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User Guide for
FEBFL7732_L28U008A
8.4 W LED Driver at Universal Line
Using Buck-Boost
Featured Fairchild Product:
FL7732
Direct questions or comments
about this evaluation board to:
“Worldwide Direct Support”
Fairchild Semiconductor.com
© 2012 Fairchild Semiconductor Corporation
1
FEBFL7732_L28U008A • Rev. 1.0.1
Table of Contents
1. Introduction ............................................................................................................................... 3
1.1. Description ....................................................................................................................... 3
1.2. Features ............................................................................................................................ 3
1.3. Internal Block Diagram .................................................................................................... 4
2. Specifications for Evaluation Board ......................................................................................... 5
3. Photographs............................................................................................................................... 6
4. Printed Circuit Board ................................................................................................................ 7
5. Schematic .................................................................................................................................. 8
6. Bill of Materials ........................................................................................................................ 9
7. Transformer Design ................................................................................................................ 10
8. Performance of Evaluation Board ........................................................................................... 11
8.1. Startup ............................................................................................................................ 12
8.2. Operation Waveforms .................................................................................................... 13
8.3. Constant-Current Regulation.......................................................................................... 14
8.4. Short- / Open-LED Protections ...................................................................................... 15
8.5. System Efficiency .......................................................................................................... 17
8.6. Power Factor and Total Harmonic Distortion ................................................................ 18
8.7. Operating Temperature .................................................................................................. 19
8.8. Electromagnetic Interference (EMI) .............................................................................. 20
9. Revision History ..................................................................................................................... 21
© 2012 Fairchild Semiconductor Corporation
2
FEBFL7732_L28U008A • Rev. 1.0.1
This user guide supports the evaluation kit for the FL7732. It should be used in
conjunction with the FL7732 datasheet as well as Fairchild’s application notes and
technical support team. Please visit Fairchild’s website at www.fairchildsemi.com.
1. Introduction
This document describes the proposed solution for universal line voltage LED driver using
the FL7732 Primary Side Regulator (PSR) buck boost controller. The input voltage range is
90 VRMS – 265 VRMS and there is one DC output with a constant current of 140 mA at
60 VMAX. This document contains a general description of the FL7732, the power supply
specification, schematic, bill of materials, and typical operating characteristics.
1.1.
Description
The FL7732 is an active Power Factor Correction (PFC) controller using single-stage
flyback topology. Primary-side regulation and single-stage topology minimize cost and
reduce external components, such as input bulk capacitor and feedback circuitry. To
improve power factor and Total Harmonic Discharge (THD), constant on-time control is
utilized with an internal error amplifier and a low bandwidth compensator. Precise
constant-current control regulates accurate output current, independent of input voltage
and output voltage. Operating frequency is proportionally changed by output voltage to
guarantee DCM operation with high efficiency and simple design. FL7732 provides
protections such as open-LED, short-LED, and over-temperature.
1.2.
Features
Cost-Effective Solution: No Input Bulk Capacitor or Feedback Circuitry
Power Factor Correction (PFC)
Integrated Power MOSFET
Accurate Constant-Current (CC) Control, Independent Online Voltage, Output
Voltage, and Magnetizing Inductance Variation
Linear Frequency Control Improves Efficiency and Simplifies Design
Open-/ Short-LED Protection
Cycle-by-Cycle Current Limiting
Over-Temperature Protection with Auto Restart
Low Startup Current: 20 μA
Low Operating Current: 5 mA
VDD Over-Voltage Protection (OVP)
VDD Under-Voltage Lockout (UVLO)
Application Voltage Range: 80 VAC ~ 308 VAC
© 2012 Fairchild Semiconductor Corporation
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FEBFL7732_L28U008A • Rev. 1.0.1
1.3.
Internal Block Diagram
Figure 1.
© 2012 Fairchild Semiconductor Corporation
Block Diagram
4
FEBFL7732_L28U008A • Rev. 1.0.1
2. Specifications for Evaluation Board
Table 1.
