Fairchild FEB-L041 service manual

User Guide for

FEB-L041

Evaluation Board

6.5W LED Driver

Featured Fairchild Product:

S3217N

FL

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

2.1. Photographs of Evaluation Board .................................................................................... 6

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

2.3. Schematic ......................................................................................................................... 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-LED / Open LED Protections ............................................................................... 15

3.5. System Efficiency .......................................................................................................... 17

3.6. Power Factor and Total Harmonic Distortion ................................................................ 18

3.7. Operating Temperature .................................................................................................. 19

3.8. Electromagnetic Interference (EMI) .............................................................................. 20

4. Revision History ..................................................................................................................... 21

This user guide supports the evaluation kit for the FLS3217N. It should be used in conjunction with the FLS3217N 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 FLS3217N Primary-Side Regulator (PSR) single-stage controller. The input voltage range is 90V 24V specification, schematic, bill of materials, and typical operating characteristics.

1.1. General Description

The FLS3217N is an active Power Factor Correction (PFC) controller using single-stage flyback topology. Primary-side regulation and single-stage topology minimize cost, reduce external components and such as input bulk capacitor and feedback circuitry. 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 Discontinuous Conduction Mode (DCM) operation with higher efficiency and simple design. FLS3217N provides protections such as open LED, short LED and over temperature.

. This document contains a general description of the FLS3217N, the power supply

MAX

RMS

– 265V

.

and there is one DC output with a constant current of 270mA at

RMS

1.2. Features

 Cost-Effective Solution without input bulk capacitor or feedback circuitry  Power Factor Correction  Integrated Power MOSFET  Accurate Constant-Current (CC) Control: Independent Online Voltage, Output-

Voltage, and Magnetizing Inductance Variation

 Linear Frequency Control for Better Efficiency and Simple Design  Open-/ Short-LED Protection  Cycle-by-Cycle Current Limiting  Over-Temperature Protection with Auto Restart  Low Startup Current: 20μA  Low Operating Current: 5mA  V  V  Application Voltage Range: 80V

Over-Voltage Protection

DD

Under-Voltage Lockout (UVLO)

DD

~ 308VAC

AC

1.3. Internal Block Diagram

Figure 1. Internal Block Diagram

2. General Specifications for Evaluation Board

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

Table 1. Evaluation Board Specifications for LED Lighting Lamp

Description Symbol Value Comments

V

90V Minimum Input Voltage

IN.MIN

V

Input

Voltage

Frequency

Voltage Current

Output

Current

Efficiency

PF/THD

Temperature

FLS3217N T

Rectifier T

V

OUT.NOMINAL

I

OUT.NOMINAL

CC Deviation

Eff

PF/THD

265V Maximum Input Voltage

IN.MAX

IN.NOMINAL

120V / 230V Nominal Input Voltage

fIN 60Hz / 50Hz Line Frequency

V

11V Minimum Output Voltage

OUT.MIN

28V Maximum Output Voltage

OUT.MAX

24V Rated Output Voltage

270mA Rated Output Current

< ±2.78% Line Input Voltage Change: 90~265V

< ±2.60% Output Voltage Change: 11~28V

Eff

90VAC

120VAC

140VAC

180VAC

230VAC

85.35% Efficiency at 265VAC Line Input Voltage

265VAC

90VAC

120VAC

140VAC

180VAC

230VAC

265VAC

54.9ºC Main Controller Temperature

FLS3217N

47.7ºC Secondary Diode Temperature

Rectifier

84.96% Efficiency at 90VAC Line Voltage

86.55% Efficiency at 120VAC Line Input Voltage

86.86% Efficiency at 140VAC Line Input Voltage

86.90% Efficiency at 180VAC Line Input Voltage

86.19% Efficiency at 230VAC Line Input Voltage

0.99 / 12.71% PF/THD at 90VAC Line Input Voltage

0.99 / 10.46% PF/THD at 120VAC Line Input Voltage

0.98 / 11.10% PF/THD at 140VAC Line Input Voltage

0.97 / 14.01% PF/THD at 180VAC Line Input Voltage

0.94 / 16.47% PF/THD at 230VAC Line Input Voltage

0.91 / 18.89% PF/THD at 265VAC Line Input Voltage

AC

2.1. Photographs of Evaluation Board

Figure 2. Top View (Dimensions: 59.9mm (L) x 25.5mm (W) x 15.0mm (H))

Figure 3. Bottom View (Dimensions: 59.9mm (L) x 25.5mm (W) x 15.0mm (H))

2.2. Printed Circuit Board

Figure 4. Top Side

Unit: mm

Figure 5. Bottom Side

2.3. Schematic

Figure 6. Evaluation Board Schematic

2.4. Bill of Materials

Item

No.

