100w led driver circuit using FL7733A - 36v-3A

2017-5-14

FSC:FairchildPSW WebDesigner - Summary

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LED Flyback - FL7733A (Save/Pri

Design Requirements

Requirements Input Mode

AC

Min Line frequency

50Hz

Min Input voltage (rms)

90V

Max Input voltage (rms)

277V

LED Operation Current per String (rms)

3A

Max LED Forward Voltage at testing current, 25C

40V

Min LED Forward Voltage at testing current, 25C

34V

Max LED String Number in parallel

1

Max LED Numbers per String

1

Min LED Numbers per String

1

LED testing Current (rms)

3A

LED Dynamic Resistance at Operation current

2Ω

Temperature coefficient of LED forward voltage

0.10%/°C

Max. LED Operation Temperature

100°C

Min LED Ambient Temperature

0°C

Max Control ICAmbient Temperature

55°C

Min Output Voltage @ specified LED Operation Current

31.5V

Max Output Voltage @ specified LED operat ion current

41V

Total Output current

3A

Driver Max Output Power

123W

Estimated Efficiency at Max Input and Min Output Vol.

82.7%

Control IC & Power Train MOSFET overshoot factor (Vos/Vro)

1.2

Voltage Derating factor

80%

Current Derating factor

80%

Max Semiconductor Junction temperature

125C

Input Specification Min Input (rms)

Max Input(rms)

AC In put (Vrms) 90.0 InputFrequency

277.0

50.0

Hz

Output Specification MinLED

MaxLED

LED No. per String 1.0 LED String No LEDcurrentperString(A)

1.0 1.0

3.0

A Min

Max

LED Forward Voltage (V) 34.0 OutputVoltageRange(V) MaxDriverOutputCurrent(rms) MaxOutputPower(W)

31.45 3.0

40.0 41.0 A

123.0

W

Min_Temp

Max_Temp

IC Ambient Temp range (C) 0.0

MOSFET Min Current Rating (Ids,rms)

55.0

19.3A

MOSFET Min Voltage Rating (Vds, pk)

668V

Recommended MOSFET Q1

FQA8N100C

FQA8N100C

http://fairchild.transim.com/psweb/Pages/Summary.aspx

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2017-5-14

FSC:FairchildPSW WebDesigner - Summary Recommended Flyback Controller IC (U1)

FL7733A

Estimated Power Switcher Conduction Losses

43.338W

Estimated Power Switcher Capacitive Losses

1.151W

Control-Compensation cap (Ccomi)

1uF

Transformer Primary to Secondary Turn Ratio (P1:S1)

1.55

AC Input Voltage Blanking Level

59V

Rvs1 Resistance

209k

Rvs2 Resistance

30.7k

Flyback Transformer Primary Inductance

62uH

Current Sensing Resistor Rcs

61.5m

Line compensation resistor Rcomp

123

Max Operation Duty Cycle

386m

Max reflected output voltage on Primary side

65.9V 537V

Max Drain to Source Voltage (PK)

5%

Targeted Peak-to-Peak Line Freq. Ripple (% of LED rms current) Output line frequency filter Cap Cout

38.2mF

Output filter Cap voltage rating

58.6V

Dimmer Hold current

438mA

Hold Current Setting Resistor Rhold

13.7k

Hold Current Setting Capacitor Chold

4.59nF

Resistor Rtcic for Constant Input Current Control

1mk

Resistor Rcic2 for Constant Input Current Control

100k

Resistor Rcic1 for Constant Input Current Control

0Ω

Resistor Rdim1 for Dimming Control

75.9k

Resistor Rdim2 for Dimming Control

38.3k

Capacitor Cdim for Dimming Control

438nF

Targeted Peak-to-Peak Line Freq. Ripple (% of LED rms current)

5%

Output line frequency filter Cap Cout

38.2mF

Output filter Cap voltage rating

58.6V

Transformer Design Transformer Primary Inductance Transformer Current Derating factor

