UM10861 SSL5231DB1246 230 V/10 W buck

UM10861 SSL5231DB1246 230 V/10 W buck
UM10861
SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED
driver demo board
Rev. 1 — 15 January 2015
User manual
Document information
Info
Content
Keywords
SSL5231DB1246, SSL5231T, non-isolated buck-boost topology, LED
driver controller, external MOSFET switch, A19 lamp shape dimmable
applications, SO8 package
Abstract
This user manual describes the performance, technical data, and the
connections of the SSL5231DB1246 demo board, using a non-isolated
buck-boost topology. The SSL5231T (SO8 package) is used as driver
controller IC.
The SSL5231DB1246 demo board is designed for dimmable A19 lamp
shape applications. It operates at 230 V (AC), with an output voltage
approximately 60 V.
UM10861
NXP Semiconductors
SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
Revision history
Rev
Date
Description
v.1
20150115
first issue
Contact information
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
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User manual
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
1. Introduction
WARNING
Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present when operating this product, constitute a
risk of electric shock, personal injury, death and/or ignition of fire.
This product is intended for evaluation purposes only. It shall be operated in a designated test
area by personnel qualified according to local requirements and labor laws to work with
non-insulated mains voltages and high-voltage circuits. This product shall never be operated
unattended.
This user manual describes the operation of the SSL5231DB1246 demo board, featuring
the MOSFET driver controller SSL5231T. The SSL5231DB1246 demo board is a
230 V/10 W non-isolated buck-boost dimmable LED driver application.
The SSL5231DB1246 demo board is designed for driving LED loads with a nominal
voltage level of 60 V and 10 W input power.
The SSL5231DB1246 demo board provides a simple and highly efficient solution for
Solid-State Lighting (SSL) applications.
1.1 Features
•
•
•
•
•
•
•
•
•
•
•
UM10861
User manual
A19 form-factor applications
Supports most available leading-edge and trailing-edge dimmers
Deep dimming level
Flicker-free dimming
Open/short LED string protection
OverCurrent Protection (OCP)
OverTemperature Protection (OTP)
Power Factor (PF) > 0.75
Efficiency > 85 % at 230 V (AC) input
Compliant with IEC61000-3-2 harmonic standard
Compliant with EN55015 conducted EMI
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
2. Safety warning
The board must be connected to the mains voltage. Avoid touching the board during
operation. An isolated housing is obligatory when used in uncontrolled, non-laboratory
environments. Galvanic isolation of the mains phase using a variable transformer is
always recommended. Figure 1 shows the symbols on how to recognize these devices.
019aab174
019aab173
a. Isolated
Fig 1.
b. Not isolated
Isolation symbols
3. Specifications
Table 1.
SSL5231DB1246 specifications
Symbol
Parameter
Value
Vmains
AC mains supply voltage
230 V (AC); 10 %
Pin
input power
10 W
VLED
LED output voltage
60 V
ILED
LED output current
 140 mA
ILED(ripple)
LED output current ripple
< 25 % (100 Hz)
ILED/Vmains
line regulation
< 3 % (Vmains: 10 %)
ILED/VLED
load regulation
5 % at VLED; 15 %

efficiency
85 %; at 230 V (AC)/50 Hz
PF
power factor
> 0.75; at 230 V (AC)/50 Hz
Toper
operating temperature
40 C to +105 C
board dimensions
90 mm  40 mm
conducted ElectroMagnetic
Interference (EMI)
EN55015
IEC61000-3-2
Class D (for Pin < 25 W limit)
dimmer compatibility
(stable light output
above on/off point)
UM10861
User manual
80 % dimmer compatibility
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
4. Board photographs
Figure 2 shows the top view and bottom view of the SSL5231DB1246 demo board. At the
left side connector of the board (Figure 2(a)), the AC mains (230 V) must be connected. At
the right connector, the LED load (60 V) must be connected. The inner part of the board
can be broken out and has an A19 lamp form factor.
a. Top view
b. Bottom view
Fig 2.
UM10861
User manual
SSL5231DB1246 demo board photographs
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
5. Functional description
5.1 Input filtering
The mains input circuitry (see Figure 10) filters the switching current from the buck-boost
converter to the mains AC. To meet the audible noise requirements and to be able to
connect the required lamps per dimmer, the mains input circuits limits the inrush current. A
provision has been added for improved dimmer triac latching.
