Datasheet FEB-L025 Datasheet (Fairchild)

User Guide for

FEB-L025

Evaluation Board

Universal Line Voltage LED Ballast

Featured Fairchild Product:

FL7732

Direct questions or comments

about this evaluation board to:

“Worldwide Direct Support”

Fairchild Semiconductor.com

Table of Contents

1. Introduction ............................................................................................................................. 3

1.1. General Description of FL7732 ........................................................................................ 3

1.2. Features ............................................................................................................................ 3

1.3. Internal Block Diagram .................................................................................................... 4

2. Specifications for Evaluation Board ........................................................................................ 5

2.1. Evaluation Board .............................................................................................................. 6

2.2. Printed Circuit Board ....................................................................................................... 7

2.3. Schematic of the Evaluation Board .................................................................................. 8

2.4. Bill of Material ................................................................................................................. 9

2.5. Transformer Design ........................................................................................................ 10

3. Performance of Evaluation Board ......................................................................................... 11

3.1. Startup ............................................................................................................................ 12

3.2. Operation Waveforms .................................................................................................... 13

3.3. Constant-Current Regulation .......................................................................................... 14

3.4. Open / Short-LED Protections ....................................................................................... 15

3.5. System Efficiency .......................................................................................................... 16

3.6. THD ................................................................................................................................ 17

3.7. Operating Temperature .................................................................................................. 18

3.8. EMI................................................................................................................................. 19

4. Revision History .................................................................................................................... 20

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 ballast using the FL7732 Primary-Side Regulator (PSR) single-stage controller. The input voltage range is 90V 350mA at 24V supply specification, schematic, bill of materials, and the typical operating characteristics.

1.1. General Description of FL7732

The FL7732 is an active Power Factor Correction (PFC) controller using single-stage flyback topology. Primary-side regulation and single-stage topology reduce external components, such as input bulk capacitor and feedback circuitry, and minimize 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 DCM operation with high efficiency and simple design. FL7732 provides open-LED, short-LED, and over-temperature protections.

– 265V

RMS

. This document contains general description of FL7732, the power

MAX

and there is one DC output with a constant current of

RMS

.

1.2. Features

 Cost-Effective Solution: No Input Bulk Capacitor or Feedback Circuitry  Power Factor Correction  Accurate Constant-Current (CC) Control, Independent Online Voltage, Output

Voltage, and Magnetizing Inductance Variation

 Linear Frequency Control Improves Efficiency and Simplifies Design  Open-LED Protection  Short-LED Protection  Cycle-by-Cycle Current Limiting  Over-Temperature Protection with Auto Restart  Low Startup Current: 20μA  Low Operating Current: 5mA  V

Under-Voltage Lockout (UVLO)

