UM10795
SSL5031BDB1209 18 W TLED universal mains non-isolated
buck LED driver demo board
Rev. 1 — 4 November 2014 User manual
Document information
Info Content
Keywords SSL5031BDB1209, SSL5031BTS, LED driver, non-isolated buck
topology, T8 applications, HSO8 package
Abstract This user manual describes the performance, technical data and the
connection of the SSL5031BDB1209 demo board, using a non-isolated
buck topology.
The SSL5031BTS is an NXP Semiconductors driver IC in a TSOP6
package, intended to provide a low cost, small form factor LED driver
design.
The SSL5031BDB1209 demo board is designed for T8 application s. It is
intended to operate at 230 V(AC), with an output voltage around 60 V.
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User manual Rev. 1 — 4 November 2014 2 of 18
Contact information
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: salesaddresses@nxp.com
NXP Semiconductors UM10795
SSL5031BDB1209 - 18 W TLED buck LED driver demo board
Revision history
Rev Date Description
v.1 20141104 first issue
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
1. Introduction
This user manua l describes th e operation of the SSL5031BDB120 9 demo board featurin g
the SSL5031BTS LED driver in a 100 V to 277 V/18 W non-isolated application.
The SSL5031BDB1209 de mo board is designed to drive LED loa ds from 40 V to 80 V with
a nominal value of 550 V for best THD performance over universal mains input.
The PCB dimensions are compatible with T8 tube applications.
The SSL5031BDB1209 demo board provides a simple and effective solution with a high
Power Factor (PF), low Total Harmonic Distortion (THD), and high efficiency for
Solid-State Ligh ting (SSL) applications. When, in a buck topo logy, the LED voltag e
exceeds 60 V, it can influence THD at low mains voltages.
1.1 Features
•T8 LED tube application
•Open/short LED string protection
•OverCurrent Protection (OCP)
•OverTemperature Protection (OTP)
•PF > 0.92 at 100 V to 264 V (AC), 50 Hz/60 Hz input
•THD < 20 % at 100 V to 264 V (AC), 50 Hz/60 Hz input
•Efficiency > 88 % at 10 0 V to 264 V (AC) inpu t
•Compliant with IEC61000-3-2 harmonic standard
•Compliant with EN55015 conducted EMI
WARNING
Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present wh en operating this product, constitute a
risk of electric shock, personal injury, death and/or ignition of fire.
This product is intended for evaluation purposes only. It shall be operated in a designated test
area by personnel qualified accordin g to local requirements and labor laws to work with
non-insulated mains voltages and high-voltage circuits. This product shall never be operated
unattended.
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
2. Safety warning
The demo board input is connected to the 230 V mains. Avoid touching the board while it
is connected to the mains voltage and when it is in operation. An isolated housing is
obligatory when used in uncontrolled, non-laboratory environments. Galvanic isolation
from the mains phase using a fixed or variable transformer is always recommended.
Figure 1 shows the symbols on how to recognize these devices.
3. Specifications
Table 1 lists the spe cification of the SSL5031BDB1209 demo board.
a. Isolated b. Not isolated
Fig 1. Isolation symbols
019aab173
019aab174
Table 1. SSL5031BDB1209 specifications
Symbol Parameter Value
Vmains AC mains supply voltage 100 V to 240 V (AC); 10 %
Pout output power 16.1 W
VLED output voltage 50 V to 65 V (55 V op timum)
ILED output current 297 mA
Iripple output current ripple at 100 Hz 15 % (peak-to-peak)
ILED(Vmains)/ILED(nom) line regulation 1.5 %; Vmains =90Vto264V
ILED(VLED)/ILED(nom) load regulation 0.7 %; VLED =10%
efficiency > 88 %;
90 V to 264 V (AC)/50 Hz/60 Hz
PF power factor >0.92;
100 V to 264 V (AC)/50 Hz/60 Hz
THD total harmonic distortion < 20 %;
90 V to 264 V (AC)/50 Hz/60 Hz
Toper operating temperature 40 C to +85 C
- board dimension s 180 mm 15 mm
- conducted electrostatic
Interference (EMI) EN55015
- IEC61000-3-2 Class D (for Pin < 25 W limit)
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
Figure 2 shows the dimensions of the demo board.