5.2 Efficiency improvement for universal mains
Resistors R7 and R8 supply the current for the SSL5231T (see Figure 11). the IC draws
an additional start-up current (ICC(startup)) just before VCC reaches the start-up voltage
level (Vstartup). The supply current in operation is therefore lower than during start-up
conditions. It prevents lamp flicker when the mains voltage is increased or decreased
slowly. This mechanism in combination with an efficiency improvement increases the
dimming performance. Figure 3 shows the start-up current waveform.
9VWDUWXS
9GHOWD9&&
9&&
O&&VWDUWXS
O&&RSHU
,&&
9*$7(
DDD
Fig 3.
Start-up current waveform
5.3 Deep dimming improvement
To improve the deep dimming performance, a secondary side bleeder circuit has been
added (see schematic in Section 7.3). When the LED current lowers during dimming, a
part of the LED output current is shunted via resistors R23 and R24.
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
5.4 Output open and output short protection
The driver board is protected when the LED load is accidentally left open. When the LED
load is accidentally left open, the output voltage increases. When the OverVoltage
Protection level is reached on the DEMOVP pin, the OVP protection is activated. This
OVP protection (OVP), is a non-latched protection. It recovers when the LED string is
reconnected. Resistors R15, R16, and R17 determine the OVP level. The voltage rating of
output capacitor C9 and C10 must be higher than the DC level which occurs when the
LED load is accidentally left open.
The measured OVP level is about 99 V.
Remark: Do not reconnect the LED string directly after an OVP condition. It can
permanently damage the LEDs. Switch off the mains and wait until the output capacitor is
discharged.
During an output short circuit, the maximum ISNS voltage limits the primary converter
current. The converter frequency drops to its absolute minimum. This mode is safe and
the input power is low. It is valid when the short happens before the mains supply is
activated. When the short happens during normal operation, components R25, R26, R27,
and Q3 of the secondary side bleeder (see Figure 12) break safely before the converter
frequency drops to its absolute minimum. By adding diode D4 (1N4148 in parallel to R27),
the save mode is entered without damaging mentioned components.
5.5 ElectroMagnetic Interference (EMI) precautions
For optimal EMI performance, the way of mounting of L1, L2, L3, and L4 are important.
• Buck-boost inductor L4:
The start of winding, which is the wire closest to the core (marked with a dot on the
coil and the schematic) must be connected to the switching side of the converter. In
this case, it must be connected to the IC ground. The outer part of the winding acts as
a shield for the inner part of the winding, which is operated at a high frequency and a
high voltage. The inductor shields itself by the outer part of the winding.
• Filter inductor L3:
The start of the winding, which is the wire closest to the core (marked with a dot on
schematic and with shortest connection lead on the coil), must be connected to the
bridge rectifier. The outer part of the winding shields the inner part of the winding.
• Filter inductors L1 and L2:
The start of the winding, which is the wire closest to the core (marked with a dot on
the schematic and with the shortest connection lead on the coil) must be connected to
the input resistors R2 and R1. The outer part of the windings of inductors L1 and L2
shields the inner part of the corresponding windings.
See Figure 2(a) for the orientation of the coils.
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
6. Performance
During performance tests Vmains = 230 V (AC) with a 20 % margin, Tamb = 25 C,
ILED = 140 mA typical, and VLED = 60 V unless otherwise specified.
6.1 Efficiency
DDD
Ș
Fig 4.
9PDLQV9
Efficiency as a function of mains voltage
6.2 Power factor
DDD
3)
Fig 5.
UM10861
User manual
9PDLQV9
Power factor as a function of mains voltage
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
6.3 Line regulation
DDD
,/('
P$
Fig 6.
9PDLQV9
LED output current as a function of mains voltage
6.4 Load regulation
DDD
,/('
P$
Fig 7.
UM10861
User manual
9/('9
LED output current as a function of LED output voltage
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
6.5 Output ripple
DDD
ULSSOH
Fig 8.
9PDLQV9
Output ripple as a function of mains voltage
6.6 ElectroMagnetic Interference (EMI)
Figure 9 shows the conducted EMI result of the SSL5231DB1246 demo board.
Fig 9.
UM10861
User manual
Conducted EMI
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
7. Schematics
7.1 AC mains input part
5
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.