62.2uH 80%

Min Flyback Transformer Primary Winding Current Rating (peak)

15.1A

Max allowed flux density

300mT

Max core_window filling factor

0.130

Targeted Primary Winding Current Density

6A/mm²

Targeted Secondary Winding Current Density

8A/mm²

Core Area Product (AeAw)

25073mm⁴

Select Inductor Core & Bobbin

1 AeAw (mm4)

Ae (mm2)

Aw (mm2)

Ve (mm3)

AL (nH/turn2)

Len (mm)

Hgt (mm)

Thk (mm) BobbinMf

Coilformerdiameter (mm)

MLT (mm)

CoreMfr

PC40ETD34-Z

TDK

18255.0

97.1

188.0

7630.0

2780.0

34.2

35.0

10.88

EPCOS

B66362B1014T001

13.4

20.9

PC40EE40-Z

TDK

20828.0

127.0

164.0

9890.0

4150.0

40.0

34.0

11.0

EPCOS

B66454A1014T001

14.95

17.8

PC40EE40-Z

TDK

20828.0

127.0

164.0

9890.0

4150.0

40.0

34.0

11.0

MH&W

BE40-1112CPFR

14.0

17.3

76.0

150-2171 (ERL35)

Wurth

21939.0

103.0

213.0

9548.0

2150.0

35.0

41.8

11.3

Wurth

070-5783

13.6

27.61

65.66

PC40EER35-Z

TDK

23326.0

107.0

218.0

9720.0

2770.0

35.0

41.0

11.0

MH&W

PC40EER35-Z

TDK

23326.0

107.0

218.0

9720.0

2770.0

35.0

41.0

11.0

MH&W

PC40EI40-Z

TDK

PC44PQ32/30ZTDK 12 150-2411 Wu rth (PQ3230)

23754.0

148.0

160.5

11400.0

4860.0

40.0

35.0

12.0

BEER35-1112CPFR BEER351116CPHFR

MH&W

24086.0

161.0

149.6

12 000.0

5140.0

32.0

30.35

22.0

EPCOS

24783.0

167.0

148.0

1 2475.0

3800.0

33.0

30.3

22.0

Wurth

BobbinPN

Winding Breadth (mm)

CorePN

BE40-1112CPFR B65880E2012D001 070-4796

13.7

26.1

13.6

26.4

14.0 16.1 16.3

17.3

60.5 87.0

61.4 60.8 76.0

18.3

62.0

18.69

66.79

PC40RM14Z-12

TDK

27590.0

178.0

155.0

12500.0

4600.0

41.6

28.8

18.7

EPCOS

B65888N1012D001

16.7

18.35

71.5

PC40ETD39-Z

TDK

32125.0

125.0

257.0

11500.0

3150.0

39.1

40.0

12.58

EPCOS

B 66364B1016T001

15.1

25.7

69.0

PC40EER40-Z

TDK

37101.0

149.0

249.0

14600.0

3620.0

40.0

45.0

13.0

MH&W

BEER40-1112CPFR

15.8

27.5

69.9

Primary Winding Turns

26Turn

Secondary Winding Turns

17Turn

Auxiliary Winding Turns

8Turn

Max Core loss at Min Input and Max Output Voltage

1.61W

Core Air Gap

1.71mm

Max Flux Density under Full Load Condition

231mT

Max Flux Density under Fault Operation Condition

289mT

Magnetic Wire Type

1


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FSC:FairchildPSW WebDesigner - Summary 0

Margin Tape for Primary Winding Primary winding Insulation type

0

Optional Wire list for primary winding

29.0AWG

Number of Strands Wound in Parallel

9

Primary Winding Power Losses at Different Input and Output Voltage InputVoltage(rms)

90.0

277.0

OutputVoltage(V)

31.45

41.0

31.45

Total Primary Winding Loss (W)

1.434

1.54

1.04

1.063

DC component of Pri winding loss (W)

