User Guide for FEBFL7733A_L50U008A Evaluation Board 8.4 W LED Driver at Universal Line Featured Fairchild Product: FL7733A Direct questions or comments about this evaluation board to: "Worldwide Direct Support" Fairchild Semiconductor.com (c) 2014 Fairchild Semiconductor Corporation 1 FEBFL7733A_L50U008A * Rev. 1.0 Table of Contents 1. Introduction ............................................................................................................................... 3 1.1. General Description of FL7733A .................................................................................... 3 1.2. FL7733A Controller Features .......................................................................................... 3 1.3. FL7733A Controller Internal Block Diagram.................................................................. 4 2. Evaluation Board Specifications ............................................................................................... 5 3. Evaluation Board Photographs ................................................................................................. 6 4. Evaluation Board Printed Circuit Board (PCB) ........................................................................ 7 5. Evaluation Board Schematic ..................................................................................................... 8 6. Evaluation Board Bill of Materials (BOM) .............................................................................. 9 7. Transformer Design ................................................................................................................ 10 8. Evaluation Board Performance ............................................................................................... 11 8.1. Startup ............................................................................................................................ 11 8.2. Operation Waveforms .................................................................................................... 12 8.3. Constant-Current Regulation ......................................................................................... 14 8.4. Short / Open-LED Protections ....................................................................................... 15 8.5. Efficiency ....................................................................................................................... 17 8.6. Power Factor (PF) & Total Harmonic Distortion (THD) .............................................. 18 8.7. Harmonics ...................................................................................................................... 19 8.8. Operating Temperature .................................................................................................. 21 8.9. Electromagnetic Interference (EMI) .............................................................................. 22 9. Revision History ..................................................................................................................... 23 (c) 2014 Fairchild Semiconductor Corporation 2 FEBFL7733A_L50U008A * Rev. 1.0 This user guide supports the evaluation kit for the FL7733A. It should be used in conjunction with the FL7733A 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 a solution for a universal AC input voltage LED driver using the FL7733A Primary-Side Regulator (PSR) single-stage controller. The input voltage range is 90 VRMS ~ 265 VRMS and there is one DC output with a constant current of 350 mA at 24 V. This document contains a general description of the FL7733A, the power supply solution specification, schematic, bill of materials, and typical operating characteristics. 