/
(
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/
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$:*
/
P+
/
P+
9%86
5
5
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59
9
1
1
a
a
:
&
Q)
9
&
Q)
9
(
$:*
(
$:*
0'6
&
Q)
9
5
ȍ
5
/
P+
:
)XVLVWRU
/('3
5
Nȍ
DDD
Fig 10. AC mains input part
7.2 Converter part
9%86
5
5
5
5
4
6381&
8
',0
&203
9&&
,616
9&&
66/7
'(0293
*1'
QF
6:
5
'
(6-
5
&
&
9
9
&
Q)
9
5
5
5
5
/('0
5
/('3
/
P+
&
9
/('3
DDD
Fig 11. Converter part
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
7.3 Secondary side bleeder
/('3
5
5
:
(
$:*
$QRGH
(
$:*
$QRGH
5
4$
)0%0
5
:
4%
)0%0
.
/('
&211
(
$:*
&DWKRGH
9/('
9
(
$:*
&DWKRGH
5
5
DDD
/('0
Fig 12. Secondary side bleeder
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
8. Bill Of Materials (BOM)
Table 2.
SSL5231DB1246 bill of materials
Reference
Description and values
Part number
Manufacturer
BD1
bridge rectifier; 1000 V; 500 mA
MD5S
Rectron
C2
capacitor; 10 nF; 5 %; 400 V; PET; THT
ECQE4103JF
Panasonic
C3
capacitor; 150 nF; 5 %; 400 V; PP; THT
ECW-F4154JL
Panasonic
C4
capacitor; 22 nF; 5 %; 400 V; PET; THT
ECQE4223JF
Panasonic
C5
capacitor; 2.2 F; 10 %; 50 V; X5R; 0805
C2012X7R1H225K125AC
TDK
C6
capacitor; 2.2 F; 10 %; 6.3 V; X7R; 0603 C1608X7R0J225K080AB
TDK
C7
capacitor; 47 nF; 10 %; 50 V; X7R; 0603
-
-
C9
capacitor; 220 F; 20 %; 100 V; ALU;
THT
ECA2AM221
Panasonic
D3
diode; 600 V; 1 A
ES1J
Fairchild
L1; L2; L3
inductor; 3.3 mH; 100 mA
22R335C
Murata
L4
inductor; 1.5 mH; 10 %; 260 mA; 2.8 
ELC10E152L
Panasonic
Q1
MOSFET-N; 650 V; 1.8 A
SPU02N60C3
Infineon
Q3(AB)
transistor; NPN; 160 V; 600 mA
FMBM5551
Fairchild
R1; R2
resistor; 10 ; 10 %; 2 W; THT
EMC2-10RK
Welwyn Components
R3; R4
resistor; 4.7 k; 1 %; 250 mW; 1206
-
-
R5; R6
resistor; 270 ; 5 %; 2 W; MFP2
MFP2-270R JI
Welwyn Components
R7; R8
resistor; 180 k; 1 %; 250 mW; 1206
-
-
R9; R10
resistor; 1.3 M; 1 %; 250 mW; 1206
-
-
R11
resistor; 27 k; 1 %; 63 mW; 0603
-
-
R12
resistor; 910 k; 1 %; 63 mW; 0603
-
-
R13
resistor; 3.9 ; 1 %; 250 mW; 1206
-
-
R14
resistor; 5.6 ; 1 %; 250 mW; 1206
-
-
R15
resistor; 5.6 k; 1 %; 100 mW; 0805
-
-
R16
resistor; 150 k; 1 %; 250 mW; 1206
-
-
R17
resistor; 160 k; 1 %; 250 mW; 1206
-
-
R22
resistor; 51 k; 1 %; 250 mW; 1206
-
-
R23; R24
resistor; 2.7 k; 5 %; 2 W; ROX
PR02000202701JR500
Vishay
R25
resistor; 330 ; 1 %; 63 mW; 0603
-
-
R26
resistor; 5.6 ; 1 %; 63 mW; 0603
-
-
R27
resistor; 5.6 ; 1 %; 250 mW; 1206
-
-
RV1
resistor; VDR; 275 V; 36 J
VDRS07H275BSE
Vishay
U1
DimIC; SSL5231T
SSL5231T
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9. Board modifications for improved performance and reduced BOM cost
After the first board definition/realization and the current schematic, an optimization has
happened concerning the performance and the BOM cost.
