Datasheet FEB-L027 Datasheet (Fairchild)

User Guide for

FEB-L027

Evaluation Board

Reference Design Report for a 17.5W T8

LED Lamp Using FL7732

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 ........................................................................................................... 3

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

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

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

3. Evaluation Board ...................................................................................................................... 6

4. Schematic .................................................................................................................................. 7

5. Bill of Materials ........................................................................................................................ 8

6. Transformer Design ................................................................................................................ 10

7. Electromagnetic Interference (EMI) Inductor (L1 & L2) Design .......................................... 11

8. Performance of Evaluation Board ........................................................................................... 12

8.1. Test Condition & Equipments ......................................................................................... 12

8.2. Startup ............................................................................................................................. 13

8.3. Operation Waveforms ..................................................................................................... 14

8.4. Constant-Current Regulation ........................................................................................... 15

8.5. Short-LED/ Open-LED Protections ................................................................................ 16

8.6. System Efficiency ............................................................................................................ 17

8.7. Power Factor & Total Harmonic Distortion .................................................................... 18

8.8. Operating Temperature .................................................................................................... 19

8.9. Electromagnetic Interference (EMI) ............................................................................... 20

9. Revision History ..................................................................................................................... 21

The following 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 a universal line voltage T8 LED lamp using the FL7732 Primary Side Regulator (PSR) single-stage controller. The input voltage range is 90V 500mA at 35V supply specification, schematic, bill of materials, and the typical operating characteristics.

1.1. General Description

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 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 open-LED, short-LED, and over-temperature protections.

– 265V

RMS

. This document contains general description of FL7732, the power

MAX

. There is one DC output with a constant current of

RMS

.

1.2. Features

 Cost-Effective Solution: No Input Bulk Capacitor and Feedback Circuitry  Power Factor Correction (PFC)  Accurate Constant-Current (CC) Control  Linear Frequency Control for Better Efficiency and Simpler Design  Open-LED Protection  Short-LED Protection  Cycle-by-Cycle Current Limiting  Over-Temperature Protection (OTP) 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 Package

1.3. Internal Block Diagram

Figure 1. Block Diagram of FL7732

2. General Specifications for Evaluation Board

Table 1. Evaluation Board 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

17.5V Minimum Output Voltage

OUT.MIN

37V Maximum Output Voltage

OUT.MAX

35V Nominal Output Voltage

500mA Nominal Output Current

< ±2.59% Line Input Voltage Change: 90~265V

< ±1.82% Output Voltage Change: 17.5~35V

Eff

90VAC

120VAC

140VAC

180VAC

220VAC

89.14% Efficiency at 265VAC Line Input Voltage

265VAC

90VAC

120VAC

140VAC

180VAC

220VAC

265VAC

T

44.8ºC

FL7732

T

59.6ºC Primary MOSFET Temperature

MOSFET

T

66.6ºC Secondary Diode Temperature

DIODE

87.02% Efficiency at 90VAC Line Input Voltage

88.67% Efficiency at 120VAC Line Input Voltage

89.22% Efficiency at 140VAC Line Input Voltage

89.60% Efficiency at 180VAC Line Input Voltage

89.54% Efficiency at 220VAC Line Input Voltage

0.999 / 7.38% PF / THD at 90VAC Line Input Voltage

0.997 / 8.98% PF / THD at 120VAC Line Input Voltage

0.995 / 11.02% PF / THD at 140VAC Line Input Voltage

0.990 / 13.87% PF / THD at 180VAC Line Input Voltage

0.978 / 16.63% PF / THD at 220VAC Line Input Voltage

0.959 / 18.75% PF / THD at 265VAC Line Input Voltage

Open-Frame Condition

(T

= 25ºC) Temperature

A

AC

Transformer

T

TRANSFORMER

64.5ºC Transformer Temperature

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

3. Evaluation Board

Dimensions: 297.81 (L) × 17.14 (W) × 11.00 (H) [mm]