4. Board photographs
5. Board connections
The SSL5031BDB1209 demo board is optimized for a 100 V to 264 V (AC)/50 Hz to
60 Hz mains supply. It is designed to work with multiple LEDs or an LED module.
Under the expected conditions, the output current is 297 mA when using an LED string
with a 55 V forward voltage (V F). The current can be a djusted using resistors R4 and R4 4.
A 55 V LED voltage gives a good THD performance at 120 V (AC) and 230 V (AC). A
lower LED voltage gives better THD at 120 V (AC). A higher LED voltage doe s better for
the higher mains voltage.
W1 and W2 are the connections for the mains voltage. J1 (LED+) and J2 (LED) are the
connections for the LED load. Figure 4 shows the connections.
Fig 2. SSL5031BDB1209 demo board dimension s
a. Top view
b. Bottom view
Fig 3. SSL5031BDB1209 demo board photographs
Fig 4. SSL5031BDB1209 board connections
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
6. Functional description
6.1 Input filtering
Capacitors C1 a nd C2 an d indu ctor L1 filter the switching current from the buck converter
to the line. Capacitors C1 and C2 also provide a low- impedance path for the switching
current. To achieve high-frequency suppression to the mains, a high PF, and low THD in
the design, the values of capacitors C1 and C2 are kept as low as necessary.
The 10 input series resistance together with the varistor MOV1 across the AC bridg e
rectifier input provides protection against tran sient surge voltages. The input resistance is
added to increase the immunity to the line surge (see Figure 12). Do not omit this resistor
or lower its value.
6.2 Efficiency improvement for universal mains
For single mains, the SSL5031BTS is normally supplied using start-up resistors R1, R2,
and R10. To keep the temperature at high mains voltage low, the power losses in these
resistors are divid e d ove r resistors R1 and R2, while R10 = 0 .
For universal mains, the start-up supply resistors must be set up to start the IC at
90 V (AC). This setup causes much unnecessary dissipation and efficiency loss at
230 V (AC).To avoid the extra loss at high mains, an optional circuit is used
(see Figure 5). The efficiency improvement from this circuit is 3 % to 5 % at 230 V (AC).
Transistor Q2 is set up as a current limited voltage source. The cur rent limited voltage
source is turned off using diode D4 and kept in off-state using capacitor C8 when the
SSL5031BTS starts switching. The supply for the IC during switching is coming from the
recovered turn-off charge in Q1 which charges capacitor C3.
Resistor R11 limits the current in Q2. Diode D4 and th e internal diode in the SSL50 31BTS
between the SW and VCC pins set the reference volt age. The maximum curr ent is limited
to , the total start-up current r equired for the SSL5031BTS to start. To
achieve flicker suppressio n at low mains volt ages, a volt age control of Q1 is implemented
using the voltage divider R11, R12, and R13. The divider is set up to start the
SSL5031BTS at 70 V (AC) mains, when capacitors C6 and C7 are fu lly disch arg ed. If the
circuit is turned on just after it has been switched off, the AC mains start-up voltage is
higher. The start-up voltage can shift up to 95 V (AC), because of the precharge in
capacitors C6 and C7. Generally, there is n * 2.5 V left in output capacitors just after the
circuit is switched off (where n = number of single LEDs in series in an LED string).
To switch off the optional circuit, remove resistor R11 and resistor R10 must be 0 .
To protect Q2 from mains surges, resistors R1 and R2 are left in place. Replace resistor
R10 with a 2.2 nF capacitor. A small efficiency penalty for the surge protection of Q2
exists.
