A N- R E F- I C L82 01 _ GU 10
7. 5W 18 0m A Sin gl e St ag e Fl o a ti ng B u ck L E D
(G U1 0 ) Co n ver ter w i th I CL 82 01 &
IP U 50 R3 K0 C E
Application Note
About this document
Scope and purpose
This document is an universal 7.5W 180mA average current controlled single stage, cascode structure for
floating bulk topology GU10 LED lamp reference design using Infineon LED driver ICL8201 (SOT23-6-1) and
CoolMOS™ IPU50R3K0CE (IPAK). It has high efficiency, high PFC and various modes of protections with very
low external component count. ICL8201 concept supports simple buck inductor without auxiliary winding.
Intended audience
This document is intended for users of ICL8201 who wish to design very low cost, high efficiency and power
factor in GU10 form factor LED lamp.
1
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Table of Contents
Table of Contents
Table of Contents..............................................................................................................................................2
1
Introduction...................................................................................................................................3
2
Reference board.............................................................................................................................3
3
Specification ..................................................................................................................................3
4
Schematic ......................................................................................................................................4
5
GU10 reference board layout .........................................................................................................4
6
6.1
6.2
Bill of material and transformer specification................................................................................5
Bill of material .....................................................................................................................................5
Transformer specification...................................................................................................................6
7
Single stage power factor correction .............................................................................................6
8
Protection functions ......................................................................................................................7
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7.1
9.7.2
9.7.3
9.7.4
9.7.5
Reference board set up, test waveforms and results .....................................................................8
Input and output .................................................................................................................................8
Start up ................................................................................................................................................8
Switching waveform............................................................................................................................9
Output waveform ..............................................................................................................................10
Input waveform .................................................................................................................................11
Protection waveforms and results (Short output, Short winding, Intelligent over temperature
protection).........................................................................................................................................12
Short output protection..............................................................................................................12
Short winding protection............................................................................................................13
Intelligent over temperature protection....................................................................................14
Test results (Power factor, Total Harmonic Distortion (THD), Efficiency, Regulation, Conducted
Emissions&Lightning surge) .............................................................................................................15
Power Factor and Total Harmonics Distortion ..........................................................................16
Output current regulation ..........................................................................................................16
Efficiency .....................................................................................................................................17
Conducted emissions (EN55015)................................................................................................18
Lightning Surge (EN61000-4-5)...................................................................................................20
10
References ...................................................................................................................................21
9.6.1
9.6.2
9.6.3
9.7
Revision History ..............................................................................................................................................21
Application Note
2
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Introduction
1
Introduction
This application note is an engineering report of GU10 LED lamp reference design for universal input 7.5W
180mA converter. The converter is using ICL8201 (SOT23-6-1), average current controlled, non-isolated
single stage buck topology in cascode structure LED driver and IPU50R3K0CE (IPAK), a CE series of high
voltage power CoolMOS™. With this cascode structure, system can achieve fast IC start up without the need
to use a costly depletion MOSFET or alternatively a low cost start up resistor that causes continuous power
losses during normal operation. This reference design is a single stage design with high efficiency and power
factor, critical conduction operation mode with single choke(without auxiliary winding), truly regulated
output current over a wide input and output voltage range, good EMI performance and various modes of
protections for high reliability with minimum external components.
2
Reference board
This document contains the list of features, the power supply specification, schematic, bill of material and
the transformer construction documentation. Typical operating characteristics such as performance curve
and scope waveforms are shown at the rear of the report.
ICL8201 (SOT23-6-1)
IPU50R3K0CE (IPAK)
(Top view)
(Bottom view)
Figure 1
REF-ICL8201_GU10 [Size( L x W x H): 33mm x 20mm x 18mm]
3
Specification
Table 1
Specification of REF-ICL8201_GU10
Input voltage & frequency
90VAC~265VAC (60/50Hz)
Output voltage, current & power
33V~47V, 180mA, 7.5W
>0.95 @ low line
Power factor
>0.80 @ high line
< 20% @ low line
THD
< 30% @ high line
Efficiency
>85%
Conducted emissions (EN55015)
Pass
Note: The PF and THD can be further optimized if this is the narrow range Vin design.
