LM3445-208277EV/NOPB

User's Guide SNVA409B – October 2009 – Revised May 2013 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB 1 Introduction The demonstration board included in this shipment is capable of converting a 176VAC to 305VAC input that has been phase dimmed to drive multiple LED’s at up to 500 mA average current. The evaluation board utilizing the LM3445 will automatically adjust the LED current and light output in relation to the triac firing angle. The target solution for this design was 230VAC input driving 8 series connected white LEDs. In this configuration the LM3445 will run at a nominal switching frequency of 80 kHz and supply a maximum of 350 mA. This is a four-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 and switching frequency. A supplied bill of materials describes the parts used on this demonstration board. A schematic and layout have also been included along with measured performance characteristics. The noted operation restrictions are valid only for the demonstration board as shipped with the schematic below. As is, the board is capable driving 8 to 16 series connected LEDs with noted performance, but the evaluation board may be modified to accept fewer or additional series LEDs with some simple design modification. Refer to Design Customizaton section and the LM3445 Triac Dimmable Offline LED Driver (SNVS570) data sheet for detailed instructions. 2 Key Features • • Vin range covering 208, 220, 230, 240, and 277VAC Multiple output configurations are possible TRI-STATE is a registered trademark of National Semiconductor Corporation. All other trademarks are the property of their respective owners. SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 1 Simplified LM3445 Schematic and Efficiency Plot 3 www.ti.com Simplified LM3445 Schematic and Efficiency Plot V+ VBUCK D2 C6 + D11 R7 BR1 C15 D10 C10 D9 R8 VLED + C17 Q9 TRIAC DIMMER - VLEDD8 VAC D6 Energy Efficient Triac Holding Circuitry D12 C13 L5 U1 LM3445 1 ASNS BLDR 10 2 FLTR1 VCC 9 3 DIM R11 Q5 C8 GATE 8 4 COFF ISNS 7 5 FLTR2 GND 6 VCC R20 R21 R27 D13 C9 Q6 C16 R26 C18 Figure 1. Schematic 2 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated Simplified LM3445 Schematic and Efficiency Plot www.ti.com EFFICIENCY (%) 90 80 16 Series LEDs @ 220 mA 12 Series LEDs @ 300 mA 8 Series LEDs @ 350 mA 70 60 180 205 230 255 277 LINE VOLTAGE (VAC) Figure 2. Efficiency Plot WARNING This LM3445 evaluation PCB is a non-isolated design. 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. SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 3 Pin-Out 4 www.ti.com Pin-Out ASNS 1 10 BLDR FLTR1 2 9 VCC DIM 3 8 GATE COFF 4 7 ISNS FLTR2 5 6 GND Figure 3. 10-Pin VSSOP Table 1. Pin Description 10 Pin VSSOP Pin # Name Description 1 ASNS PWM output of the triac dim decoder circuit. Outputs a 0 to 4V PWM signal with a duty cycle proportional to the triac dimmer on-time. 2 FLTR1 First filter input. The 120Hz PWM signal from ASNS is filtered to a DC signal and compared to a 1 to 3V, 5.85 kHz ramp to generate a higher frequency PWM signal with a duty cycle proportional to the triac dimmer firing angle. Pull above 4.9V (typical) to TRI-STATE® DIM. 3 DIM Input/output dual function dim pin. This pin can be driven with an external PWM signal to dim the LEDs. It may also be used as an output signal and connected to the DIM pin of other LM3445 or LED drivers to dim multiple LED circuits simultaneously. 4 COFF 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. 5 FLTR2 Second filter input. A capacitor tied to this pin filters the PWM dimming signal to supply a DC voltage to control the LED current. 