DD

 Gate Output Maximum Voltage Clamped at 18V  SOP-8

1.3. Internal Block Diagram

Figure 1. Block Diagram of FL7732

2. Specifications for Evaluation Board

Table 1. Specifications for LED Lighting Lamp

Description Symbol Value Comments

V

90V Minimum Input Voltage

IN.MIN

V

Input

Output

Efficiency

PF/THD

Temperature

Voltage

Frequency

Voltage

Current

FL7732

Primary

MOSFET

Secondary

Diode

V

OUT.NOMINAL

I

OUT.NOMINAL

CC Deviation

PF/THD

265V Maximum Input Voltage

IN.MAX

IN.NOMINAL

110V/220V Nominal Input Voltage

fIN 60Hz/50Hz Line Frequency

V

12V Minimum Output Voltage

OUT.MIN

28V Maximum Output Voltage

OUT.MAX

24V Nominal Output Voltage

350mA Nominal Output Current

< ±3.17% Line Input Voltage Change: 90~265V

< ±1.93% Output Voltage Change: 12~24V

Eff

90VAC

Eff

120VAC

Eff

140VAC

Eff

180VAC

Eff

220VAC

Eff

T

88.40% Efficiency at 265VAC Line Input Voltage

265VAC

90VAC

120VAC

140VAC

180VAC

220VAC

265VAC

50.8ºC

FL7732

57.3ºC Primary MOSFET Temperature

MOSFET

T

56.2ºC Secondary Diode Temperature

DIODE

87.51% Efficiency at 90VAC Line Input Voltage

88.76% Efficiency at 120VAC Line Input Voltage

89.39% Efficiency at 140VAC Line Input Voltage

89.59% Efficiency at 180VAC Line Input Voltage

89.20% Efficiency at 220VAC Line Input Voltage

0.998/10.04% PF/THD at 90VAC Line Input Voltage

0.995/10.04% PF/THD at 120VAC Line Input Voltage

0.991/11.83% PF/THD at 140VAC Line Input Voltage

0.982/15.29% PF/THD at 180VAC Line Input Voltage

0.964/18.19% PF/THD at 220VAC Line Input Voltage

0.935/22.05% PF/THD at 265VAC Line Input Voltage

Open-Frame Condition

(T

= 25ºC) FL7732 Temperature

A

AC

Transformer

T

TRANSFORMER

52.3ºC Transformer Temperature

All data of the evaluation board was measured with the board enclosed in a case and an external temperature around 25°C.

2.1. Evaluation Board

Figure 2. Top View (Dimensions: 58.0mm (L) x 26.5mm (W) x 18.0mm (H)

Figure 3. Bottom View (Dimensions:58.0mm (L) x 26.5mm (W) x 18.0mm (H)

2.2. Printed Circuit Board

Figure 4. Top Pattern

Figure 5. Bottom Pattern

2.3. Schematic of the Evaluation Board

Figure 6. Schematic

2.4. Bill of Materials

Item

No.

1 BD1 MB6S 1 0.5A/600V Bridge Diode Fairchild Semiconductor

2 Q1 FQU5N60CTU 1 2.8A/600V Main Switch Fairchild Semiconductor

3 U1 FL7732_F116 1 Main Controller Fairchild Semiconductor

4 F1 SS-5-1A 1 250V/1A Fuse Bussmann

5 M1 SVC 471 D-07A 1 Metal Oxide Varistor Samwha

6 L1 R08123KT00 2 12mH Filter Inductor, 8Φ Bosung

7 D1, D2 1N4007 2 1A/1000V Diode Fairchild

8 D3 ES3D 1 3A/200V Fast Rectifier Fairchild

9 C1 ECW-F2W104JAQ 1 104/450V Film Capacitor Panasonic - ECG

10 C2 C1206C103KCRACTU 1 103/500V SMD Capacitor 3216 Kemet

11 C3 C0805C103K5RACTU 1 103/50V SMD Capacitor 2012 Kemet

12 C4 C0805C220J5GACTU 1 220/50V SMD Capacitor 2012 Kemet

13 C5 C0805C105Z3VACTU 1 105/25V SMD Capacitor 2012 Kemet

14 C6 KMG 470µF/35V 1 470µF/35V Electrolytic Capacitor Samyoung

15 C7 KMG 10µF/50V 1 10µF/50V Electrolytic Capacitor Samyoung

16 C8 SCFz2E472M10BW 1 472/250V Y-Capacitor Samwha

17 C9 MPX AC275V 223K 1 223/AC275V X-Capacitor Carli

18 C10 MPX AC275V 333K 1 333/AC275V X-Capacitor Carli

19 R1, R2 RC1206JR-07300KL 2 300KΩ SMD Resistor 3216 Yageo

20 R3 RC1206JR-0724KL 1 24KΩ SMD Resistor 3216 Yageo

21 R4 RC0805FR-07150KL 1 150KΩ SMD Resistor 2012 Yageo

22 R5 RC0805JR-0722KL 1 22KΩ SMD Resistor 2012 Yageo

23 R6 RC1206JR-0710RL 1 10Ω SMD Resistor 3216 Yageo

24 R7 RSMF1JT200K 1 200KΩ/1W Metal Oxide Film Resistor Stackpole Elec.

25 R8 RC0805JR-071R6L 1 1.6Ω SMD Resistor 2012 Yageo

26 R9 RC0805JR-071R8L 1 1.8Ω SMD Resistor 2012 Yageo

27 R10 RC0805JR-070RL 1 0Ω SMD Resistor 2012 Yageo

28 T1 RM Core 1 1mH RM6 Transformer TDK

Part

Reference

Part No. Qty. Description Manufacturer

2.5. Transformer Design

Figure 7. Transformer Bobbin Structure

Figure 8. Pin Configuration and Transformer Winding Structure

Note:

