LM3444-120VFLBK/NOPB

User's Guide SNVA454E – September 2010 – Revised May 2013 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver 1 Introduction This demonstration board highlights the performance of a LM3444 based Flyback LED driver solution that can be used to power a single LED string consisting of 4 to 8 series connected LEDs from an 90 VRMS to 135 VRMS, 60 Hz input power supply. The key performance characteristics under typical operating conditions are summarized in this application note. This is a two-layer board using the bottom and top layer for component placement. The demonstration board can be modified to adjust the LED forward current, the number of series connected LEDs that are driven and the switching frequency. Refer to the LM3444 AC-DC Offline LED Driver (SNVS682) data sheet for detailed instructions. A bill of materials is included that describes the parts used on this demonstration board. A schematic and layout have also been included along with measured performance characteristics. 2 Key Features • • • 3 Applications • • • 4 Line injection circuitry enables PFC values greater than 0.99 Adjustable LED current and switching frequency Flicker free operation Solid State Lighting Industrial and Commercial Lighting Residential Lighting Performance Specifications Based on an LED Vf = 3.57V Symbol Parameter Min Typ Max VIN Input voltage 90 VRMS 120 VRMS 135 VRMS VOUT LED string voltage 12 V 21.4 V 30 V ILED LED string average current - 350 mA - POUT Output power - 7.6 W - fsw Switching frequency - 79 kHz - PowerWise is a trademark of Texas Instruments. All other trademarks are the property of their respective owners. SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 1 Performance Specifications www.ti.com Figure 1. Demo Board 2 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated LM3444 120VAC, 8W Isolated Flyback LED Driver Demo Board Schematic www.ti.com 5 LM3444 120VAC, 8W Isolated Flyback LED Driver Demo Board Schematic V+ T1 VLED+ D4 C1 R2 R1 D1 C3 R7 R3 + C4 + D5 D3 Q1 R22 VLED± D8 D7 VCC C7 1 NC C8 NC 10 R16 2 NC VCC 9 3 NC GATE 8 4 COFF ISNS 7 5 GND 6 R12 Q2 C12 FILTER R15 FILTER R13 R14 LM3444 C11 C13 R6 RT1 L1 LINE C2 C6 D2 V+ F1 NEUTRAL L2 R24 INPUT EMI FILTER AND RECTIFIER CIRCUIT WARNING The LM3444 evaluation board has exposed high voltage components that present a shock hazard. Caution must be taken when handling the evaluation board. Avoid touching the evaluation board and removing any cables while the evaluation board is operating. Isolating the evaluation board rather than the oscilloscope is highly recommended. SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 3 LM3444 Device Pin-Out www.ti.com WARNING The ground connection on the evaluation board is NOT referenced to earth ground. If an oscilloscope ground lead is connected to the evaluation board ground test point for analysis and AC power is applied, the fuse (F1) will fail open. The oscilloscope should be powered via an isolation transformer before an oscilloscope ground lead is connected to the evaluation board. WARNING The LM3444 evaluation board should not be powered with an open load. For proper operation, ensure that the desired number of LEDs are connected at the output before applying power to the evaluation board. 6 LM3444 Device Pin-Out NC 1 10 NC NC 2 9 VCC NC 3 8 GATE COFF 4 7 ISNS FILTER 5 6 GND Table 1. Pin Description 10-Pin VSSOP 4 Pin # Name Description 1 NC No internal connection. 2 NC No internal connection. 3 NC No internal connection. 4 COFF 5 FILTER OFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant OFF time of the switching controller. Filter input. A capacitor tied to this pin filters the error amplifier. Could also be used as an analog dimming input. 6 GND Circuit ground connection. 7 ISNS LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the maximum LED current. 8 GATE Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck controller. 9 VCC Input voltage pin. This pin provides the power for the internal control circuitry and gate driver. 