user guide for febfl7921rmx l65u100a evaluation board · user guide for febfl7921rmx_l65u100a...

© 2015 Fairchild Semiconductor Corporation FEBFL7921RMX_L65U100A • Rev. 1.0

User Guide for

FEBFL7921RMX_L65U100A

Evaluation Board

LED Driver for 100 W Smart Lamp with

High PF and Low THD

Featured Fairchild Product:

FL7921R

Direct questions or comments about this evaluation board to:

“Worldwide Direct Support”

Fairchild Semiconductor.com

http://www.fairchildsemi.com/cf/

© 2015 Fairchild Semiconductor Corporation 2 FEBFL7921RMX_L65U100A • Rev. 1.0

Table of Contents

1. Introduction ............................................................................................................................... 3

1.1. Description ....................................................................................................................... 3 1.2. Features ............................................................................................................................ 3 1.3. Block Diagram ................................................................................................................. 4

2. Evaluation Board Specifications ............................................................................................... 5

3. Photographs............................................................................................................................... 6

4. Printed Circuit Board ................................................................................................................ 7

5. Schematic .................................................................................................................................. 8

6. Bill of Materials ........................................................................................................................ 9

Bill of Materials (Continued) ...................................................................................................... 10

Bill of Materials (Continued) ...................................................................................................... 11

7. Transformer and Winding Specifications ............................................................................... 12

7.1. Flyback Transformer ...................................................................................................... 12 7.2. Boost Inductor ................................................................................................................ 13

8. Test Conditions & Test Equipment......................................................................................... 14

9. Performance of Evaluation Board ........................................................................................... 15

9.1. System Efficiency and No Load Power Consumption ................................................... 15 9.2. Power Factor [PF] and Total Harmonic Distortion [THD] ............................................ 17

9.3. Harmonics Performance Analysis .................................................................................. 18 9.4. Constant Current & Constant Voltage (CC / CV) .......................................................... 20 9.5. Analog Dimming ............................................................................................................ 22

9.6. Temperature Checking Results ...................................................................................... 24 9.7. Startup Behavior of PFC and PWM ............................................................................... 25

9.8. Operation Waveforms .................................................................................................... 28 9.9. Short-Circuit Protection ................................................................................................. 31 9.10. Over-Temperature Protection (External Detection) ................................................... 32 9.11. Voltage Stress of the MOSFET & Rectifier ............................................................... 33

9.12. EMI ............................................................................................................................. 35

10. Revision History ..................................................................................................................... 37


This user guide supports the evaluation kit for the FL7921R. It should be used in

conjunction with the FL7921R datasheets and technical support team. Please visit

Fairchild’s website at www.fairchildsemi.com.

1. Introduction

This document describes the proposed solution for a universal LED driver using the

FL7921R CRM PFC and QR PWM controller. The wide input voltage range is 90 VRMS –

305 VRMS and output is constant voltage/current of 50 V / 2 A. This document contains

general description of FL7921R, the LED driver specification, schematic, a bill of

materials, and the typical operating characteristics.

1.1. Description

The highly integrated FL7921R combines a Power Factor Correction (PFC) controller

and a Quasi-Resonant PWM controller. For PFC, FL7921R uses a controlled on-time

technique to provide a regulated DC output voltage and to perform natural power factor

correction. An innovative THD optimizer reduces input current distortion at zero-

crossing duration to improve THD performance. The PFC function is always on

regardless of the PWM stage load condition to ensure that high PF can be achieved at

light load condition. For PWM, FL7921R provides several functions to enhance power

system performance: valley detection, green-mode operation, high / low line over-power

compensation. Protection functions include secondary-side open-loop and over-current

with auto-recovery protection, external recovery triggering, adjustable over-temperature

protection through the RT pin and external NTC resistor, internal over-temperature

shutdown, VDD pin OVP, DET pin over-voltage for output OVP, and brown-in / out for

AC input voltage UVP. All protections are auto recovery mode except PWM current

sense pin open protection.

1.2. Features

Integrated PFC and Flyback Controller

Critical-Mode PFC Controller

Zero-Current Detection for PFC Stage

Quasi-Resonant Operation for PWM Stage

Internal Minimum tOFF 8 µs for QR PWM Stage

Internal 10 ms Soft-Start for PWM

High / Low Line Over-Power Compensation

Auto Recovery Over-Current Protection

Auto Recovery Open-Loop Protection

Auto Recovery Over-Temperature Protection

Adjustable Over-Temperature with external NTC through the RT pin

Auto Recovery VDD Pin and Output Voltage OVP


1.3. Block Diagram

CSPWM

2 16 7

3

4

11

5

10

9 12 13

1

8

6

14

2.5V

INV

2.35V

COMP

0.45V

CSPFCBlanking

Circuit

0.82V

Sawtooth

Generator

/tON-max

THD

Optimizer

Multi-Vector Amp.

ZCD

OPFC

DRV

DRV

GND

10V

2.1V/1.75VInhibit

Timer

PFC Zero Current

Detector

VDD

Two Steps

UVLO

18V/10V/7.5V

Internal

Bias

Recovery

OVP

UVP

Disable

Function

0.2V

Restarter

PFC

Current Limit

15.5VLatched or

Recovery

17.5V

OPWM

DET

FB

RT VIN

HV

RANGE

IHV

Debounce

100ms

2.1V/2.45V PFC RANGE Ccontrol

1V/1.3V

2.75V

2.65V

2.75V

RANGE

2.9V

RANGE

4.2V

2R

R

Debounce

Time

100µA

Soft-Start

10ms

PWM

Current Limit

Internal

OTPRecovery

110µs

10ms

0.8V

0.5V

IRT

Prog. OTP

/ Externally Triggering

Blanking

Circuit

Brownout

Q

QSET

CLR

S

R

Q

QSET

CLR

S

R

VB & clamp

Vcomp to

1.6V

FB OLPTimer

50msVB

Over0Power

Compensation

Starter

2.25ms

28µs

15 NC

24V

OVP

1.2V

VINV

Startup

S/H

tOFF-MIN

(8µs/37µs/2.25ms)

DET OVP

2.5V

tOFF

Blanking

(4µs)

VDET

Valley

Detector

IDET

1st

Valley

tOFF-MIN

+9µs

Debounce

100ms

Brownout

comparator

Recovery

Output Open-loop (FB pin)

Output Short Circuit (FB pin)

Debounce

70µs

DET pin OVP

VDD pin OVP

Output Over Power/ Overload (FB pin)

Recovery

Recovery

2.1V

IZCD

1V

Recovery

Latched or

Recovery

3V

Latched

CS OVP

RT Pin Prog OTP

RT Pin Externally Triggering

IDET

Figure 1. FL7921R Block Diagram


2. Evaluation Board Specifications

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

Table 1. Summary of Features and Performance

Description Symbol Value Comments

Input Voltage

VIN.MIN 90 VAC Minimum Input Voltage

VIN.MAX 305 VAC Maximum Input Voltage

Frequency fIN 60 Hz / 50 Hz Line Frequency

Output

Voltage VOUT-Max 50 V Maximum Output Voltage

VOUT_Min. 27 V Minimum Output Voltage

Current IOUT-Max 2.0 A Maximum Output Current

IOUT_Min. 0.0 A Minimum Output Current

Efficiency at VOUT= 47 V

(VOUT = 27 V)

Eff90VAC 89.41% (88.93%) Efficiency at 90 VAC Line Input Voltage






Standby Power

Eff90VAC 0.320 W Standby Power at 90 VAC Line Input Voltage






PF / THD at VOUT = 47 V (VOUT = 27 V)

PF/THD 90VAC 0.999 / 3.63%

(0.998 / 5.01%) PF/THD at 90 VAC Line Input Voltage

PF/THD115VAC 0.998 / 4.15%


PF/THD230VAC 0.988 / 6.19%


PF/THD264VAC 0.980 / 7.26%


PF/THD277VAC 0.977 / 7.74%


PF/THD300VAC 0.965 / 12.68%


Temperature at 90 VAC, (277 VAC)

