Texas Instruments Incorporated AN-2097 User's Guide

AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED

1 Introduction

This demonstration board highlights the performance of a LM3444 based Flyback LED driver solution that can be used to power a single LED string consisting of 4 to 10 series connected LEDs from an 180 V to 265 V conditions are summarized in this application note.

This is a four-layer board using the bottom and top layer for component placement. The demonstration board can be modified to adjust the LED forward current, the number of series connected LEDs that are driven and the switching frequency. Refer to the LM3444 datasheet for detailed instructions.

A bill of materials is included that describes the parts used on this demonstration board. A schematic and layout have also been included along with measured performance characteristics.

2 Key Features

• Line injection circuitry enables PFC values greater than 0.98

• Adjustable LED current and switching frequency

• Flicker free operation

, 50 Hz input power supply. The key performance characteristics under typical operating

RMS

User's Guide

SNVA462F–November 2010–Revised May 2013

Driver

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3 Applications

• Solid State Lighting

• Industrial and Commercial Lighting

• Residential Lighting

4 Performance Specifications

Based on an LED Vf= 3.6V

Symbol Parameter Min Typ Max

OUT

LED

OUT

Input voltage 180 V

LED string voltage 13 V 21.5 V 36 V

LED string average current - 350 mA -

Output power - 7.5 W -

Switching frequency - 67 kHz -

RMS

230 V

RMS

265 V

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PowerWise is a trademark of Texas Instruments. All other trademarks are the property of their respective owners.

SNVA462F–November 2010–Revised May 2013 AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver

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FILTER

VCC

COFF

FILTER

VCC

GATE

ISNS

GND

V+

LED +

LED ±

LINE

NEUTRAL

V+

VR1

RT1

C4 C5

R12

INPUT EMI FILTER AND RECTIFIER

R3R8R2

R13

C10

C11

C12

R14

C13

R15

D10

C15C14

C18R20

R19

R22 R21

R23

C20

PGND SGND

LM3444 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic

Figure 1. Demo Board

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5 LM3444 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic

AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver SNVA462F–November 2010–Revised May 2013

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LM3444 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic

WARNING

The LM3444 evaluation board has exposed high voltage components that present a shock hazard. Caution must be taken when handling the evaluation board. Avoid touching the evaluation board and removing any cables while the evaluation board is operating.

WARNING

The ground connection on the evaluation board is NOT referenced to earth ground. If an oscilloscope ground lead is connected to the evaluation board ground test point for analysis and the mains AC power is applied (without any isolation), the fuse (F1) will fail open. For bench evaluation, either the input AC power source or the bench measurement equipment should be isolated from the earth ground connection. Isolating the evaluation board (using 1:1 line isolation transformer) rather than the oscilloscope is highly recommended.

WARNING

The LM3444 evaluation board should not be powered with an open load. For proper operation, ensure that the desired number of LEDs are connected at the output before applying power to the evaluation board.

SNVA462F–November 2010–Revised May 2013 AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver

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SNS

GATE

COFF

5 6FILTER GND

LM3444 Device Pin-Out

6 LM3444 Device Pin-Out

7 Pin Descriptions – 10 Pin VSSOP

Pin # Name Description

1 NC No internal connection. 2 NC No internal connection. 3 NC No internal connection. 4 COFF OFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant

5 FILTER Filter input. A capacitor tied to this pin filters the error amplifier. Could also be used as an analog dimming

6 GND Circuit ground connection. 7 ISNS LED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the

8 GATE Power MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck

9 V

10 NC No internal connection.

OFF time of the switching controller.

input.

maximum LED current.

controller. Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.

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8 Bill of Materials

Designator Description Manufacturer Part Number RoHS

AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver SNVA462F–November 2010–Revised May 2013

U1 Offline LED Driver, PowerWise™ Texas Instruments LM3444 Y C1 Ceramic, X7R, 250VAC, 10% Murata Electronics DE1E3KX332MA5BA01 Y

C2 Ceramic, Polypropylene, 400VDC, 10% WIMA MKP10-.033/400/5P10 Y C3 CAP, CERM, 330pF, 630V, +/-5%, C0G/NP0, 1206 TDK C3216C0G2J331J Y C4 Ceramic, X7R, 250V, X2, 10%, 2220 Murata Electronics GA355DR7GF472KW01L Y

C5 CAP, Film, 0.033µF, 630V, +/-10%, TH EPCOS Inc B32921C3333K Y

C9, C11 CAP, CERM, 1µF, 50V, +/-10%, X7R, 1210 MuRata GRM32RR71H105KA01L Y

C10 CAP, CERM, 0.47µF, 50V, +/-10%, X7R, 0805 MuRata GRM21BR71H474KA88L Y C12 Aluminium Electrolytic, 680uF, 35V, 20%, Nichicon UHE1V681MHD6 Y C13 CAP, CERM, 1µF, 35V, +/-10%, X7R, 0805 Taiyo Yuden GMK212B7105KG-T Y C14 CAP, CERM, 0.1µF, 25V, +/-10%, X7R, 0603 MuRata GRM188R71E104KA01D Y C15 CAP, TANT, 47uF, 16V, +/-10%, 0.35 ohm, 6032-28 AVX TPSC476K016R0350 Y

C18 CAP, CERM, 2200pF, 50V, +/-10%, X7R, 0603 MuRata GRM188R71H222KA01D Y C20 CAP, CERM, 330pF, 50V, +/-5%, C0G/NP0, 0603 MuRata GRM1885C1H331JA01D Y

