Datasheet FEB-L034 Datasheet (Fairchild)

User Guide for

FEB-L034

Evaluation Board

Universal Line Voltage LED Ballast

Featured Fairchild Product:

FL7701

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. Photographs............................................................................................................................... 6

4. Printed Circuit Board ................................................................................................................ 6

5. Schematic .................................................................................................................................. 7

6. Bill of Materials ........................................................................................................................ 8

7. Performance of Evaluation Board ............................................................................................. 9

7.1. Typical Waveforms: Startup .......................................................................................... 10

7.2. Operating Frequency & Minimum Duty ........................................................................ 11

7.3. Typical Waveforms: Steady State .................................................................................. 12

7.4. Typical Waveforms: Abnormal Mode (LED-Open) ...................................................... 15

7.5. Typical Waveforms: Abnormal Mode (Inductor Short) ................................................ 16

7.6. System Efficiency .......................................................................................................... 17

7.7. Power Factor at Rated Load Condition .......................................................................... 18

7.8. THD Performance at Rated Load Condition ................................................................. 19

7.9. Thermal Performance at Rated Load Condition ............................................................ 20

7.10. Electromagnetic Interference (EMI) Result ................................................................... 22

8. Revision History ..................................................................................................................... 24

This user guide supports the evaluation kit for the FL7701. It should be used in conjunction with the FL7701 datasheets 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 an universal input 18.3W LED ballast using the FL7701. The input voltage range is 90V output with a constant current of 470mA at 39V description of FL7701, the power supply specification, schematic, bill of materials, and the typical operating characteristics.

1.1. General Description

The FL7701 LED lamp driver is a simple IC with a Power Factor Correction (PFC) function. The special “adopted digital” technique of the IC can automatically detect input voltage condition Zero-Crossing Detector (ZCD) and send a internal reference signal for high power factor. When AC input is applied to the IC, PFC function is automatically enabled. When DC input is applied to the IC, PFC function is automatically disabled. The FL7701 does not need a bulk capacitor (electrolytic capacitor) for supply rails stability, which can significantly affect to LED lamp system.

– 264V

RMS

. This document contains general

MAX

and there is one DC

RMS

1.2. Features

 Digitally Implemented Active PFC Function

(No Additional Circuit Necessary for High PF)

 Built-in HV Supplying Circuit: Self Biasing  AOCP Function with Auto-Restart Mode  Built-in Over-Temperature Protection (OTP)  Cycle-by-Cycle Current Limit  Low Operating Current: 0.85mA (Typical)  Under-Voltage Lockout with 5V Hysteresis  Programmable Oscillation Frequency  Programmable LED Current  Analog Dimming Function  Soft-Start Function  Precise Internal Reference: ±3%

1.3. Internal Block Diagram

HV

VCC

3

VCC

ZCD

time

I

AD

ZCD

UVLO

JFET

8

ADIM

RT

GND

5

Oscillator

4

6

DAC

Soft-Start

Digital Block

Reference

TSD

+

LEB

Leading-Edge

Blanking

Q

R

S

AOCP

+

2.5V

OUT

2

1

CS

Figure 1. Block Diagram

Table 1. Pin Definitions

Pin Name Description

1 CS 2 OUT 3 VCC

4 RT

5 ADIM

6 GND 7 NC No Connection 8 HV

Current Sense. Limits output current, depending on the sensing resistor voltage. The CS pin is also used to set the LED current regulation.

Output. Connects to the MOSFET gate. Supply Voltage. Supply pin for stable IC operation; ZCD signal detection

used for accurate PFC function. Resistor. Programmable operating frequency using an external resistor

connected to this PIN and the IC has fixed frequency when this pin is left open or floating.

Analog Dimming. Connects to the internal current source and can change the output current using an external resistor. If ADIM is not used, connect a

0.1µF bypass capacitor between ADIM and GND.

GROUND. Ground for the IC.

High Voltage. Connect to the high-voltage line and supply current to the IC

2. General Specifications for Evaluation Board

All data for this table was measured at an ambient temperature of 25°C.