0.404

0.584

0.126

0.164

AC component of Pri winding loss (W)

1.03

0.956

41.0

0.914

0.899

0

Margin Tape for Secondary Winding Secondary Winding Insulation type

1

Optional Wire list for Secondary winding

30.0AWG

Number of strands wound in parallel of second winding

29

Secondary Winding Power Losses at Different Input and Output Voltage InputVoltage(rms)

90.0

277.0

OutputVoltage(V)

31.45

41.0

Total Secondary Winding Loss (W)

0.699

0.673

0.699

0.701

DC component of Sec winding loss (W)

0.522

0.443

0.614

0.604

AC component of Sec winding loss (W)

0.177

Auxiliary winding Insulation type

1

Optional Wire list for Aux winding

37.0AWG

Number of Strands Wound in Parallel

1

31.45

0.23

41.0

0.085

0.097

Auxilari Winding Power Losses at Different Input and Output Voltage InputVoltage(rms)

90.0

OutputVoltage(V)

277.0

31.45

41.0

31.45

41.0

Total Primary Winding Loss (W)

0.00019544

0.00022632

0.00015427

0.00015427

DC component of Pri winding loss (W)

0.0001028

0.0001028

0.0001028

0.0001028

AC component of Pri winding loss (W)

9.264e-05

0.00012352

5.147e-05

5.147e-05

Transformer Power Losses Breakdown Information 90.0

Input Voltage (rms) Output Voltage

277.0

31.45

Total Primary Winding Loss

41.0

1.434

DC component of Pri winding loss

Secondary Winding Loss

1.54

0.404

AC component of Pri w inding loss

DC component of Sec winding loss

0.584

0.673 0.443

0.614

0.23 0.00022632

2.133

2.213 1.54224

1.02002

3.31

3.755

2.759

1.739

Finished Heights of one Tape Layer

63um

Winding Height Reduction due to Shared Layers

0m

Unfilled winding heights

5.70mm

Transformer Primary Leakage Inductance

1.31uH

Np1

2

Insulation

3

Ns

Pi n (S> F) 5to3

Wi re Si ze an d Type 29X9

AWG

Heavy

polyester Tape t=0.025 NS- to NS+

0.00015427 1.764 1.6085 3.373

8

Total Layers of Insulation Tape

Wi n d in g

0.097

0.00015427

1.17655

1

0.604

0.085

Magnetic Core Loss

No

0.899 0.701

Total winding loss

Total Power loss of Winding+core

0.164

0.914 0.699

0.177

0.00019544

1.063 0.126

0.956

0.522

AC component of Sec winding loss

41.0

1.04

1.03

0.699

Aux Winding loss

31.45

30X29

AWG

Tu rn s 13.0

Wi n di n g Me thod

SolenoidWinding

Ma rg in tape

N/A

1 layer Reinforced


17.0

Solenoid Winding

N/A

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FSC:FairchildPSW WebDesigner - Summary 4

Insulation

5

Na

6

Insulation

7

Np2

8

Insulation

polyester Tape t=0.025 2 to 6

37X1

AWG

1 layer Reinforced

8.0

polyester Tape t=0.025 3to4

29X9

AWG

Solenoid Winding

N/A

2 layers Heavy

13.0

polyester Tape t=0.025

*

Transformer Primary side Inductance (Pin5 - Pin4)

*

TransformerleakageInductance

Safety Standard

SolenoidWinding

N/A

6 layers

62.1714 1.31443

uH uH

EN 61347-2-13 Reinforced Insulation

Power Circuit Min Average-Forward-Current Rating

3.36A

Min Peak-Reverse-Voltage Rating

587V

Forward Voltage at 25C

1V

Max loss at Min Input and Max output Voltage

3.16W

Transformer Primary Leakage Inductance

1.31uH

Max Voltage of Snubber Capacitor (Vsn)

143V

Snubber Resistor (Rsn) Power loss

5.97W

Snubber Resistor (Rsn)

