Datasheet FEB-L026 Datasheet (Fairchild)

User Guide for

FEB-L026

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

3.5. Power Factor .................................................................................................................. 16

3.6. PF & 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 700mA 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 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 overtemperature 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

Eff

PF/THD

265V Maximum Input Voltage

IN.MAX

IN.NOMINAL

110V/220V Nominal Input Voltage

fIN 60Hz/50Hz Line Frequency

V

11V Minimum Output Voltage

OUT.MIN

28V Maximum Output Voltage

OUT.MAX

24V Nominal Output Voltage

700mA Nominal Output Current

< ±2.94% Line Input Voltage Change: 90~265V

< ±2.88% Output Voltage Change: 11~28V

Eff

90VAC

120VAC

140VAC

180VAC

220VAC

87.87% Efficiency at 265VAC Line Input Voltage

265VAC

90VAC

120VAC

140VAC

180VAC

230VAC

265VAC

T

54.7ºC

FL7732

T

63.0ºC Primary MOSFET Temperature

MOSFET

T

70.5ºC Secondary Diode Temperature

DIODE

86.45% Efficiency at 90VAC Line Input Voltage

88.45% Efficiency at 120VAC Line Input Voltage

88.76% Efficiency at 140VAC Line Input Voltage

89.03% Efficiency at 180VAC Line Input Voltage

88.77% Efficiency at 220VAC Line Input Voltage

0.984/15.29% PF/THD at 90VAC Line Input Voltage

0.986/14.27% PF/THD at 120VAC Line Input Voltage

0.984/13.61% PF/THD at 140VAC Line Input Voltage

0.978/14.12% PF/THD at 180VAC Line Input Voltage

0.955/17.69% PF/THD at 230VAC Line Input Voltage

0.936/19.91% PF/THD at 265VAC Line Input Voltage

Open-Frame Condition

(T

= 25ºC) FL7732 Temperature

A

AC

Transformer

T

TRANSFORMER

59.7ºC Transformer Temperature

All data of the evaluation board were measured under a condition where the board was enclosed in a case and external temperature was around 25°C.

2.1. Evaluation Board

Figure 2. Top View (Dimensions:79mm (L) x 30mm (W) x 20mm (H))

Figure 3. Bottom Views (Dimensions:79mm (L) x 30mm (W) x 20mm (H))

2.2. Printed Circuit Board

Dimension: mm

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 DF06S 1 1.5A/600V Bridge Diode