Table 2. Summary of Features and Performance

Description Symbol Value Comments

V

90V Minimum Input Voltage

IN.MIN

Input Voltage Range

AC Input Frequency

Output Voltage

Output Current

Output Power

(1)

(2)

Efficiency

Temperature

Initial Application

Notes:

1. The output current has I in parallel with the LED. Ensure the capacitor voltage rating is high enough to withstand an open-LED condition or use a Zener diode for protection.

2. The output power is not equal to the apparent power due to the slight phase shift between the output voltage and current.

V

IN.NORMAL

V

f

V

OUT,MAX

V

OUT,NORMAL

V

I

OUT.NORMAL

CC deviation < ±4.5%

110V / 220V Normal Input Voltage

264V Maximum Input voltage

IN.MAX

47Hz Minimum Input Frequency

IN.MIN

64Hz Maximum Input Frequency

IN.MAX

41V Maximum Output Voltage

39V Normal Output Voltage

37V Minimum Output Voltage

OUT,MIN

470mA Normal Output Current

Line Input Voltage Change:

Output Power 18.3W

>83% At Full Load

T

< 63°C

FL7701

T

< 69°C

DM filter

T

FRD,ES3J

T

MOSFET

T

inductor

PCB Size

ripple. To reduce ripple current, use a large electrolytic capacitor

LEDPK

< 61°C

< 68°C

< 50°C

At full load (all at open-frame,

room temperature / still air)

18mm (width) x 295mm (length) x

90~264VAC

10mm (height)

L-Tube

3. Photographs

Figure 3. Width: 18mm Figure 4. Height: 10mm (Include PCB)

Figure 2. Top View, Length: 295mm

4. Printed Circuit Board

Figure 5. Top Side (18mm x 295mm)

Figure 6. Bottom Side (18mm x 295mm)

5. Schematic

Figure 7. Schematic

6. Bill of Materials

Item

No.

1 U1 FL7701 1 Controller Fairchild Semiconductor 2 Fuse SS-5-1A 1 1A/250V Fuse Cooper Bussmann 3 MOV MOV-10D471K 1 VARISTOR 470V 10MM RADIAL Bourns Inc.

4 L1 LF-1480-253 1 Line Filter 5 L2, L3 RFB0810-472 2 4.7mH Inductor Coil Craft

6 L4, L5 PCH-45x-475 2 4.7mH Inductor Coil Craft 7 BD DF04S 1 400V / 1.5A, Bridge Rectifier Fairchild Semiconductor

8 D1 1N4148 1

9 D2 RS1M 1 1000V / 1A, Fast Rectifier F airchild Semiconductor 10 D3 ES3J 1 600V / 3A, Fast Rectifier Fairchild Semiconductor 11 ZD1 MMSZ5230B 1 4.7V / 0.5W Zener Diode Fairchild Semiconductor 12 Q1 FQD2N60 1 2A / 600V MOSFET Fairchil d Semiconductor 13 Q2 FQN1N50C 1 1A / 500V MOSFET Fairchild Semiconductor

14 C1

15 C2 MPE 630V104K 1

16 C3 MPE 400V334K 1

Part

Reference

Part Number Qty. Description Manufacturer

Sejin Telecom

(www.sejintel.com)

PCX2 335M MKP

100nF

100V / 200mA, Small Signal

Diode

1 100nF / 275VAC, X-Cap PILKOR

0.1µF / 630VAC, 10%, Polypropylene

0.33µF / 400VAC, 10%, Polypropylene

Fairchild Semiconductor

Sungho

17 C4, C5 C1206C225K5PACTU 2 18 C6 19 C7 C1206C102K5PACTU 1 20 C8 C1206C105K5PACTU 1

21 C9 KMG 330µF / 63V 1 330µF/63V Electrolytic Capacitor SamYoung 22 R1, R2 RC1106JR-07151RL 2 23 R3 RC0805JR-07331RL 1 24 R4, R5 RC1106JR-070R9RL 2 25 R6 RC1106JR-07204RL 1 26 R7 RC1106JR-07153RL 1 27 R8 RC0805JR-07823RL 1 28 R9 10.0KBZTB-ND 1 29 R10 RC1106JR-07000RL 1