1. Fly 1 connects to the primary side ground and Fly 2 connects to the secondary-side ground directly.

Table 2. Winding Specifications

No. Winding Pin (S → F) Wire Turns Winding Method

1 NP1 4  P 0.2φ 36 Ts Solenoid Winding

2 Insulation: Polyester Tape t = 0.025mm, 3-Layer

3 NS Fly2  2 0.32φ 24 Ts Solenoid Winding

4 Insulation: Polyester Tape t = 0.025mm, 3-Layer

5 NP2 P  5 0.2φ 36 Ts Solenoid Winding

6 Insulation: Polyester Tape t = 0.025mm, 3-Layer

7

8 Insulation: Polyester Tape t = 0.025mm, 3-Layer

NA

Fly1  3

Table 3. Electrical Characteristics

Pin Specification Remark

Inductance 4 – 5 1mH ±10% 50kHz, 1V

Leakage 4 – 5 13µH 50kHz, 1V Short All Output Pins

0.12φ 18 Ts Solenoid Winding

3. Performance of Evaluation Board

Table 4. Test Condition & Equipments

Ambient Temperature T

AC Power Source: ES2000S by PSTATIONES Power Analyzer: PZ4000 by YOKOGAWA Multi Meter: 2002 by KEITHLEY : 8842A by LIKE

Test Equipment

Oscilloscope: WaveRunner 104Xi by LeCroy EMI Test Receiver: ESCS30 by ROHDE & SCHWARZ Two-Line V-Network: ENV216 by ROHDE & SCHWARZ Thermometer: Fluke Ti20 LED: EHP-AX08EL/GT01H-P01(1W) by Everlight

= 25°C

A

3.1. Startup

Startup time is 926ms (VIN = 90VAC) ~ 315ms (VIN = 265VAC). The results were measured by using 8-LED load. Startup Time at 8-LED (24V/350mA); C1 [V

[V

], C3 [V

IN

Figure 9. V

OUT

], C2

DD

], C4 [I

].

OUT

= 90VAC / 60Hz Figure 10. V

IN

= 115VAC / 60Hz

IN

Figure 11. V

= 230VAC / 50Hz Figure 12. V

IN

= 265VAC / 50Hz

IN

3.2. Operation Waveforms

Output current ripple is under 282mAp-p with a rated output current of 700mA. The results were measured by using actual 8-LED load. Operation Waveforms at 8-LED (24V/350mA); C1 [V

Figure 13. V

], C2 [VIN], C3 [V

CS

= 90VAC / 60Hz Figure 14. V

IN

], C4 [I

OUT

].

= 115VAC / 60Hz

IN

Figure 15. V

= 230VAC / 50Hz Figure 16. V

IN

= 265VAC / 50Hz

IN

3.3. Constant-Current Regulation

Constant-current deviation in the wide output voltage range from 12V to 24V is less than ±1.93% at each line input voltage. Line regulation at the rated 6-LED is less than ±3.17%. The results were measured by using LED load.

Output Voltage [V]

Output Current [A]

Figure 17. Constant Current Regulation, Measured by LED Load

Table 5. Constant Current Regulation by Output Voltage Change (12~24V)

Input Voltage Min. Current [A] Max. Current [A] Tolerance

90VAC / 60Hz 0.349 0.363 ±1.93%

120VAC / 60Hz 0.350 0.364 ±1.92%

140VAC / 60Hz 0.349 0.360 ±1.53%

180VAC / 50Hz 0.345 0.353 ±1.13%

220VAC / 50Hz 0.345 0.353 ±1.13%

265VAC / 50Hz 0.339 0.344 ±0.73%

Table 6. Constant Current Regulation by Line Voltage Change (90~265VAC)