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 10 BLDR Input voltage pin. This pin provides the power for the internal control circuitry and gate driver. Bleeder pin. Provides the input signal to the angle detect circuitry as well as a current path through a switched 230Ω resistor to ensure proper firing of the triac dimmer. EFFICIENCY (%) 90 80 16 Series LEDs @ 220 mA 12 Series LEDs @ 300 mA 8 Series LEDs @ 350 mA 70 60 180 205 230 255 277 LINE VOLTAGE (VAC) Figure 4. LM3445 Efficiency vs Input Voltage 8, 12 and 16 Series connected LEDs 4 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated LM3445 Evaluation Board Schematic www.ti.com 5 LM3445 Evaluation Board Schematic Figure 5. LM3445 Evaluation Board Schematic SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 5 Bill of Materials LM3445 Evaluation Board 6 www.ti.com Bill of Materials LM3445 Evaluation Board Table 2. Bill of Materials 6 REF DES Description MFG MFG Part Number U1 IC Driver LED W/TRIAC DIM 10VSSOP Texas Instruments LM3445 BR1 Bridge Rectifier 600V 0.8A MINIDIP Diodes Inc HD06-T C1 47 nF X7R 1206 10% 500V Ceramic Vishay/Vitramon VJ1206Y473KXEAT5Z C2, C4 10 nF 330VAC FILM EPCOS Inc B32911A3103M C3, C23, C35 DNP C5, C7 1000 pF X7R 1206 500V Ceramic AVX 399-3436-1-ND C6 10 nF X7R 603 5% 100V Ceramic AVX 06031C103JAT2A C8 470 nF X7R 603 25V Ceramic Murata GRM188R71E474KA12D C9, C16 100 nF X7R 603 25V Ceramic Kemet C0603C104K3RACTU C10 220 nF X5R 603 25V Ceramic AVX 06033D224KAT2A C11, C12 22 uF ED-Radial 250V Electrolytic Panasonic-ECG EEU-ED2E220 C13, C14 22 uF X5R 1210 25V Ceramic MuRata GRM32ER61E226KE15L C15 10 nF Film MK Series 305VAC EPCOS B32921A2104M C17 1 uF X7R 1206 100V Ceramic Murata GRM31CR72A105KA01L C18 220 pF X7R 603 100V Ceramic Yageo CC0603KRX7R9BB221 C19 1 nF X7R 603 50V Ceramic Kemet C0603C102K5RACTU C20 22 nF X7R 603 50V Ceramic Kemet C0603C223K5RACTU C21 4.7 uF X5R 1206 10V Ceramic TDK Corporation C3216X7R1E475K D2 Diode 70V SOT323 Dual Fairchild BAV99WT1G D5, D8 Schottky 40V 120 mA SOD-123 NXP Semiconductor BAS40H,115 D6 Zener 15V 350 mW SOT-23 Fairchild BZX84C15 D7, D9, D10, D11 Diode GP 1A 1000V MINI-SMA Comchip Technology CGRM4007-G D12 Diode 600V 2.2A TO-252 Cree CSD01060E D13 Zener 500 mW 5.6V SOD123 ON Semiconductor MMSZ5V6T1G D14 Shunt Regulator 0.5% SOT23 Zetex ZTL431BFTA F1 Fuse 1.25A 600V 3812 TELCOM SMP Bel Fuse SMP 1.25 J1 Terminal Block 2POS 5.08mm Phoenix Contact 1715721 L1, MH1, MH2, MH3, MH4 DNP NEHDW1, R9, R10, R28, R32, R33 DNP L2 1.4 mH 10% DO5040H Coilcraft DO5040H-145KL L3 1.0 mH 10% MSS1038 Coilcraft MSS1038-105KL L5 160Ω Impedance SMD Ferrite Chip Steward HI1206T161R-10 Q1, Q8 NMOS 100V 170 mA SOT-23 Farichild BSS123 Q2, Q3 NPN 60V 600 mA Fair Child MMBT4401 Q4 PMOS 50V 130 mA SOT-23 Fairchild Semiconductor BSS84 Q5 NMOS 600V 3.9A DPAK Fairchild FCD4N60TM_WS Q6 PNP 40V SOT-23 Fairchild MMBT4403 Q7 PNP 300V 500 mA SOT-23 Fairchild MMBTA92 Q9 NMOS 600V 4A D2PAK STMicroelectronics STB4NK60ZT4 Q10 PNP 30V 100 mA SOT23 ON Semiconductor BC858CLT1G R1 820Ω 1W 5% 2512 SMD Vishay/Dale CRCW2512820RJNEG R2 7.5 kΩ 1% Vishay-Dale CRCW06037K50FKEA R3, R4 100 kΩ 1% 1/4W Rohm Semiconductor MCR18EZPF1003 R5 20 kΩ 1% Vishay-Dale CRCW060320k0FKEA AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated Bill of Materials LM3445 Evaluation Board www.ti.com Table 2. Bill of Materials (continued) R6 49.9 kΩ 1% Vishay-Dale CRCW080549K9FKEA R7, R8 200 kΩ 1% 1/4W Vishay-Dale CRCW1206200KFKEA R11 280 kΩ 1% Vishay/Dale CRCW0603280KFKEA R12 249Ω 1% Vishay-Dale CRCW0805249RFKEA R13 3.3 MΩ 1% Vishay/Dale CRCW08053M30FKEA R14 100Ω 1% Vishay-Dale CRCW1206100RFKEA R40 150Ω 1% Vishay-Dale CRCW1206150RFKEA R16 0Ω 5% Vishay/Dale CRCW06030000Z0EA R17 100kΩ 1% 1/4W Rohm Semiconductor MCR18EZHF1003 R18, R34, R35 0Ω 1/4W Vishay/Dale CRCW12060000Z0EA R19 4.7Ω 1% Vishay/Dale CRCW08054R70FNEA R20 10Ω 1% 1/4W Vishay/Dale 541-10.0FCT-ND R21 1.8Ω 5% 1/3W Vishay/Dale CRCW12101R80JNEA R22, R23, R24 1 MΩ 1% 1/4W Vishay/Dale CRCW12061M00FKEA R25 49.9 kΩ 1% Panasonic - ECG ERJ-3EKF4992V R26, R29 33.2 kΩ 1% Vishay/Dale CRCW060333K2FKEA R27 221 kΩ 1% Vishay/Dale CRCW0603221KFKEA R30 2 kΩ 1% Vishay/Dale CRCW06032K00FKEA R31 402 kΩ 1% Vishay-Dale CRCW0603402KFKEA R36 150Ω 1% Vishay-Dale CRCW0805150RFKEA R38 249Ω 1% 1/4W Vishay-Dale CRCW1206249RFKEA R41 402 kΩ 1% Rohm Semiconductor MCR18EZHF4023 RT1 Inrush Limiter 80 Ω 20% Cantherm MF72-080D9 TP1, TP5, TP10, TP11, TP12, TP13, TP14 Terminal DBL Turret 0.109"L Brass Keystone Electronics 1502-2 SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 7 PCB Layout 7 www.ti.com PCB Layout Figure 6. Top Layer 8 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated PCB Layout www.ti.com Figure 7. Bottom Layer WARNING The LM3445 evaluation boards have no isolation or any type of protection from shock. Take caution when handling evaluation board. Avoid touching evaluation board, and