D4
R11
----------255 A=
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6.3 THD and LED voltage
Because this application is a universal mains application, the output LED voltage chosen
is important. If the chosen value is too low , THD at high voltage is too high. If it is too high,
THD at low mains voltage is too high.
To obtain equal distribution of the THD, the optimum LED voltage for the universal mains
application is 55 V to 60 V (see Figure 8).
6.4 Open-load protection
The driver board is protected when the LED load is accidentally left open. The open-load
protection is a non-latched protection. Two circuits set the open-load output voltage. One
circuit sets the open-load output voltage when the IC does not operate because of a
defect. The othe r circ uit se ts it when the IC is operating normally. In all cases, the output
voltage must never exceed the rated DC voltage of the output capacitor.
Do not reconnect the LEDs directly after an open load situation. The output capacitor is
charged to a higher voltage than the total LED voltage, which forces an uncontrolled
discharge current through the LEDs when connected. It can damage the LEDs
permanently.
IC not operating:
The voltage divider consisting of R1, R2, and R10 sets the output voltage in the VCC pin
of the IC referenced to the GND pin of the IC and resistor R9.
(1)
If the optional circuit (see Figure 5) is used, the current (set by ) and the parallel
current path (set by resisto rs R11, R12, and R13 an d dio d e D4) set th e ou tp ut voltage at
260 V (AC), the total current is about 285 A.
Fig 5. SSL5031BTS efficiency improvement circuit
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
As a rule of thumb, li mit resistor R9 to . In this way, the voltage is not sufficient
to illuminate the LEDs (n is the number of LEDs in series at the output).
The non-operating output voltage must not be equal to or exceed the voltage set by the
operating mode. It is good practice to set the level in non-operating mode 5 V to 10 V
lower than in oper at ing mo de .
IC operating:
When the volt age in the non- oper ating mode is set to a safe leve l for the output capacitor,
the voltage in the operating mo de can be set. Th e DEM O VP pin de te cts overvo ltage. It
triggers when 4 consecutive high-frequency cycles at 1.8 V are detected at the DEMOVP
pin. sets the output voltage.
The output voltage must never exceed the rated DC voltage of the output capacitor.
n2.5 V
285 A
---------------------------
Vout R5 R6 R7 R8+++
R5 R6+
----------------------------------------------------
=
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
6.5 External overtemperature protection and LED current foldback
Figure 12 shows the footpr ints of resistors R5 an d R6. The purpose of the se resistors is to
provide thermal prote ction. To reduce light outp ut when using output cu rren t foldback, the
DEMOVP pin can be used as an input. Replace resistor R5 by a 470 PTC resistor.
Resistor R6 is kept at 5.1 k. If the foldback option is not used, r esistor R5 can be shorted
and resistor R6 can be set to 5.6 k. Do not use a value > 18 k for resistor R6. If the
value of resistor R6 is increased too much, the DEMOVP pin can cause false OVP
triggering.
6.6 Sense resistors
To optimally profit from the excellent current stability of the SSL5031BTS,
overtemperature 50 ppm MELF type resistors are preferred to sense the LED current. The
output current stability drops to 3 % compared to 7 % over the full temperature range for
normal 200 ppm 1206 type resistors.
When the sense resistor is operating at high temperatures, it s po we r ra ting m ust be ra te d
by a factor 2.
To keep the temperatu re at high power low (< 80 C) when the bo ard is oper ating a t room
temperature level, a 1 W power resistor is used.
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
7. Performance
7.1 Efficiency
7.2 Power factor
Fig 6. Efficiency as a function of mains voltage
Fig 7. Power factor as a function of mains voltage
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
7.3 Total harmonic distortion
7.4 Line regulation
Fig 8. Total harmonic distortion as a function of mains voltage
Fig 9. Output LED current as a function of mains voltage
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
7.5 Load regulation
7.6 ElectroMagnetic Interference (EMI)
Figure 11 shows the conducted EMI resu lt of the SSL5031BDB1209 demo board.