C0805C104K3RACTU

2.2µF / 50V SMD Capacitor 3216

1

0.1µF / 25V SMD Capacitor 2012

1nF / 50V SMD Capacitor 3216

1µF / 50V SMD Capacitor 3216

150Ω RES, SMD, 1/4W, 3216 330Ω RES, SMD, 1/8W, 2012

0.9Ω RES, SMD, 1/4W, 3216

200kΩ RES, SMD, 1/4W, 3216

15kΩ RES, SMD, 1/4W, 3216 82kΩ RES, SMD, 1/8W, 2012

10kΩ / 1W Resistor

0Ω RES, SMD, 1/4W, 3216

Kemet Kemet Kemet Kemet

Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo

7. Performance of Evaluation Board

Table 3. Test Condition & Equipments

Test Temperature

Test Equipment

TA = 25°C, Open-Flame AC Source : PCR500L by Kikusui

Power Meter : PZ4000 by Yokogawa Oscilloscope : waverunner 64Xi by Lecroy EMI Test Receiver: ESCS30 by ROHDE & SCHWARZ Two-Line V-Network: ENV216 by ROHDE & SCHWARZ Thermometer : CAM SC640 by FLIR SYSTEMS LED: EHP-AX08EL/GT01H-P03 (3W) by Everlight

7.1. Typical Waveforms: Startup

Figure 8 through Figure 11 show the typical startup performance at different input voltage conditions. When AC input voltage is applied to the system, the FL7701 automatically operates in AC Mode after finishing an internally fixed, seven-cycle, soft-start period.

Figure 8. Soft-Start Characteristics at 90V

(47Hz ) CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

AC

INDUCTOR

Figure 10. Soft-Start Characteristics at 90VDC

(64Hz), CCH2: V

, CH3: V

OUT

DRAIN

, CH4: I

INDUCTOR

Figure 9. Soft-Start Characteristics at 264VAC

(47Hz), CH2: V

, CH3: V

OUT

Figure 11. Soft-Start Characteristics at 264V

(64Hz), CCH2: V

, CH3: V

OUT

DRAIN

, CH4: I

INDUCTOR

DC

INDUCTOR

7.2. Operating Frequency & Minimum Duty

µ

The recommended switching frequency of FL7701 is around 20kHz ~ 250kHz and it is determined by the RT resistor and has prefixed output frequency in RT-open condition. The maximum duty ratio is fixed below 50% and pre-fixed minimum on time is around 400ns. There are two considerable points to design properly. The first, consider the minimum duty at low input voltage because the FL7701 cannot get higher than 50% duty ratio. This means the FL7701 should have duty margin. The other is minimum on-time at high input voltage condition. The FL7701 cannot control output power when the set point is smaller than on time at very high input voltage. On-time margin must be considered.

Minimum On Time:

s

5.2

Switching Frequency:

21.72kHz

Figure 12. Operating Frequency & Minimum Duty

CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

INDUCTOR

7.3. Typical Waveforms: Steady State

Figure 13 through Figure 22 show the normal operation waveforms by input voltage and input frequency. The output voltage and current always keeps a certain output level with

(input frequency ×2) ripple and the test results are provided in Table 5.