Bridge Diode

TGBU4J 69.9°C (53.5°C) Bridge Diode Temperature at 25°C

MOSFET TFCPF190N60E 55.1ºC (53.3°C) PFC MOSFET Temperature at 25°C

TFCPF400N80Z 62.2°C (54.7°C) Flyback MOSFET Temperature at 25°C

Rectifier TRHRP860 60.0°C (56.1°C) PFC Rectifier Temperature at 25°C

TFFPF20UP30DNTU 69.3°C (70.6°C) Flyback Rectifier Temperature at 25°C


3. Photographs

Figure 2. Photograph (168 x 35 mm

2) Top View

Figure 3. Photograph (168 x 35 mm

2) Bottom View


4. Printed Circuit Board

Figure 4. Top Side

Figure 5. Bottom Side


5. Schematic

Figure 6. Evaluation Board Schematic

12

34

56

78

ABCD

87

65

43

21

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Pre

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ripti

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MOV/471

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83

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2

4

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1

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81

PF

C_V

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R/1

50

K/0

80

5/1

%

C1

C/224P/0805

C5

C/474P/0805

C4

C/3

34

P/0

80

5

R1

3R

/0R

/08

05

PF

C_

VO

+C

12

C/8

2u/5

00

V

1 2

3 4

L1

L/9

00

uH

/TR

N0

00

3

R3

3

R/1R/1206/1%

R3

4

R/1R/1206/1%

R45

R/1R6/1206/1%

R46

R/1R6/1206/1%

1

2 3

Q2

Q/F

CP

19

0N

60

E

21

D3

D/L

L4

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8

21

D2

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HR

P8

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21

D5

D/L

L4

14

8

R2

9

R/1

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/12

06

1

2 3

Q3

Q/F

CPF

40

0N

80

Z

R3

5

R/1

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/2WR

37

R/0R/1206

C18

C/2

22P

/1kV

2 1

D4

D/S

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+C

14

C/3

3u

F/5

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R28

R/0

R/1

206

21

D7

D/1

N49

35

C1

6

C/2

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C

+

C2

1

C/470u/63V

R4

7R

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LE

D+

1 2

34

U3

U/F

OD

81

7A

R4

2R

/0R

/120

6

R4

3

R/1

k/0

805

/1%

AK

R

U4

U/K

A4

31

LZ

NL

C2

3C

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05

R2

1

R/1

00

R/1

20

6

C2

6

C/471P/0805

C2

5

C/N

C

F1

F/4

A/2

50

V

R5

5

R/1.5M/1206

R5

6

R/1.5M/1206

R5

9

R/4

70R

/120

6

C2

7

C/471P/0805

C2

9

C/222P/0805

FL

79

21

10

0W

(50

V/2

A)