Specifications for LED Lighting Lamp
Description
Symbol
Value
Comments
VIN.MIN
90 V
Minimum Input Voltage
VIN.MAX
265 V
Maximum Input Voltage
VIN.NOMINAL
120 V / 230 V
Nominal Input Voltage
fIN
60 Hz / 50 Hz
Line Frequency
VOUT.MIN
11 V
Minimum Output Voltage
VOUT.MAX
75 V
Maximum Output Voltage
VOUT.NOMINAL
60 V
Rated Output Voltage
IOUT.NOMINAL
140 mA
Rated Output Current
< ±3.27%
Line Input Voltage Change: 90 ~265 VAC
< ±2.19%
Output Voltage Change: 35 ~75 V
Eff90VAC
88.96%
Efficiency at 90 VAC Line Voltage
Eff120VAC
90.75%
Efficiency at 120 VAC Line Input Voltage
Eff140VAC
90.93%
Efficiency at 140 VAC Line Input Voltage
Eff180VAC
90.89%
Efficiency at 180 VAC Line Input Voltage
Eff230VAC
89.49%
Efficiency at 230 VAC Line Input Voltage
Eff265VAC
88.81%
Efficiency at 265 VAC Line Input Voltage
PF / THD90VAC
0.981 / 16.08%
PF / THD at 90 VAC Line Input Voltage
PF / THD120VAC
0.977 / 17.29%
PF / THD at 120 VAC Line Input Voltage
PF / THD140VAC
0.973 / 17.85%
PF / THD at 140 VAC Line Input Voltage
PF / THD180VAC
0.958 / 19.68%
PF / THD at 180 VAC Line Input Voltage
PF / THD230VAC
0.934 / 21.41%
PF / THD at 230 VAC Line Input Voltage
PF / THD265VAC
0.901 / 24.80%
PF / THD at 265 VAC Line Input Voltage
FL7732
TFL7732
53.7ºC
Main Controller Temperature
MOSFET
TMOSFET
56.3ºC
MOSFET
Rectifier
TRectifier
47.1ºC
Secondary Diode Temperature
Voltage
Input
Frequency
Voltage Current
Output
Current
Efficiency
PF/THD
Temperature
CC Deviation
All data of the evaluation board was measured with the board enclosed in a case and
external temperature around 25°C.
© 2012 Fairchild Semiconductor Corporation
5
FEBFL7732_L28U008A • Rev. 1.0.1
3. Photographs
Figure 2.
Figure 3.
Top View (Dimensions: 55.2 mm (L) x 21.0 mm (W) x 15.0 mm (H))
Botom View (Dimensions: 55.2 mm (L) x 21.0 mm (W) x 15.0 mm (H))
© 2012 Fairchild Semiconductor Corporation
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FEBFL7732_L28U008A • Rev. 1.0.1
4. Printed Circuit Board
Unit: mm
Figure 4.
Top Pattern
Figure 5.
© 2012 Fairchild Semiconductor Corporation
Bottom Pattern
7
FEBFL7732_L28U008A • Rev. 1.0.1
5. Schematic
Figure 6.
© 2012 Fairchild Semiconductor Corporation
Schematic
8
FEBFL7732_L28U008A • Rev. 1.0.1
6. Bill of Materials
Item No.
Part
Reference
Part No.
Qty.