removing any cables while evaluation board is operating. Isolating the evaluation board rather than the oscilloscope is highly recommended. SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 9 Design Customization Procedure 8 www.ti.com Design Customization Procedure The LM3445 data sheet outlines a typical implementation and design procedure for a LM3445 based triacdimmable LED driver. One feature includes the use of a PNP transistor to translate the LED string voltage and maintain a constant off time. This allows a constant LED current to be maintained regardless of the number of series LEDs. For input voltages above 150VAC a suitable PNP transistor becomes difficult to find. An alternate implementation uses a current source to supply a constant current to charge the off-time capacitor. This circuit has been implemented on this demonstration board and is described below: VCC Vz D13 Q6 C16 R26 R27 COFF C18 Figure 8. Circuit Customization Diagram This method eliminates the need for the LED voltage translation transistor but requires adjustment to the circuit values when a different LED string voltage is required and it is desired to keep the LED string average current the same. Sample calculations illustrating the design procedure are shown below: 8.1 Specifications Number of LEDs, N = 8 VLED = 3.4V * N VIN = 230VAC fSW target = 80 kHz VFLTR2 = 750 mV Δi = 310 mA Efficiency Estimate, n = 0.75 Iave = 350mA VZ =5.6V VBE= 0.5V C18 = 220 pF 8.2 Inductor Selection Based on the design parameters above, calculate the target inductor value: § §1 V ·· VLED ¨1 - ¨¨ ˜ LED ¸¸¸ ¨ ¸ V n BUCK ¹¹ © © L= 'i ˜ fsw § § ·· (8 x 3 .4) ¨1 - ¨ 1 ˜ 8 x 3.4 ¸¸ ¨ ¨0. 75 230 x 2 ¸¸ ¹¹ © © = 0. 31˜ 80k = 974 #H (1) Select 1mH 10 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated Design Customization Procedure www.ti.com 8.3 Current Source Component Selection Calculate tOFF to obtain the target inductor ripple current using the additional target parameters we defined: t off = = 'i ˜ L VLED 0.31A x 1 mH 8 x 3.4V = 11.4 Ps (2) Using the target tOFF result the current source output can be calculated using: Is = = C18 ˜1.276 t off 220 pF x1. 276 11.4 Ps = 24.6 PA (3) Finally, R27 can be selected using the current, Zener voltage, and transistor parameters: R27 = (VZ - VBE) IS (5.6V - 0.5V) = 24.6 PA = 207 k:, select 221 k: 8.4 (4) Average LED Current The LM3445 constant off-time control loop regulates the peak inductor and therefore, peak LED current. The average LED current is related to the peak inductor current by the following relationship: ipk = Iave + 'i 2 0.31 2 = 505 mA = 0.35 + (5) Now that our current source and peak current are defined we can adjust the peak current detect level to obtain the desired average output current . On this demo board the current sense resistors are the parallel combination of R20 and R21, equal to Rsense: R sense = 750 mV i pk = 750 mV 505 mA = 1.48: (6) A 10Ω and 1.8Ω are selected as R20 and R21 for a net resistance of 1.52Ω 8.4.1 Holding Current This LM3445 High Voltage demo board includes five circuit blocks (Figure 9) that work together to draw additional current from the line at key points in the dimming cycle and ensure a minimum level of current is drawn from the triac dimmer at all times. A description of their operation is outlined below. References are made to Q1 and D9 which can be found on Figure 1. • Triac edge detect circuit: When the triac fires a sharp edge is created that can be captured by a properly sized R-C circuit. The combination of C5/C7 and R3/R4 create a negative pulse on R2 for a reverse phase dimmer or a positive pulse on R2 for a forward phase dimmer. The pulse polarity determines which subsequent block will use the signal. SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 11 Design Customization Procedure www.ti.com • Forward phase detect/Valley Fill Enable and Valley Fill triac holding current circuit: With Q3 turning on with each rectified AC edge from a forward phase dimmer, a duty cycle divider is created that adjusts the voltage at the anode of D2A. With the values implemented, the result is an average of ~2V at the anode of D2A when the rising edge is present on R2 allowing the gate voltage of Q4 to rise and fall with the valley