Figure 13. Input Voltage: 90VAC, Input Frequency:

47Hz, CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

LED

Figure 15. Input Voltage: 110VAC, Input Frequency:

47Hz, CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

LED

Figure 14. Input Voltage: 90V

64Hz, CH2: V

, CH3: V

OUT

, Input Frequency:

AC

, CH4: I

DRAIN

LED

Figure 16. Input Voltage: 110V

64Hz, CH2: V

OUT

, CH3: V

, Input Frequency:

AC

, CH4: I

DRAIN

LED

Figure 17. Input Voltage: 180VAC, Input Frequency:

47Hz, CH2: V

Figure 19. Input Voltage: 220V

47Hz, CH2: V

, CH3: V

OUT

, CH3: V

OUT

, CH4: I

DRAIN

, Input Frequency:

AC

, CH4: I

DRAIN

LED

Figure 18. Input Voltage: 180V

64Hz, CH2: V

Figure 20. Input Voltage: 220V

64Hz, CH2: V

OUT

AC

, CH3: V

AC

, CH3: V

, Input Frequency:

DRAIN

, CH4: I

LED

, Input Frequency:

DRAIN

, CH4: I

LED

Figure 21. Input Voltage: 264V

47Hz, CH2: V

, CH3: V

OUT

, Input Frequency:

AC

, CH4: I

DRAIN

LED

Figure 22. Input Voltage: 264V

64Hz, CH2: V

OUT

, CH3: V

, Input Frequency:

AC

, CH4: I

DRAIN

LED

IO [A]

0.52

0.51

0.5

0.49

0.48

0.47

0.46

0.45

0.44

0.43

0.42 90Vac 110Vac 180Vac 220Vac 264Vac

Figure 23. CC Deviation Curve

Table 4. Output Characteristics by Input Voltage & Frequency

47Hz 64Hz

90VAC 110VAC 180VAC 220VAC 264VAC

V

LED(RMS)

37.73V 468.2mA 37.78V 451.6mA

38.07V 487.6mA 38.13V 475.7mA

38.25V 489.4mA 38.23V 481.4mA

38.25V 485.6mA 38.26V 478.7mA

38.18V 482.1mA 38.20V 475.4mA

I

LED(RMS)

V

LED(RMS)

I

LED(RMS)

Deviation 4.33% 6.19%

7.4. Typical Waveforms: Abnormal Mode (LED-Open)

Figure 24 shows the open-load condition test method. If the LED disconnects from the system, the output voltage increases up to match the voltage of the input source. Add the output voltage clamping circuit or the special protection circuit to protect components, especially output capacitor.

Figure 24. Open-LED Condition

The Figure 25 shows the test results of waveform in LED-open condition; the output voltage clamps a certain level.

Figure 25. Output Waveforms at LED-OPEN Condition

CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

LED

7.5. Typical Waveforms: Abnormal Mode (Inductor Short)

Figure 26 and Figure 27 show the test method and result of an inductor short. The FL7701 uses an Abnormal Over-Current Protection (AOCP) function, limiting the current on RCS in the event of an inductor short.

Figure 26. Inductor Short Condition

Figure 27. Test Result of Inductor Short Condition

CH2: V

, CH3: V

OUT

DRAIN

, CH4: I

LED

7.6. System Efficiency

Figure 28 shows system efficiency results for different AC input voltage frequency conditions. As shown, the input frequency has negligible effect on system efficiency.

Efficiency

VIN

Figure 28. System Efficiency

Table 5. Test Result of System Efficiency

Input Voltage Efficiency (%)

90VAC

110VAC

180VAC

220VAC

264VAC

47Hz 83.63 64Hz 83.55 47Hz 86.18 64Hz 86.06 47Hz 88.52 64Hz 88.56 47Hz 88.58 64Hz 88.52 47Hz 87.53 64Hz 87.51

7.7. Power Factor at Rated Load Condition

Figure 29 shows the system Power Factor (PF) performance for the entire input voltage range (90V changes slightly according to the input frequency.

PF

to 264VAC) at different input frequency conditions (47Hz, 64Hz). The PF

AC

VIN

Figure 29. Power Factor

Table 6. Power Factor Test Results

Input Voltage Power Factor

90VAC

110VAC

180VAC

220VAC

264VAC

47Hz 0.95 64Hz 0.95 47Hz 0.96 64Hz 0.96 47Hz 0.94 64Hz 0.93 47Hz 0.91 64Hz 0.90 47Hz 0.88 64Hz 0.85

7.8. THD Performance at Rated Load Condition

Figure 30 shows the Total Harmonic Distortion (THD) performance at different input frequencies. Test results are similar; THD meets international regulations (under 30%).