1 BD1 MB6S 1 Bridge Diode

2 CF1, CF2 PX473K3IC2 2 473 / 275VAC, X-Capacitor Carli

3 CS1 C1206C102KDRACTU 1 102 / 1kV, SMD Capacitor 3216 Samwha

4 CY1 SCFz2E472M10BW 1 472 / 250V, Y-Capacitor Samwha

5 CO1 KMG 330µF / 35V 1

6 C1 MPE 400V / 103K 1 103 / 400V, Film Capacitor Sungho

7 C2 KMG 10µF / 35V 1

8 C3 C0805C104K3RACTU 1 104 / 25V, SMD Capacitor 2012 Kemet

9 C4 C0805C200M3GACTU 1 200 / 25V, SMD Capacitor 2012 Kemet

10 C5 C1206C205K3PACTU 1 205 / 25V, SMD Capacitor 2012 Kemet

11 DS1, D1 RS1M 2 1A / 1000V, Diode

12 DO1 ES3D 1 3A / 200V, Fast Rectifier

13 F1 SS-5-1A 1 1A / 250V, Fuse Bussmann

14 LF1 R06103KT00 1 10mH, 8Ø Filter inductor Bosung

15 MOV1 SVC 471D07 1 Varistor Samwha

16 RS1, RS2 RC1206JR-07200KL 2 200kΩ, SMD Resistor 3216 Yageo

17 RCS1 RC1206JR-072R2L 1 2.2Ω, SMD Resistor 3216 Yageo

18 RCS2 RC1206JR-072RL 1 2.0Ω, SMD Resistor 3216 Yageo

19 RO1 RC1206JR-0720KL 1 20kΩ, SMD Resistor 3216 Yageo

20 R2, R3, R4 RC1206JR-07150KL 3 150kΩ, SMD Resistor 3216 Yageo

21 R1 RC1206JR-07100KL 1 100kΩ, SMD Resistor 3216 Yageo

22 R5 RC1206JR-0724KL 1 24kΩ, SMD Resistor 3216 Yageo

23 R6 RC1206JR-070RL 1 0Ω, SMD Resistor 3216 Yageo

24 T1 RM6 1 Transformer TDK

25 U1 FLS3217N 1 Main Controller

Part

Reference

Value Qty. Description Manufacturer

Fairchild

Semiconductor

330µF / 35V, Electrolytic

Capacitor

10µF / 35V, Electrolytic

Capacitor

Samyoung

Fairchild

Semiconductor

Fairchild

Semiconductor

Fairchild

Semiconductor

2.5. Transformer Design

54

3

6

21

Figure 7. Transformer Bobbin Structure and Pin Configuration

Figure 8. Transformer Winding Structure

Table 2. Winding Specifications

Winding Pin (S → F) Wire Tu r n s Winding Method

No.

N

1

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

3

P1

NS

2  6 0.2φ 52 Ts Solenoid Winding

NS +  NS- 0.25φ (TIW) 26 Ts Solenoid Winding

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

N

5

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

7

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

P1

N

A

6  1 0.2φ 26 Ts Solenoid Winding

5  3 0.2φ 20 Ts Solenoid Winding

Table 3. Electrical Characteristics

Pin Specification Remark

Inductance 2 – 1 1.4mH ±10% 60kHz, 1V

Leakage 2 – 1 10µH 60kHz, 1V Short All Output Pins

3. Performance of Evaluation Board

Table 4. Test Condition & Equipments

Ambient Temperature

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-P01(1W) by Everlight

T

= 25°C

A

3.1. Startup

V

Figure 9.

Startup time is 0.92s at VIN=90VAC. The results were measured using actual LED load. Startup time, C1 [V

], C2 [VIN], C3 [V

DD

OUT

], C4 [I

OUT

].

920ms 667ms

=90VAC / 60Hz Figure 10.

IN

=120VAC / 60Hz

IN

349ms 349ms 311ms

Figure 11. VIN=230VAC / 50Hz Figure 12. VIN=265VAC / 50Hz

3.2. Operation Waveforms

V

Output current ripple is under ±220mA with a rated output current of 270mA. The results were measured using actual LED load. Operation waveforms; V

[270mA], C1 [V

Figure 13.

IN

], C2 [VIN], C3 [V

CS

=90VAC / 60Hz Figure 14.

OUT

], C4 [I

OUT

].

: [24V], I

OUT

:

=120VAC / 60Hz

IN

Figure 15.

=220

IN

/ 50Hz Figure 16.

AC

=265

IN

/ 50Hz

AC

3.3. Constant Current Regulation

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

2.8% at each line input voltage. Line regulation at the rated output voltage (24V) is less than 2.6%. The results were measured using E-load.