10 NC No internal connection. AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Bill of Materials www.ti.com 7 Bill of Materials Designator Description Manufacturer Part Number AA1 Printed Circuit Board - 551600530-001A C1 CAP .047UF 630V METAL POLYPRO EPCOS Inc B32559C6473K000 C2 CAP 10000PF X7R 250VAC X2 2220 Murata Electronics North America GA355DR7GB103KY02L C3, C4 CAP 330UF 35V ELECT PW Nichicon UPW1V331MPD6 C6 CAP .10UF 305VAC EMI SUPPRESSION EPCOS B32921C3104M C7 CAP, CERM, 0.1µF, 16V, +/-10%, X7R, 0805 Kemet C0805C104K4RACTU C8 CAP CER 47UF 16V X5R 1210 MuRata GRM32ER61C476ME15L C11 CAP CER 2200PF 50V 10% X7R 0603 MuRata GRM188R71H222KA01D C12 CAP CER 330PF 50V 5% C0G 0603 MuRata GRM1885C1H331JA01D C13 CAP CER 2200PF 250VAC X1Y1 RAD TDK Corporation CD12-E2GA222MYNS SMAJ120A D1 DIODE TVS 150V 600W UNI 5% SMB Littlefuse D2 RECT BRIDGE GP 600V 0.5A MINIDIP Diodes Inc. RH06-T D3 DIODE RECT GP 1A 1000V MINI-SMA Comchip Technology CGRM4007-G D4 DIODE SCHOTTKY 100V 1A SMA ST Microelectronics STPS1H100A D5 DIODE ZENER 30V 1.5W SMA ON Semiconductor 1SMA5936BT3G D7 DIODE ZENER 12V 200MW Fairchild Semiconductor MM5Z12V D8 DIODE SWITCH 200V 200MW Diode Inc BAV20WS-7-F F1 FUSE BRICK 1A 125V FAST 6125FA Cooper/Bussmann 6125FA J1, J2, J3, J4, TP8, TP9, TP10 16 GA WIRE HOLE, 18 GA WIRE HOLE 3M 923345-02-C J5, J6 CONN HEADER .312 VERT 2POS TIN Tyco Electronics 1-1318301-2 L1, L2 INDUCTOR 4700UH .13A RADIAL TDK Corporation TSL0808RA-472JR13-PF Q1 MOSFET N-CH 600V 90MA SOT-89 Infineon Technologies BSS225 L6327 Q2 MOSFET N-CH 600V 1.8A TO-251 Infineon Technology SPU02N60S5 R1, R3 RES 200K OHM 1/4W 5% 1206 SMD Vishay-Dale CRCW1206200KJNEA R2, R7 RES, 309k ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW1206309KFKEA R6, R24 RES, 10.5k ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080510K5FKEA R12 RES 4.7 OHM 1/10W 5% 0603 SMD Vishay-Dale CRCW06034R70JNEA R13 RES 10 OHM 1/8W 5% 0805 SMD Vishay-Dale CRCW080510R0JNEA R14 RES 1.50 OHM 1/4W 1% 1206 SMD Vishay-Dale CRCW12061R50FNEA R15 RES 3.48K OHM 1/10W 1% 0603 SMD Vishay-Dale CRCW06033K48FKEA R16 RES 191K OHM 1/10W 1% 0603 SMD Vishay-Dale CRCW0603191KFKEA R22 RES 40.2 OHM 1/8W 1% 0805 SMD Vishay-Dale CRCW080540R2FKEA RT1 CURRENT LIMITOR INRUSH 60OHM 20% Cantherm MF72-060D5 T1 Transformer Wurth Electronics 750311553 Rev. 01 TP2-TP5 Terminal, Turret, TH, Double Keystone Electronics 1502-2 TP7 TEST POINT ICT - - U1 Offline LED Driver, PowerWise™ Texas Instruments LM3444 SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 5 Demo Board Wiring Overview 8 www.ti.com Demo Board Wiring Overview TP3 TP4 LED + J6 J5 NEUTRAL LINE LED TP2 TP5 Figure 2. Wiring Connection Diagram 6 Test Point Name I/O Description TP3 LED + Output LED Constant Current Supply Supplies voltage and constant-current to anode of LED string. TP2 LED - Output LED Return Connection (not GND) Connects to cathode of LED string. Do NOT connect to GND. TP5 LINE Input AC Line Voltage Connects directly to AC line of a 120VAC system. TP4 NEUTRAL Input AC Neutral Connects directly to AC neutral of a 120VAC system. AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Demo Board Assembly www.ti.com 9 Demo Board Assembly Figure 3. Top View Figure 4. Bottom View SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 7 Typical Performance Characteristics 10 www.ti.com Typical Performance Characteristics Original Circuit: R14 = 1.50Ω; Modification A: R14 = 1.21Ω; Modification B: R14 = 1.00Ω; Modification C: R14 = 0.75Ω 86 86 84 8 LEDs EFFICIENCY (%) EFFICIENCY (%) 84 82 6 LEDs 80 82 80 Mod B Mod C 4 LEDs 78 Original Mod A 78 76 76 80 90 100 110 120 130 140 80 LINE VOLTAGE (VRMS) 90 100 110 120 130 140 LINE VOLTAGE (VRMS) Figure 5. Efficiency vs Line Voltage Original Circuit Figure 6. Efficiency vs. Line Voltage Modified Circuits 1.0 1.0 0.8 0.8 0.7 ILED(A) ILED(A) Mod C 6 LEDs 4 LEDs 0.4 0.2 0.7 Mod B 0.4 0.2 Mod A 8 LEDs Original 0.0 0.0 80 90 100 110 120 130 140 80 LINE VOLTAGE (VRMS) Figure 7. LED Current vs. Line Voltage Original Circuit 8 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver 90 100 110 120 130 140 LINE VOLTAGE (VRMS) Figure 8. LED Current vs. Line Voltage Modified Circuits SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Typical Performance Characteristics www.ti.com 1.000 15 0.996 POUT(W) POWER FACTOR 12 0.992 8 LEDs 9 6 LEDs 0.988 6 4 LEDs 0.984 3 80 0.980 80 90 100 110 120 130 140 LINE VOLTAGE (VRMS) 90 100 110 120 130 140 LINE VOLTAGE (VRMS) Figure 9. Power Factor vs. Line Voltage Original Circuit Figure 10. Output Power vs. Line Voltage Original Circuit 15 Mod C POUT(W) 12 Mod B 9 6 Mod A Original 3 80 90 100 110 120 130 140 LINE VOLTAGE (VRMS) Figure 11. Output Power vs.Line Voltage Modified Circuits Figure 12. Power MOSFET Drain Voltage Waveform (VIN = 120VRMS, 6 LEDs, ILED = 350mA) Figure 13. Current Sense Waveform (VIN = 120VRMS, 6 LEDs, ILED = 350mA) Figure 14. FILTER Waveform (VIN = 120VRMS, 6 LEDs, ILED = 350mA) SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 9 PCB Layout 11 www.ti.com PCB Layout Figure 15. Top Layer Figure 16. Bottom Layer 10 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Transformer Design www.ti.com 12 Transformer Design Mfg: Wurth Electronics, Part #: 750311553 Rev. 01 SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 11 Experimental Results 13 www.ti.com Experimental Results The LED driver is designed to accurately emulate an incandescent light bulb and therefore behave as an emulated resistor. The resistor value is determined based on the LED string configuration and the desired output power. The circuit then operates in open-loop, with a fixed duty cycle based on a constant on-time and constant off-time that is set by selecting appropriate circuit components. 13.1 Performance In steady state, the LED string voltage is measured to be 21.38 V and the average LED current is measured as 357 mA. The 120 Hz current ripple flowing through the LED string was measured to be 170 mApk-pk at full load. The magnitude of the ripple is a function of the value of energy storage capacitors connected across the output port. The ripple current can be reduced by increasing the value of energy storage capacitor or by increasing the LED string voltage. The LED driver switching frequency is measured to be close to the specified 79 kHz. The circuit operates with a constant duty cycle of 0.28 and consumes 9.25 W of input power. The driver steady state performance for an LED string consisting of 6 series LEDs is summarized in the following table. Table 2. Measured Efficiency and Line Regulation (6 LEDs) VIN (VRMS) IIN (mARMS) PIN(W) VOUT (V) ILED (mA) POUT (W) 90 60 5.37 20.25 216 4.38 Efficiency (%) Power Factor 81.6 0.9970 95 63 5.95 20.47 238 4.87 81.8 0.9969 100 66 6.57 20.67 260 5.38 81.9 0.9969 105 69 7.23 20.86 285 5.94 82.1 0.9969 110 72 7.89 21.05 309 6.50 82.3 0.9968 115 75 8.59 21.23 334 7.09 82.5 0.9967 120 77 9.25 21.38 357 7.65 82.7 0.9965 125 80 9.94 21.53 382 8.23 82.8 0.9961 130 82 10.62 21.68 406 8.80 82.9 0.9957 135 84 11.26 21.80 428 9.34 83.0 0.9950 Table 3. LED Current, Output Power versus Number of LEDs for Various Circuit Modifications (VIN = 120 VAC) # of LEDs (1) 12 Original Circuit (1) Modification A (1) Modification B (1) Modification C (1) ILED (mA) POUT (W) ILED (mA) POUT (W) ILED (mA) POUT (W) ILED (mA) POUT (W) 4 508 7.57 624 9.55 710 11.05 835 13.24 6 357 7.65 440 9.58 500 11.02 590 13.35 8 277 7.69 337 9.59 382 11.00 445 13.00 Original Circuit: R14 = 1.50Ω; Modification A: R14 = 1.21Ω; Modification B: R14 = 1.00Ω; Modification C: R14 = 0.75Ω AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Electromagnetic Interference (EMI) www.ti.com 13.2 Power Factor Performance The LED driver is able to achieve close to unity power factor (P.F. ~ 0.99) which meets Energy Star requirements. This design also exhibits low current harmonics as a percentage of the fundamental current (as shown in Figure 17) and therefore meets the requirements of the IEC 61000-3-2 Class-3 standard. Figure 17. Current Harmonic Performance vs. EN/IEC61000-3-2 Class C Limits 14 Electromagnetic Interference (EMI) The EMI input filter of this evaluation board is configured as shown in the