Application Note
3
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Schematic and GU10 reference board layout
4
Schematic
Figure 2
Schematic of REF-ICL8201_GU10
5
GU10 reference board layout
The reference board has double layers PCB with dimension of 33x20mm and thickness of 0.8mm is used. The
maximum height of the demo board is 18mm. With its compact form factor, this reference board is able to fit
into GU10 lamp.
Figure 3
Top view
Top and bottom view
Application Note
Bottom view
4
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
BOM
6
Bill of material and transformer specification
6.1
Bill of material
Table 2
ICL8201 (GU10) BOM Rev.A
No.
Designator
Name
Manufacturer
Part Number
Description
QTY
1
BD1
Bridge
Rectifier
VISHAY
GENERAL
MB6S-E3/80
BRIDGE RECTIFIER, 0.5A, 600V, SMD
1
2
C1
SMD Cap
MURATA
GRM31CR72J153KW03L
SMD, 1206, 15nF/630VDC
1
3
C2
Film Cap
PANASONIC
ECWF2W224JAQ
CAP, FILM, PP, 220NF, 450V, RAD
1
4
C3
SMD Cap
Yageo
CC0603KRX7R8BB103
CAP CER 10nF 25V 10% X7R 0603
1
5
C4
SMD Cap
MURATA
GRM31A5C2J101JW01D
MURATA, MLCC, X7R, 630V 100pF,1206
1
6
C5, C6
Alu Elec Cap
PANASONIC
EEUFR1H101
CAP, ALU ELEC, 100UF, 50V, RAD
2
7
C7
SMD Cap
MURATA
GRM188R61E225KA12D
CAP, MLCC, X5R, 2.2UF, 25V, 0603
1
8
C8
SMD Cap
MURATA
GRM188R71A225KE15D
CAP CER 2.2uF 10V 10% X7R 0603
1
9
CX1
Film Cap
Kemet
PHE840MK5100MK01R17
Film Capacitors 275volts 0.010uF 20%
LS=7.5mm
1
10
D1
Switching
Diode
ON Semi
MUR160G
DIODE, ULTRA-FAST, 1A, 600V, DO-15
1
11
F1
Fuse
Vishay
NFR25H0001008JA500
12
L1, L2
FILTER_CHOKE
Wurth
7447462102
13
L3
Main CHOKE
Wurth
750342584
RES, METAL FILM, 1R, 5%, 500MW,
AXIAL
Wurth INDUCTOR, AXIAL 1.0MUH,
250mA
1
2
EE13; 600uH,±10%
1
14
Q1
Mosfet
Infineon
IPU50R3K0CE
500V, 1.7A, 3.0ohm, I-PAK
1
15
R1A, R1B, R1C
SMD Resistor
Yageo
RV1206JR-07330KL
RES SMD 330K OHM 1/4W 5% 1206
3
16
R3
SMD Resistor
VISHAY DALE
CRCW12061R10FNEA
RES SMD 1.2 OHM 1/4W 1% 1206
1
17
R2
SMD Resistor
BOURNS
CR0603-JW-472ELF
RESISTOR, 0603, 4.7K, 5%, 0.1W
1
18
U1
IC
Infineon
ICL8201
LED Buck Controller, SOT23-6-1
1
19
Z1
VARISTOR5
Multicomp
MCV471K05DS
VARISTOR, 775, 5mm DISC
1
20
ZD1
Zener Diode
ON Semi
MMSZ5242BT1G
DIODE ZENER 15V 500MW SOD123
1
MULTICOMP
1N4148W
SMALL SIGNAL, 75V, SOD-123F
1
Micro
Commercial
1N4148WX-TP
SWITCHING DIODE, 300mA, 100V,
SOD323
1
21
D2
22
D3
Application Note
Switching
Diode
Switching
Diode
5
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Transformer specification and Single stage PFC
6.2
Transformer specification
Figure 4
Transformer structure
7
Single stage power factor correction
Single stage power factor correction (PFC) zero current detection bulk helps realising highly efficient, cost
effective and compact LED driver design. In this reference board, ICL8201 achieves the single stage power factor
correction by fixing on time over half AC sinusoidal cycle waveform.
As can be noted from below picture, the averaged input current is shaped to be approximately sinusoidal and thus
high power factor is achieved with input current harmonics fulfilling the requirements of EN 61000-3-2 standard.
