LM3445 - 230VAC, 6W- 15W Isolated Flyback LED DriverAN-2069
LM3445 - 230VAC, 6W- 15W
Isolated Flyback LED Driver
Introduction
This demonstration board highlights the performance of a
LM3445 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
power supply. The key performance characteristics under
typical operating 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 LM3445 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.
Performance Specifications
to 265 V
RMS
, 50 Hz input
RMS
National Semiconductor
Application Note 2069
Montu Doshi
November 23, 2010
Key Features
•
Drop-in compatibility with TRIAC dimmers
•
Line injection circuitry enables PFC values greater than
LM3445 230VAC, 8W Isolated Flyback LED Driver Demo Board Schematic
AN-2069
Warning:
Warning:
Warning:
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The LM3445 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.
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 evaliation board
(using 1:1 isolation line isolation transformer) rather than the oscilloscope is highly recommended.
The LM3445 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.
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LM3445 Device Pin-Out
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Pin Description 10 Pin MSOP
Pin #NameDescription
1ASNSPWM output of the triac dim decoder circuit. Outputs a 0 to 4V PWM signal with a duty cycle proportional to the triac
dimmer on-time.
2FLTR1First filter input. The 120Hz PWM signal from ASNS is filtered to a DC signal and compared to a 1 to 3V, 5.85 kHz
ramp to generate a higher frequency PWM signal with a duty cycle proportional to the triac dimmer firing angle. Pull
above 4.9V (typical) to tri-state DIM.
3DIMInput/output dual function dim pin. This pin can be driven with an external PWM signal to dim the LEDs. It may also
be used as an output signal and connected to the DIM pin of other LM3445 or LED drivers to dim multiple LED
circuits simultaneously.
4COFFOFF time setting pin. A user set current and capacitor connected from the output to this pin sets the constant OFF
time of the switching controller.
5FLTR2Second filter input. A capacitor tied to this pin filters the PWM dimming signal to supply a DC voltage to control the
LED current. Could also be used as an analog dimming input.
6GNDCircuit ground connection.
7ISNSLED current sense pin. Connect a resistor from main switching MOSFET source, ISNS to GND to set the maximum
LED current.
8GATEPower MOSFET driver pin. This output provides the gate drive for the power switching MOSFET of the buck
controller.
9V
10BLDRBleeder pin. Provides the input signal to the angle detect circuitry as well as a current path through a switched
Input voltage pin. This pin provides the power for the internal control circuitry and gate driver.
CC
230Ω resistor to ensure proper firing of the triac dimmer.
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Bill of Materials
DesignatorDescriptionManufacturerPart NumberRoHS
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AA1Printed Circuit Board-Y
U1Triac Dimmable Offline LED Driver, PowerWiseNational
Note 1: Original Circuit (6 LEDs operating at 350mA): R21 = 2.7Ω; Modification A (10 LEDs operating at 375mA): R21 = 1.8Ω; Modification B (8 LEDs operating
at 350mA): R21 = 2.2Ω; Modification C (4 LEDs operating at 315mA): R21 = 3.9Ω
Note 2: The output power can be varied to acheive desired LED current by interpolating R14 values between the maximum of 3.9 Ω and minimum of 1.8 Ω
Note 3: The maximum output voltage is clamped to 36 V. For operating LED string voltage > 36 V, replace D6 with suitable alternative
(500 mV/div); Time (4 µs/div)
, 6 LEDs, I
RMS
LED
= 350mA)
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30126921
Ch1: Output Voltage (10 V/div); Ch3: LED Current
(100 mA/div); Time (4 ms/div)
FLTR2 (Pin-5) and ISNS (Pin-7) Voltage
(VIN=230V
, 6 LEDs, I
RMS
= 350mA
LED
Ch1: FLTR2 Voltage (200 mV/div); ISNS Voltage
(200 mV/div); Time (4 µs/div)
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30126920
30126922
PCB Layout
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Top Layer
Bottom Layer
30126907
30126908
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Experimental Results
The LED driver is designed to accurately emulate an incandescent light bulb and therefore behave as an emulated
resistor. The resistor value is determined based on the LED
string configuration and the desired output power. The circuit
then operates in open-loop, with a fixed duty cycle based on
a constant on-time and constant off-time that is set by selecting appropriate circuit components. Like an incandescent
lamp, the driver is compatible with both forward and reverse
phase dimmers.
NON-DIMMING PERFORMANCE
In steady state, the LED string voltage is measured to be 20.5
V and the average LED current is measured as 350 mA. The
measured to be 194 mA
ripple is a function of the value of energy storage capacitors
connected across the output port and the TRIAC firing angle.
The ripple current can be reduced by increasing the value of
energy storage capacitor or by increasing the LED string voltage. With TRIAC dimmers, the ripple magnitude is directly
proportional to the input power and therefore reduces at lower
LED current.
The LED driver switching frequency is measured to be close
to the specified 67 kHz. The circuit operates with a constant
duty cycle of 0.21 and consumes near 8.75 W of input power.