(1) Vmains = 230 V (AC)
(2) Vmains =90V(AC)
Fig 10. LED current as a function of LED voltage
Fig 11. EMI performance
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
8. Schematic
Fig 12. SSL5031BDB1209 demo board schematic
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9. Bill Of Materials (BOM)
Table 2. SSL5031BDB1209 bill of materials
Reference Description and values Part number Manufacturer
BD1 bridge rectifier; 600 V; 0.8 A B6S-G Comchip Tech
C1 capacitor; 0.1 F; 450 V CL21-450V-0.1F-K ZhongShan AIDI Electronics
C2 capacitor; 0.15 F; 450 V CL21-450V-0.15F-K ZhongShan AIDI Electronics
C3 capacitor; 1 F; 50 V; X7R; 0805 UMK212B7105KG-T Taiyo Yuden
C4 capacitor; 0.22 F; 10 %; 50 V; X7R;
0603 UMK107B7224KA-TR Taiyo Yuden
C6; C7 capacitor; 120 F; 100 V 100ZLJ120M10X25 Rubycon
C8 capacitor; 47 nF; 10 %; 50 V ; X7R; 0603 C0603C473K5RACTU KEMET
C9 capacitor; 100 nF; 10 %; 450 V CL21-450V-0.1µF-K ZhongShan AIDI Electronics
D1 diode; 100 V; 300 mA 1N4148W-7-F Diode Inc.
D2 diode; fast; 600 V; 1 A MURS160-E3-52T Vishay
D3 diode; TVS; 15 V; 5 A PESD15VL1BA NXP Semiconductors
D5 diode; Zener; 13 V; 250 mA BZX384-C13 NXP Semiconductors
F1 fuse; 250 V (AC); 1 A; 2410 MF2410F1.000TM AEM
K1 terminal block; 2p; 5.08 mm 1508060000 Weidmüller
K2 terminal block; 2p; 5.08 mm 20020109-H021A01LF FCI
L1 inductor; 3300 H SDR1006-332KL Bourns
L2 inductor, 680 H MSS1210-6824KLB Coilcraft
Q1 MOSFET-N; 650 V; 1.8 A SPD02N60C3 Infineon
Q2 transistor; 500 V; NPN PMBT45 NXP Semiconductors
R1; R2; R7;
R8 resistor; 100 k; 1 %; 250 mW; 1206 - -
R3 resistor; 220 ; 1 %; 125 mW; 0805 - -
R4; R44 resistor ; 2.7 ; MCFRFTDV2R70 Multicomp
R5 resistor; 470 ; 1 % ; 63 mW; 0603 - -
R6 resistor; 5.1 k; 1 %; 63 mW; 0603 - -
R9 resistor; 82 k; 1 %; 250 mW; 1206 - -
R10 resistor; 1 ; 1 %; 250 mW; 1206 - -
R11; R12 resistor ; 750 k; 1 %; 250 mW; 1206 - -
R13 resistor; 620 k; 1 %; 63 mW; 0603 - -
R45 resistor; 10 ; 10 %; 2 W; EMC EMC2-10RK Welwyn Components
R47 resistor; 51 k; 1 %; 63 mW; 0603
RV1 resistor; VDR; 275 V; 63 J VDRS10P275BSE Bourns
U1 IC; SSL5031BTS; HSO8 SSL5031BTS NXP Semiconductors
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SSL5031BDB1209 - 18 W TLED buck LED driver demo board
10. Board layout
a. Top view
b. Bottom view
Fig 13. SSL5031BDB1209 dem o bo ard layout
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11. Abbreviations
12. References
[1] SSL5031 BT S da ta sheet — Compact high power factor/low-THD buck LED driver
IC
Table 3. Abbreviations
Acronym Description
EMI ElectroMagnetic Interference
LED Light-Emitting Diode
OCP OverCurrent Protection
OTP OverTemperature Protection
PF Power Factor
SSL Solid-State Lighting
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13. Legal information
13.1 Definitions
Draft — The document is a draft version only. The content is still under
internal review and subject to formal approval, which may result in
modifications or additions. NXP Semiconductors does not give any
representations or warranties as to the accuracy or completeness of
information included herein and shall have no liab ility for the consequences of
use of such information.