Figure 2. Top / Bottom of Evaluation Board Figure 3. PCB Pattern Top / Bottom of

Evaluation Board

4. Schematic

250V/1A

LN

F

1

10D471

RV

1

20mH

R

1

L

1MΩ R

CX

1

47nF/450V

2

1MΩ

1N4007

40mH

1N4007

L

2

D

2

1N4007

D

3

D

1

1N4007

D

4

100pF

1.5Ω

1Ω

UF4007

R

4

100K

47nF/450V

C

1

47nF/450V

100KΩ

D

3.3nF

5

1mH

L

C

2

R

3

750KΩ

C

3

R

5

750KΩ

R

6

750KΩ

R

7

N1

2.2uF C

8

GND

VS

R

11

10Ω

R

13

NC

GATE

2

150kΩ

R

9

765

COMI

VDD

4

D

7

1N4148

FL7732

U1

C

5

104

22µF/35V

FDPF5N60NZ

Q

1

UF4007

C

4

4.7Ω

D

6

R

8

N2

3

GND

CS

1

C

10

R

0

12

R

14

10KΩ

R

15

R

16

18kΩ

R

10

T1

10pF

C

7

2.2nF C

Y1

470µF/50V

N3

D

9

UF4007

D

8

C

12

C

13

470µF/50V

47kΩ

R

19

UF4007

5µH/jump

L

C

14

4

40V/0.5A

V

O

C

11

100pF

R

17

18

20Ω

Figure 4. Evaluation Board Schematic

5. Bill of Materials

Item

No.

1 C1, C2 MPE 400V473K 14S 2 47nF / 400V MPE Film Capacitor Sungho

3 C3 C1206C332KDRACTU 1 3.3nF / 1kV SMD Capacitor 3216 Kemet

4 C4 KMG 22µF / 35V 1 22F / 35V Electrolytic Capacitor Samyoung

5 C5 C0805C104K5RACTU 1 100nF / 50V SMD Capacitor 2012 Kemet

7 C7 C0805C100J5GACTU 1 10pF / 50V SMD Capacitor 2012 Kemet

8 C8 C0805C225Z3VACTU 1 2.2µF / 25V SMD Capacitor 2012 Kemet

10 C10 C0805C101J5GACTU 1 100pF / 50V SMD Capacitor 2012 Kemet

11 C11 DEBB33A101KC1B 1 100pF / 1kV Ceramic Capacitor Murata

12 C12, C13, C14 KMG 470F / 50V 3 470F / 50V Electrolytic Capacitor Samyoung

15 CX1 MPX AC275V 473K 1 47nF / AC275V X-Capacitor Carli

16 CY1 SCFz2E222M10BW 1 2.2nF / 250V Y-Capacitor Samwha

17

18

19 D7 1N4148 1 100V / 1A Small Signal Rectifier

21 F1 0672001.MXE 1 1A / 250VAC Fuse Littelfuse

22 L1 20mH 1 20mH SPI Electronic

23 L2 40mH 1 40mH SPI Electronic

24 L3 R08102KT00 2 1mH Filter Inductor, 8 Bosung

25 L4 Jumper 1 5H / Jump

26 Q1 FDPF5N60NZ 1 4.5A / 600V Main MOSFET

27 R1, R2 RC1206JR-071ML 2 1M SMD Resistor 3216 Yageo

28 R3, R4 RC1206JR-07100KL 2 100K SMD Resistor 3216

29 R5, R6, R7 RC1206JR-07750KL 3 750K SMD Resistor 3216

30 R8 RC1206JR-074R7L 1 4.7 SMD Resistor 3216

31 R9 RC0805FR-07150KL 1 150K SMD Resistor 2012

32 R10 RC0805JR-0718KL 1 18K SMD Resistor 2012

33 R11 RC1206JR-0710RL 1 10 SMD Resistor 3216

34 R12 RC0805JR-070RL 1 0 SMD Resistor 2012 Yageo

35 R13 RC0805JR-0710KL 1 10K SMD Resistor 2012

36 R14, R15 RC1206JR-071R5L 2 1.5 SMD Resistor 3216

37 R16 RC1206FR-071RL 1 1.0 SMD Resistor 3216 Yageo

38 R17, R18 RC1206JR-0720RL 2 20 SMD Resistor 3216

39 R19 RC1206JR-0747KL 1 47k SMD Resistor 3216 Yageo

41 RV1 SVC 471 D-10A 1 Metal Oxide Varistor Samwha

42 T1

Part

Reference

D1, D2, D3,

D4

D5, D6, D8,

D9

Part Number Qty. Description Manufacturer

IN4007 4

UF4007 4 1000V / 1A Fast Rectifier

PG1054.410NL

(1150-CDC-MX4)

1 Transformer, 585H Pulse Electronics

1000V / 1A General-Purpose

Rectifier

Fairchild

Semiconductor

Fairchild

Semiconductor

Fairchild

Semiconductor

Fairchild

Semiconductor

Yageo

Bill of Materials (Continued)

Item

No.