1.1. General Description of FL7733A The FL7733A is an active Power Factor Correction (PFC) controller used in a singlestage flyback topology or buck-boost topology. Primary-side regulation and a singlestage topology reduce external components, such as the input bulk capacitor and feedback circuitry, minimizing cost. To improve power factor and Total Harmonic Distortion (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 Discontinuous Current Mode (DCM) operation, resulting in high efficiency and a simple design. The FL7733A provides open-LED, short-LED, and over-temperature protections. 1.2. Controller Features High Performance Cost-Effective Solution; No Input Bulk Capacitor / Secondary Feedback Circuitry Power Factor Correction THD <10% Over Universal Input Line Range CC Tolerance: < 1% Over Universal Input Line Voltage Variation < 1% by 50% ~ 100% Load Voltage Variation < 1% by 20% Magnetizing Inductance Variation High-Voltage Startup with VDD Regulation Adaptive Feedback Loop Control for No Overshoot at Startup High Reliability LED Short / Open Protection Output Diode Short Protection Sensing Resistor Short / Open Protection VDD Over-Voltage Protection (OVP) VDD Under-Voltage Lockout (UVLO) Over-Temperature Protection (OTP) All Protections are Auto Restart Cycle-by-Cycle Current Limit Application Voltage Range: 80 VAC ~ 308 VAC (c) 2014 Fairchild Semiconductor Corporation 3 FEBFL7733A_L50U008A * Rev. 1.0 1.3. Controller Internal Block Diagram Figure 1. (c) 2014 Fairchild Semiconductor Corporation 4 Block Diagram FEBFL7733A_L50U008A * Rev. 1.0 2. Evaluation Board Specifications Table 1. Specifications for LED Lighting Load Description Symbol Value Comments VIN.MIN 90 VAC Minimum AC Input Voltage VIN.MAX 265 VAC Maximum AC Input Voltage VIN.NOMINAL 120 V / 230 V Nominal AC Input Voltage fIN 60 Hz / 50 Hz Line Frequency VOUT.MIN 13 V Minimum Output Voltage VOUT.MAX 28 V Maximum Output Voltage VOUT.NOMINAL 24 V Nominal Output Voltage IOUT.NOMINAL 350 mA Nominal Output Current < 0.29% Line Input Voltage Change: 90~265 VAC < 0.72% Output Voltage Change: 13~28 V Eff90VAC 86.41% Efficiency at 90 VAC Input Voltage Eff120VAC 87.88% Efficiency at 120 VAC Input Voltage Eff140VAC 88.25% Efficiency at 140 VAC Input Voltage Eff180VAC 88.68% Efficiency at 180 VAC Input Voltage Eff230VAC 88.95% Efficiency at 230 VAC Input Voltage Eff265VAC 88.96% Efficiency at 265 VAC Input Voltage PF / THD90VAC 0.996 / 3.85% PF/THD at 90 VAC Input Voltage PF / THD120VAC 0.992 / 3.61% PF/THD at 120 VAC Input Voltage PF / THD140VAC 0.988 / 4.16% PF/THD at 140 VAC Input Voltage PF / THD180VAC 0.975 / 4.90% PF/THD at 180 VAC Input Voltage PF / THD230VAC 0.945 / 6.01% PF/THD at 230 VAC Input Voltage PF / THD265VAC 0.914 / 7.06% PF/THD at 265 VAC Input Voltage FL7733A TFL7733A 52.9C Open-Frame Condition (TA = 25C) FL7733A Temperature Primary MOSFET TMOSFET 61.2C Primary MOSFET Temperature Secondary Diode TDIODE 52.8C Secondary Diode Temperature Transformer TTRANSFORMER 56.0C Transformer Temperature Voltage Input Frequency Voltage Output Current Efficiency PF/THD Temperature CC Deviation All data of the evaluation board measured with the board enclosed in a case and external temperature around 25C. (c) 2014 Fairchild Semiconductor Corporation 5 FEBFL7733A_L50U008A * Rev. 1.0 3. Evaluation Board Photographs Dimensions: 64 mm (L) x 26 mm (W) x 26 mm (H) Figure 2. Figure 3. (c) 2014 Fairchild Semiconductor Corporation 6 Top View Bottom View FEBFL7733A_L50U008A * Rev. 1.0 4. Evaluation Board Printed Circuit Board (PCB) Figure 4. Figure 5. (c) 2014 Fairchild Semiconductor Corporation 7 Top Pattern (in mm) Bottom Pattern FEBFL7733A_L50U008A * Rev. 1.0 (c) 2014 Fairchild Semiconductor Corporation N L MOV1 /470 F1 1A/250V CF1 /47nF C5 /2.2F CF2 /47nF LF1/ 10mH Figure 6. 