Description
Manufacturer
1
BD1
MB6S
1
Bridge Diode
Fairchild
Semiconductor
2
CF1, CF2
MPE400V683K
2
68 nF / 400 V, Film Capacitor
Sungho
3
CO1, CO2
KMG 47 µF / 100 V
1
47 µF / 100 V,
Electrolytic Capacitor
Samyoung
4
C2
KMG 10 µF / 35 V
1
10 µF / 35 V, Electrolytic Capacitor
Samyoung
5
C3
C0805C104K3RACTU
1
0.1 µF / 25 V, SMD Capacitor 2012
Kemet
6
C4
C0805C200M3GACTU
1
20 pF / 25 V, SMD Capacitor 2012
Kemet
7
C5
C1206C105K3PACTU
1
1 µF / 25 V, SMD Capacitor 2012
Kemet
8
D2
1N4003
1
1 A / 200 V, Diode
Fairchild
Semiconductor
9
DO1
ES3J
1
3 A / 600 V, Fast Rectifier
Fairchild
Semiconductor
10
F1
SS-5-1A
1
1 A / 250 V, Fuse
Bussmann
11
LF1
R06153KT00
1
15 mH, 8Ø Filter Inductor
Bosung
12
MOV1
SVC 471D07
1
Varistor
Samwha
13
C2
KMG 10 µF / 35 V
1
10 µF / 35 V, Electrolytic Capacitor
Samyoung
14
RCS1
RC0805JR-071R2L
1
1.2 Ω, SMD Resistor 2012
Yageo
15
RCS2
RC0805JR-071R8L
1
1.8 Ω, SMD Resistor 2012
Yageo
16
RO1
RC1206JR-07220KL
1
220 kΩ, SMD Resistor 3216
Yageo
17
R1, R2
RC1206JR-07100KL
2
100 kΩ, SMD Resistor 3216
Yageo
18
R4
RC0805JR-07150KL
1
150 kΩ, SMD Resistor 2012
Yageo
19
R5
RC1206JR-0724KL
1
24 kΩ, SMD Resistor 3216
Yageo
20
R6
RC0805JR-0710RL
1
10 Ω, SMD Resistor 2012
Yageo
21
T1
RM6
1
Transformer
TDK
22
Q1
FQU5N60C
1
2.8 A / 600 V, MOSFET
Fairchild
Semiconductor
23
U1
FL7732_F116
1
Main Controller
Fairchild
Semiconductor
© 2012 Fairchild Semiconductor Corporation
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FEBFL7732_L28U008A • Rev. 1.0.1
7. Transformer Design
Figure 7.
Transformer Bobbin Structure and Pin Configuration
Figure 8.
Table 2.
Transformer Winding Structure
Winding Specifications
No
Winding
Pin (S F)
Wire
Turns
Winding Method
1
Np
62
0.25Ø
108 Ts
Solenoid Winding
2
Insulation: Polyester Tape t = 0.025 mm, 3-Layer
3
Na
4
54
0.13Ø
32 Ts
Solenoid Winding
Insulation: Polyester Tape t = 0.025 mm, 3-Layer
Table 3.
Electrical Characteristics
Pin
Inductance
Leakage
© 2012 Fairchild Semiconductor Corporation
6–2
10
Specification
Remark
1.4 mH ±10%
60 kHz, 1 V
15 µH
60 kHz, 1 V Short All Output Pins
FEBFL7732_L28U008A • Rev. 1.0.1
8. Performance of Evaluation Board
Table 4.
Electrical Characteristics
TA = 25°C
Ambient Temperature
Test Equipment
© 2012 Fairchild Semiconductor Corporation
AC Power Source: PCR500L by Kikusui
Power Analyzer: PZ4000000 by Yokogawa
Electronic Load: PLZ303WH by KIKUSUI
Multi Meter: 2002 by KEITHLEY, 45 by FLUKE
Oscilloscope: 104Xi by LeCroy
Thermometer: Thermal CAM SC640 by FLIR SYSTEMS
LED: Samsung LED 1W
11
FEBFL7732_L28U008A • Rev. 1.0.1
8.1.
Startup
Startup time is 0.38 s at VIN = 90 VAC. The results were measured using actual LED load.
C1 [VDD], C2 [VIN], C3 [VOUT], and C4 [IOUT].
383 ms
Figure 9.
300 ms
VIN = 90 VAC / 60 Hz
Figure 10.
173 ms
Figure 11.
VIN = 120 VAC / 60 Hz
150 ms
VIN = 230 VAC / 50 Hz
© 2012 Fairchild Semiconductor Corporation
Figure 12.
12
VIN = 265 VAC / 50 Hz
FEBFL7732_L28U008A • Rev. 1.0.1
8.2.
Operation Waveforms
The results were measured using actual LED load. C1 [VCS], C2 [VIN], C3 [VOUT], and
C4 [IOUT].
Figure 13.
VIN = 90 VAC / 60 Hz
Figure 14.
VIN = 120 VAC / 60 Hz
Figure 15.
VIN = 230 VAC / 50 Hz
Figure 16.
VIN = 265 VAC / 50 Hz
© 2012 Fairchild Semiconductor Corporation
13
FEBFL7732_L28U008A • Rev. 1.0.1
8.3.