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 Max. Current Tolerance

90V

[60Hz] 262mA 276mA ±2.60%

AC

120V

140V

180V

230V

265V

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

Output

Voltage

26V 263mA 275mA 274mA 272mA 270mA 264mA ±2.41%

24V 263mA 275mA 275mA 271mA 271mA 265mA ±2.23%

22V 262mA 276mA 277mA 270mA 273mA 267mA ±2.60%

20V 262mA 273mA 271mA 272mA 269mA 262mA ±2.78%

[60Hz] 272mA 276mA ±0.73%

AC

[60Hz] 269mA 278mA ±1.65%

AC

[50Hz] 266mA 272mA ±1.12%

AC

[50Hz] 263mA 273mA ±1.87%

AC

[50Hz] 259mA 267mA ±1.52%

AC

90V

AC

[60Hz]

120VAC

[60Hz]

140VAC

[60Hz]

180VAC

[50Hz]

220VAC

[50Hz]

265VAC

[50Hz]

Tolerance

3.4. Short-LED / Open LED Protections

In short-LED condition, the OCP level is reduced from 0.7V to 0.2V because FLS3217N lowers OCP level when V

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

S

The results were measured using actual LED load. Short-LED condition, C1: [V

[V

], C3: [V

IN

], C4: [I

OUT

].

Figure 18. VIN=90VAC / 60Hz Figure 19. VIN=120VAC / 60Hz

], C2:

DD

Figure 20. VIN=230VAC / 50Hz Figure 21. VIN=265VAC / 50Hz

In open-LED condition, output voltage is limited around 30V by OVP in V

. Output

DD

over-voltage protection level can be controlled by the turns ratio of auxiliary and secondary windings. The results were measured by using actual LED load. Open-LED condition; C1: [V

], C2: [VIN], C3: [V

DD

OUT

], C4: [I

OUT

].

Figure 22. VIN=90VAC / 60Hz Figure 23. VIN=120VAC / 60Hz

Figure 24. VIN=230VAC / 50Hz Figure 25. VIN=265VAC / 50Hz

3.5. System Efficiency

Power efficiency is 84.96% ~ 86.90% in 90 ~ 265VAC input voltage range. The results were measured 30 minutes after startup using actual LED load.

Efficiency

90.0%

85.0%

80.0%

75.0%

70.0%

65.0%

84.96%

86.55%

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

86.86%

86.90%

86.19%

85.35%

Figure 26. System Efficiency

Table 7. System Efficiency

Input Voltage Input Power

90VAC [60Hz] 7.46W 264mA 24.02V 6.34W 84.96%

120VAC [60Hz] 7.72W 277mA 24.13V 6.68W 86.55%

140VAC [60Hz] 7.65W 275mA 24.12V 6.65W 86.86%

Output

Current

Output

Voltage

Output

Power

180VAC [50Hz] 7.54W 272mA 24.07V 6.55W 86.90%

220VAC [50Hz] 7.56W 271mA 24.06V 6.52W 86.19%

265VAC [50Hz] 7.49W 266mA 24.02V 6.39W 85.35%

Efficiency

3.6. Power Factor and Total Harmonic Distortion

FLS3217N shows excellent power factor and performance. Total harmonic discharge is much less than the 20% specification. The results were measured 30 minutes after startup by using actual LED load.

Figure 27. Power Factor and Total Harmonic Distortion

Table 8. Power Factor and Total Harmonic Distortion

Input Voltage Output Current Output Voltage Power Factor THD

90VAC [60Hz] 264mA 24.02V 0.99 12.71%

120VAC [60Hz] 277mA 24.13V 0.99 10.46%

140VAC [60Hz] 275mA 24.12V 0.98 11.10%

180VAC [50Hz] 272mA 24.07V 0.97 14.01%

230VAC [50Hz] 271mA 24.06V 0.94 16.47%

265VAC [50Hz] 266mA 24.02V 0.91 18.89%

3.7. Operating Temperature

V

Temperature of the all components on this board is less than 55ºC. The results were measured 60 minutes after startup using actual LED load.

Transformer: 50.0 ºC

FLS3217N: 54.9 ºC

Figure 28. Board Temperature Top;

V

OUT

[24V], I

[270mA]

OUT

[90

IN

Bottom Top

Rectifier: 47.4 ºC

AC

],

Figure 29. Board Temperature Bottom;

V

[90VAC], V

IN

OUT

[24V], I

[270mA]

OUT

Bottom Top

Transformer: 45.1 ºC

FLS3217N: 52.6 ºC

Figure 30. Board Temperature Top; VIN [265VAC],

V

OUT

[24V], I

[270mA]

OUT

Figure 31. Board Temperature Bottom, V

[265V

Rectifier: 47.7 ºC

], V

OUT

[24V], I

AC

[270mA]

OUT

IN

3.8. Electromagnetic Interference (EMI)

The all measurement was conducted in observance of EN55022 criteria. The results were measured 60 minutes after startup by using actual LED load.

Figure 32. VIN=110VAC, V

OUT

[24V], I

OUT

[270mA]

Figure 33. VIN=220VAC, V

OUT

[24V], I

[270mA]

OUT

4. Revision History

Rev. Date Description

1.0.0 June 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.

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.

Fairchild FEB-L041 service manual

Specifications and Main Features

Frequently Asked Questions

User Manual