High Power Factor Offline Flyback Controller AL1788EV1User Guide

Transcription

1 AL788EVUser Guide General Description The AL788 is a high performance high Power Factor Corrected (PFC) LED driver controller. It is a Primary Side controller designed for driving the Flyback converter. Based on Valley-ON Quasi-resonant mode, AL788 is operating at Boundary Conduction Mode (BCM) which is good for EMI. It is universal Flyback solution with high PF and low THD. The AL788EV is designed to serve as an example for dual-cv (Constant Voltage) Output where main CV output requires high PFC and a secondary CV output is for wireless connectivity. Key Features Input Voltage Range: 8.0V to 25V Primary Side Control or Secondary Side Control (No Opto Coupler required) AC-to-CV Regulation Valley-on function to achieve low switching loss High Power Factor (PF) and Low Total Harmonic Distortion (THD) for wide Loading range High Efficiency Low system BOM cost Low Standby Power Under Voltage Lockout (UVLO) Over Voltage Protection (OVP) Over Current Protection (OCP) Output Short Protection (OSP) Over-temperature protection (OTP): Thermal shutdown and auto thermal recovery AL788EV Board Specifications Parameter Input Voltage Power Rating Main output: (Vout / Io) Standby Power Protections Efficiency XYZ Dimension Application Value 00Vac to 240V AC 32Watt Evaluation Board View: CV: VO - 42V / 750mA CV2: 3V3-3.3V / 200mA <500 mw (No Load on CV, 5mA for CV2) UVLO, OVP, OSP, OLP, OTP >87% for Vo Full Load 4.5 x 45 x 35 mm -Channel Dimmable White 2- Channel Tunable White Smart Lightning dual CV-output power Figure : Top View AL788 Figure 2: Bottom View Application: High PFC and low THD power supply Smart Connected LED Light Bulbs Smart Connected LED Tubes, Panel Lights, Troffers and Ceiling Lights AL788 EV Draft 0.2 Page of 9

2 2 GND BS High Power Factor Offline Flyback Controller AL788 Pin Assignment CS 6 Out GND 2 5 Vcc COMP 3 4 FB Top View (SOT26) Pin Name Pin Number Descriptions CS Primary Current Sensing GND 2 Ground COMP 3 Loop Compensation Pin FB 4 Voltage Sensing Feedback VCC 5 Power Supply OUT 6 Gate Driver Output Evaluation Board Schematic BD KBP206G RX3 NA C3 R3 RX5 NA L0 UU0.5/2mH RX RX2 NA NA CX NA CX2 NA VR 470V RX6 NA 4 ~ - + ~ C0 0.33uF L C uF L RX4 NA R0 750K R02 750K + C03 2.2uF R7 R04 NA 200K D03 R03 448W 0R + C04 47uF C05 R05 200K 470PF D0 RSM D02 RSMSWF 68PF 00R T0B PQ2625(0.4mH) D3,2 UF5JD D32 NA 0 3 R5 C5 4 NA NA 9 D5 DFLS ,8 + C32 470uF + C33 D34 NA + C52 200uF/35V 470uF D33 NA R52 K C32A 22K VO VO2 GND FS T2.0A-250V GND GND2 GND3 L N U0 AL788 CS OUT 2 GND VCC 6 5 R06 80K D04 448W R08 22R Q0 DMG9N65 VO2 U6 AP32 5 VIN C63 0.uF 6 SW L6 4.7uH 3V3 R6 324K C09 0.uF R5 K C07 2.2uF 3 4 COMP FB R0 0R C06 NA C08 0.uF R07.5K R 0R3 R2 0R3 R3 2R2 R09 5K R4 NA CY 2200pF C6 uf R6 00K C62 00nF 4 3 EN FB C64 2.2uF D6 SBRA40S R K R63 6K VO GND 2 VO2 GND 2 3V3 GND 2 CON 2P-2.54mm CON2 2P-2.54mm CON3 2P-2.54mm Figure 3: Evaluation Board Schematic AL788EV Draft 0.2 Page 2 of 9

3 Evaluation Board Layout Figure 4: PCB Board Layout Top View Figure5: PCB Board Layout Bottom View AL788EV Draft 0.2 Page 3 of 9