43 U1 FL7732_F116 1 Main Controller

Part

Reference

Part Number Qty. Description Manufacturer

Fairchild

Semiconductor

6. Transformer Design

Figure 5. Transformer Bobbin Structure and Pin Configuration

Table 2. Electrical Characteristics

Pin Specifications Remark

Inductance 2 – 1 585µH ± 10% 100kHz, 0.1V

Leakage 2 – 1 6µH 100kHz, 0.1V Short All Output Pins

7. Electromagnetic Interference (EMI) Inductor (L1 & L2) Design

Figure 6. Transformer Bobbin Structure and Pin Configuration

Table 3. Winding Specifications

Part Ref. Winding Pin (S  F) Wire Turns Inductance

L1

L2

N1 1  3 0.25  (2UEW) 68.5 22mH Min.

N2 2  4 0.25  (2UEW) 68.5 22mH Min.

N1 1  3 0.25  (2UEW) 74.5 50mH Min.

N2 2  4 0.25  (2UEW) 74.5 50mH Min.

Table 4. Material List

No. Item Material Manufacturer UL No.

1 PCB CEM1 CHANG CHUN PLASTICS

2 Core R8K VAKOS INDUSTRIES

3 Wire

4 Varnish 468-2(+) RIPLEY RESIN ENGINEERING

5 Epoxy

TYPU-130 TA YA ELECTRIC WIRE & CABLE

TYA1-130 TA YA ELECTRIC WIRE & CABLE

UEW-U SIAM PACIFIC ELECTRIC WIRE & CABLE

H907

G-9008 GUDAK CHEMISTRY TECH

DONG GUAN HUA CHUANG

CHEMICALINDUSTRY

E80513(S)

E84201(S)

E196993

E81777

8. Performance of Evaluation Board

8.1. Test Condition & Equipments

Ambient Temperature

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: Therma CAM SC640 by FLIR SYSTEMS LED: EHP-AX08EL/GT01H-P03(3W) by Everlight

T

= 25°C

A

8.2. Startup

Startup time is 1.3s (VIN = 90VAC) ~ 330ms (VIN = 265VAC)

Figure 7. V

Time at 10-LED (35V/500mA); C1 [V

C2 [V

= 90VAC / 60Hz, Startup

IN

], C3 [V

IN

OUT

], C4 [I

OUT

Figure 8. VIN = 115VAC / 60Hz Startup Time

],

DD

]

at 10-LED (35V/500mA); C1 [V

[V

], C3 [V

IN

OUT

], C4 [I

OUT

],

DD

], C2

Figure 9. V

Time at 10-LED (35V/500mA); C1 [V

= 230VAC / 50Hz, Startup

IN

[V

], C3 [V

IN

OUT

], C4 [I

OUT

], C2

DD

]

Figure 10. VIN = 265VAC / 50Hz, Startup

Time at 10-LED (35V/500mA); C1 [V

C2 [V

], C3 [V

IN

OUT

], C4 [I

OUT

DD

]

],

8.3. Operation Waveforms

Output current ripple is under 115mAp-p with a rated output current of 500mA.

Figure 11. V Waveforms at 10-LED (35V/500mA); C1

[VCS], C2 [VIN], C3 [V

= 90VAC / 60Hz, Operation

IN

], C4 [I

OUT

Figure 12. VIN = 115VAC / 60Hz Operation

Waveforms at 10-LED (35V/500mA); C1

]

[VCS], C2 [VIN], C3 [V

OUT

], C4 [I

OUT

]

Figure 13. V

= 220VAC / 50Hz, Operation

IN

Waveforms at 10-LED (35V/500mA); C1

[VCS], C2 [VIN], C3 [V

OUT

], C4 [I

OUT

]

Figure 14. VIN = 265VAC / 50Hz, Operation

Waveforms at 10-LED (35V/500mA); C1

[VCS], C2 [VIN], C3 [V

OUT

], C4 [I

OUT

]

8.4. Constant-Current Regulation

Constant-current deviation in the wide output voltage range from 5-LED (17.5V) to 10-

LED (35V) is less than ±1.82% at each line input voltage. Line regulation is less than

±2.59%. The results were measured using LED load.

