A N- R E F- I C L82 01 _ Si n gl e E nd C a p T8
18W 27 0m A Sin gl e St ag e Fl o a ti ng B u ck L E D
(S in gl e E n d C ap T8 ) C on v er ter wi th I C L8 2 01
& IP S6 5R 1 K5 C E
About this document
Scope and purpose
This document is a 18W 270mA average current controlled single stage, cascade structure for floating bulk
topology Single End Cap T8 LED lamp reference design using Infineon LED driver ICL8201 (SOT23-6-1) and
CoolMOS™ IPS65R1K5CE (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 Single End Cap T8 form factor LED lamp.
1
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Table of Contents
Table of Contents
Table of Contents..............................................................................................................................................2
1
Introduction...................................................................................................................................3
2
Reference board.............................................................................................................................3
3
Specification ..................................................................................................................................3
4
Schematic ......................................................................................................................................4
5
Single End Cap T8 reference board layout .....................................................................................5
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, Open output, Short winding, and Thermal
performance & Intelligent over temperature protection) ...............................................................12
Short output protection..............................................................................................................12
Open output protection..............................................................................................................13
Short winding protection............................................................................................................14
Intelligent over temperature protection....................................................................................15
Test results (Power factor, Total Harmonic Distortion (THD), Efficiency, Regulation & Conducted
Emissions)..........................................................................................................................................16
Power Factor and Total Harmonics Distortion ..........................................................................17
Output current regulation ..........................................................................................................17
Efficiency .....................................................................................................................................18
Conducted emissions (EN55015)................................................................................................19
Lightning Surge (EN61000-4-5)...................................................................................................20
10
References ...................................................................................................................................21
9.6.1
9.6.2
9.6.3
9.6.4
9.7
Revision History ..............................................................................................................................................21
Application Note
2
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Introduction
1
Introduction
This application note is an engineering report of Single End Cap T8 LED lamp reference design for High Line
input 18W 66V converter. The converter is using ICL8201 (SOT23-6-1), average current controlled, nonisolated single stage buck topology in cascade structure LED driver and IPS65R1K5CE (IPAK), a CE series of
high voltage power CoolMOS™. The distinguishing features of this reference design are high efficiency and
power factor with single stage design, critical conduction operation mode with single choke (without
auxiliary winding), truly regulated output current over a wide output voltage range, good EMI performance
and various modes of protections for high reliability with small form factor which can be easily fit into single
end cap of standard T8 LED lamp.
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)
IPS65R1K5CE (IPAK)
(Top view)
(Bottom view)
Figure 1
REF-ICL8201_T8 [Size( L x W x H): 42mm x 20mm x 15mm]
3
Specification
Table 1
Specification of REF-ICL8201_T8
Input voltage & frequency
170VAC~277 VAC (50Hz)
Output voltage, current & power
55V~75V, 270mA, 18W
Power factor
>0.95
THD
< 20%
Efficiency
>90%
Conducted emissions (EN55015)
>10dB margin
Application Note
3
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Schematic
4
Schematic
Figure 2
Schematic of REF-ICL8201_T8
Application Note
4
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Reference board layout and BOM
5
Single End Cap T8 reference board layout
The reference board has double layers PCB with dimension of 42x20mm and thickness of 1mm is used. The
maximum height of the demo board is 15mm. With its compact form factor, this reference board is able to fit