fill diode cathode voltage VVF (VVF is connected to the cathode of D9) and turn Q4 on while the valley fill circuit is providing power to the load. Additional loading at this time is important because as the valley fill capacitors are providing current to the load, no current is being provided by the input through the triac and a condition for triac mis-fire would otherwise be created. When a fast rising edge is not present, Q3 will remain off and the D2A anode voltage and Q4 gate will rise to VCC and ensure Q4 will not turn on. The final piece of the circuit is D2B. The cathode of D9 can rise to ½Vin while the valley fill capacitors are charging. Since the Q4 gate is rated at ±20 volts a diode is added from the gate to VCC clamping this point at a diode drop above VCC. When using a reverse phase dimmer the waveform edge rises with the line frequency requiring ~4ms to reach the peak. This is not a fast enough edge to create a signal at the base of Q3 meaning this circuit will naturally not operate when using a reverse phase dimmer or when no dimmer is present. • Linear RHOLD Insertion circuit : Adds holding current as LEDs are dimmed to 50% or lower. A variable voltage between 0 and 5 volts is generated at the Q1 gate by averaging the DIM pin 5.9kHz square wave. The DIM pin, normally an input, is used as an output in this implementation as it outputs a square wave with a duty cycle that varies with triac firing angle. As the LEDs are dimmed, the voltage at the Q1 gate will rise pulling a current equal to the Q1 source voltage divided by R36. • Reverse phase holding current circuit: Adds holding current when a reverse phase triac edge is detected. The triac edge detect R-C creates a negative pulse on the emitter of Q2 each cycle a reverse phase dimmer is present and dimming. This turns on Q10 and connects R12 to the Q9 pass FET adding holding current and sharpening the turn-off of the reverse phase dimmer. Linear RHOLD Insertion Circuit VCC Valley fill triac holding current circuit Forward phase detect/Valley Fill VCC Enable Triac edge detect Reverse phase holding current V+ BLDR VCC BLDR C5 R5 D2B R31 VVF DIM Q1 C7 R3 R4 R41 R36 C35 R6 Q10 R14 Q4 R25 C10 C21 D2A R10 R38 Q2 R12 Q3 R2 C6 Figure 9. High Voltage Demo Board with Five Circuit Blocks 8.5 Output Variation without Component Adjustment If the variation of converter operating parameters is not a concern, the number of LEDs can be adjusted without changes to the evaluation board component values. The effects of changing the LED string voltage without adjustment of the values can be seen below. This can also be used as a guide to understand the variation that will be seen if the LED string voltage does change during operation. With the present design the net change was approximately 18.7 mA and 1.35 kHz per LED or approximately 5.5 mA and 400Hz per volt. 12 AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback Copyright © 2009–2013, Texas Instruments Incorporated Design Customization Procedure 600 90.0k fsw 80.0k 400 Iave 200 70.0k 60.0k 2 AVERAGE CURRENT (mA) NOMINAL OPERATING FREQUENCY (Hz) www.ti.com 0 4 6 8 10 12 14 16 NUMBER of SERIES LEDs (Vf = 3.4V per LED) Figure 10. Output Variation w/0 Component Adjustment If variation due to a change in string voltage is a concern, these effects can be minimized by increasing the inductance value and/or raising the switching frequency. A larger inductance reduces the peak-to-peak ripple current. If made large enough it will become the dominant parameter effecting the peak-to-peak ripple current. If the peak-to-peak current variation can be minimized, so will the average output current. 8.6 Thermal Limitation All triac holding current is drawn through the stand-off FET Q9. At approximately 50% dimming (90° firing angle) the power dissipation in Q9 is at its maxmimum. If it is desired to dim for an extended period at this operating point the input voltage should be limited to a maximum of 240VAC. SNVA409B – October 2009 – Revised May 2013 Submit Documentation Feedback AN-1995 LM3445 208-277VAC Non-Isolated Evaluation PCB Copyright © 2009–2013, Texas Instruments Incorporated 13 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. 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