Output

Voltage

24.5V 0.349A 0.364A 0.350A 0.353A 0.352A 0.344A ±2.75%

21.5V 0.355A 0.350A 0.360A 0.350A 0.353A 0.344A ±2.22%

18.5V 0.363A 0.353A 0.354A 0.345A 0.349A 0.340A ±3.17%

90V

[60Hz]

AC

120V

[60Hz]

AC

140V

[60Hz]

AC

180V

[50Hz]

AC

220V

[50Hz]

AC

265V

[50Hz]

AC

Tolerance

3.4. Open / Short-LED Protections

In short-LED condition, OCP level is reduced from 0.7V to 0.2V because FL7732 lowers OCP level when V results were measured by using actual LED load. Short-LED Condition; C1 [V

[V

], C3 [V

IN

OUT

Figure 18. V

voltage is less than 0.4V during output diode conduction time. The

S

], C4 [I

].

OUT

= 90VAC / 60Hz Figure 19. V

IN

], C2

DD

= 265VAC / 50Hz

IN

In open-LED condition, output voltage is limited around 30V by OVP in V over-voltage protection level can be controlled by the turns ratio of auxiliary and secondary windings. Open-LED Condition; C1 [V

Figure 20. V

], C2 [VIN], C3 [V

DD

= 90VAC / 60Hz Figure 21. V

IN

. Output

DD

], C4 [I

OUT

= 265VAC / 50Hz

IN

OUT

].

3.5. System Efficiency

The system efficiency is 87.51 ~ 89.59% in 90 ~ 265VAC input voltage range. The results were measured at 30 minutes after startup by using LED load.

Efficiency

Input Voltage

Figure 22. System Efficiency

Table 7. System Efficiency

Input Voltage

90V

[60Hz] 9.935 0.354 24.56 8.694 87.51%

AC

120V

140V

180V

220V

265V

[60Hz] 10.196 0.367 24.66 9.050 88.76%

AC

[60Hz] 9.663 0.352 24.54 8.638 89.39%

AC

[50Hz] 9.677 0.353 24.56 8.670 89.59%

AC

[50Hz] 9.708 0.353 24.53 8.659 89.20%

AC

[50Hz] 9.550 0.345 24.47 8.442 88.40%

AC

Input Power

[W]

Output

Current [A]

Output

Voltage [V]

Output

Power [W]

Efficiency

3.6. THD

FL7732 shows excellent THD performance. THD is less than 25% of the specification. Power Factor is very high; with enough margin from the 0.9 specification. The results were measured at 30 minutes after startup.

PF

THD

Input Voltage

Figure 23. Power Factor and Total Harmonic Discharge

Table 8. Power Factor and THD

Input Voltage PF THD

90V

[60Hz] 0.998 10.04%

AC

120V

140V

180V

220V

265V

[60Hz] 0.995 10.04%

AC

[60Hz] 0.991 11.83%

AC

[50Hz] 0.982 15.29%

AC

[50Hz] 0.964 18.19%

AC

[50Hz] 0.935 22.05%

AC

3.7. Operating Temperature

The temperature of the all components on this board is less than 60ºC. The results were measured 60 minutes after startup.

Figure 24. Board Temperature - Top View, VIN [90VAC] I

OUT

Figure 25. Board Temperature - Bottom View, VIN [90VAC] I

[350mA]

OUT

V

3.8. EMI

All measurements were conducted in observance of EN55022 criteria. The results were measured 30 minutes after startup.