R10

R/22K/0805/1%

R52

R/1

82K

/08

05

/1%

+C

22

C/470u/63V

IC_

VD

D

LE

D+

LE

D-

1

HS

1

HS

/2X

97

R9

R/6

8K

/12

06

R5

4R

/68

K/1

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6

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D1

0

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L4

14

8

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0

C/22uF/50V

R58

R/0R/1206

IC_

VD

D1

1 2

C3

C/10P/0805

RA

NG

E1

CO

MP

2

INV

3

CS

PF

C4

CS

PW

M5

OP

FC

6

VD

D7

OP

WM

8

FB

11

RT

12

VIN

13

ZC

D1

4

N.C

.1

5

HV

16

GN

D9

DE

T1

0

U1

U/F

L7

92

1

R3

1

R/3

.6K

/08

05

C6

C/1

02

P/0

80

5TR

2

NT

C/1

00K

R4

R/4

.7M

/12

06

R6

R/4

.7M

/12

06

R1

R/4

.7M

/12

06

R2

R/4

.7M

/12

06

R3

R/8

2K

/08

05

R7

R/1

60

K/0

80

5/1

%

R1

6

R/1

0R

/12

06

R18

R/0

R1

8/2

W

R1

5

R/4

0.2

K/1

20

6

N1

N2

N3

N4

N5

N1

2N

6N

7N

8

N9

N10

N1

1

N1

3N

14

N1

5

N1

6

N1

7

N1

8

N19

N2

2

N23

N24

N2

5

N2

6

N27

N2

8

RANGE

CO

MP

INV

CS

PF

C

CSPWM

OP

FC

OP

WM

DE

T

FB

RT

VIN

ZC

D

HV

N2

1

2 1

D8

D/S

1J

R8

R/0

R/1

20

6

R1

9

R/1

0K

/12

06

R20

R/10K/1206

Q4

Q/MMBT2907A

Q1

Q/M

MB

T2

90

7A

C15

C/104P/63V/1206

N3

9

N4

0

C13

C/104P/63V/1206

13

2

D1

D/F

FPF

20

UP3

0D

N

R38

R/3

30

R/1

206

/1%

R40

R/3

30

R/1

206

/1%

R41

R/3

30

R/1

206

/1%

C1

1

C/4

71P

/1K

V/1

20

6

+C

24 C/NC

L3

L/I

-127

R1

2

R/0

R1

R14

R/3

00k/1

206

R26

R/51K/0805

R1

7

R/1

0K

/080

5

R23

R/8

.2K

/080

5

2 1

D12

D/L

L4148

2

13

Q5

Q/M

MB

T222

2A

21

ZD

1

15V

OU

T1

1

IN1(-

)2

IN1(+

)3

GN

D4

IN2(+

)5

IN2(-

)6

OU

T2

7

VC

C8

U2

LM

290

4

21

D6

D/R

S1D

Nb

Nd

C2

8

C/104P/63V/1206

+C

34

C/22uF/50V

C31

C/104P/1206

C3

2

C/4

73

P/0

805

R2

4

R/1

0K

/08

05

C17

C/1

03

P/0

80

5

LE

D+ R3

0

R /160K /0805/1%

R39

R /7.68K /0805/1%

R27

R /10K /0805

C3

3

C/3

32P/0

80

5

R25

R/7

5K

/0805

2 1

D11

D/L

L4

148

21

D9

D/S

1M

C9

C/0.33u/450V

C7

C/NC

VD

D

Nc

Ne

Ng

Nh

Nk

IN l

No

Np

Nq

Nr

Nz

181

03 4

765

TX

1

TR

AN

S11

_1

1 2

HS

3

HS

/2X

97

1 2

HS

2

HS

/2X

72

12

3

R2

2

10

K

Fly

A-D

IM +

A-D

IM -

A-D

IM +

A-D

IM +

R36

R/1R/1206/1%

C20

C/N

C/0

80

5

R4

4

R/N

C/0

80

5

1

2

CN

3

1

2

CN

2 R32

R/2

4.9

K/0

805

Nj

R1

1 R/1

80K

/08

05

+C

19

C/4.7uF/50V

Vo

Vo

R4

8

R /787K /0805/1%

No


6. Bill of Materials

Item No. Reference No. Part Number Qty. Description Manufacturer

1 R13 RP0805T 0000 1 0 Ω ±5%, 0805 SMD Resistor Taiwan Resistor

2 R39 RP0805T 7681 1 7.68 kΩ ±-1%, 0805 SMD

Resistor Taiwan Resistor

3 R31 RP0805T 3601 1 3.6 kΩ ±1%, 0805 SMD Resistor Taiwan Resistor

4 R43 RP0805T 1001 1 1 kΩ ±5%, 0805 SMD Resistor Taiwan Resistor


6 R17, R24, R27 RP0805T 1002 3 10 kΩ ±5%, 0805 SMD Resistor Taiwan Resistor







13 R7, R30 RP0805T 1603 2 160 kΩ ±1%, 0805 SMD Resistor Taiwan Resistor




17 R8, R28, R37,

R42, R58 RP1206T 0000 5 0 Ω ±5%, 1206 SMD Resistor Taiwan Resistor

18 R45, R46 RP1206T 1R6 2 1.6 Ω ±5%, 1206 SMD Resistor Taiwan Resistor

19 R33, R34, R36 RP1206T 1R 3 1 Ω ±5%, 1206 SMD Resistor Taiwan Resistor

20 R16, R29 RP1206T 10R 2 10 Ω ±5%, 1206 SMD Resistor Taiwan Resistor

21 R38, R40, R41 RP1206T 3300 3 330 Ω ±5%, 1206 SMD Resistor Taiwan Resistor







28 R55, R56 RP1206T 1504 2 1.5 MΩ ±1%, 1206 SMD Resistor Taiwan Resistor

29 R1, R2, R4, R6 RP1206T 4704 4 4.7 MΩ ±5%, 1206 SMD Resistor Taiwan Resistor

30 C3 MLCC100K050B 1 10 pF / 50 V ±10% X7R Taiwan Resistor


Bill of Materials (Continued)


31 C6 MLCC102K050B 1 1 nF / 50 V ±10% X7R Taiwan Resistor



34 C29 MLCC222K050B 1 2.2 nF / 50 V ±10% X7R Taiwan Resistor


36 C33 MLCC332K050B 1 3.3 nF / 50 V ±10% X7R Taiwan Resistor


38 C26, C27 MLCC471K050B 2 470 pF / 50 V ±10% X7R Taiwan Resistor



41 C15, C28, C13 MLCC104K100B 3 100 nF / 100 V ±10% X7R Taiwan Resistor


43 C11 MLCC471K102B 1 470 pF / 1 kV ±10% X7R Taiwan Resistor

44 C18 MLCC222K102B 1 2.2 nF /1 kV ±10% X7R Taiwan Resistor

45 R22 1 1/4”TOP 10 kΩ, Variable Resistor Taiwan Resistor

46 R12 MPR 5W 01J 1 0Ω1 5 W Tzai Yuan

47 R18 CR-200 018J 1 2 W, 0.18 Ω ±5%, DIP Resistor Taiwan Resistor

48 R35 CR-200 R1003 1 2 W, 100 kΩ ±5%, DIP Resistor Taiwan Resistor

49 MOV1 MOV471KD10SBNL 1 10 ψ 470 V UNIT-TEEK

50 TR2 TTC105104KSY 1 5 ψ 100 kΩ Thinking

51 C2 PX334K2WD32 1 330 nF / 310 V, X2 Capacitor Kenjet

52 C9, C10 MTF334 2 0.33 µF / 450 V ±10%, MTF

Capacitor Kenjet

53 C16 E2GA222MYASA 1 2.2 nF / 250 V ±20%, Y1

Capacitor WYX

54 C19 LHK 4.7 µF/ 50 V 1 4.7 µF / 50 V 105C 5*11 mm,

Electrolytic Capacitor JACKCON

55 C22, C21 L-ESR 470 µF/ 63 V 2 470 µF / 63 V 105C 13*21 mm L-

, Electrolytic Capacitor JACKCON

56 C30, C34 LHK 22 µF/ 50 V 2 22 µF / 50 V 105C 5*11 mm,

Electrolytic Capacitor JACKCON

57 C12 RD 82 µF/ 500 V 1 82 µF / 500 V 105C 18*45 mm

RD, Electrolytic Capacitor SAMXON

58 C14 LHK 33 µF/ 50 V 1 33 µF / 50 V 105C 5*11 mm

LHK, Electrolytic Capacitor JACKCON

59 TX1 I-129 1 POT33 887 µH SUMIDA PS13-

150, Transformer SUMIDA

60 L4 I-130 1 RM-10, 434 µH PS15-146,

Inductor 勝輝

61 L2 TRN0183 1 T18X10X10 L=30 mH 勝輝

http://www.thinking.com.tw/


Bill of Materials (Continued)