THD

Figure 30. Total Harmonic Distortion Performance

Table 7. THD Test Result

Input Voltage THD (%)

90VAC

110VAC

180VAC

220VAC

264VAC

VIN

47Hz 27.24 64Hz 27.25 47Hz 21.18 64Hz 21.54 47Hz 22.88 64Hz 23.97 47Hz 24.10 64Hz 24.71 47Hz 24.19 64Hz 25.40

7.9. Thermal Performance at Rated Load Condition

The Figure 31 through Figure 35 show the temperature checking results on the board, depending on different input voltage conditions. All of the components temperatures are below 69°C in whole input voltage condition.

MOSFET (Q1):

67.2℃

Diode (D3):

50.4℃

Figure 31. Thermal Test Result at 90VACCondition

MOSFET (Q1):

64.2℃

Diode (D3):

54.9℃

IC TEMP:

53.1℃

IC TEMP:

53.8℃

Filter L2 TEMP:

68.3℃

Filter L3 TEMP:

68.3℃

Filter L2 TEMP:

61.2℃

Filter L3 TEMP:

61.6℃

Inductor TEMP:

41.3℃

Inductor TEMP: 44.7℃

Figure 32. Thermal Test Result at 110V

MOSFET (Q1):

56.1℃

Diode (D3):

58.8℃

IC TEMP:

56.4℃

Filter L3 TEMP:

43.5℃

Condition

AC

Filter L2 TEMP:

43.1℃

Inductor TEMP:

46.9℃

Figure 33. Thermal Test Result at 180V

Condition

AC

MOSFET (Q1):

55.0℃

Diode (D3):

59.4℃

MOSFET (Q1):

56.1℃

Diode (D3):

60.9℃

IC TEMP:

58.9℃

Filter L3 TEMP:

37.4℃

Filter L2 TEMP:

36.8℃

Figure 34. Thermal Test Result at 220VAC Condition

IC TEMP:

62.9℃

Filter L3 TEMP:

34.8℃

Filter L2 TEMP:

34.1℃

Inductor TEMP:

48.0℃

Inductor TEMP:

49.5℃

Figure 35. Thermal Test Result at 264VAC Condition

Table 8. Temperature Performance by Input Voltage

IC MOSFET (Q1) Diode (D3) Filter L2 Filter L3 Inductor

90VAC 110VAC 180VAC 220VAC 264VAC

53.1°C 67.2°C 50.4°C 68.3°C 68.3°C 41.3°C

53.8°C 64.2°C 54.9°C 61.2°C 61.6°C 44.7°C

56.4°C 56.1°C 58.8°C 43.1°C 43.5°C 46.9°C

58.9°C 55.0°C 59.4°C 36.8°C 37.4°C 48.0°C

62.9°C 56.1°C 60.9°C 34.1°C 34.8°C 49.5°C

7.10. Electromagnetic Interference (EMI) Result

All measurement was conducted in observance of CISPR22 criteria. This regulation is tighter than the CISPR15 regulation for lighting applications.

Figure 36. Conducted Emission-Line at 110VAC, Full Load (10-LED in Series)

Figure 37. Conducted Emission-Neutral at 110V

, Full Load (10-LED in Series)

AC

Figure 38. Conducted Emission-Line at 220VAC, Full Load (10-LED in Series)

Figure 39. Conducted Emission-Neutral at 220VAC, Full Load (10-LED in Series)

8. Revision History

Rev. Date Description

1.0.0 July 2012 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.

This board is intended to be used by certified professionals, in a lab environment, following proper safety procedures. Use at your own risk. 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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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.

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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.

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U.S. origin products and products made with U.S. origin technology are subject to U.S Re-export laws. In the event of re-export, the user will be responsible to ensure the appropriate U.S. export regulations are followed.

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