Output Voltage [V]

Output Current [A]

Figure 15. Constant-Current Regulation – Measured by LED Load

Table 5. Constant-Current Regulation by Output Voltage Change (17.5V ~ 35V)

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

90V

[60Hz] 0.501 0.515

AC

120V

140V

180V

220V

265V

[60Hz] 0.502 0.521

AC

[60Hz] 0.501 0.506

AC

[50Hz] 0.496 0.501

AC

[50Hz] 0.488 0.497

AC

[50Hz] 0.485 0.5

AC

±1.36%

±1.82%

±0.49%

±0.50%

±0.91%

±1.50%

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

Output

Voltage

35V 0.515A 0.521A 0.506A 0.50A 0.494A 0.50A

31.5V 0.514A 0.512A 0.505A 0.496A 0.491A 0.498A

28V 0.509A 0.510A 0.502A 0.501A 0.488A 0.490A

90V

120VAC 140VAC 180VAC 220VAC 265VAC Tolerance

AC

±2.59%

±2.24%

±2.16%

8.5. Short-LED/ Open-LED Protections

In short-LED condition, the OCP level is reduced from 0.7V to 0.2V because the FL7732 lowers the OCP level when the V conduction time. The results are measured using actual LED load.

Figure 16. V

Condition; C1 [V

= 90VAC / 60Hz, Short-LED

IN

], C2 [VIN], C3 [V

DD

[I

]

OUT

In open-LED condition, output voltage is limited around 30V by OVP in VDD. Output over-voltage protection level can be controlled by the turn ratio of the auxiliary and secondary windings.

voltage is less than 0.4V during output diode

S

Figure 17. VIN = 265VAC / 50Hz, Short-LED

OUT

], C4

Condition; C1 [V

], C2 [VIN], C3 [V

DD

[I

]

OUT

], C4

Figure 18. V

Condition; C1 [V

= 90VAC / 60Hz, Open-LED

IN

], C2 [VIN], C3 [V

DD

]

[I

OUT

], C4

Figure 19. VIN = 265VAC / 60Hz, Open-LED Condition; C1 [V

], C2 [VIN], C3 [V

DD

]

[I

OUT

], C4

8.6. System Efficiency

System efficiency is 87.02% ~ 89.6% in 90 ~ 265VAC input voltage range. The results were measured after 30 minutes since startup by using LED load.

Efficiency

Input Voltage

Figure 20. System Efficiency

Table 7. System Efficiency

Input Voltage

90V

[60Hz] 20.380 0.509 34.83 17.735 87.02%

AC

120V

140V

180V

220V

265V

[60Hz] 20.219 0.514 34.88 17.928 88.67%

AC

[60Hz] 19.825 0.508 34.79 17.687 89.22%

AC

[50Hz] 19.453 0.503 34.68 17.430 89.60%

AC

[50Hz] 19.065 0.494 34.55 17.071 89.54%

AC

[50Hz] 19.198 0.495 34.55 17.113 89.14%

AC

Input

Power [W]

Output

Current [A]

Voltage [V]

Output

Power [W]

Efficiency

8.7. Power Factor & Total Harmonic Distortion

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

PF THD

Input Voltage

Figure 21. Power Factor & Total Harmon ic Distortion

Table 8. Power Factor & Total Harmonic Distortion

Input Voltage PF THD

90V

[60Hz] 0.999 7.38%

AC

120V

140V

180V

220V

265V

[60Hz] 0.997 8.98%

AC

[60Hz] 0.995 11.02%

AC

[50Hz] 0.990 13.87%

AC

[50Hz] 0.978 16.63%

AC

[50Hz] 0.959 18.75%

AC

8.8. Operating Temperature

Temperature of the all components on this board is less than 67ºC.

The results were measured 60 minutes after startup.

Bottom Top

Rectifier: 66.6 ºC

FL7732: 44.8 ºC

MOSFET:

º

Trans: 64.5 ºC

Trans: 61.0 ºC

Figure 22. Board Temperature – VIN [90VAC / 60Hz], 10-LED (35V / 500mA)

Bottom Top

Rectifier: 65.3 ºC

FL7732: 43.1 ºC

Trans: 55.8 ºC

Figure 23. Board Temperature – VIN [265VAC / 50Hz], 10-LED (35V / 500mA)

MOSFET:

º

Trans: 58.5 ºC

8.9. Electromagnetic Interference (EMI)

All measurements were conducted in observance of EN55022 criteria.

The results were measured 30 minutes after startup.

Figure 24. EMI Results – 10-LED (35V/500mA), Conduction Line; VIN = 220VAC

Figure 25. EMI Results – 10-LED (35V/500mA), Conduction Neutral; VIN = 220VAC

9. Revision History

Rev. Date Description

1.0.0 July 2011 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. 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.

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.