2 CF1 MPX AC275V 104K 1 104/AC275V X-Capacitor Carli

3 CF2

4 CS1 C1206C103KDRACTU 1 103/1kV SMD Capacitor 3216 Kemet

5 CY1 SCFz2E472M10BW 1 472/250V Y-Capacitor Samwha

6 Co1, Co2 KMG 470µF/35V 2 470µF/35V Electrolytic Capacitor Samyoung

7 C1 MPE 630V104K 14S 1 104/630V MPE Film Capacitor Sungho

8 C2 KMG 22µF/50V 1 22µF/35V Electrolytic Capacitor Samyoung

9 C3 C0805C104K5RACTU 1 104/50V SMD Capacitor 2012

10 C4 C0805C200J5GACTU 1 200/50V SMD Capacitor 2012 Kemet

11 C5 C0805C225Z3VACTU 1 225/25V SMD Capacitor 2012 Kemet

12 DS1 RS1M 1 1000V/1A Ultra-Fast Recovery Diode

13 Do1 ES3D 1 200V/3A, Fast Rectifier

14 D1 1N4003 1 200V/1A, General Purpose Rectifier

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

16 LF1 R10402KT00 1 4mH Inductor, 10Ø Bosung

17 MOV1 SVC 471 D-07A 1 Metal Oxide Varistor Samwha

18 Q1 FDD5N60NZ 1 600V/4A, N-Channel MOSFET

19 RG1, R6 RC1206JR-0710L 2 10Ω SMD Resistor 3216

20 RS1, RS2 RC1206JR-07100KL 2 100kΩ SMD Resistor 3216

21 Rcs1, Rcs2 RC1206JR-071RL 2 1Ω SMD Resistor 3216

22 Rcs3 RC1206JR-072R4L 1 2.4Ω SMD Resistor 3216

23 Ro1 RC1206JR-0720KL 1 20KΩ SMD Resistor 3216

24 R4 RC1206JR-07150KL 1 150KΩ SMD Resistor 3216

25 R1, R2, R3 RC1206JR-0768KL 3 68KΩ SMD Resistor 3216

26 R5 RC1206JR-0724KL 1 24KΩ SMD Resistor 3216

27 T1 RM8 Core 1 12-Pin, Transformer TDK

28 U1 FL7732M_F116 1 Main PSR Controller

Part

Reference

Part Number Qty. Description Manufacturer

Fairchild

Semiconductor

MPX AC275V 473K

1 473/AC275V X-Capacitor

Carli

Kemet

Fairchild

Semiconductor

Fairchild

Semiconductor

Fairchild

Semiconductor

Fairchild

Semiconductor

Yageo

Fairchild

Semiconductor

2.5. Transformer Design

Figure 7. Transformer Bobbin Structure and Pin Configuration

Figure 8. Transformer Winding Structure

Table 2. Winding Specifications

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

1 NP1 12  1 0.25φ 30 Ts Solenoid Winding

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

3 NS 7  8 0.5φ (TIW) 20 Ts Solenoid Winding

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

5 NP2 1  2 0.25φ 30 Ts Solenoid Winding

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

7 NA 6  5 0.25φ 15 Ts Solenoid Winding

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

Table 3. Electrical Characteristics

Pin Specifications Remark

Inductance 12–2 750µH ±10% 60kHz, 1V

Leakage 12–2 6µH 60kHz, 1V Short All Output Pins

3. Performance of Evaluation Board

Table 4. Test Condition & Equipments

Ambient Temperature T

AC Power Source: PCR500L by Kikusui Power Analyzer: PZ4000000 by Yokogawa Electronic Load: PLZ303WH by KIKUSUI

Test Equipment

Multi Meter: 2002 by KEITHLEY, 45 by FLUKE Oscilloscope: 104Xi by LeCroy Thermometer: Thermal CAM SC640 by FLIR SYSTEMS LED: EHP-AX08EL/GT01H-P03 (3W) by Everlight

= 25°C

A

3.1. Startup

Startup time is 890ms (VIN = 90VAC) ~ 362ms (VIN = 265VAC). The results were measured by using 7-LED load. Startup Time at 7-LED (25V/700mA); C1 [V

[V

], C3 [V

IN

Figure 9. V

IN

OUT

], C4 [I

OUT

].

= 90VAC / 60Hz Figure 10. VIN = 115VAC / 60Hz

DD

], C2

Figure 11. V

= 230VAC / 50Hz Figure 12. VIN = 265VAC / 50Hz

IN

V

/

V

/

3.2. Operation Waveforms

Output current ripple is under 250mAp-p with a rated output current of 700mA. Operation Waveforms at 7-LED (25V/700mA); C1 [V

[I

].

OUT

Figure 13. V

IN

= 90V

/ 60Hz

AC

Figure 14.

], C2 [VIN], C3 [V

CS

IN

= 115

AC

60Hz

OUT

], C4

Figure 15. V

= 230V

IN

/ 50Hz

AC

Figure 16.

IN

= 265

AC

50Hz

3.3. Constant-Current Regulation

Constant current deviation in the wide output voltage range from 11V to 28V is less than

2.88% at each line input voltage. Line regulation at the rated output voltage (24V) is less than 2.80%. The results were measured using E-load [CR Mode].