8 Gate 2 VS 5 CS 1 6 COMI 3 GND 7 NC VDD 4 U1 FL7733 C1 400V/ 68nF 8 HV BD1 /MB6S R7 /330 C3 /10nF R2 /30k R1 /30k Rcs1 2.0 R6 /10 Rcs2 2.4 Q1/ FQU5N60C C2 /10F D2 /1N4003 T1 R5 /27k R4 /180k NA CS1 /10nF NP DS1 /RS1M RS1 RS2 /100k /100k Cy1 2.2nF Co1 /470F C4 /5pF NS Do1 /ES3D Ro1 /20k + 5. Evaluation Board Schematic Schematic FEBFL7733A_L50U008A * Rev. 1.0 6. Evaluation Board Bill of Materials (BOM) Item No. Part Reference Part Number Qty. Description Manufacturer 1 BD1 MB8S 1 Bridge Diode Fairchild Semiconductor 2 CF1 MPX AC275V 473 K 2 47 nF / AC275V, X-Capacitor Carli 3 CS1 C1206C103KDRACTU 1 10 nF / 1 kV, SMD Capacitor 1206 Kemet 4 CY1 SCFz2E222M10BW 1 2.2 nF / 250 V, Y-Capacitor Samwha 5 Co1 NXH 470 F 35 V 1 470 F / 35 V, Electrolytic Capacitor Samyoung 6 C1 MPE400V683K 1 68 nF / 400 V, MPE Film Capacitor Sungho 7 C2 KMG10 F 35 V 1 10 F / 35 V, Electrolytic Capacitor Samyoung 8 C3 C0805C104K5RACTU 1 100 nF / 50 V, SMD Capacitor 2012 Kemet 9 C4 C0805C519C3GACTU 1 5 pF / 25 V, SMD Capacitor 2012 Kemet 10 C5 C0805C225J3RACTU 1 2.2 F / 25 V, SMD Capacitor 2012 Kemet 11 DS1 RS1M 1 1000 V / 1 A, Ultra-Fast Recovery Diode Fairchild Semiconductor 12 Do1 ES3D 1 200 V / 3 A, Fast Rectifier Fairchild Semiconductor 13 D2 1N4003 1 200 V / 1 A, General-Purpose Rectifier Fairchild Semiconductor 14 F1 SS-5-1A 1 250 V / 1 A, Fuse Bussmann 15 LF1 R10302KT00 1 10 mH, Inductor, 8O Bosung 16 MOV1 SVC471D-07A 1 Metal Oxide Varistor Samwha 17 Q1 FQU5N60C 1 600 V / 4 A, N-Channel MOSFET Fairchild Semiconductor 18 R6 RC0805JR-0710RL 1 10 , SMD Resistor 0805 Yageo 19 RS1, RS2 RC1206JR-07100KL 2 100 k, SMD Resistor 1206 Yageo 20 Rcs1 RC1206JR-072RL 1 2 , SMD Resistor 1206 Yageo 21 Rcs2 RC1206JR-072R4L 1 2.4 , SMD Resistor 1206 Yageo 22 R7 RC0805JR-07330RL 1 330 , SMD Resistor 0805 Yageo 23 Ro1 RC1206JR-0720KL 1 20 k, SMD Resistor 1206 Yageo 24 R4 RC0805JR-07180KL 1 180 k, SMD Resistor 0805 Yageo 25 R1, R2 RC1206JR-0730KL 2 30 k, SMD Resistor 1206 Yageo 26 R5 RC0805JR-0727KL 1 27 k, SMD Resistor 0805 Yageo 27 T1 RM6 Core 1 6-Pin, Transformer TDK 28 U1 FL7733A 1 Main PSR Controller Fairchild Semiconductor (c) 2014 Fairchild Semiconductor Corporation 9 FEBFL7733A_L50U008A * Rev. 1.0 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 NP1 6 1 0.20 54 Ts Solenoid Winding NS NS+ NS- 2 Insulation: Polyester Tape t = 0.025 mm, 3-Layer 3 4 0.25 (TIW) 25 Ts Solenoid Winding Insulation: Polyester Tape t = 0.025 mm, 3-Layer NP2 5 6 12 0.20 27 Ts Solenoid Winding Insulation: Polyester Tape t = 0.025 mm, 3-Layer 7 NA 8 53 0.20 17 Ts Solenoid Winding Insulation: Polyester Tape t = 0.025 mm, 3-Layer Table 3. Electrical Characteristics Pins Specifications Inductance 6-2 1.0 mH 10% 60 kHz, 1 V Leakage 6-2 10 H 60 kHz, 1 V, Short All Output Pins (c) 2014 Fairchild Semiconductor Corporation 10 Remark FEBFL7733A_L50U008A * Rev. 1.0 8. Evaluation Board Performance Table 4. Test Condition & Equipment List TA = 25C Ambient Temperature Test Equipment 8.1. 