4 Bill of Material (BOM) # Name QTY Part Number Description Note U0 AL788W6-7 2 U6 AP32 3 D0 RSM 4 D02 RSMSWF 5 D03,D04 2 N448W Single-Stage Flyback and PFC controller for CV regulation (SOT236).4MHz,.5A Asynchronous DC-DC buck converter (SOT236).0A surface mount fast recovery rectifier (SMA).0A surface mount fast recovery rectifier (SOD23F) Surface mount fast switching diode (SOD23) Diodes, Inc. Diodes, Inc. Diodes, Inc. Diodes, Inc. Diodes, Inc. 6 D3 UF5JD 5A ULTRA-FAST rectifier (TO252) Diodes, Inc. 7 D5 DFLS00 8 D6 SBRA40S.0A High voltage schottky barrier rectifier (POWERDI@23).0A SBR Super Barrier Rectifier (SOD23) Diodes, Inc. Diodes, Inc. 9 D33,D34 2 NA Not fitted (for Regulation) Diodes, Inc. 0 BD KBP206G Q0 DMG9N65CTI 2.0A Glass passivated bridge rectifier (KBP) N-Channel Enhancement Mode MOSFET (ITO-220AB) Diodes, Inc. Diodes, Inc. 2 C0 0.33uF/400V EMI filter and Storage capacitor 3 C uF/400V EMI filter and Storage capacitor 4 C03 2.2uF/50V Storage capacitor for startup (5*) 5 C04 47uF/35V VCC hold-up capacitor (5*) 6 C05 470PF/KV Snubber capacitor (206) 7 C06 0 NA Not fitted ( 0805 for CS filter) 8 C07 2.2uF/6V Compensation capacitor 9 C08 0.uF VCC Filter 20 C09 0.uF Compensation capacitor 2 C3 68pF/KV Snubber capacitor (206) 22 C33,C uF/63V 42V output filter capacitor 23 C32A 22K 42V dummy load (206) 24 C52 220uF/35V 7.5V output filter capacitor AL788EV Draft 0.2 Page 4 of 9

5 25 C6.0uf 3.3V buck converter input filter 26 C62 00nF 3.3V buck converter push-pull capacitor 27 C63 0.uF Bootstrap capacitor for 3.3V converter 28 C64 2.2uF/6V 3.3V buck converter output filter 29 CX,CX2 0 NA Not fitted (for EMI filter) 30 CY 2200pF-Y EMI filter 3 FS T2.0A-250V Fuse LittleFuse 32 L0 0mH EMI filter (UU0.5) 33 L02,L mH EMI filter (DR0*4) 34 L6 4.7uH 3.3V buck converter inductor (PCMB053T-4R7MS) Cyntec (Fortron Co.,Ltd.) 2 750K Startup resistor (startup time<000ms) 35 R02,R K Startup resistor (startup time<500ms) K Startup resistor (startup time<400ms) 36 R03 0R VCC filter resistor 37 R05,R K Snubber resistor (206) 38 R06 80K Feedback resistor 39 R07.5K Feedback resistor 40 R08 22R Gate Resistor 4 R09 5K Discharge resistor for to avoid capacitive coupling driving the MOSFET 42 R0 0R Jumper (for CS filter) 43 R2,R 2 0R3 MOSFET Drain current sense resistor 44 R3 2R2 MOSFET Drain current sense resistor 45 R5 K Compensation resistor 46 R52 K 7.5V dummy load (206) 47 R6 324K Compensation resistor 48 R3 00R Snubber resistor (206) 49 R6 00K RC delay of 3.3V converter EN 50 R K 3.3V converter voltage feedback resistor AL788EV Draft 0.2 Page 5 of 9

6 5 R63 6K 3.3V converter voltage feedback resistor 52 R7 0 NA (pcs) Not fitted (sunnber) 53 RX,RX2,R X3, RX4,RX5,R X6, R4,R5,C 5 0 NA (9pcs) Not fitted 54 T0B PQ2625_0.4mH Transformer 55 VR 47K Varistor for EMC 56 CON 2P-2.54mm VO (42V)output connector 57 CON2 2P-2.54mm VO2 (7.5V) output connector 58 CON3 2P-2.54mm 3V3 output connector AL788EV Draft 0.2 Page 6 of 9