In the current board, some component numbers and places are reserved, which are not
used in current optimized schematic.
Table 3 shows an overview of the skipped components with the corresponding remarks.
Table 3.
UM10861
User manual
Board modification for improved performance and cost reduction
Part reference
Remark
C8
not mounted
C10
not mounted
C11
not mounted
CX1
not mounted
D1
not mounted
D2
not mounted
D4
not mounted
Q2
not mounted
R18
Shorted by wire or 0  resistor
R19
not mounted
R20
not mounted
R21
not mounted
R28
Shorted by wire or 0  resistor
R29
Shorted by wire or 0  resistor
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10. Board layout
Figure 13 shows the top view and the bottom view of the SSL5231DB1246 demo board
layout. Figure 14 shows the component placement.
a. Top view
b. Bottom view
Fig 13. SSL5231DB1246 demo board layout
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SSL5231DB1246 230 V/10 W buck-boost dimmable A19 LED driver
a. Top view
b. Bottom view
Fig 14. SSL5231DB1246 demo board component placement
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11. Abbreviations
Table 4.
Abbreviations
Acronym
Description
EMI
ElectroMagnetic Interference
LED
Light-Emitting Diode
OCP
OverCurrent Protection
OTP
OverTemperature Protection
PF
Power Factor
SSL
Solid-State Lighting
12. References
[1]
UM10861
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SSL5231T data sheet — Compact High Power Factor Dimmable LED driver IC
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13. Legal information
13.1 Definitions
Draft — The document is a draft version only. The content is still under
internal review and subject to formal approval, which may result in
modifications or additions. NXP Semiconductors does not give any
representations or warranties as to the accuracy or completeness of
information included herein and shall have no liability for the consequences of
use of such information.
NXP Semiconductors does not accept any liability related to any default,
damage, costs or problem which is based on any weakness or default in the
customer’s applications or products, or the application or use by customer’s
third party customer(s). Customer is responsible for doing all necessary
testing for the customer’s applications and products using NXP
Semiconductors products in order to avoid a default of the applications and
the products or of the application or use by customer’s third party
customer(s). NXP does not accept any liability in this respect.
Export control — This document as well as the item(s) described herein
may be subject to export control regulations. Export might require a prior
authorization from competent authorities.
13.2 Disclaimers
Limited warranty and liability — Information in this document is believed to
be accurate and reliable. However, NXP Semiconductors does not give any
representations or warranties, expressed or implied, as to the accuracy or
completeness of such information and shall have no liability for the
consequences of use of such information. NXP Semiconductors takes no
responsibility for the content in this document if provided by an information
source outside of NXP Semiconductors.
In no event shall NXP Semiconductors be liable for any indirect, incidental,
punitive, special or consequential damages (including - without limitation - lost
profits, lost savings, business interruption, costs related to the removal or
replacement of any products or rework charges) whether or not such
damages are based on tort (including negligence), warranty, breach of
contract or any other legal theory.
Notwithstanding any damages that customer might incur for any reason
whatsoever, NXP Semiconductors’ aggregate and cumulative liability towards
customer for the products described herein shall be limited in accordance
with the Terms and conditions of commercial sale of NXP Semiconductors.
Right to make changes — NXP Semiconductors reserves the right to make
changes to information published in this document, including without
limitation specifications and product descriptions, at any time and without
notice. This document supersedes and replaces all information supplied prior
to the publication hereof.
Suitability for use — NXP Semiconductors products are not designed,
authorized or warranted to be suitable for use in life support, life-critical or
safety-critical systems or equipment, nor in applications where failure or
malfunction of an NXP Semiconductors product can reasonably be expected
to result in personal injury, death or severe property or environmental
damage. NXP Semiconductors and its suppliers accept no liability for
inclusion and/or use of NXP Semiconductors products in such equipment or
applications and therefore such inclusion and/or use is at the customer’s own
risk.
Applications — Applications that are described herein for any of these
products are for illustrative purposes only. NXP Semiconductors makes no
representation or warranty that such applications will be suitable for the
specified use without further testing or modification.