Application Note
6
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Protection functions
Figure 5
Voltage and current waveforms in half AC cycle
8
Protection functions
The protection functions of ICL8201 are listed below.
Table 3
ICL8201 protection functions
VCS Short (Pin 1) to GND
VCS Open (Pin 1)
VCon Short (PIN 3) to GND
VCon OPEN (PIN 3)
Short OUTPUT
Short Winding (Main Choke)
Intelligent Over Temperature Protection (iOTP)
Application Note
Latch
Latch
Latch
Latch
Latch
Latch
Latch
7
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9
Reference board set up, test waveforms and results
9.1
Input and output
The input of REF-ICL8201_GU10 is Live (L) and Neutral (N) wires and its operating input AC voltage range is
90VAC ~265 VAC.
The output of REF-ICL8201_GU10 is LED+ and LED- wires which can supply 40V, 180mA to the LED module.
Attention: As this is a non-isolated design, high voltage exists at the output! An isolated transformer is
advised to be used during evaluating of this reference board.
9.2
Start up
When the AC input voltage is applied to the reference board, VCC capacitor will be charged through external
LED module, Buck choke (L3), external power switch (Q1) and VCC diode (D3). Once the VCC voltage reaches
7.5V, the IC will start switching with a digital soft start and enter into normal operation.
C1(Yellow) : Bulk voltage (VBulk)
C2( Red) : Supply voltage (VCC)
C3(Blue) : LED module voltage (VLED)
C4(Green) : LED module current (ILED)
Figure 6
Start up waveform
Application Note
8
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9.3
Switching waveform
The current mode controller, ICL8201 uses zero current switching technique without zero crossing detection
winding but by sensing the drain pin voltage of the controller. This helps to simplify the structure of the buck
choke without auxiliary winding and improve both EMI and efficiency performance. Typical switching
waveform of ICL8201 is as shown below.
VDS_high_max150℃). If the
temperature continues to increase and exceeds Tj > 160 °C, the IC will enter LATCH OFF mode. Figure 17 is
the real testing curve (ILED vs. AMB) which is tested under the condition of putting GU10 board into oven.
Measuring the ILED corresponding to AMB (Ambient Temperature) from -25℃ to +135℃. GU10 board starts
to reduce ILED from 155mA@ AMB=125℃ to 76.7mA@ AMB=132.9℃ which is about 50% of 155mA. Continue
to increase AMB, GU10 board enter to latch mode @ AMB=135℃.
Figure 16
Standard curve of Intelligent Over-Temperature Protection (iOTP)
Figure 17
GU10 Board iOTP testing results (ILED vs. AMB)
Application Note
14
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9.7
Table 4
Test results (Power factor, Total Harmonic Distortion (THD), Efficiency,
Regulation, Conducted Emissions&Lightning surge)
Power Factor, THD, Efficiency & Regulation
40V, 180mA LED load
Vout
Iout
Pout
(VDC)
(mA)
(W)
Vin & fin
(VAC/Hz)
Pin
(W)
PF
THD
△Iout
(%)
Efficiency (%)
90V/60Hz
120V/60Hz
135V/60Hz
185V/50Hz
7.88
7.91
7.96
8.22
0.98
0.98
0.98
0.96
17.45
14.32
15.00
19.00
41.4
41.4
41.4
41.4
175.5
176
176
178
7.27
7.29
7.29
7.37
-2.50
-2.22
-2.22
-1.11
92.20
92.12
91.54
89.65
230V/50Hz
265V/50Hz
8.5
8.75
0.91
0.87
23.90
27.40
41.41
41.42
180
182
7.45
7.54
0.00
1.11
87.69
86.15
33V, 180mA LED load
Vout
Iout
Pout
(VDC)
(mA)
(W)
△Iout
(%)
Efficiency (%)
Average Efficiency (%)
89.89
Vin & fin
(VAC/Hz)
Pin
(W)
PF
THD
90V/60Hz
120V/60Hz
6.33
6.36
0.99
0.98
14.00
15.24
33.1
33.1
174
175
5.76
5.79
-3.33
-2.78
90.99
91.08
135V/60Hz
185V/50Hz
230V/50Hz
265V/50Hz
6.43
6.65
6.89
7.11
0.97
0.93
0.87
0.82
17.10
22.24
27.23
30.80
33.1
33.12
33.14
33.15
176
178