dBµV dBµV

100

EN55015Q

90

1 PK

MAXH

80

2 A

MAXH

70

60

EN55015A

50

40

30

20

10

0

150 kHz 30 MHz

1 MHz 10 MHz

RBW 9 kHz

MT 10 ms

PREAMP OFFAtt 10 dB

RBW 9 kHz

MT 10 ms

dBµV dBµV

100

EN55015Q

90

1 PK

MAXH

80

2 A

TDF

MAXH

70

PRN

6DB

60

EN55015A

50

40

30

20

10

0

150 kHz 30 MHz

1 MHz 10 MHz

PREAMP OFFAtt 10 dB

TDF

PRN

6DB

Date: 19.DEC.2011 17:57:11

Date: 19.DEC.2011 18:00:37

Figure 26. LIVE - V

dBµV dBµV

100

EN55015Q

90

1 PK

MAXH

80

2 A

MAXH

70

60

EN55015A

50

40

30

20

10

0

150 kHz 30 MHz

Date: 19.DEC.2011 17:58:57

= 115V

IN

I

[350mA]

OUT

1 MHz 10 MHz

RBW 9 kHz

MT 10 ms

PREAMP OFFAtt 10 dB

AC,VOUT

[24V],

Figure 27. LIVE - V

dBµV dBµV

100

EN55015Q

90

1 PK

MAXH

80

2 A

TDF

MAXH

70

PRN

6DB

60

EN55015A

50

40

30

20

10

0

150 kHz 30 MHz

Date: 19.DEC.2011 18:00:37

Figure 28. LIVE - V

= 115V

IN

I

OUT

AC, VOUT

[350mA]

[24V],

Figure 29. LIVE - V

= 230V

IN

I

[350mA]

OUT

RBW 9 kHz

MT 10 ms

1 MHz 10 MHz

PREAMP OFFAtt 10 dB

AC,VOUT

= 230V

IN

I

OUT

AC, VOUT

[350mA]

[24V],

TDF

PRN

6DB

[24V],

4. Revision History

Rev. Date Description

1.0.0 April 2012 Initial Release

Manufacturer & Part number are added in BOM

1.1.0 June 2012

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.

DISCLAIMER

FAIRCHILD SEMICONDUCTOR RESERVES THE RIGHT TO MAKE CHANGES WITHOUT FURTHER NOTICE TO ANY PRODUCTS HEREIN TO IMPROVE RELIABILITY, FUNCTION, OR DESIGN. FAIRCHILD DOES NOT ASSUME ANY LIABILITY ARISING OUT OF THE APPLICATION OR USE OF ANY PRODUCT OR CIRCUIT DESCRIBED HEREIN; NEITHER DOES IT CONVEY ANY LICENSE UNDER ITS PATENT RIGHTS, NOR 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.

As used herein:

1. Life support devices or systems are devices or systems which, (a) are intended for surgical implant into the body, or (b) support or sustain life, or (c) whose failure to perform when properly used in accordance with instructions for use provided in the labeling, can be reasonably expected to result in significant injury to the user.

ANTI-COUNTERFEITING POLICY

Fairchild Semiconductor Corporation's Anti-Counterfeiting Policy. Fairchild's Anti-Counterfeiting Policy is also stated on our external website, www.fairchildsemi.com, under Sales Support.

Counterfeiting of semiconductor parts is a growing problem in the industry. All manufacturers of semiconductor products are experiencing counterfeiting of their parts. Customers who inadvertently purchase counterfeit parts experience many problems such as loss of brand reputation, substandard performance, failed applications, and increased cost of production and manufacturing delays. Fairchild is taking strong measures to protect ourselves and our customers from the proliferation of counterfeit parts. Fairchild strongly encourages customers to purchase Fairchild parts either directly from Fairchild or from Authorized Fairchild Distributors who are listed by country on our web page cited above. Products customers buy either from Fairchild directly or from Authorized Fairchild Distributors are genuine parts, have full traceability, meet Fairchild's quality standards for handling and storage and provide access to Fairchild's full range of up-to-date technical and product information. Fairchild and our Authorized Distributors will stand behind all warranties and will appropriately address any warranty issues that may arise. Fairchild will not provide any warranty coverage or other assistance for parts bought from Unauthorized Sources. Fairchild is committed to combat this global problem and encourage our customers to do their part in stopping this practice by buying direct or from authorized distributors.

FL7732 is changed to FL7732MY_F116 (no frequency hopping) PF/THD at 50Hz is added EMI test result is updated

2. A critical component is any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness.