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Abstract
The ISL6745ALEVAL3Z is a low cost, high performance LED driver with power factor correction function, and is compatible with the widely used wall dimmers. It uses Intersils voltage mode PWM controller ISL6745A to operate a SEPIC converter in discontinuous conduction mode (DCM). The design gives high flexibility on both the input side and output load. With the same circuit configuration, it works well with and without a triac dimmer. While connecting to any AC source from 50V to 140V without dimmer, it gives high power factor correction with high waveform factor of the input current. As it is powered through a phase controlled wall dimmer, the averaged rectified voltage varies as to the phase angle of the wall dimmer. The brightness of the LED is dimmed by changing the LED current, which is proportional to the averaged rectified voltage. This driver circuit can be used for various LED lighting applications. The number of LEDs in a string can be as many as 14, or as few as 4. Therefore, this design provides the luminaire manufacturers a high performance, low-cost solution for LED drivers compatible with the TRIAC phase-control dimmers.
Design Specifications
Configuration with Sinusoidal AC Source
Input VAC: 50V ~140V Typical Power Factor PF: 0.98 Typical Efficiency : 80% Output Current ILED: 10mA ~ 670mA Output Voltage VOUT: 10V ~ 46V Switching Frequency FS: 100kHz Output Voltage Ripple VRPP: 50mV(P-P)
|VAC| L1
C2
R1 AC C1 Q1 L2 LED C0 STRING
RCS TRIAC DIMMER BRIDGE PWM DIMMING REFERENCE GENERATING ISL6745A VERR PWM CONTROLLER VX EL5420 OP AMP CURRENT CONTROLLER Rs
CAUTION: These devices are sensitive to electrostatic discharge; follow proper IC Handling Procedures. 1-888-INTERSIL or 1-888-468-3774 | Intersil (and design) is a registered trademark of Intersil Americas Inc. Copyright Intersil Americas Inc. 2009. All Rights Reserved All other trademarks mentioned are the property of their respective owners.
Circuit Description
Unlike the active power factor correction converters, a voltage follower works in discontinuous conduction mode with comparatively constant duty ratio (D) within each utility cycle. There is no need for a PFC controller, or input voltage/current sense circuit. A simplified block diagram is shown in Figure 4. A typical waveform of the voltage after a triac dimmer is shown in Figure 3, where high dv/dt is noticed as the triac is turned on. A small capacitor C1 is recommended here to filter out the switching noises. C1 should be very small so that the voltage across it follows closely the rectified input voltage |VAC|. An Electrolytic
IIN D1 D3 P1
A damper resistor R1 is needed to reduce the ringing effect because of the high dv/dt caused by the phase-angle dimming control of the triac. A minimum resistance should be used to ensure as low as possible power loss, while achieving normal dimming function. This resistor can be shorted if the driver is not triac dimmer controlled. L1 and L2 are selected so that the converter operates in DCM. The details of the design of the two inductors and capacitor C2 can be found in Application Note AN1411. One simple and low-cost solution for LED lamp brightness dimming is to control the LED current. It is assumed that the brightness of the LED lamp is linearly proportional to its current in normal conditions. Although the tune and color may change with operating current, the current based dimming method is acceptable for common LED luminaire applications. The current reference signal is in proportion to the averaged rectified voltage |VAC| . The average voltage versus the phase angle of triac dimmer is shown in Figure 5 for a commercial dimmer.
IO P0
AC
POWER C1 CONVERTER D2 D4
C0
R0
Vo
3 C7 C27 C12
F 47u 47u 220n F
VR4 18V
R25 14.0k 1%
The schematic diagram of the current reference circuit is shown in Figure 6, where |VAC| is the rectified voltage after the rectifier. The high performance Op-Amp EL5420 clamps the current reference if the averaged input of U3A is beyond the bias voltage.
|VAC|
R8 1% 100k R9 100k 1% C5 DNP R10 14.3k 1% C6 R32 2.2F 150k R29 BAT 54 CR4 VX 3 1 2 11 2 EL5420 U3A 3 + 4 C20 6.8F R27 10.0k 1% R28 59.0k 5V1 1%
5V1
The bias circuit is shown in Figure 8 together with the reference voltages for the control circuit. At the beginning, the |VAC| increases so that the voltage at the gate of Q0 is about 12V, Q0 is turned on, and C7 is charged up with |VAC| through R4. The ISL6745A starts to work as soon as the VDD is above its threshold. The output capacitor is charged up once the converter begins to work. The VB2 presents an alternative bias choice for the driver for high voltage applications. If it is connected to the 3rd of the LED strings, 3 times of p-n junction voltage presents when LED strings start conducting current. This will shut off the current path of Q0, CR3, and prevents the Q0 from conducting current in normal operation conditions. The following circuit in Figure 9 shows a soft-start circuit with overvoltage protection and delayed start-up circuit. The VR2, R39, R15 set up the over voltage protection of the output voltage applied to LED strings. For an overvoltage of any reasons, the Q3 will be turned on, and the SS charges will be discharged through R15. In order to suppress the LED over-shot current during start-up, a delayed start-up circuit consisting of U4D and Q5 is necessary. Only after SS voltage is beyond 3.6V, the Q5 will be turned off, and Vx is presented in the reference generation circuit. This greatly reduces the over-shot of the LED strings during start-up.
R11 100 SS 3V6 VX 5V1 VX R15 51.1 1 2 VERR 3 R19 2k C28 1.2n 4 5 30.1k R39 1.0k C24 0.1F R26 1% C17 220p CS U1 SS RTD VERR CS CT VDD VDDP OUTB OUTA GND 10 9 8 7 6 VDD C13 470n Gate
The LED current reference can be changed through R10 and R29 for applications with different rated operating current. Figure 7 shows the LED current control circuit, where U4C provides 10 times of gain to reduce the power loss in the current sense resistor Rs. The integration circuit implemented with U3B eliminates any discrepancy between the reference (IREF) and the LED current (ILED). The time constant set by C19 and R33 should be large enough so that the second order harmonics will not appear in the control signal. A typical way is to set the time constant to 0.5 times of the utility frequency.