180
183
5.83
5.90
5.97
6.07
-2.22
-1.11
0.00
1.67
90.60
88.65
86.58
85.32
Vin & fin
(VAC/Hz)
Pin
(W)
PF
THD
47V, 180mA LED load
Vout
Iout
Pout
(VDC)
(mA)
(W)
△Iout
(%)
Efficiency (%)
Average Efficiency (%)
90V/60Hz
120V/60Hz
135V/60Hz
185V/50Hz
230V/50Hz
265V/50Hz
8.93
8.9
8.95
9.25
9.55
9.85
0.98
0.98
0.98
0.97
0.93
0.89
20.80
15.05
14.70
17.40
21.95
25.42
-2.78
-2.78
-2.22
-1.11
0.56
1.67
91.91
92.22
92.23
90.25
88.91
87.19
90.45
Application Note
46.9
46.9
46.9
46.9
46.91
46.93
175
175
176
178
181
183
8.21
8.21
8.25
8.35
8.49
8.59
15
Average Efficiency (%)
88.87
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9.7.1
Power Factor and Total Harmonics Distortion
The measured power factor and total harmonics distortion (THD) at different input voltages is as shown
below. The power factor is >0.95 @ low line and >0.80 @ high line. THD is less than 30% over the whole input
voltage range.
Figure 18
Power Factor and THD versus AC line voltage (40V, 180mA LED load)
9.7.2
Output current regulation
Below figure shows the LED output current versus line voltage. The output current is regulated within ±3.5%
over the whole input voltage range.
Figure 19
Output current versus AC line voltage
The following figure shows the LED output current versus output voltage (LED module’s forward voltage).
With the number of different LED changes, which corresponding to forward voltage of 33V, 40V and 47V, the
output current is regulated within ±1%.
Application Note
16
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
Figure 20
Output current versus output voltage (Vin=230VAC, 50Hz)
9.7.3
Efficiency
The following figure shows the efficiency verses AC line voltage which exhibits >85% over the whole AC input
range due to zero current turn on operation.
Figure 21
Efficiency versus AC line voltage
Application Note
17
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9.7.4
Conducted emissions (EN55015)
The conducted emissions test was performed at full load and there is approximately 2dB margin observed
for both line and neutral measurements.
Figure 22
Conducted emissions(Line) at 110VAC, 60Hz & full load
Figure 23
Conducted emissions(Neutral) at 110VAC, 60Hz & full load
Application Note
18
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
Figure 24
Conducted emissions(Line) at 230VAC, 50Hz & full load
Figure 25
Conducted emissions(Neutral) at 230VAC, 50Hz & full load
Application Note
19
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
Reference board set up, test waveforms and results
9.7.5
Lightning Surge (EN61000-4-5)
The Board was subjected to ±500V differential mode combination wave surge at 230Vac and full load using 5
strikes at each condition, and there was not any nonrecoverable interruption of output requiring supply
repair or recycling of input voltage.
Table 5
Testing Results
Level
(V)
Input
Voltage
(V)
Injection
Location
Injection
Phase
(°)
Type
Test Results
(Pass /Fail)
+500V
230
L, N
0
Surge (2 Ω)
PASS
-500V
230
L, N
0
Surge (2 Ω)
PASS
+500V
230
L, N
90
Surge (2 Ω)
PASS
-500V
230
L, N
90
Surge (2 Ω)
PASS
+500V
230
L, N
180
Surge (2 Ω)
PASS
-500V
230
L, N
180
Surge (2 Ω)
PASS
+500V
230
L, N
270
Surge (2 Ω)
PASS
-500V
230
L, N
270
Surge (2 Ω)
PASS
Figure 26
Testing Setup
Application Note
20
Revision 1.0, 2015-05-25
7.5W 180mA Single Stage Floating Buck LED (GU10)
Converter with ICL8201 & IPU50R3K0CE
References
10
[1]
References
ICL8201 data sheet, Infineon Technologies AG
Revision History
Major changes since the last revision
Page or Reference
Application Note
Description of change
21
Revision 1.0, 2015-05-25
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