Customers are responsible for the design and operation of their applications
and products using NXP Semiconductors products, and NXP Semiconductors
accepts no liability for any assistance with applications or customer product
design. It is customer’s sole responsibility to determine whether the NXP
Semiconductors product is suitable and fit for the customer’s applications and
products planned, as well as for the planned application and use of
customer’s third party customer(s). Customers should provide appropriate
design and operating safeguards to minimize the risks associated with their
applications and products.
Evaluation products — This product is provided on an “as is” and “with all
faults” basis for evaluation purposes only. NXP Semiconductors, its affiliates
and their suppliers expressly disclaim all warranties, whether express, implied
or statutory, including but not limited to the implied warranties of
non-infringement, merchantability and fitness for a particular purpose. The
entire risk as to the quality, or arising out of the use or performance, of this
product remains with customer.
In no event shall NXP Semiconductors, its affiliates or their suppliers be liable
to customer for any special, indirect, consequential, punitive or incidental
damages (including without limitation damages for loss of business, business
interruption, loss of use, loss of data or information, and the like) arising out
the use of or inability to use the product, whether or not based on tort
(including negligence), strict liability, breach of contract, breach of warranty or
any other theory, even if advised of the possibility of such damages.
Notwithstanding any damages that customer might incur for any reason
whatsoever (including without limitation, all damages referenced above and
all direct or general damages), the entire liability of NXP Semiconductors, its
affiliates and their suppliers and customer’s exclusive remedy for all of the
foregoing shall be limited to actual damages incurred by customer based on
reasonable reliance up to the greater of the amount actually paid by customer
for the product or five dollars (US$5.00). The foregoing limitations, exclusions
and disclaimers shall apply to the maximum extent permitted by applicable
law, even if any remedy fails of its essential purpose.
Safety of high-voltage evaluation products — The non-insulated high
voltages that are present when operating this product, constitute a risk of
electric shock, personal injury, death and/or ignition of fire. This product is
intended for evaluation purposes only. It shall be operated in a designated
test area by personnel that is qualified according to local requirements and
labor laws to work with non-insulated mains voltages and high-voltage
circuits.
The product does not comply with IEC 60950 based national or regional
safety standards. NXP Semiconductors does not accept any liability for
damages incurred due to inappropriate use of this product or related to
non-insulated high voltages. Any use of this product is at customer’s own risk
and liability. The customer shall fully indemnify and hold harmless NXP
Semiconductors from any liability, damages and claims resulting from the use
of the product.
Translations — A non-English (translated) version of a document is for
reference only. The English version shall prevail in case of any discrepancy
between the translated and English versions.
13.3 Trademarks
Notice: All referenced brands, product names, service names and trademarks
are the property of their respective owners.
GreenChip — is a trademark of NXP Semiconductors N.V.
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14. Contents
1
1.1
2
3
4
5
5.1
5.2
5.3
5.4
5.5
6
6.1
6.2
6.3
6.4
6.5
6.6
7
7.1
7.2
7.3
8
9
10
11
12
13
13.1
13.2
13.3
14
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety warning . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Board photographs . . . . . . . . . . . . . . . . . . . . . . 5
Functional description . . . . . . . . . . . . . . . . . . . 6
Input filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Efficiency improvement for universal mains . . . 6
Deep dimming improvement. . . . . . . . . . . . . . . 6
Output open and output short protection . . . . . 7
ElectroMagnetic Interference (EMI) precautions 7
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Line regulation . . . . . . . . . . . . . . . . . . . . . . . . . 9
Load regulation . . . . . . . . . . . . . . . . . . . . . . . . . 9
Output ripple . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ElectroMagnetic Interference (EMI) . . . . . . . . 10
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC mains input part . . . . . . . . . . . . . . . . . . . . 11
Converter part. . . . . . . . . . . . . . . . . . . . . . . . . 11
Secondary side bleeder . . . . . . . . . . . . . . . . . 12
Bill Of Materials (BOM) . . . . . . . . . . . . . . . . . . 13
Board modifications for improved
performance and reduced BOM cost . . . . . . . 14
Board layout . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . 17
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Legal information. . . . . . . . . . . . . . . . . . . . . . . 18
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Please be aware that important notices concerning this document and the product(s)
described herein, have been included in section ‘Legal information’.
© NXP Semiconductors N.V. 2015.
All rights reserved.
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
Date of release: 15 January 2015
Document identifier: UM10861
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