The driver steady state performance for an LED string consisting of 6 series LEDs without using a triac dimmer is
summarized in the following table.
at full load. The magnitude of the
pk-pk
100 Hz current ripple flowing through the LED string was
MEASURED EFFICIENCY AND LINE REGULATION (6 LEDS, NO TRIAC DIMMER)
VIN (V
)IIN (mA
RMS
)PIN(W)V
RMS
(V)I
OUT
(mA)P
LED
(W)Efficiency (%) Power Factor
OUT
18031.735.3519.67221.644.3681.40.9375
19033.395.9619.85244.824.8681.50.9394
20035.116.6120.04269.165.3981.60.9493
21036.857.3020.22294.825.9681.60.9493
22038.538.0120.40321.266.5581.80.9451
23040.188.7520.56348.707.1782.00.9463
24041.759.5020.74375.707.7982.00.9477
25043..3910.3020.90404.828.4682.10.9490
26045.0711.1421.05434.489.1582.00.9500
DIMMING PERFORMANCE
The LED driver is capable of matching or exceeding the dimming performance of an incandescent lamp. Using a simple
rotary TRIAC dimmer, smooth and near logarithmic dimming
performance is achieved. By varying the firing angle of the
MEASURED DIMMING PERFORMANCE
VIN (V
)VO (V)I
RMS
229.3920.51343.17.04
220.4720.35320.86.53
210.2420.16294.85.94
199.0519.98266.85.33
190.3219.80245.84.87
180.3319.61222.74.37
170.5119.42200.13.89
156.3919.31187.43.62
149.1119.15171.63.29
140.3518.97154.02.92
129.6118.75133.12.50
119.718.53115.32.14
110.1718.3399.11.82
100.5518.1183.51.51
90.7517.8768.81.23
79.7217.5953.10.93
70.4217.3440.80.71
60.9117.0830.10.81
49.9416.7719.80.33
45.0416.6416.00.27
TRIAC dimmer and measuring the corresponding input and
output parameters, the dimming performance of the demonstration board driving 6 LEDs is summarized in the table
below.
(mA)P
LED
OUT
(W)
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CURRENT THD
Dimming Characteristics
The LED driver is able to achieve close to unity power factor
(P.F. ~ 0.94) which meets Energy Star requirements. This
design also exhibits low current harmonics as a percentage
Current Harmonic vs. EN/IEC61000-3-2 Class C Limits
30126924
of the fundamental current (as shown in the following figure)
and therefore meets the requirements of the IEC 61000-3-2
Class-3 standard.
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Circuit Operation With Rotary
Forward Phase Triac Dimmer
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Input waveforms at full brightness setting
Ch1: Input Voltage (100 V/div); Ch3: Input Current
30126925
(20 mA/div); Time (4 ms/div)
Input waveforms at half brightness setting (90° firing angle)
Output waveforms at full brightness setting
Ch1: Output Voltage (10 V/div); LED Current
30126928
(100 mA/div); Time (4 ms/div)
Output waveforms at half brightness setting (90° firing angle)
Ch1: Input Voltage (100 V/div); Ch3: Input Current
30126926
(20 mA/div); Time (4 ms/div)
Input waveforms at minimum brightness setting
Ch1: Input Voltage (100 V/div); Ch3: Input Current
30126927
(20 mA/div); Time (4 ms/div)
Ch1: Output Voltage (10 V/div); LED Current
30126929
(100 mA/div); Time (4 ms/div)
Output waveforms at minimum brightness setting
Ch1: Output Voltage (10 V/div); LED Current
30126930
(100 mA/div); Time (4 ms/div)
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Electromagnetic Interference (EMI)
The EMI input filter of this evaluation board is configured as
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shown in the following circuit diagram.
FIGURE 1. Input EMI Filter and Rectifier Circuit
30126931
In order to get a quick estimate of the EMI filter performance,
only the PEAK conductive EMI scan was measured and the
FIGURE 2. Peak Conductive EMI scan per CISPR-22, Class B Limits
Note 4: CISPR 15 compliance pending
data was compared to the Class B conducted EMI limits published in FCC – 47, section 15.(Note 4)
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Thermal Analysis
The board temperature was measured using an IR camera
(HIS-3000, Wahl) while running under the following conditions:
VIN = 230 V
RMS
I
= 348 mA
LED
# of LEDs = 6
P
= 7.2 W
OUT
The results are shown in the following figures.
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FIGURE 3. Top Side Thermal Scan
30126933
FIGURE 4. Bottom Side Thermal Scan
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30126934
Circuit Analysis and Explanations
INJECTING LINE VOLTAGE INTO FILTER-2 (ACHIEVING
AN-2069
PFC > 0.94)
If a small portion (750mV to 1.00V) of line voltage is injected
at FLTR2 of the LM3445, the circuit is essentially turned into
a constant power flyback as shown in Figure 5.
FIGURE 5. Line Voltage Injection Circuit
The LM3445 works as a constant off-time controller normally,
but by injecting the 1.0VPk rectified AC voltage into the FLTR2
30126935
pin, the on-time can be made to be constant. With a DCM
Flyback, Δi needs to increase as the input voltage line increases. Therefore a constant on-time (since inductor L is
constant) can be obtained.
By using the line voltage injection technique, the FLTR2 pin
has the voltage wave shape shown in Figure 6 on it with no
triac dimmer in-line. Voltage at V
below 1.25V. At 1.25V current limit is tripped. C11 is small
peak should be kept
FLTR2
enough not to distort the AC signal but adds a little filtering.
Although the on-time is probably never truly constant, it can
be observed in Figure 7 how (by adding the rectified voltage)
the on-time is adjusted.
30126937
FIGURE 6. FLTR2 Waveform with No Dimmer
For this evaluation board, the following resistor values are
used:
R3 = R8 = 309 kΩ
R20 = 1.91 kΩ
Therefore the voltages observed on the FLTR2 pin will be as
follows for listed input voltages:
For VIN = 180V
For VIN = 230V
For VIN = 265V
RMS
RMS
RMS
, V
FLTR2, Pk
, V
FLTR2, Pk
, V
FLTR2, Pk
= 0.78V
= 1.00V
= 1.15V
Using this technique, a power factor greater than 0.94 can be
achieved without additional passive active power factor control (PFC) circuitry.
FIGURE 7. Typical Operation of FLTR2 Pin
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Notes
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Notes
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