3.44k

Worst Case Average Voltage across Snubber Resistor

143V

Max Snubber Resistor Peak to Peak Ripple Voltage (% of its average DC voltage)

5.45%

Snubber Capacitor (Csn)

76.2nF

Vsn Based on Selected Rsn and Csn

7.81V

Max voltage stress on MOSFET based on Selected Snubber

521V

Max

MOSFET Turn On Resistor Rg_on

2.2

MOSFET Turn Off Resistor Rg_off

10Ω

MOSFET Max. Peak Switching Current

12.1A

Max MOSFET rms Current

3.16A

Max MOSFET Capacitive Loss Max MOSFET on/off Switching Loss

1.12W 2.62W

Max Control IC Power Loss

96.1mW

Max MOSFET Conduction Loss at Max Temp

30.4W

Worst Case MOSFET Junction Temp

125C

Is Heat Sink Needed for MOSFET Thermal Dissipation?

Yes

Desired MOSFET Case to Ambient Thermal Impendence

2.23C/W

Min Average Forward-Current Rating (If_av)

3.75A

Min Peak Reverse-Voltage Rating (Vrrm)

393V

Diode Forward Voltage at 25C

1.5V

Diode Reverse Recovery Time

35ns

Output diode Max conduction loss at full load

4.32W

Input Circuit EMI DM Inductor Lin1 Parasitic Capacitance

100pF

EMI Filter Cap Cin2

434nF

EMI Filter Cap Cin1

2.10uF

EMI Filter Differential Mode Inductor Lin1 Recommended EMI Inductor Current Rating

2.28mH 3.29A


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P ow e rFa c tora n dTH D

@1 2 0 V

PowerFactor@lowOutput

0.991

PowerFactor@HighOutput

0.991

@2 2 0 V 0.969 0.97

THD@MinLEDswfulldrivingcurrent

5.6%

11.24%

THD@MaxLEDswfulldrivingcurrent

5.67%

10.76%

3.78

Active Shaping Current Sensor Rrbld Max shaping Current during Dimmer phase-cut period

132mA

Active Bleeding Current Setting Resistor Rmbld

125k

Offset Resistor R offset for Fault Short-Circuit Protection

Open

Max. Power Loss of Active Bleeder MOSFETbld Q

5.25W

Efficiency I n p u tVol ta g e(Vr ms )

90. 0 0

277. 00

Output Voltage (V)

31.50

41.00

Total Loss (W) Driver Efficiency

42.43 68.982%

48.60 71.68%

I n p uV t ol ta g e(Vr ms )

31.50

41.00

23.98 79.731%

28.80 81.027%

90

Output Voltage (V) 31.45 41.0 MOSFET (Q1) Total Power Loss 25.963 31.32 MOSFET Capacitive Loss (W) 0.132 0.222 MOSFET on/off switching Loss (W) 0.452 0.655 MOSFET Conduction Loss (W) 25.379 30.444 Current Sensor (Rcs) Loss (W) 0.424 0.613 Control IC Power Loss (W) 0.074 0.099 Output Diode ( Dr) Power Loss (W) 4.32 4.32 Rectifier Bridge (BD Power Loss (W) 2.368 3.162 Total Transformer Power Loss (W) 3.31 3.755 Primary Snubber Resistor (Rsn) Power loss 5.966 5 .327 Max. MOSFET (Q1) Temp (C) 125.0 Desired MOSFET Case to Ambient Thermal Impedance

Loss Summary for Min Input and Min Output Voltage

Loss Summary for Max Input and Min Output Voltage


2 77 31.45 11.675

41.0 15.845 0.743 1.117 1.84 2.624 9.092 12.103 0.133 0 .172 0.074 0.099 4.32 4.32 0.745 0.979 2.759 3.373 4.279 4.013