62 L5 TRN0184 1 T6026 L=400 µH 勝輝

63 L1 TRN0003 1 L1=L2=900 µH 勝輝

64 L3 WURTH

7447452100 1 WURTH 7447452100 10 µH WURTH

65 ZD1 MMSZ5245B 1 15 V,0.5 W SOD-123, Zener Fairchild

66 BD1 GBU4J 1 VRRM=600 V; IF @100C=4 A,

Bridge Rectifier Fairchild

67 D7 1N4935 1 1 A / 200 V Fairchild

68 D1 FFPF20UP30DNTU 1 20 A, 300 V Fairchild

69 D3, D5, D10, D11,

D12 LL4148 5 200 mA / 100 V Fairchild

70 D2 RHRP860 1 8 A / 400 V Fairchild

71 D6 RS1D (代FR103) 1 1 A / 200 V Fairchild

72 D4, D8 S1J 2 1 A / 600 V Fairchild

73 D9 S1M 1 1 A / 1000 V Fairchild

74 Q2 FCP190N60E 1 600 V, 20.6 A, 190 mΩ Fairchild

75 Q3 FCPF400N80Z 1 800 V, 11 A, 400 mΩ Fairchild

76 Q5 MMBT2222A 1 NPN General Purpose Amplifier Fairchild

77 Q1, Q4 MMBT2907A 2 PNP General Purpose Amplifier Fairchild

78 U2 LM2904MX 1 SOP-8 Fairchild

79 U1 IC Controller FL7921RMX

1 SOP-16 IC Fairchild

80 U3 FOD817A 1 Current Transfer Ratio :80–160% Fairchild

81 U4 KA431LZTA 1 Adjustable/2.5 V, 0.5% Fairchild

82 CN1 INLET 2P 90° 1 R-201SN90(B06) RICH BAY

83 CN2,CN3 PIN HDR 2*2P 2.54 mm 180°

1 2.54 mm 180° MOST WELL

84 CN2 JUMPER 1 6 mm CLOSE T&A

85 F1 FUSE GLASS

250V4A SLOWELY 1 3.6*10 36ES SLEEK

86 HS1 HEAT SINK MCH0090

1 61-10176-1Z HTC


1 47.5 x 20 x 3 mm LONG TENG

FENG


1 70 x 20 x 3 mm LONG TENG

FENG

89 LED+, LED- SG004-05 Pin

ψ2.2*18.2 mm OEM-10

2 KANG YANG

90 A-DIM+, A-DIM- TEST PIN 2 KANG YANG

91 PCB PCB PLM0338V2 1 SK


7. Transformer and Winding Specifications

7.1. Flyback Transformer

Core: POT3319

Bobbin: POT3319 (10 Pins)

(Flying wire needs to have

3cm to connect PCB.)

Figure 7. Transformer Specifications & Construction

Table 2. Winding Specifications

Pin (S → F) Wire Turns Winding Method

N1 1 → 2 0.32 φ×1 24 Solenoid Winding

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

E1 Shield: 0.025 mm × 7 mm, 0.9 turns, one end should be connected to pin 4


N2 10 → Flying 0.4 φ×1

(Triple insulation wire) 16 Solenoid Winding


N2 10 → Flying 0.4 φ×1

(Triple insulation wire) 16 Solenoid Winding


E1 Shield: 0.025 mm × 7 mm, 0.9 turns, one end should be connected to pin 4


N4 2 → 3 0.32 φ×1 24 Solenoid Winding


N3 5 → 4 0.3 φ×1 6 Solenoid Winding(To wind distribution evenly across the full winding width.)


N5 6 → 7 0.3 φ×1

(Triple insulation wire) 8

Solenoid Winding(To wind distribution evenly across the full winding width.)


Table 3. Electrical Characteristics

Pin Specification Remark

Primary-Side Inductance 1－3 887 µH ± 5% 100 kHz, 1 V

Primary-Side leakage Inductance 1－3 8 µH ± 5% Short One of the Secondary Windings


7.2. Boost Inductor

Core: RM10

Bobbin: RM10 (12 Pins, only keep useful 4 pins)

Figure 8. Transformer Specifications & Construction

Table 4. Winding Specifications

No Pin (S - F) Wire Turns Winding Method

N1 112 0.1 Ф ×35 45 Ts Solenoid Winding

Insulation: Mylar® Tape t = 0.03 mm, 2-Layer

N2 58 0.35 Ф×1 6 Ts Solenoid Winding(To wind distribution evenly across the full winding width.)


Core RM-10

1.2T Closed loop shielding to PIN8


Table 5. Electrical Characteristics

Pin Specification Remark

Primary-Side Inductance 2－11 434 µH ± 5% 100 kHz, 1 V


8. Test Conditions & Test Equipment

Table 6. Test Conditions & Test Equipment

Evaluation Board # FEBFL7921RMX_L65U100A

Test Temperature TA = 25°C

Test Equipments

AC Power Source: 6800 by EXTECH

DC Power Source: E3631A by Agilent

Power Analyzer: 6630 by Chroma

Electronic Load: 63030 by Chroma

Programmable Electronic Load: 63103A by Chroma

Power Meter: WT210 by YOKOGAWA

Oscilloscope: 24MXs-B by LeCroy

EMI Test Receiver: ESPI by ROHDE & SCHWARZ

Two-Line V-Network: ESH3-Z5 by ROHDE & SCHWARZ

Thermometer: Ti110 by FLUKE


9. Performance of Evaluation Board

9.1. System Efficiency and No Load Power Consumption

System Efficiency

Figure 9 and Table 7 are the system efficiency curve and the data measured over whole

line voltages at two output voltage conditions [47 V / 27 V] that LEDs can be connected

with the maximum and minimum numbers.