Constant-Current Regulation
Constant Current (CC) deviation in the wide output voltage range from 35 V to 75 V is
less than 2.2% at each line input voltage. Line regulation at the rated output voltage
(60 V) is less than 2.2%. The results were measured by using E-load.
Figure 17.
Table 5.
Constant-Current Regulation – Measured by E-LOAD [CR Mode]
Constant-Current Regulation by Output Voltage Change (35~75 V)
Input Voltage
Min. Current
Max. Current
Tolerance
90 VAC [60 Hz]
133 mA
138 mA
±1.85%
120 VAC [60 Hz]
133 mA
136 mA
±1.12%
140 VAC [60 Hz]
133 mA
138 mA
±1.85%
180 VAC [50 Hz]
134 mA
140 mA
±2.19%
230 VAC [50 Hz]
139 mA
142 mA
±1.07%
265 VAC [50 Hz]
141 mA
143 mA
±0.70%
Table 6.
Constant Current Regulation by Line Voltage Change (90~265 VAC)
Output
Voltage
90 VAC
[60 Hz]
120 VAC 140 VAC
[60 Hz] [60 Hz]
180 VAC
[50 Hz]
220 VAC 265 VAC
[50 Hz] [50 Hz]
65 V
138 mA
136 mA
134 mA
138 mA
142 mA
143 mA
±2.90%
60 V
138 mA
136 mA
135 mA
136 mA
140 mA
142 mA
±2.17%
55 V
138 mA
136 mA
133 mA
135 mA
139 mA
141 mA
±2.92%
50 V
137 mA
136 mA
133 mA
134 mA
140 mA
141 mA
±3.27%
© 2012 Fairchild Semiconductor Corporation
14
Tolerance
FEBFL7732_L28U008A • Rev. 1.0.1
8.4.
Short- / Open-LED Protections
In short-LED condition, the OCP level is reduced from 0.7V to 0.2V because FL7732
lowers the OCP level when the VS voltage is less than 0.4V during output diode
conduction time. The results were measured using actual LED load. C1 [VDD], C2 [VIN],
C3 [VOUT], and C4 [IOUT].
Figure 18.
VIN = 90VAC / 60Hz
Figure 19.
VIN = 120VAC / 60Hz
Figure 20.
VIN = 230VAC / 50Hz
Figure 21.
VIN = 265VAC / 50Hz
© 2012 Fairchild Semiconductor Corporation
15
FEBFL7732_L28U008A • Rev. 1.0.1
In open-LED condition, the output voltage is limited around 75 V by OVP in VDD. The
output over-voltage protection level can be controlled by the turn ratio of the auxiliary
and secondary windings. The results were measured by using actual LED load. C1 [VDD],
C2 [VIN], C3 [VOUT], and C4 [IOUT].
Figure 22.
VIN = 90 VAC / 60 Hz
Figure 23.
VIN = 120 VAC / 60 Hz
Figure 24.
VIN = 230 VAC / 50 Hz
Figure 25.
VIN = 265 VAC / 50 Hz
© 2012 Fairchild Semiconductor Corporation
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FEBFL7732_L28U008A • Rev. 1.0.1
8.5.
System Efficiency
Power efficiency is 88.81% ~ 90.93% in the 90 ~ 265 VAC input voltage range. The
results were measured after 30 minutes since startup by using actual LED load.
Efficiency
Figure 26.
Table 7.
System Efficiency
System Efficiency
Input Voltage
Input Power
Output
Current
Output
Voltage
Output
Power
Efficiency
90 VAC [60 Hz]
8.93 W
135 mA
58.84 V
7.94 W
88.96%
120 VAC [60 Hz]
8.58 W
132 mA
58.78 V
7.79 W
90.75%
140 VAC [60 Hz]
8.46 W
131 mA
58.72 V
7.69 W
90.93%
180 VAC [50 Hz]
8.76 W
135 mA
58.81 V
7.96 W
90.89%
230 VAC [50 Hz]
9.08 W
138 mA
58.91 V
8.13 W
89.49%
265 VAC [50 Hz]
9.24 W
139 mA
58.95 V
8.21 W
88.81%
© 2012 Fairchild Semiconductor Corporation
17
FEBFL7732_L28U008A • Rev. 1.0.1
8.6.