D1 DIODE TVS 250V 600W UNI 5% SMD Littelfuse P6SMB250A Y

SMD

North America

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Bill of Materials

Designator Description Manufacturer Part Number RoHS

D2 Diode, Switching-Bridge, 600V, 0.8A, MiniDIP Diodes Inc. HD06-T Y D3 Diode, Silicon, 1000V, 1A, SOD-123 Comchip CGRM4007-G Y

Technology

D4 Diode, Schottky, 100V, 1A, SMA STMicroelectronics STPS1H100A Y

D5, D10 Diode, Zener, 13V, 200mW, SOD-323 Diodes Inc DDZ13BS-7 Y

D6 Diode, Zener, 36V, 550mW, SMB ON Semiconductor 1SMB5938BT3G Y

D7, D8, D9 Diode, Schottky, 100V, 150 mA, SOD-323 STMicroelectronics BAT46JFILM Y

F1 Fuse, 500mA, 250V, Time-Lag, SMT Littelfuse Inc 0443.500DR Y H1, H2, H5, H6 Standoff, Hex, 0.5"L #4-40 Nylon Keystone 1902C Y H3, H4, H7, H8 Machine Screw, Round, #4-40 x 1/4, Nylon, Philips B&F Fastener NY PMS 440 0025 PH Y

panhead Supply J1, J2 Conn Term Block, 2POS, 5.08mm PCB Phoenix Contact 1715721 Y L1, L2 Inductor, Radial Lead Inductors, Shielded, 4.7mH, TDK Corporation TSL080RA-472JR13-PF Y

130mA, 12.20ohm, 7.5mm Radial,

LED+, LED-, Terminal, 22 Gauge Wire, Terminal, 22 Guage Wire 3M 923345-02-C Y

TP7, TP8

Q1 MOSFET, N-CH, 600V, 200mA, SOT-223 Fairchild FQT1N60CTF_WS Y

Semiconductor Q2 Transistor, NPN, 300V, 500mA, SOT-23 Diodes Inc. MMBTA42-7-F Y Q3 MOSFET, N-CH, 650V, 800mA, IPAK Infineon SPU01N60C3 Y

Technologies R1 RES, 221 ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW1206221RFKEA Y

R2, R7 RES, 200k ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW1206200KFKEA Y R3, R8 RES, 309k ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW1206309KFKEA Y

R4, R12 RES, 10k ohm, 5%, 0.25W, 1206 Vishay-Dale CRCW120610K0JNEA Y

R13 RES, 33.0 ohm, 1%, 0.25W, 1206 Vishay-Dale CRCW120633R0FKEA Y R14 RES, 10 ohm, 5%, 0.125W, 0805 Vishay-Dale CRCW080510R0JNEA Y R15 RES, 10.0k ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW060310K0FKEA Y R19 RES, 10 ohm, 5%, 0.1W, 0603 Vishay-Dale CRCW060310R0JNEA Y R20 RES, 1.91k ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW06031K91FKEA Y R21 RES, 2.70 ohm, 1%, 0.25W, 1206 Panasonic ERJ-8RQF2R7V Y R22 RES, 10.7 ohm, 1%, 0.125W, 0805 Vishay-Dale CRCW080510R7FKEA Y R23 RES, 324k ohm, 1%, 0.1W, 0603 Vishay-Dale CRCW0603324KFKEA Y RT1 Current Limitor Inrush, 60Ohm, 20%, 5mm Raidal Cantherm MF72-060D5 Y

T1 FLBK TFR, 2.07 mH, Np=140T, Ns=26T, Na= 20T Wurth Elektornik 750815040 REV 1 Y

TP9, TP10 Terminal, Turret, TH, Double Keystone 1502-2 Y

Electronics

VR1 Varistor 275V 55J 10mm DISC EPCOS Inc S10K275E2 Y

SNVA462F–November 2010–Revised May 2013 AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver

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Transformer Design

9 Transformer Design

Mfg: Wurth Electronics, Part #: 750815040 Rev. 01

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Parameter Test Conditions Value

D.C. Resistance (3-1) 20°C 1.91 Ω ± 10% D.C. Resistance (6-4) 20°C 0.36 Ω ± 10%

D.C. Resistance (10-13) 20°C 0.12 Ω ± 10%

Inductance (3-1) 10 kHz, 100 mVAC 2.12 mH ± 10% Inductance (6-4) 10 kHz, 100 mVAC 46.50 µH ± 10%

Inductance (10-13) 10 kHz, 100 mVAC 74.00 µH ± 10%

Leakage Inductance (3-1) 100 kHz, 100 mAVAC (tie 6+4, 10+13) 18.0 µH Typ., 22.60 µH Max.

Dielectric (1-13) tie (3+4), 4500 VAC, 1 second 4500 VAC, 1 minute

Turns Ratio (3-1):(6-4) 7:1 ± 1% Turns Ratio (3-1):(10:13) 5.384:1 ± 1%

AN-2097 LM3444 - 230VAC, 8W Isolated Flyback LED Driver SNVA462F–November 2010–Revised May 2013

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+ 13 hidden pages

Texas Instruments Incorporated AN-2097 User's Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Introduction

2 Key Features

3 Applications

4 Performance Specifications

5 LM3444 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic

6 LM3444 Device Pin-Out

7 Pin Descriptions – 10 Pin VSSOP

8 Bill of Materials

9 Transformer Design