13.2 Disclaimers
Limited warr a nty and liability — Information in this document is believed to
be accurate and reliable. However, NXP Semiconductors does not give any
representations or warranties, expressed or implied, as to the accuracy or
completeness of such information and shall have no liability for the
consequences of use of such information. NXP Se miconductors takes no
responsibility for the content in this document if provided by an inf ormation
source outside of NXP Semiconductors.
In no event shall NXP Semiconductors be liable for any indirect , incidental,
punitive, special or consequ ential damages (including - wit hout limitatio n - lost
profits, lost savings, business interruption, costs related to the removal or
replacement of any products or rework charges) whether or not such
damages are based on tort (including negligence), warranty, breach of
contract or any other legal theory.
Notwithstanding any damages that customer might incur for any reason
whatsoever, NXP Semiconduct ors’ aggregate and cumulati ve liability toward s
customer for the products described herein shall be limited in accordance
with the Terms and conditions of commercial sale of NXP Semicondu ctors.
Right to make changes — NXP Semiconductors reserves the right to make
changes to information published in this document, including without
limitation specifications and product descriptions, at any time and without
notice. This document supersedes and replaces all informa tion supplied prior
to the publication hereof .
Suitability for use — NXP Semiconductors products are not designed,
authorized or warranted to be suit able for use in life support, life-crit ical or
safety-critical systems or equipment, nor in applications where failure or
malfunction of an NXP Semiconductors product can reasonably be expected
to result in personal injury, death or severe property or environmental
damage. NXP Semiconductors and its suppliers accept no liability for
inclusion and/or use of NXP Semiconductors prod ucts in such equipment or
applications and theref ore such inclusi on and/o r use is at the cu stome r’s own
risk.
Applications — Applications that are described herein for any of these
products are for illustrative purposes only. NXP Semiconductors makes no
representation or warranty that such applications will be suitable for the
specified use without further testing or modificat i on.
Customers are responsible for the design and operation of their applications
and products using NXP Semiconductors pr oducts, and NXP Semiconductors
accepts no liability for any assistance with applications or customer product
design. It is customer’s sole responsibility to determine whether the NXP
Semiconductors product is su itable and f it for the customer’s applications and
products planned, as well as for the planned application and use of
customer’s third party customer(s). Customers should provide appropriate
design and operating safeguards to minimize the risks associated with their
applications and products.
NXP Semiconductors does not accept any liability related to any default,
damage, costs or problem which is based on any weakness or default in the
customer’s applications or products, or the application or use by customer’s
third party customer(s). Customer is responsible for doing all necessary
testing for th e customer’s applications and pro ducts using NXP
Semiconductors products in order to avoid a default of the applications and
the products or of the application or use by cust omer’s third party
customer(s). NXP does not accept any liability in this respect.
Export control — This document as well as the item(s) described herein
may be subject to export control regulatio ns. Export might require a prior
authorization from competent authorities.
Evaluation products — This product is provided on an “as is” and “with all
faults” basis for eval uation purposes only. NXP Semiconductors, its affiliates
and their supplie rs expressly disclaim all warrant ies, whether express, impl ied
or statutory, including but not limited to the implied warranties of
non-infringement, mercha ntability and fitness for a particular purpose. The
entire risk as to the quality, or arising out of the use or performance, of this
product remains with customer.
