LM3444A9

LM3444 A19 Edison Retrofit Evaluation Board LM3444 A19 Edison Retrofit Evaluation Board National Semiconductor Application Note 2083 Clinton Jensen December 2, 2010 Introduction The evaluation board included in this shipment converts 85VAC to 135VAC input and drives five to thirteen series connected LED’s at the currents listed in the Evaluation Board Operating Conditions section. This is a two-layer board using the bottom and top layer for component placement. The board is surrounded by a larger area allowing for extra test points and connectors for ease of evaluation. The actual board size is contained inside the larger outer area and can be cut out for the smallest size possible. The evaluation board can be modified to adjust the LED forward current and the number of series connected LEDs. The topology used for this evaluation board eliminates the need for passive power factor correction and results in high efficiency and power factor with minimal component count which results in a size that can fit in a standard A19 Edison socket. Output current is regulated within ±15% of nominal from circuit to circuit and over line voltage variation. Refer to the LM3444 datasheet for details on the LM3444 IC. A bill of materials below describes the parts used on this demonstration board. A schematic and layout have also been included below along with measured performance characteristics including EMI/EMC data. The above restrictions for the input voltage are valid only for the demonstration board as shipped with the schematic below. Please refer to the LM3444 data sheet for detailed information regarding the LM3444 device. The board is currently set up to drive five to thirteen series connected LEDs, but the evaluation board may be modified to accept more series LEDs. Refer to the tables in this document for modifying the board to accept more LEDs and/or adjust for different current levels. Evalution Board Operating Conditions VIN = 85VAC to 135VAC 5 to 13 series connected LEDs as configured with the currents listed below Can drive up to 18 series LEDs (see table) ILED = 340 mA (5 LEDs) ILED = 300 mA (7 LEDs) ILED = 260 mA (9 LEDs) ILED = 230 mA (11 LEDs) ILED = 205 mA (13 LEDs) Simplified LM3444 Schematic 30131201 Warning: The LM3444 evaluation boards have no isolation or any type of protection from shock. Caution must be taken 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. Warning: This LM3444 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. AN-2083 © 2010 National Semiconductor Corporation 301312 www.national.com AN-2083 Pin-Out 30131203 10-Pin MSOP Pin Description 10 Pin MSOP Pin # 1 2 3 4 5 6 7 8 9 10 Name NC NC NC COFF FILTER GND ISNS GATE VCC NC Description No internal connection. No internal connection. No internal connection. 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. Circuit ground connection. LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the maximum LED current. Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck controller. Input voltage pin. This pin provides the power for the internal control circuitry and gate driver. No internal connection. www.national.com 2 AN-2083 LM3444 Evaluation Board Schematic 30131207 3 www.national.com AN-2083 Bill of Materials LM3444 Evaluation Board REF DES U1 C1, C10 C2 C3 C4/RBLDR (Note 1) C5 C6 C8 C12 C15 C14 D1 D2 D4 D7 D8 F1 J5, J10 L1, L2 L3 M1 M2 M3 M4 Q1 Q2 R1, R3 R2, R7 R4 R6, R24 R10 R12 R14 R15 R16 R22 RT1 TP1, TP2, TP3, TP4 Description IC DRIVER LED 10MSOP Ceramic, 47000pF, 500V, X7R, 1210 CAP FILM MKP .0047µF 310VAC X2 CAP 470µF 50V ELECT PW RADIAL DNP Ceramic, .33µF, 250V, X7R, 1812 CAP .10µF 305VAC EMI SUPPRESSION Ceramic, 47µF, X5R, 16V, 1210 Ceramic, 470pF, 50V, X7R, 0603 Ceramic, 0.1µF, 16V, X7R, 0603 Ceramic, 0.47µF, 16V, X7R, 0603 DIODE SCHOTTKY 1A 200V PWRDI 123 Bridge Rectifier, Vr = 400V, Io = 0.8A, Vf = 1V DIODE FAST 1A 300V SMA DIODE ZENER 15V 500MW SOD-123 DIODE SCHOTTKY 1A 200V PWRDI 123 FUSE 1A 125V FAST CONN HEADER .312 VERT 2POS TIN INDUCTOR 3900µH .12A RADIAL 820µH, Shielded Drum Core JUMPER WIRE 0.3" J6 TO J1 JUMPER WIRE 0.3" J7 to J4 JUMPER WIRE 0.3" J2 TO J8 JUMPER WIRE 0.3" J3 TO J9 MOSFET N-CH 240V 260MA SOT-89 MOSFET N-CH 250V 4.4A DPAK RES 200kΩ, 0.25W, 1%, 1206 RES 274kΩ, 0.25W, 1%, 1206 RES 430Ω, 1/2W, 5%, 2010 RES 30.1kΩ, 0.25W, 1%, 1206 DNP RES 4.7Ω, 0.1W, 5%, 0603 RES 1.54Ω, 1/4W, 1%, 1206 RES 3.16kΩ, 0.1w, 1%, 0603 RES 255kΩ, 0.1W, 1%, 0603 RES 40.2Ω, 0.125W, 1%, 0805 CURRENT LIMITOR INRUSH 60Ω 20% Terminal, Turret, TH, Double Vishay-Dale Vishay-Dale Vishay-Dale Vishay-Dale Vishay-Dale Cantherm Keystone Electronics CRCW06034R70JNEA