into Single End Cap T8 lamp.
Figure 3
Top view
Top and bottom view
6
Bill of material and transformer specification
6.1
Bill of material
Table 2
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Bottom view
Bill of material
Designator
F1
RV1
BR1
L1
D1
D2,D5
D4
D6
D7
C1
C2
C3
C4
C5
C6
C7, C8
C9
R1, R2, R10
R4, R5
R6
R8
R9
R11
R12
T1
Q1
Q2
Q3
U1
Ferrite Bead Core
PCB
Application Note
Manufacturer
Littlefuse
EPCOS
Micro Commercial
Bourns
ON Semi
ON Semi
Infineon
ON Semi
MULTICOMP
Kemet
Faratronic
Murata
Yageo
Yageo
Murata
RUBYCON
Rubycon
Yageo
KOA Spear
Vishay
Yageo
Yageo
Yageo
Yageo
Wurth
Infineon
NXP
Infineon
Infineon
KEMET
Part Number
0263003.MXL
B72210S0301K101
LMB6S-TP
RL875-222K-RC
MUR260G
MMSZ5245BT1G
BAS 16 E6327
MMSZ5268BT1G
1N4007G
F861AP154M310L
C222G154K40
GRM188R71A225KE15D
CC0603KRX7R8BB103
CC1206JRNPOBBN220
GRM21BR71E225KA73L
100ZLJ33M8X11.5
400PX2R2MEFC8X11.5
RC1206FR-071ML
RK73H2BTTD5103F
RCWE1206R750FKEA
RC0603FR-071KL
RC0603FR-0710KL
RC0805JR-07560KL
RC0603JR-074R7L
750342737
IPS65R1K5CE
PBHV9050T
SMBT3904
ICL8201
B-20F-38
5
Description
FUSE, PCB, 3A, 250V, VERY FAST ACTING
VARISTOR 423V 2.5KA DISC 10MM
BRIDGE RECTIFIER 0.8A 600V LMBS-1
INDUCTOR, 2.2mH, ±10%, 180mA, DCR=6.25Ω
DIODE, RECTIFIER, 2A, 600V, DO-15
DIODE ZENER 15V 500MW SOD123
DIODE SWITCH 80V 0.25A SOT23
DIODE, ZENER, 82V, 500mW, SOD-123
DIODE, STANDARD, 1A, 1000V, DO41
CAP FILM 0.15UF 630VDC RADIAL (P=10mm)
CAP FILM 0.15UF 400VDC 10% RADIAL
CAP CER 2.2uF 10V 10% X7R 0603
CAP CER 10nF 25V 10% X7R 0603
CAP CER 22pF 500V 5% NP0 1206
CAP CER 2.2uF 25V 10% X7R 0805
CAP ALU 100V, 33uF, ±20%, 10,000hrs @ 105
CAP, ALU ELEC, 2.2UF, 400V, RAD
RES 1.00M OHM 1/4W 1% 1206 SMD
RES 510K OHM 1/4W 1% 1206 SMD
RES 0.75R OHM 1/2W 1% 1206 SMD
RES 1K OHM 1/10W 1% 0603 SMD
RES 10K OHM 1/10W 1% 0603 SMD
RES 560K OHM 1/8W 5% 0805 SMD
RES 4.7 OHM 1/10W 5% 0603 SMD
EP13, 850uH, ±10%
MOSFET, 650V, 3.1A, 1.5Ω, IPAK
TRANS PNP 500V 150MA SOT23
TRANS NPN 40V 150MA SOT23
LED Buck Controller, SOT23-6-1
FERRITE CORE, CYLINDRICAL, 1.5MM X 4.3MM
FR4, 2 Layer, 1oz, Soldermask, 42x20x15 mm
Qty
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Transformer Specification and 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, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
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)
Latch
Latch
Latch
Latch
Latch
Latch
Latch
Note: Over voltage protection circuit (shown in Figure 2) is externally added in this reference board and it is
auto restart mode.
Application Note
7
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
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_T8 is Live (L) and Neutral (N) wires and its operating input AC voltage range is
170VAC ~277 VAC.
The output of REF-ICL8201_T8 is V+ and V- wires which can supply 66V, 270mA 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 (T1), external power switch (Q1) and VCC diode (D4). 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
Startup waveform
Application Note
8
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
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_max30 minutes under conditions of
open frame board and 25°C Ambient temperature.
Figure 16
Bottom Side. U1=57.2°C; Q1=66.7°C (66V, 270mA LED load@Vin=230VAC/50Hz)
ICL8201 has Intelligent over temperature protection shown as below (Figure 17). It reduces the output
current in 7 digital steps down to 50% of target value of ILED in the event of overheating IC (Tj>150℃). If the
temperature continues to increase and exceeds Tj > 160 °C, the IC will enter LATCH OFF mode.
Figure 17
Standard curve of Intelligent Over-Temperature Protection (iOTP)
Application Note
15
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Reference board set up, test waveforms and results
9.7
Test results (Power factor, Total Harmonic Distortion (THD), Efficiency,
Regulation & Conducted Emissions)
Table 4
Power Factor, THD, Efficiency & Regulation
66V, 270mA LED load
Vin @ 50Hz
(VAC)
170
200
230
265
277
Pin
(W)
19.30
19.28
19.34
19.46
19.48
PF
THD
0.98
0.98
0.97
0.96
0.95
13.47
12.48
12.88
14.13
14.62
Vout
(VDC)
66.34
66.35
66.38
66.40
66.40
Iout
(mA)
268
267
267
268
268
Pout
(W)
17.78
17.72
17.72
17.80
17.80
△Iout
(%)
-0.74
-1.11
-1.11
-0.74
-0.74
Efficiency (%)
Average Efficiency (%)
92.12
91.89
91.64
91.45
91.35
91.69
Average Efficiency (%)
75V, 270mA LED load
Vin @ 50Hz
(VAC)
Pin
(W)
PF
THD
Vout
(VDC)
Iout
(mA)
Pout
(W)
△Iout
(%)
Efficiency (%)
170
200
230
265
21.65
21.61
21.64
21.75
0.98
0.98
0.98
0.96
15.48
13.20
12.68
13.29
74.60
74.65
74.65
74.67
268
267
267
267
19.99
19.93
19.93
19.94
-0.74
-1.11
-1.11
-1.11
92.35
92.23
92.11
91.66
277
21.77
0.96
13.64
74.67
267
19.94
-1.11
91.58
91.99
55V, 270mA LED load
Vin @ 50Hz
(VAC)
Pin
(W)
PF
THD
Vout
(VDC)
Iout
(mA)
Pout
(W)
△Iout
(%)
Efficiency (%)
Average Efficiency (%)
170
200
230
265
277
16.16
16.17
16.22
16.33
16.36
0.98
0.98
0.96
0.94
0.93
12.12
12.76
14.08
15.80
16.34
55.30
55.30
55.30
55.36
55.36
267
267
266
266
266
14.77
14.77
14.71
14.73
14.73
-1.11
-1.11
-1.48
-1.48
-1.48
91.37
91.31
90.69
90.18
90.01
90.71
Application Note
16
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
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 above 0.95 and THD is less than 15% over the whole input voltage range.