Figure 9. System Efficiency

Table 7. Test Results

Output Voltage

Input Voltage

90 VAC 60 Hz

115 VAC 60 Hz

230 VAC 50 Hz

264 VAC 50 Hz

277 VAC 50 Hz

300 VAC 50 Hz

47 V 89.41% 90.69% 91.56% 91.59% 91.62% 91.63%

27 V 88.93% 89.61% 89.24% 89.12% 89.05% 89.18%

80%

82%

84%

86%

88%

90%

92%

90 120 150 180 210 240 270 300

Vo=47V

Vo=27V

Input Voltage(V)

Eff

icie

ncy


No Load Power Consumption

Table 8 shows the results of the system power consumptions measured over whole line

inputs at no load condition. The power loss shows less than 0.5 W whole line inputs.

Table 8. Test Result

Input Voltage Input Power (mW) Output Voltage (V)

90 VAC / 60 Hz 320 50.28

115 VAC / 60 Hz 292 50.28

230 VAC / 50 Hz 322 50.33

264 VAC / 50 Hz 322 50.33

277 VAC / 50 Hz 322 50.33

300 VAC / 50 Hz 325 50.33


9.2. Power Factor [PF] and Total Harmonic Distortion [THD]

Figure 10 and Table 9 show PF and THD performance measured over whole line voltages

at two output voltage conditions [47 V / 27 V] that LEDs can be connected with the

maximum and minimum numbers. PF can beyond 0.9 and THD can be less than 30% in

whole input lines although min LED numbers are connected.

Figure 10. PF and THD


Input Voltage Output Voltage

VO=47 V VO=27 V

90 VAC / 60 Hz PF 0.999 0.998

THD (%) 3.63 5.01

115 VAC / 60 Hz PF 0.998 0.996

THD (%) 4.15 5.60

230 VAC / 50 Hz PF 0.988 0.970

THD (%) 6.19 10.41

264 VAC / 50 Hz PF 0.980 0.952

THD (%) 7.26 13.26

277 VAC / 50 Hz PF 0.977 0.944

THD (%) 7.74 14.42

300 VAC / 50 Hz PF 0.965 0.919

THD (%) 12.68 23.44

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

0.500

0.550

0.600

0.650

0.700

0.750

0.800

0.850

0.900

0.950

1.000

90 120 150 180 210 240 270 300

Input Voltage(V)

PF@Vo=47V

PF@Vo=27V

THD@Vo=47V

THD@Vo=27VPF

TH

D(%

)


9.3. Harmonics Performance Analysis

Figure 11 through Figure 14 show results measured per current harmonic order in each

line voltage [90 VAC and 277 VAC] and two output voltage conditions [47 V / 27 V] that

LEDs can be connected with the maximum and minimum numbers.

Figure 11. Harmonic Performance Results at 90 VAC and VO=47 V



9.4. Constant Current & Constant Voltage (CC / CV)

CC and CV tolerance over whole input line voltages and wide output voltage ranges are

less ±1% and ±3% as shown respectively in Table 10 and Table 11. Figure 15 shows the

typical CC / CV graph with very stable performance and it was measured using electronic

load with CR mode at each line voltage from 90 VAC to 300 VAC.

Table 10. CC Test Results

Input Voltage Min. Current

(mA) Max. Current

(mA) Tolerance Remark

90 VAC / 60 Hz 2003.44 2008.13 ±0.12%

< ±1%

115 VAC / 60 Hz 2004.38 2007.19 ±0.07%

230 VAC / 50 Hz 2003.44 2007.19 ±0.09%

277 VAC / 50 Hz 2003.44 2007.19 ±0.09%

300 VAC / 50 Hz 2003.44 2007.19 ±0.09%

Total 2003.44 2008.13 ±0.12%

Table 11. CV Test Results

Input Voltage Min. Voltage

(V) Max. Voltage

(V) Tolerance Remark

90 VAC / 60 Hz 48.27 50.12 ±1.88%

< ±3%

115 VAC / 60 Hz 48.27 50.35 ±2.11%

230 VAC / 50 Hz 47.86 50.39 ±2.58%

277 VAC / 50 Hz 48.49 50.36 ±1.89%

300 VAC / 50 Hz 48.50 50.40 ±1.92%

Total 47.86 50.40 ±2.58%


Figure 15. CC / CV Performance

0

10

20

30

40

50

60

0 500 1000 1500 2000

90Vac

115Vac

230Vac

277Vac

300Vac

Output Current (mA)

Ou

tpu

t V

olt

ag

e (

V)


9.5. Analog Dimming

Figure 16 and Table 12 show dimming curve and output current measured according to 0

to 10 V applied. In demo board, analog dimming function can be implemented simply by

adjusting reference voltage in current regulation feedback circuits so that analog dimming

signal coming from 0 to 10 V dimmer can be connected directly in secondary side as

shown in Figure 17. The output current can be adjusted within the range of 0%~100% at

rated input line voltage and output voltage.