CRCW12083R54FNEA CRCW06033K16FKEA CRCW0603255KFKEA CRCW080540R2FKEA MF72-060D5 1502-2 TDK Corporation EPCOS MuRata MuRata MuRata MuRata Diodes Inc. Diodes Inc. Fairchild Semi conductor Fairchild Semi conductor Diodes Inc. Cooper/Bussman Tyco Electronics J.W. Miller/Bourns Coilcraft Inc. 3M 3M 3M 3M Infineon Technologies Fairchild Semi conductor Vishay-Dale Vishay-Dale Vishay-Dale Vishay-Dale C4532X7R2E334K B32921C3104M GRM32ER61C476ME15L GRM188R71H471KA01D GRM188R71C104KA01D GRM188R71C474KA88D DFLS1200-7 HD04-T ES1F MMSZ5245B DFLS1200-7 6125FA1A 1-1318301-2 RL875S-392K-RC MSS1038-824KL 923345-03-C 923345-03-C 923345-03-C 923345-03-C BSS87 L6327 FDD6N25TM CRCW1206200kFKEA CRCW1206274kFKEA CRCW2010430RJNEF CRCW120630k1FKEA MFG National Semiconductor Johanson Dielectrics Vishay/BC Components Nichicon MFG Part Number LM3444MM 501S41W473KV4E BFC233820472 UPW1H471MHD Note 1: C4/RBLDR is a dual purpose pad which is unpopulated by default. A ceramic capacitor (C4) may be used here if extra high frequency bypassing is desired across the LED load. Alternatively a bleeder resistor (RBLDR) in the range of 10kΩ to 100kΩ may be placed here to quickly discharge C3 and prevent prolonged LED glow due to the energy stored in C3. www.national.com 4 AN-2083 Output Current versus Number of LEDs for Various Modifications # of LEDs 2 3 4 5 6 7 8 9 10 11 12 13 14 (Note 5) 15 (Note 5) 16 (Note 5) 17 (Note 5) 18 (Note 5) 340 315 300 275 260 245 230 215 205 196 190 183 175 170 248 235 222 210 200 190 180 170 164 156 150 142 135 130 265 250 237 224 212 200 190 180 170 162 155 148 142 137 Output Current (mA) Original Circuit Output Current (mA) Modification A (Note 2) Output Current (mA) Modification B (Note 3) Output Current (mA) Modification C (Note 4) 520 500 475 455 432 412 Note 2: Modification A: R14 = 2.37Ω, R16 = 150kΩ, C3 = 330µF, 63V. Note 3: Modification B: R14 = 2.2Ω, R16 = 165kΩ. Note 4: Modification C: R14 = 1.2Ω, R16 = 137kΩ, L3 = 470µH, C3 = 1000µF, 25V. Note 5: For all applications using greater than 13 LEDs a 330µF, 63V output capacitor (C3) was used. 5 www.national.com AN-2083 Typical Performance Characteristics Efficiency vs. Line Voltage Original Circuit Power Factor vs. Line Voltage Original Circuit 30131202 30131204 Efficiency vs. Line Voltage Modification A Power Factor vs. Line Voltage Modification A 30131211 30131212 Efficiency vs. Line Voltage Modification B Power Factor vs. Line Voltage Modification B 30131213 30131214 www.national.com 6 AN-2083 PCB Layout 30131210 Top Layer 30131209 Bottom Layer Warning: The LM3444 evaluation boards have no isolation or any type of protection from shock. Caution must be taken 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. 7 www.national.com AN-2083 EMI/EMC Information 30131215 Radiated EMI 30131216 Conducted EMC. Line = Blue, Neutral = Black. Frequency Neutral Line 154 kHz 1.1 MHz Quasi-peak Amplitude 57 Quasi-peak Limit 66 Quasi-peak Delta -9 Average Amplitude 47 31 Average Limit 56 46 Average Delta -9 -15 www.national.com 8 AN-2083 Notes 9 www.national.com LM3444 A19 Edison Retrofit Evaluation Board Notes For more National Semiconductor product information and proven design tools, visit the following Web sites at: www.national.com Products Amplifiers Audio Clock and Timing Data Converters Interface LVDS Power Management Switching Regulators LDOs LED Lighting Voltage References PowerWise® Solutions Temperature Sensors PLL/VCO www.national.com/amplifiers www.national.com/audio www.national.com/timing www.national.com/adc www.national.com/interface www.national.com/lvds www.national.com/power www.national.com/switchers www.national.com/ldo www.national.com/led www.national.com/vref www.national.com/powerwise WEBENCH® Tools App Notes Reference Designs Samples Eval Boards Packaging Green Compliance Distributors Quality and Reliability Feedback/Support Design Made Easy Design Support www.national.com/webench www.national.com/appnotes www.national.com/refdesigns www.national.com/samples www.national.com/evalboards www.national.com/packaging www.national.com/quality/green www.national.com/contacts www.national.com/quality www.national.com/feedback www.national.com/easy www.national.com/solutions www.national.com/milaero www.national.com/solarmagic www.national.com/training Applications & Markets Mil/Aero PowerWise® Design University Serial Digital Interface (SDI) www.national.com/sdi www.national.com/wireless www.national.com/tempsensors SolarMagic™ THE CONTENTS OF THIS DOCUMENT ARE PROVIDED IN CONNECTION WITH NATIONAL SEMICONDUCTOR CORPORATION (“NATIONAL”) PRODUCTS. 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