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: EHP-AX08EL/GT01H-P03 (3 W) by Everlight Startup Figure 9 and Figure 10 show the overall startup performance at rated output load. The output load current starts flowing after about 0.2 s and 0.1 s for input voltage 90 VAC and 265 VAC condition when the AC input power switch turns on. CH1: VDD (10 V / div), CH2: VIN (100 V / div), CH3: VLED (20 V / div), CH4: ILED (200 mA / div), Time Scale: (100 ms / div), Load: 7 series-LEDs. 0.1 s 0.2 s Figure 9. Figure 10. VIN = 90 VAC / 60 Hz (c) 2014 Fairchild Semiconductor Corporation 11 VIN = 120 VAC / 60 Hz FEBFL7733A_L50U008A * Rev. 1.0 8.2. Operation Waveforms Figure 11 to Figure 14 show AC input and output waveforms at rated output load. CH1: IIN (200 mA / div), CH2: VIN (100 V / div), CH3: VLED (20 V / div), CH4: ILED (200 mA / div), Time Scale: (5 ms / div), Load: 7 series LEDs. Figure 11. VIN = 90 VAC / 60 Hz Figure 12. VIN = 120 VAC / 60 Hz Figure 13. VIN = 230 VAC / 50 Hz Figure 14. VIN = 265 VAC / 50 Hz (c) 2014 Fairchild Semiconductor Corporation 12 FEBFL7733A_L50U008A * Rev. 1.0 Figure 15 to Figure 18 show key waveforms of single-stage flyback converter operation for line voltage at rated output load. CH1: VCS (500 mA / div), CH2: VDS (200 V / div), CH3: VSEC-Diode (100 V / div), CH4: ISEC-Diode (2.0 A / div), Load: 7 series-LEDs. Figure 15. VIN = 90 VAC / 60 Hz, [2.0 ms / div] Figure 16. VIN = 90 VAC / 60 Hz, [5.0 s / div] Figure 17. VIN = 265 VAC / 60 Hz, [2.0 ms / div] Figure 18. VIN = 265 VAC / 60 Hz, [5.0 s / div] (c) 2014 Fairchild Semiconductor Corporation 13 FEBFL7733A_L50U008A * Rev. 1.0 8.3. Constant-Current Regulation The output current deviation for wide output voltage ranges, from 13 V to 28 V, is less than 0.8% at each line voltage. Line regulation at the rated output voltage (24 V) is less than 0.3%. The results were measured with E-load [CR Mode]. Figure 19. Table 5. Constant-Current Regulation Constant-Current Regulation by Output Voltage Change (13 ~ 28 V) Input Voltage Min. Current [mA] Max. Current [mA] Tolerance 90 VAC [60 Hz] 346 350 0.57% 120 VAC [60 Hz] 346 351 0.72% 140 VAC [60 Hz] 346 351 0.72% 180 VAC [50 Hz] 347 352 0.72% 230 VAC [50 Hz] 347 352 0.72% 265 VAC [50 Hz] 348 353 0.71% Table 6. Constant-Current Regulation by Line Voltage Change (90 ~ 265 VAC) Output Voltage 90 VAC [60 Hz] 120 VAC [60 Hz] 140 VAC [60 Hz] 180 VAC [50 Hz] 230 VAC [50 Hz] 265 VAC [50 Hz] Tolerance 26 V 347 mA 348 mA 348 mA 348 mA 349 mA 349 mA 0.29% 24 V 348 mA 349 mA 349 mA 350 mA 350 mA 350 mA 0.29% 22 V 349 mA 350 mA 349 mA 350 mA 351 mA 351 mA 0.29% (c) 2014 Fairchild Semiconductor Corporation 14 FEBFL7733A_L50U008A * Rev. 1.0 8.4. Short- / Open-LED Protections Figure 20 to Figure 23 show waveforms for protections operated when the LED is shorted and recovered. Once the LED short occurs, SCP is triggered and VDD starts hiccup mode with JFET regulation times [250 ms]. This lasts until the fault condition is eliminated. Systems can restart automatically when returned to normal condition. CH1: VGATE (10 V / div), CH2: VIN (100 V / div), CH3: VDD (5 V / div), IOUT (200 mA / div), Time Scale: (200 ms / div). LED Short Figure 20. Auto Restart Figure 21. VIN = 90 VAC / 60 Hz, [LED Short] VIN = 90 VAC / 60 Hz, [LED Restore] JFET Turn Off JFET Turn On LED Short Figure 22. Auto Restart Figure 23. VIN = 265 VAC / 50 Hz, [LED Short] (c) 2014 Fairchild Semiconductor Corporation 15 VIN = 265 VAC / 50 Hz, [LED Restore] FEBFL7733A_L50U008A * Rev. 1.0 Figure 24 to Figure 27 show waveforms for protections operated when the LED is opened and recovered. Once the LED has opened, VS OVP or VDD OVP are triggered and VDD starts "Hiccup" Mode with JFET regulation times [250 ms]. This lasts until the fault condition is eliminated. Systems can restart automatically