following circuit diagram. R6 RT1 L1 LINE V+ C2 C6 D2 F1 NEUTRAL L2 R24 Figure 18. Input EMI Filter and Rectifier Circuit SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 13 Electromagnetic Interference (EMI) www.ti.com In order to get a quick estimate of the EMI filter performance, only the PEAK conductive EMI scan was measured and the data was compared to the Class B conducted EMI limits published in FCC – 47, section 15. Figure 19. Peak Conductive EMI Scan per CISPR-22, Class B Limits If an additional 33nF of input capacitance (C6) is utilized in the input filter, the EMI conductive performance is further improved as shown in Figure 20. Figure 20. Peak Conductive EMI Scan With Additional 33nF of Input Capacitance 14 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Thermal Analysis www.ti.com 15 Thermal Analysis The board temperature was measured using an IR camera (HIS-3000, Wahl) while running under the following conditions: VIN = 120 VRMS ILED = 350 mA # of LEDs = 6 POUT = 7.3 W The results are shown in the following figures. Figure 21. Top Side Thermal Scan SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 15 Thermal Analysis www.ti.com Figure 22. Bottom Side Thermal Scan 16 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated Circuit Analysis and Explanations www.ti.com 16 Circuit Analysis and Explanations 16.1 Injecting Line Voltage Into FILTER (Achieving PFC > 0.99) If a small portion (750mV to 1.00V) of line voltage is injected at FILTER of the LM3444, the circuit is essentially turned into a constant power flyback, as shown in Figure 23. V+ R2 LM3444 NC NC 10 2 NC VCC 9 3 NC GATE 8 4 COFF ISNS 7 5 FILTER GND 6 1 R7 COFF FILTER R15 C11 Figure 23. Line Voltage Injection Circuit The LM3444 works as a constant off-time controller normally, but by injecting the 1.0V rectified AC voltage into the FILTER pin, the on-time can be made to be constant. With a DCM Flyback, Δi needs to increase as the input voltage line increases. Therefore a constant on-time (since inductor L is constant) can be obtained. By using the line voltage injection technique, the FILTER pin has the voltage wave shape shown in Figure 24 on it. Voltage at VFILTER peak should be kept below 1.25V. At 1.25V current limit is tripped. C11 is small enough not to distort the AC signal but adds a little filtering. Although the on-time is probably never truly constant, it can be observed in Figure 25 how (by adding the rectified voltage) the on-time is adjusted. VFILTER t Figure 24. FILTER Waveform SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver Copyright © 2010–2013, Texas Instruments Incorporated 17 Circuit Analysis and Explanations www.ti.com For this evaluation board, the following resistor values are used: R2 = R7 = 309kΩ R15 = 3.48kΩ Therefore the voltages observed on the FILTER pin will be as follows for listed input voltages: For VIN = 90VRMS, VFILTER = 0.71V For VIN = 120VRMS, VFILTER = 0.95V For VIN = 135VRMS, VFILTER = 1.07V Using this technique, a power factor greater than 0.99 can be achieved without additional passive active power factor control (PFC) circuitry. As line voltage increases, the voltage across the inductor increases, and the peak current increases. 750 mV 1M Nearly a constant ontime as the line varies PWM I-LIM D x LED Current 1.27V 1k ISNS 1V 1V LEADING EDGE BLANKING FILTER The PWM reference increases as the line voltage increases. PGND RSNS 125 ns CFILTER Figure 25. Typical Operation of FILTER Pin 18 AN-2082 LM3444 -120VAC, 8W Isolated Flyback LED Driver SNVA454E – September 2010 – Revised May 2013 Submit Documentation Feedback Copyright © 2010–2013, Texas Instruments Incorporated IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. Buyers should obtain the latest relevant information before placing orders and should verify that such information is current and complete. All semiconductor products (also referred to herein as “components”) are sold subject to TI’s terms and conditions of sale supplied at the time of order acknowledgment. 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