In no event shall NXP Semiconductors, it s aff iliates or thei r suppliers be liable
to customer for any special, indirect, consequ ential, punitive or incidental
damages (including without li mit ation d amages for l oss of bu siness, bu siness
interruption, loss of use , loss of data or information, and the like) arising out
the use of or inability to use the product, whet her or not based on tort
(including negligence), st rict liability, breach of contract, breach of warrant y or
any other theory, even if advised of the possibility of such damages.
Notwithstanding any damages that customer might incur for any reason
whatsoever (including without limitation, all damages referenced above and
all direct or general damages), the entire liability of NXP Semiconductors, its
affiliates and their suppliers and customer’s exclusive remedy for all of the
foregoing shall be limited to actual damages incurred by customer base d on
reasonable reliance up to the greater of the amount actually paid by customer
for the product o r five dollars (U S$5.00). The for egoing limita tions, exclusions
and disclaimers shall apply to the maximum extent permitt ed by applicable
law, even if any remedy fails of its essential purpose.
Safety of high-voltage evaluation products — The non-insulated high
voltages that are present when operating this produc t, co nstitute a risk of
electric shock, personal injury, death and/or ignition of fire. This product is
intended for evaluation pur poses only. It shall be operated in a designated
test area by personnel that is qual ified according to local requirements and
labor laws to work with non-insulated mains voltages and high-voltage
circuits.
The product does not comply with IE C 60950 based national or regional
safety standards. NXP Semiconductors does not accept any liab ility for
damages incurred due to inappropriate use of this product or related to
non-insulated high volt ages. Any use of this product is at customer’s own risk
and liability. The customer shall fully indemnify and hold harmless NXP
Semiconductors from any liability, damages and claims resulting from the use
of the product.
Translations — A non-English (translated) version of a document is for
reference only. The English version shall prevail in case of any discrepancy
between the translated and English versions.
13.3 Trademarks
Notice: All referenced b rands, produc t names, service names and trademarks
are the property of their respect i ve ow ners.
GreenChip — is a trademark of NXP Semico nductors N.V.
NXP Semiconductors UM10795
SSL5031BDB1209 - 18 W TLED buck LED driver demo board
© NXP Semiconductors N.V. 2014. All rights reserved.
For more information, please visit: http://www.nxp.co m
For sales office addresses, please send an email to: salesaddresses@nxp.com
Date of release: 4 November 2014
Document identifier: UM10795
Please be aware that important notices concerning this document and the product(s)
described herein, have been included in section ‘Legal information’.
14. Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Safety warning . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Specification s. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Board photographs . . . . . . . . . . . . . . . . . . . . . . 5
5 Board connections . . . . . . . . . . . . . . . . . . . . . . 5
6 Functional de scription . . . . . . . . . . . . . . . . . . . 6
6.1 Input filtering. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6.2 Efficiency improvement for universal mains . . . 6
6.3 THD and LED voltage. . . . . . . . . . . . . . . . . . . . 7
6.4 Open-load protection . . . . . . . . . . . . . . . . . . . . 7
6.5 External overtemperature protection and LED
current foldback . . . . . . . . . . . . . . . . . . . . . . . . 9
6.6 Sense resistors. . . . . . . . . . . . . . . . . . . . . . . . . 9
7 Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.2 Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.3 Total harmonic distortion. . . . . . . . . . . . . . . . . 11
7.4 Line regulation . . . . . . . . . . . . . . . . . . . . . . . . 11
7.5 Load regulation. . . . . . . . . . . . . . . . . . . . . . . . 12
7.6 ElectroMagnetic Interference (EMI) . . . . . . . . 12
8 Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
9 Bill Of Materials (BOM) . . . . . . . . . . . . . . . . . . 14
10 Board layout. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
11 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . 16
12 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13 Legal information. . . . . . . . . . . . . . . . . . . . . . . 17
13.1 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.2 Disclaimers. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
13.3 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
14 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mouser Electronics
Authorized Distributor
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SSL5031BDB1209UL