when returned to normal condition. VGATE (10 V / div), CH2: VIN (100 V / div), CH3: VDD (10 V / div), VOUT (10 V / div), Time Scale: (200 ms / div). Auto Restart LED Open Figure 24. VIN = 90 VAC / 60 Hz, [LED Short] Figure 25. Auto Restart LED Open Figure 26. VIN = 90 VAC / 60 Hz, [LED Restore] VIN = 265 VAC / 50 Hz, [LED Short] Figure 27. VIN = 265 VAC / 50 Hz, [LED Restore] If the LED load is re-connected after an open-LED condition, the output capacitor is quickly discharged through the LED load and the inrush current by the discharge could destroy LED load. (c) 2014 Fairchild Semiconductor Corporation 16 FEBFL7733A_L50U008A * Rev. 1.0 8.5. Efficiency System efficiency is 86.41% ~ 88.96% over input voltages 90 ~ 265 VAC. The results were measured using actual, rated LED loads 30 minutes after startup. Figure 28. Table 7. System Efficiency System Efficiency Input Voltage Input Power Output Current Output Voltage Output Power Efficiency 90 VAC [60 Hz] 9.52 W 0.351 A 23.43 V 8.23 W 86.41% 120 VAC [60 Hz] 9.39 W 0.352 A 23.45 V 8.25 W 87.88% 140 VAC [60 Hz] 9.38 W 0.352 A 23.49 V 8.28 W 88.25% 180 VAC [50 Hz] 9.33 W 0.354 A 23.40 V 8.27 W 88.68% 230 VAC [50 Hz] 9.35 W 0.355 A 23.42 V 8.32 W 88.95% 265 VAC [50 Hz] 9.38 W 0.356 A 23.46 V 8.34 W 88.96% (c) 2014 Fairchild Semiconductor Corporation 17 FEBFL7733A_L50U008A * Rev. 1.0 8.6. Power Factor (PF) & Total Harmonic Distortion (THD) The FL7733A evaluation board shows excellent THD performance, much less than 10%. The results were measured using actual, rated LED loads ten (10) minutes after startup. PF THD Figure 29. Table 8. Power Factor & Total Harmonic Distortion Power Factor & Total Harmonic Distortion Input Voltage Output Current Output Voltage Power Factor THD 90 VAC [60 Hz] 0.351 A 23.43 V 0.996 3.85% 120 VAC [60 Hz] 0.352 A 23.45 V 0.992 3.61% 140 VAC [60 Hz] 0.352 A 23.49 V 0.988 4.16% 180 VAC [50 Hz] 0.354 A 23.40 V 0.975 4.90% 230 VAC [50 Hz] 0.355 A 23.42 V 0.945 6.01% 265 VAC [50 Hz] 0.356 A 23.46 V 0.914 7.06% (c) 2014 Fairchild Semiconductor Corporation 18 FEBFL7733A_L50U008A * Rev. 1.0 8.7. Harmonics Figure 30 to Figure 33 show current harmonics measured using actual, rated LED loads. (c) 2014 Fairchild Semiconductor Corporation Figure 30. VIN = 90 VAC / 60 Hz Figure 31. VIN = 120 VAC / 60 Hz 19 FEBFL7733A_L50U008A * Rev. 1.0 (c) 2014 Fairchild Semiconductor Corporation Figure 32. VIN = 230 VAC / 50 Hz Figure 33. VIN = 265 VAC / 50 Hz 20 FEBFL7733A_L50U008A * Rev. 1.0 8.8. Operating Temperature Temperatures on all components for this board are less than 62C. The results were measured using actual, rated LED loads 60 minutes after startup. Top Top MOSFET: 61.2 C MOSFET: 59.3 C Trans: 56.0 C Trans: 56.9 C Figure 35. VIN = 90 VAC / 60 Hz Figure 34. Bottom Bottom Rectifier: 52.8 C Rectifier: 52.3 C FL7733A: 52.9 C Figure 36. VIN = 265 VAC / 50 Hz FL7733A: 53.3 C Figure 37. VIN = 90 VAC / 60 Hz VIN = 265 VAC / 50 Hz The IC temperature can be improved by the PCB layout. (c) 2014 Fairchild Semiconductor Corporation 21 FEBFL7733A_L50U008A * Rev. 1.0 8.9. Electromagnetic Interference (EMI) All measurements were conducted in observance of EN55022 criteria. The results were measured using actual, rated LED loads 30 minutes after startup. Figure 38. Figure 39. (c) 2014 Fairchild Semiconductor Corporation 22 VIN [110 VAC, LIVE] VIN [220 VAC, Neutral] FEBFL7733A_L50U008A * Rev. 1.0 9. Revision History Rev. 1.0 Date Description Oct. 2014 Initial Release 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. 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