Figure 17. Constant-Current Regulation, Measured by E-Load [CR Mode]

Table 5. Constant-Current Regulation by Output Voltage Change (11~28V)

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

90V

[60Hz] 656 682 ±1.94%

AC

120V

140V

180V

230V

265V

[60Hz] 657 696 ±2.88%

AC

[60Hz] 679 696 ±1.24%

AC

[50Hz] 685 703 ±1.30%

AC

[50Hz] 675 696 ±1.53%

AC

[50Hz] 666 681 ±1.11%

AC

Table 6. Constant-Current Regulation by Line Voltage Change (90~265V

Output

Voltage

90V

[60Hz]

AC

120V

[60Hz]

26V 678mA 660mA 681mA 700mA 690mA 678mA ±2.94%

24V 676mA 659mA 679mA 697mA 684mA 678mA ±2.80%

22V 673mA 657mA 683mA 694mA 692mA 681mA ±2.74%

AC

140V

[60Hz]

AC

180V

[50Hz]

AC

220V

[50Hz]

AC

265V

[50Hz]

AC

)

AC

Tolerance

3.4. Short- / Open-LED Protections

V

/

V

/

In short-LED condition, OCP level is reduced from 0.7V to 0.2V because FL7732 lowers OCP level when V

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

S

results were measured by using actual LED load. Short-LED Condition; C1 [V

[V

], C3 [V

IN

OUT

], C4 [I

OUT

].

Figure 18. V

IN

= 90V

/ 60Hz

AC

], C2

DD

Figure 19.

= 265VAC

IN

50Hz

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

Figure 20. V

IN

= 90V

/ 60Hz

AC

], C2 [VIN], C3 [V

DD

Figure 21.

OUT

], C4 [I

= 265VAC

IN

OUT

].

50Hz

3.5. Power Factor

System efficiency is 86.45% ~ 89.03% in 90 ~ 265VAC input voltage range. The results were measured at 30 minutes after startup by using 7-LED.

90.0%

85.0%

80.0%

75.0%

70.0%

65.0%

88.45%

88.76%

89.03%

88.77%

87.87%

86.45%

90Vac 120Vac 140Vac 180Vac 230Vac 265Vac

Figure 22. System Efficiency

Table 7. System Efficiency

Input Voltage

90V

[60Hz] 18.91 0.678 24.10 16.35 86.45%

AC

120V

140V

180V

220V

265V

[60Hz] 18.02 0.663 24.04 15.94 88.45%

AC

[60Hz] 18.78 0.687 24.27 16.67 88.76%

AC

[50Hz] 19.31 0.704 24.43 17.19 89.03%

AC

[50Hz] 18.99 0.693 24.34 16.86 88.77%

AC

[50Hz] 19.05 0.689 24.28 16.74 87.87%

AC

Input

Power [W]

Output

Current [A]

Output

Voltage [V]

Output

Power [W]

Efficiency

3.6. PF & THD

FL7732 shows excellent THD performance. THD is much less than 30% specification. The results were measured at 30 minutes after startup.

Figure 23. Power Factor & Total Harmonic Distortion

Table 8. PF & THD

Input Voltage Output Current Output Voltage Power Factor THD

90VAC [60Hz] 0.678A 24.10V 0.98 15.29%

120VAC [60Hz] 0.663A 24.04V 0.99 14.27%

140VAC [60Hz] 0.687A 24.27V 0.98 13.61%

180VAC [50Hz] 0.704A 24.43V 0.98 14.12%

230VAC [50Hz] 0.693A 24.34V 0.96 17.69%

265VAC [50Hz] 0.689A 24.28V 0.94 19.01%

3.7. Operating Temperature

Temperature of the all components on this board is less than 71 ºC. The results were measured at 30 minutes after startup.

Bottom Top

FL7732: 54.2 ºC

FL7732: 54.7 ºC

MOSFET: 63.0 ºC Rectifier: 70.5 ºC

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

Bottom Top

MOSFET: 58.4 ºC Rectifier: 70.5 ºC

Trans: 59.7 ºC

[700mA]

OUT

Trans: 57.0 ºC

Figure 25. Board Temperature - VIN[265VAC], I

[700mA]

OUT

3.8. EMI

The all measurement was conducted in observance of EN55022 criteria. The results were measured at 30 minutes after startup by using actual LED load.

Figure 26. EMI, V

= 110VAC

IN

Figure 27. EMI, V

OUT

[24V], I

[700mA], EMI, V

OUT

= 220VAC

IN

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.

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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.