Power Factor (PF) and Total Harmonic Distortion (THD)
FL7732 shows excellent power factor and performance. Total harmonic distortion is less
than 25%. The results were measured after 30 minutes since startup by using actual LED
load.
Figure 27.
Table 8.
Power Factor and Total Harmonic Distortion
Power Factor and Total Harmonic Distortion
Input Voltage
Output Current Output Voltage
Power Factor
THD
90 VAC [60 Hz]
135 mA
58.84 V
0.981
16.08%
120 VAC [60 Hz]
132 mA
58.78 V
0.977
17.29%
140 VAC [60 Hz]
131 mA
58.72 V
0.973
17.85%
180 VAC [50 Hz]
135 mA
58.81 V
0.958
19.68%
230 VAC [50 Hz]
138 mA
58.91 V
0.934
21.41%
265 VAC [50 Hz]
139 mA
58.95 V
0.901
24.80%
© 2012 Fairchild Semiconductor Corporation
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FEBFL7732_L28U008A • Rev. 1.0.1
8.7.
Operating Temperature
Temperatures of the all components on this board are less than 57ºC. The results were
measured after 60 minutes since startup by using actual LED load.
Top
Bottom
Transformer: 48.9 ºC
Main Controller: 53.7ºC
MOSFET: 56.3 ºC
Figure 28.
Rectifier: 47.1 ºC
Board Temperature – VIN [90 VAC], VOUT [60 V], IOUT [140 mA]
Top
Bottom
Transformer: 49.1
Main Controller: 53.4ºC
Rectifier: 47.1ºC
MOSFET: 52.9 ºC
Figure 29.
© 2012 Fairchild Semiconductor Corporation
Board Temperature – VIN [265 VAC], VOUT [60 V], IOUT [140 mA]
19
FEBFL7732_L28U008A • Rev. 1.0.1
8.8.
Electromagnetic Interference (EMI)
All measurements were conducted in observance of EN55022 criteria. The results were
measured after 30 minutes since startup by using actual LED load.
Figure 30.
VOUT [60 V], IOUT [140 mA], VIN=110 VAC
Figure 31.
VOUT [60 V], IOUT [140 mA], VIN=220 VAC
© 2012 Fairchild Semiconductor Corporation
20
FEBFL7732_L28U008A • Rev. 1.0.1
9. Revision History
Rev.
Date
Description
1.0.0
July 2012
Initial Release
1.0.1
Nov. 2012
Modified, edited, formatted document. Changed User Guide number from
FEB-L028 to FEBFL7732_L28U008A
WARNING AND DISCLAIMER
Replace components on the Evaluation Board only with those parts shown on the parts list (or Bill of Materials) in the Users’ Guide. Contact an
authorized Fairchild representative with any questions.
The Evaluation board (or kit) is for demonstration purposes only and neither the Board nor this User’s Guide constitute a sales contract or create any
kind of warranty, whether express or implied, as to the applications or products involved. Fairchild warrantees that its products meet Fairchild’s
published specifications, but does not guarantee that its products work in any specific application. Fairchild reserves the right to make changes without
notice to any products described herein to improve reliability, function, or design. Either the applicable sales contract signed by Fairchild and Buyer or,
if no contract exists, Fairchild’s standard Terms and Conditions on the back of Fairchild invoices, govern the terms of sale of the products described
herein.
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THE RIGHTS OF OTHERS.
LIFE SUPPORT POLICY
FAIRCHILD’S PRODUCTS ARE NOT AUTHORIZED FOR USE AS CRITICAL COMPONENTS IN LIFE SUPPORT DEVICES OR SYSTEMS
WITHOUT THE EXPRESS WRITTEN APPROVAL OF THE PRESIDENT OF FAIRCHILD SEMICONDUCTOR CORPORATION.
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2. A critical component is any component of a life support device or
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Counterfeiting of semiconductor parts is a growing problem in the industry. All manufacturers of semiconductor products are experiencing
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© 2012 Fairchild Semiconductor Corporation
21
FEBFL7732_L28U008A • Rev. 1.0.1
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