R18 C19 2.2F 3.01M C21 DNP 6 5 R33 61.9k 1% 1%
-
C16
11
VERR
IREF
10 ISEN + 8 U4C EL5420 C10 ILED 9 0.1F R3411 196k R35 10.0k
5V1
SS
OVP
IREF
10X The overall schematics of the driver and the associated BOM are presented in the last pages of this application note. The fixture of the PCB is a 2-layer board with dimensions 3.15 by 2.65 inches. Figures 10 and 11 show the top view
PF
0.8720 81.06 0.8972 80.73 0.9212 80.48 0.9427 80.41 0.9585 80.74 0.9761 80.40 0.9811 80.13
0.9875 80.28 0.9899 79.88 0.9947 79.41 0.9974 77.83 0.9979 74.62 0.9956 62.66
V/INPUT
I/INPUT
FIGURE 11. BOTTOM VIEW OF PCB LAYOUT FIGURE 12. INPUT VOLTAGE AND CURRENT @ 140V
V/INPUT
V/INPUT
V/INPUT
V/INPUT
I/INPUT
V/INPUT
V/INPUT
V/INPUT C1: VIN 100V/DIV I/INPUT I/INPUT C4: IIN 500mA/DIV V/INPUT C1: VIN 100V/DIV
The temperature test of the board, and critical components of the driver with/without dimmer is shown in Tables 3 and 4 for 110V input full load conditions.
TABLE 3. CIRCUIT WORK WITHOUT DIMMER FOR 6 LEDS
COMP Q1 L1 L2 L3 C4 R4
T = +85C 98 88 90 88 88 86 97 89 109 88
T = +25C 36 26 33 26 26 26 37 33 49 29
T = 0C 11 3 3 3 3 0 13 3 10 3
T = -40C -30 -35 -34 -37 -37 -37 -26 -34 -24 -37
R12 Q0
V/INPUT
CR2 C8
COMP Q1 L1 L2 L3 C4 R3
T = +25C 38 30 30 28 28 84 37 30 48 28
T = 0C 13 2 2 2 2 50 10 5 7 2
T = -40C -28 -37 -37 -37 -37 -18 -25 -34 -32 -37
References
1. ISL6745A datasheet, Intersil Corporation 2. ISL5420 datasheet, Intersil Corporation
I/LED C4: IIN 200mA/DIV
3. ISL6745EVAL2Z Offline High Brightness White LED Driver With High Power Factor for Universal Input, Intersil Corporation application note: AN1411 4. Z. Ye, et al, Design Considerations of a High Power Factor SEPIC Converter for High Brightness White LED Lighting Applications, IEEE PESC conference record, 2008, June 2008, Greece, pp 2657- 2663.
BRIDGE RECTIFIER SMC SOT23 SOT23 X2-CAP SM1812 SM1812 SM1210 SM0603 SM1210 12.5x20mm SM0603 SM0603 SM0603 SM0603 SM0805 SM0603 SM0603 SM0603 SM0603 SM0805 SM0603 FUSE NPO/C0G
25
TR5 COILCRAFT COILCRAFT PULSE KEYSTONE MSS1278-334KLB MSD1278-334KLB PA2050.393NL 1514-2 FQD1N50TM IPD60R385CP
P1, P2, P3, P4, P5 TERMINAL Q0 Q1 Q3, Q5 R1, R2, R6 R3, R7 R4 R8, R9 R10 R11 R12 R13 R14 1A 3.2A BSS138 1.0M 0 100 100k 14.3k 100 0.05 10 499 DPAK DPAK SOT23 SM1206 RES-2W SM1206 SM1206 SM0603 SM0603 SM2512 SM0805 SM1206 5% 5% 5% 1% 1% 5% 5% 5% 5%
FAIRCHILD INFINEON
LITTELFUSE TMOV14R140E
10
BRIDGE RECTIFIER SMC SOT23 SOT23 X2-CAP SM1812 SM1812 SM1210 SM0603 SM1210 12.5x20mm SM0603 SM0603 SM0603 SM0603 SM0805 SM0603 SM0603 SM0603 SM0603 SM0805 SM0603 FUSE NPO/C0G
25
TR5 COILCRAFT COILCRAFT PULSE KEYSTONE FAIRCHILD INFINEON MSS1278-334KLB MSD1278-334KLB PA2050.393NL 1514-2 FQD1N50TM IPD60R385CP
11
48 49 50 51 52 53 54 55 56 57 58 59 60 61
1 1 1 1 1 1 1 1 1 1 1 1 1 1
14.0k 30.1k 59.0k 150k 61.9k 196k 1.0k ISL6745A EL5420 11V 24V 5.1V DNP -
SM0603 SM0603 SM0603 SM0603 SM0603 SM0603 SM0603 MSOP10 TSSOP14 SOT23 SOT23 SOT23 SOT23 -
1% 1% 1% 5% 5% 1% 5% INTERSIL INTERSIL DIODES VISHAY DIODES DIODES LITTELFUSE ISL6745AAU EL5420CRZ BZX84C11 MMBZ5252 BZX84B5V1LT1 BZX84C18 TMOV14R140E
Intersil Corporation reserves the right to make changes in circuit design, software and/or specifications at any time without notice. Accordingly, the reader is cautioned to verify that the Application Note or Technical Brief is current before proceeding.
For information regarding Intersil Corporation and its products, see www.intersil.com 12
AN1487.0 July 28, 2009