Figure 16. Analog Dimming Curve

Table 12. Output Current according to A-DIM

VIN (VAC)

VOUT (V)

A-DIM (V)

0 1 2 3 4 5 6 7 8 9 10

Output Current

(A)

90 47 0.000 0.195 0.393 0.592 0.791 0.990 1.188 1.387 1.586 1.785 1.981

30 0.000 0.196 0.395 0.594 0.793 0.991 1.190 1.389 1.588 1.785 1.983

277 47 0.000 0.195 0.393 0.592 0.791 0.990 1.188 1.387 1.586 1.785 1.981

30 0.000 0.196 0.395 0.594 0.795 0.991 1.192 1.391 1.590 1.786 1.985

0

0.5

1

1.5

2

2.5

0 1 2 3 4 5 6 7 8 9 10

90Vac@Vo=47V

90Vac@Vo=30V

277Vac@Vo=47V

277Vac@Vo=30V

A-DIM(V)

I o(A

)


External Circuit for Analog Dimming

Output current can be changed by adjusting the reference voltage level of op-amp. On

demo board, jumper should be moved from CN2 to CN3 and 0 to 10 V signal should be

connected to A-DIM+. The output current formula show as below:

sencccc

DIMcco

RR

VRI

.1

2

(1)

Rcc.sen

Rcc1

Rcc2

Figure 17. Analog Dimming Circuit


9.6. Temperature Checking Results

Figure 18 and Figure 19 show the temperature of active components measured at 90 VAC

line voltage and full load condition. Figure 20 and Figure 21 are results for 277 VAC input

voltage and full load condition. The results were measured after 60 minutes since startup.


Components 90 VAC / 60 Hz 277 VAC / 50 Hz Remark

Bridge Diode 69.9°C 53.5°C Top-Side

FET (PFC) 55.1°C 53.3°C Top-Side

FET (QR PWM) 62.2°C 54.7°C Top-Side

Rectifier (PFC) 60.0°C 56.1°C Top-Side

Rectifier (QR PWM) 69.3°C 70.6°C Top-Side

Figure 18. 90 VAC / 60 Hz; Top Side Figure 19. 90 VAC / 60 Hz; Bottom Side

Figure 20. 277 VAC / 50 Hz; Top Side Figure 21. 277 VAC / 50 Hz; Bottom Side


9.7. Startup Behavior of PFC and PWM

Startup Time

Figure 22 and Figure 23 show the overall startup performance at full load condition. The

output load current starts flowing after about 883 ms at 90 VAC input and 322 ms at

277 VAC input when the AC input power switch turns on.


Input Voltage Turn On Time Remark

90 VAC / 60 Hz 0.883 s < 1 s

277 VAC / 50 Hz 0.322 s

Waveforms: CH1: VIN(200 V / div), CH2: V

DD(5 V / div),

CH3: V

O(PWM)

(10 V / div), CH4: IO(500 mA / div), Time Scale: (500 ms / div)

Figure 22. 90 VAC / 60 Hz Figure 23. 277 VAC / 50 Hz


PFC Behavior

Figure 24 to Figure 27 show startup performance of boost converter [PFC] on the board.

Output voltage can be changed as two levels depending on input lines. In this board,

output voltage is set as 290 V at 90 VAC and 445 V at 277 VAC respectively.

Waveforms: CH1: VDD

(5 V / div), CH2: VCOMP

(1 V / div),

CH3: VGS(PFC)

(10 V / div), CH4: VO-PFC

(100 V / div), Time Scale: (500 ms / div)


Waveforms: CH1: VO(PWM)

(10 V / div), CH2: VGS(PWM)

(10 V / div), CH3: V

GS(PFC)

(10 V / div), CH4: VO(PFC)

(100 V / div) Time Scale: (500 ms / div)



PWM Behavior

Figure 28 through Figure 31 show startup performance of the flyback converter [QR

PWM] on the board.

Waveforms: CH1: VDD

(5 V / div), CH2: VFB

(1 V / div),

CH3: VGS(PWM)

(10 V / div), CH4: IO-PWM

(500 mA / div), Time Scale: (500 ms / div)


Waveforms: CH1: VO(PFC)

(100 V / div), CH2: VFB

(1 V / div), CH3: V

GS(PWM)


(500 mA / div) Time Scale: (500 ms / div)



9.8. Operation Waveforms

Normal Operation

Figure 32 through Figure 35 shows the AC input voltage and current waveforms

respectively for each input line [90 VAC ~ 277 VAC] at rated output load condition.