7 Transformer Design: Transformer Pin & Wire Description: Circuit: Cross sectional view: Primary Secondary L5,2 Tape*2Ts for fix core 3 4 5,6 2 L L2 L3 L4 Start 9,0 7,8 Over core L5 L4 L3 L2 F wire shielding L T T T T T T 6 F Teflon Tube Name Start Finish Wire Specification (φ) Turns(Ts) Method Layer(s) Tape Layer(s) L 3 2 2UEW-B 0.25mm x 2P 2 Close T F 6 2UEW-B 0.2mm x P 54 Close T L UEW-B 0.2mm x P 2 Space T L3 2 0 Triple wire-b 0.4mm x 2P 2 Close 2 T L4 9 7 Triple wire-b 0.4mm x 2P 6 Space T L5 2 2UEW-B 0.25mm x 2P 8 Close T OVER CORE 2Ts Electrical Characteristic: # Test Item Winding Pin Rating Unit Tolerance Remark 2. Inductance L and L mh 00KHz / V AL788EV Draft 0.2 Page 7 of 9

8 Demo Board Performance Test Output Turn ON Waveform: 0V VO/500mA, 3V3/200mA Turn ON Waveform 230V VO/500mA, 3V3/200mA Turn ON Waveform CH:VO CH3:3.3V CH:VO CH3:3.3V Output Ripple Voltage Waveform: 0Vac VO/750mA, 3V3/200mA Output Ripple 230Vac VO/750mA, 3V3/200mA Output Ripple CH:VO CH3:3.3V CH:VO CH3:3.3V AL788EV Draft 0.2 Page 8 of 9

9 Standby Power and Efficiency Performance: Startup Resistor: R0=R02=750Kohm High Power Factor Offline Flyback Controller Power Factor and Total Harmonic Distortion Performance: AL788EV Draft 0.2 Page 9 of 9

10 UVLO, Startup Time and Standby Power : UVLO-ON and UVLO-OFF R0=R02=750K, Startup time=562ms CH:VCC CH2:Vgate CH:VCC CH2:VO CH3:3.3V CH4:VH R0=R02=375K, Startup time=38ms R0=R02=545K, Startup time=408ms CH:VCC CH2:VO CH3:3.3V CH4:VH CH:VCC CH2:VO CH3:3.3V CH4:VH Startup Time and Standby Power vs. Startup Resistor Startup Resistor 500Kom 090Kohm 750Kohm Startup Time 562ms 408ms 38ms Standby Power 390.2mW 47.5mW 47.6mW Note: Low startup resistors reduce the startup time, but will increase standby power. AL788EV Draft 0.2 Page 0 of 9

11 MOSFET (Q0) Voltage Waveform: 264Vac Full Load normal Waveform 264Vac Full Load turn on waveform VDS_max=476V VDS_max=496V Valley Switching Performance: 264Vac Full Load MOSFET VDS Waveform 264Vac Full Load Output Ripple Waveform VOFull Load VCS_90V=0.434V Full Load VCS_264V=0.30V AL788EV Draft 0.2 Page of 9

12 Output Rectifier Diode (D3) Voltage Waveform: 264Vac Full Load normal Waveform 264Vac Full Load turn on waveform VDF_max=428V Current Sense Voltage Waveform: 90Vac Full Load normal Waveform VDF_max=56V 264Vac Full Load normal Waveform Full Load VCS_90V=0.434V Full Load VCS_264V=0.30V AL788EV Draft 0.2 Page 2 of 9

13 Over Current Protection: 0Vac; OCP current:.2a 230Vac; OCP current:.5a CH:VDS CH4:IO CH:VDS CH4:IO Short Circuit Protection: 0Vac; Output Short and Auto Recover 230Vac; Output Short and Auto Recover CH:VDS CH4:IO CH:VDS CH4:IO AL788EV Draft 0.2 Page 3 of 9

14 Conducted EMI Test: Load Condition: VO add 54ohm Resistor (750mA). Two-Wires Input 0Vac/L Full Load (750mA) Two-Wires Input 0Vac/N Full Load (750mA) RBW 9 khz Marker [T ] RBW 9 khz Marker [T ] MT s dbµv MT s 40.4 dbµv Att 0 db khz Att 0 db khz dbµv 00 MHz 0 MHz dbµv 00 MHz 0 MHz PK PK MAXH 80 MAXH 80 2 AV MAXH 70 TDS 2 AV MAXH 70 TDS EN55022Q EN55022Q EN55022A EN55022A DB 6DB khz 30 MHz 50 khz 30 MHz EDIT PEAK LIST (Final Measurement Results) Date: Trace: 23.JUN.207 6:02:54 EN55022Q Trace2: EN55022A Trace3: --- TRACE FREQUENCY LEVEL dbµv DELTA LIMIT db Quasi Peak MHz Average MHz Average MHz Quasi Peak MHz Average MHz Quasi Peak MHz Quasi Peak MHz Average MHz Quasi Peak MHz Average MHz EDIT PEAK LIST (Final Measurement Results) Date: Trace: 23.JUN.207 EN55022Q 6:0:08 Trace2: Trace3: --- EN55022A TRACE FREQUENCY LEVEL dbµv DELTA LIMIT db Quasi Peak MHz Quasi Peak MHz Quasi Peak MHz Average MHz Average MHz Average MHz Quasi Peak MHz Average MHz Average MHz Quasi Peak MHz Date: 23.JUN.207 6:02:28 Date: 23.JUN.207 6:00:37 AL788EV Draft 0.2 Page 4 of 9