Figure 18
Power Factor and THD versus AC line voltage (66V, 270mA LED load)
9.7.2
Output current regulation
Below figure shows the LED output current versus line voltage. The output current is regulated within ±2%
over the whole input voltage range.
Figure 19
Output current versus AC line voltage
Application Note
17
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Reference board set up, test waveforms and results
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 55V, 66V and 75V, the
output current is regulated within ±2%.
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 >90% over the whole AC input
range due to quasi resonant operation.
Figure 21
Efficiency versus AC line voltage
Application Note
18
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Reference board set up, test waveforms and results
9.7.4
Conducted emissions (EN55015)
The conducted emissions test was performed at 230VAC, 50Hz with full load and there is approximately 10dB
margin observed for both line and neutral measurements.
Figure 22
Conducted emissions(Line) at 230 VAC, 50Hz & full load
Figure 23
Conducted emissions(Neutral) at 230 VAC, 50Hz & full load
Application Note
19
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
Reference board set up, test waveforms and results
9.7.5
Lightning Surge (EN61000-4-5)
The Board was subjected to ±1KV differential mode combination wave surge at 230Vac and full load using 5
strikes at each condition, thanks to the external lightning surge improvement circuit(shown in Figure 2) and
Infineon 650V CE MOSFET (IPS65R1K5CE),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)
+1000V
230
L, N
0
Surge (2 Ω)
PASS
-1000V
230
L, N
0
Surge (2 Ω)
PASS
+1000V
230
L, N
90
Surge (2 Ω)
PASS
-1000V
230
L, N
90
Surge (2 Ω)
PASS
+1000V
230
L, N
180
Surge (2 Ω)
PASS
-1000V
230
L, N
180
Surge (2 Ω)
PASS
+1000V
230
L, N
270
Surge (2 Ω)
PASS
-1000V
230
L, N
270
Surge (2 Ω)
PASS
Figure 24
Testing Setup
Application Note
20
Revision 1.0, 2015-05-27
18W 270mA Single Stage Floating Buck LED (Single End Cap T8)
Converter with ICL8201 & IPS65R1K5CE
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, 2015-05-27
Trademarks of Infineon Technologies AG
AURIX™, C166™, CanPAK™, CIPOS™, CIPURSE™, CoolMOS™, CoolSET™, CORECONTROL™, CROSSAVE™, DAVE™, DI-POL™, EasyPIM™, EconoBRIDGE™,
EconoDUAL™, EconoPIM™, EconoPACK™, EiceDRIVER™, eupec™, FCOS™, HITFET™, HybridPACK™, I²RF™, ISOFACE™, IsoPACK™, MIPAQ™, ModSTACK™,
my-d™, NovalithIC™, OptiMOS™, ORIGA™, POWERCODE™, PRIMARION™, PrimePACK™, PrimeSTACK™, PRO-SIL™, PROFET™, RASIC™, ReverSave™,
SatRIC™, SIEGET™, SINDRION™, SIPMOS™, SmartLEWIS™, SOLID FLASH™, TEMPFET™, thinQ!™, TRENCHSTOP™, TriCore™.
Other Trademarks
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Integrated Products, Inc. MICROTEC™, NUCLEUS™ of Mentor Graphics Corporation. MIPI™ of MIPI Alliance, Inc. MIPS™ of MIPS Technologies, Inc., USA.
muRata™ of MURATA MANUFACTURING CO., MICROWAVE OFFICE™ (MWO) of Applied Wave Research Inc., OmniVision™ of OmniVision Technologies, Inc.
Openwave™ Openwave Systems Inc. RED HAT™ Red Hat, Inc. RFMD™ RF Micro Devices, Inc. SIRIUS™ of Sirius Satellite Radio Inc. SOLARIS™ of Sun
Microsystems, Inc. SPANSION™ of Spansion LLC Ltd. Symbian™ of Symbian Software Limited. TAIYO YUDEN™ of Taiyo Yuden Co. TEAKLITE™ of CEVA, Inc.
TEKTRONIX™ of Tektronix Inc. TOKO™ of TOKO KABUSHIKI KAISHA TA. UNIX™ of X/Open Company Limited. VERILOG™, PALLADIUM™ of Cadence Design
Systems, Inc. VLYNQ™ of Texas Instruments Incorporated. VXWORKS™, WIND RIVER™ of WIND RIVER SYSTEMS, INC. ZETEX™ of Diodes Zetex Limited.
Last Trademarks Update 2011-11-11
www.infineon.com
Edition 2015-01-23
Published by
Infineon Technologies AG
81726 Munich, Germany
© 2015 Infineon Technologies AG.
All Rights Reserved.
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