Waveforms: CH1: VIN

(200 V / div), CH4: IIN

(1 A / div), Time Scale:

(10 ms / div)




Normal Operation of MOSFET (PFC)

Figure 36 through Figure 39 shows key waveforms of the PFC stage operated normally at

rated output load condition.

Waveforms: CH1: VCS-PFC

(200 mV / div), CH2: VCOMP

(1 V / div), CH3: V

DS-PFC

(200 V / div), CH4: VO-PFC





Normal Operation of MOSFET and Rectifier (QR PWM)

Figure 40 through Figure 43 shows key waveforms of the Flyback stage operated

normally at rated output load condition.

Waveforms: CH1: VCS-PWM

(200 mV / div), CH2: VFB

(1 V / div), CH3: V

DS-PWM


(500 mA / div), Time Scale: (10 µs / div)


Waveforms: CH1: VAK-PWM


(1 V / div), CH3: V

DS-PWM


(500 mA / div), Time Scale: (10 µs / div)



9.9. Short-Circuit Protection

Output-Short Protection

Figure 44 and Figure 45 show waveforms related when LED is shorted.

Waveforms: CH1: VDD


(1 V / div),

CH3: VDS-PWM


(500 mA / div), Time Scale: (1 s / div)


Auto-Recovery Protection

Figure 46 and Figure 47 show waveforms related when LED is recovered from short

condition. IC operates in hiccup mode during output short then system can be recovered

normally once the output short is removed.

Waveforms: CH1: VDD


(1 V / div),

CH3: VDS-PWM


(500 mA / div), Time Scale: (1 s / div)


LED Short


9.10. Over-Temperature Protection (External Detection)

RT<0.8 V

Figure 48 and Figure 49 show waveforms that over-temperature protection is triggered

when RT voltage is less than 0.8 V.

Waveforms: CH1: VGS-PFC

(10 V / div), CH2: VRT

(500 mV / div), CH3: V

DD

(5 V / div), CH4: VGS-PWM



RT<0.5 V

The IC operates at hiccup mode during system happens over-temperature phenomenon.

Figure 50 and Figure 51 show related waveforms when system recovers from over-

temperature protection. IC operate hiccup mode during OTP and system can restart once

system is recovered to normal conditions.

Waveforms: CH1: VGS-PFC

(10 V / div), CH2: VRT

(500 mV / div), CH3: V

DD

(5 V / div), CH4: VGS-PWM




9.11. Voltage Stress of the MOSFET & Rectifier

Table 15 shows the maximum voltage across by MOSFET and Rectifier at steady state

and startup procedures. All components designed have margins more than 10% of their

rating voltage.


Components

90 VAC / 60 Hz 300 VAC / 50 Hz

Remark Steady State

Power On

Steady State

Power On

PFC MOSFET (VDS-PFC) 359 V 359 V 509 V 509 V 600 V

QR PWM MOSFET (VDS-PWM) 574 V 574 V 724 V 724 V 800 V

PFC Rectifier (VAK-PFC) 320 V 334 V 513 V 513 V 600 V

QR PWM Rectifier (VAK-PFC) 157 V 161 V 224 V 250 V 300 V

Steady State

Figure 52 and Figure 53 show voltage waveforms of MOSFETs and rectifiers used in

boost and flyback converters at steady state.

Waveform: CH1: VDS-PFC

(500 V / div), CH2: VAK-PFC

(200 V / div), CH3: V

DS-PWM

(500 V / div), CH4: VAK-PWM




Power On

Figure 54 and Figure 55 show voltage waveforms of MOSFETs and rectifiers used in

boost and flyback converters at startup.

Waveform: CH1: VDS-PFC

(500 V / div), CH2: VAK-PFC

(200 V / div), CH3: V

DS-PWM

(500 V / div), CH4: VAK-PWM




9.12. EMI

Test Conditions

Frequency Subrange: 150 kHz – 30 MHz, Probe: 2-Line-LISN ESH3-Z5

Signal Path: Receiver-2-Line-LISN ESH3-Z5, Detectors: Peak; Average

Load is Resistance(24 )

Test Results:

Figure 56. 115 VAC / 60 Hz, L Figure 57. 115 VAC / 60 Hz, N


150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

1 PK

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:24:31

150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

1 PK

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:22:27

150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

1 PK

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:26:19

150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

1 PK

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:26:19



150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

1 PK

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:31:38

150 kHz 30 MHz

2 AV

CLRWRTDF

dBµV

dBµV

CLRWR

6DB

1 PK

MT 10 ms

RBW 9 kHz

PREAMP OFFAtt 10 dB

PRN

1 MHz 10 MHz

0

10

20

30

40

50

60

70

80

90

100

EN55022A

EN55022Q

Date: 26.AUG.2015 15:29:53


10. Revision History

Rev. Date Description

1.0.0 September 2015 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.

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.

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.

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.

EXPORT COMPLIANCE STATEMENT

These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations for the ultimate destination listed on the commercial invoice. Diversion contrary to U.S. law is prohibited.

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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