10-Pin, Header, 100 mil TE Connectivity 7 1 R Ω RES, SMD, 1/8 W 8 1 R kω RES, SMD, 1/8 W 9 2 R202, R kω RES, SMD, 1/8 W 10 2 R Ω RES, SMD, 1 W STD R kω RES, SMD, 1/8 W 12 1 R kω RES, SMD, 1/8 W 13 1 R kω RES, SMD, 1/8 W 14 1 R kω RES, SMD, 1/8 W 15 1 R kω RES, SMD, 1/8 W 16 1 R Ω RES, SMD, 1 W STD U200 KA431A Adjustable Shunt Regulator SO U201 FAN4274 OPAMP, Dual, CMOS, 200 µa MSOP Corporation 12 RD-400 Rev

13 Efficiency (%) Efficiency (%) 4. Electrical Performance 100% RD-400, System Efficiency 70W, 50V, 4x350mA 95% 85W, 60V, 4x350mA 90% 85% 80% Input Voltage (VAC) Figure 6. Efficiency RD-400, System Power Factor W, 50V, 4x350mA 85W, 60V, 4x350mA Input Voltage (VAC) Figure 7. Power Factor 2013 Corporation 13 RD-400 Rev

14 Percent Max LED Current (%) Percent Max LED Current (%) RD-400, PWM Dimming (120VAC, 250Hz, 3.3VDIM, 50V, 4x350mA, 70W) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% PWM Dimming Duty Cycle (%) Figure 8. PWM. Dimming RD-400, Analog Dimming (120VAC, 50V, 4x350mA, 70W) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Dimming Voltage (VDC) Figure 9. Analog Dimming 2013 Corporation 14 RD-400 Rev

15 Harmonic Current (A) Harmonic Current (A) RD-400, System THD EN , 115VAC, 85W (4x350mA) Measured Harmonic Current Class C (Lighting) Limit Harmonic Number Figure 10. Total Harmonic Discharge: V IN=115 V AC, P OUT=85 W, THD=8.91% 0.14 RD-400, System THD EN , 230VAC, 85W (4x350mA) Measured Harmonic Current Class C (Lighting) Limit Harmonic Number Figure 11. Total Harmonic Discharge: V IN=230 V AC, P OUT=85 W, THD=21.52% 2013 Corporation 15 RD-400 Rev

16 5. Related Resources FL7930C Single-Stage Flyback and Boundary Mode PFC Controller for Lighting FAN6300H Highly Integrated Quasi-Resonant Current Mode PWM Controller FSL138MRT Green-Mode Power Switch (FPS ) for High Input Voltage FAN Channel LED Current Balance Controller for Lighting FAN7382 Half Bridge Gate Driver FAN3111C Single 1A High-Speed, Low-Side Gate Driver Reference Design Disclaimer Corporation ( ) provides these reference design services as a benefit to our customers. has made a good faith attempt to build for the specifications provided or needed by the customer. provides this product as is and without recourse and MAKES NO WARRANTY, EXPRESSED, IMPLIED OR OTHERWISE, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Customer agrees to do its own testing of any reference designs in order to ensure design meets the customer needs. Neither nor Customer shall be liable for incidental or consequential damages, including but not limited to, the cost of labor, requalifications, rework charges, delay, lost profits, or loss of goodwill arising out of the sale, installation or use of any product. Subject to the limitations herein, will defend any suit or proceeding brought against Customer if it is based on a claim that any product furnished hereunder constitutes an infringement of any intellectual property rights. must be notified promptly in writing and given full and complete authority, information and assistance (at s expense) for defense of the suit. will pay damages and costs therein awarded against Customer but shall not be responsible for any compromise made without its consent. In no event shall s liability for all damages and costs (including the costs of the defense by ) exceed the contractual value of the products or services that are the subject of the lawsuit. In providing such defense, or in the event that such product is held to constitute infringement and the use of the product is enjoined,, in its discretion, shall procure the right to continue using such product, or modify it so that it becomes noninfringing, or remove it and grant Customer a credit for the depreciated value thereof. s indemnity does not extend to claims of infringement arising from s compliance with Customer s design, specifications and/or instructions, or the use of any product in combination with other products or in connection with a manufacturing or other process. The foregoing remedy is exclusive and constitutes s sole obligation for any claim of intellectual property infringement and makes no warranty that products sold hereunder will not infringe any intellectual property rights. All solutions, designs, schematics, drawings, boards or other information provided by to Customer are confidential and provided for Customer s own use. Customer may not share any materials with other semiconductor suppliers Corporation 16 RD-400 Rev