@ Max MOSFET Ambient Temp = 2.23496 C/W

55.0

Loss Summary for Min Input and Max Output Voltage

Loss Summary for Max Input and Max Output Voltage

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Schematic


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Part List

Ref

Q t y P ar t N u m b er

U1

1

FL7733AMX

Fairchild Semiconductor

M a n u f ac t u r er

Ccom

1

08053C105JAT2A

AVX


Desc r i p ti o n P SR Flyback LED Driver Cap Ceramic 1uF 25V X7R 5% SMD 0805 125C Embossed T/R

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Cin1

1

Custom

Capacitor68uF|227V

Cin2

1

PHE840MB6470MB16R17

Kemet

Cap Film Suppression X2 0.47uF 760VDC/275VAC PP 20% (18 X 11 X 19mm) Radial 15mm 105C Bulk

Cout

8.0

B41505A8338M000

Epcos

Aluminum Electrolytic Capacitors - Snap In 3300UF 63V AL-ELKO SNAP IN

Cout_hf1

1

BFC241611004

Vishay

Cap Film 0.1uF 63V PP 2% (7.2 X 6 X 11mm) Radial 5mm 85C Ammo Pack

Cps

1

B81122C1472M

Epcos

Suppression Film Capacitors 0.0047uF 250V 20% Class Y2

Csnb

1

ECQ-E2683JF

Panasonic

Cap Film 0.068uF 250V PET 5% (10.3 X 4.5 X 7.5mm) Radial 7.5mm 105C Bulk

Cvdd

1

AFC226M35D16B-F

Cornell Dubilier

CAP 22UF 35V ALUM ELECT SMD

Cvdd_hf

1

06035C104KAT2A

AVX

Cap Ceramic 0.1uF 50V X7R 10% SMD 0603 125C Paper T/R

Cvs

1

06035C220KAT2A

AVX

Cap Ceramic 22pF 50V X7R 10% SMD 0603 125C T/R

Dgate

1

1N4151_T50R


Diode Small Signal Switching 75V 0.15A 2-Pin DO-35 T/R

Din1

1

FFD04H60S


Diode Switching 600V 4A 3-Pin(2+Tab) DPAK T/R

Din2

1

FFD04H60S



Din3

1

FFD04H60S



Din4

1

FFD04H60S



Dout

1

FFP04U40DNTU


Dsnb

1

EGP10K


ES1F

Fairchild Semiconductor Di ode Switching 300V 1A 2-Pin DO-214AC T/R

Dvdd

1

Fuse

1

Custom

Lin1

1

Custom

MOV

1

Diode Switching 400V 4A 3-Pin(3+Tab) TO-220 Tube Diode Switching 800V 1A 2-Pin DO-41 T/R

Resistor10 |330V Inductor2.28mH|10

Custom

Varistor

Q1

1

FQA8N100C


Trans MOSFET N-CH 1KV 8A 3-Pin(3+Tab) TO-3P(N) Rail

Rcomp

1

CR0603-FX-1240ELF

Bourns

Res Thick Film 0603 124 Ohm 1% 0.1W(1/10W) ?100ppm/C Molded SMD Paper Tape on Plastic Reel

Rcs

1

Custom

Resistor61.5m

Rg_on

1

CRCW06032R20FKEA

Vishay

Rg_on_off

1

CR0603-FX-10R0ELF

Bourns

Res Thick Film 0603 2.2 Ohm 1% 0.1W(1/10W) ?100ppm/C Molded SMD Paper T/R

Rout1

1

CMF5516K500FHEK

Vishay

16.5K

Rsnb

1

B12J3K5E

Ohmite

Res Wirewound 3.5K Ohm 5% 12W 260ppm/ C Ceramic AXL

Res Thick Film 0603 10 Ohm 1% 0.1W(1/10W) ?100ppm/C Molded SMD Paper Tape on Plastic Reel 1% 1/2W ±50ppm/

℃ 175 ℃

-55℃ 7.06mm N/R N/R 2.29mm

Simulation Results Transient Results Po weTrr a in

C ont r ol

Output


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100w led driver circuit using FL7733A - 36v-3A

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