15 Two-Wires Input 230Vac/L Full Load (750mA) Two-Wires Input 230Vac/N Full Load (750mA) RBW 9 khz Marker [T ] RBW 9 khz Marker [T ] MT s 42.3 dbµv MT s dbµv Att 0 db khz Att 0 db khz dbµv 00 MHz 0 MHz dbµv 00 MHz 0 MHz PK PK MAXH 80 MAXH 80 2 AV MAXH 70 TDS 2 AV MAXH 70 TDS EN55022Q EN55022Q EN55022A EN55022A DB 6DB khz 30 MHz 50 khz 30 MHz EDIT PEAK LIST (Final Measurement Results) Date: Trace: 23.JUN.207 EN55022Q 6:0:34 Trace2: Trace3: --- EN55022A TRACE FREQUENCY LEVEL dbµv DELTA LIMIT db 2 Average MHz Average MHz Quasi Peak MHz Quasi Peak MHz Quasi Peak MHz Average MHz Quasi Peak MHz Average MHz Quasi Peak MHz Average MHz EDIT PEAK LIST (Final Measurement Results) Date: Trace: 23.JUN.207 EN55022Q 6:08:55 Trace2: EN55022A Trace3: --- TRACE FREQUENCY LEVEL dbµv DELTA LIMIT db Quasi Peak MHz Quasi Peak 7.3 MHz Average MHz Quasi Peak MHz Average MHz Quasi Peak MHz Average MHz Average MHz Quasi Peak MHz Average MHz Date: 23.JUN.207 6:0:4 Date: 23.JUN.207 6:08:20 AL788EV Draft 0.2 Page 5 of 9

16 Thermal Test Result High Power Factor Offline Flyback Controller Two-Wires Input 0Vac/L Full Load (750mA) Two-Wires Input 0Vac/N Full Load (750mA) TOP- Input Voltage=264Vac BOT- Input Voltage=264Vac TOP- Input Voltage=230Vac BOT-Input Voltage=230Vac TOP- Input Voltage=90Vac BOT-Input Voltage=90Vac AL788EV Draft 0.2 Page 6 of 9

17 Input / Output Application Description: AL788-CDK0 Application Description VIN_ACN CN CN2 VIN_ACL CN3 VIN_ACN CN CN2 VIN_ACL CN2 Input Pin Functions: Connector PIN# Name Function Description VIN_ACL VIN_ACL Connect to AC (L) Input VIN_ACN VIN_ACN Connect to AC (N) Input Output Pin Functions: Connector PIN# Name Function Description VO VO 42V Output for CV 750mA_max output CN VO 42V Output for CV 2 GND GND GND GND GND VO2 VO2 7.5V Output for CV 50mA_max output CN2 VO2 7.5V Output for CV 50mA_max output 2 GND GND GND2 GND GND 3V3 3V3 3.3V Output for MCU 200mA_Max output CN3 3V3 3.3V Output for MCU 200mA_Max output 2 GND GND GND3 GND GND AL788EV Draft 0.2 Page 7 of 9

18 Quick Start Guide The evaluation board is preset at 42V (VO) and 3.3V (3V3) for universal voltage input 00V < V ac < 240V Ensure that the AC source is switched OFF or disconnected. Connect the AC line wires of power supply to L and N on the board. Turn on the AC main switch. Measure CVout to check VO and 3V3 to ensure proper output voltages (42V and 3.3V) Use Case examples for smart light bulb development AL788DCK0 + AL794EV (30V DC-to-CC Linear CCR) AL788CDK0 + AL8860EV (40V DC-to-CC Switching Buck) Reference web site: AL794EV - AL8860EV - AL788EV Draft 0.2 Page 8 of 9

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