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FL6632 Primary-Side-Regulated LED Driver with Power Factor Correction Features Description Cost-Effective Solution: No Input Bulk Capacitor or Feedback Circuitry Power Factor Correction This highly integrated PWM controller provides several features to enhance the performance of low-power flyback converters. The proprietary topology enables simplified circuit design for LED lighting applications. Linear Frequency Control Improves Efficiency and Simplifies Design Open-LED Protection Accurate Constant-Current (CC) Control, Independent Online Voltage, Output Voltage, and Magnetizing Inductance Variation Short-LED Protection Cycle-by-Cycle Current Limiting Over-Temperature Protection with Auto Restart Low Startup Current: 20 A Low Operating Current: 5 mA VDD Under-Voltage Lockout (UVLO) Gate Output Maximum Voltage Clamped at 18V By using single-stage topology with primary-side regulation, a LED lighting board can be implemented with few external components and minimized cost. No input bulk capacitor or feedback circuitry is required. To implement good power factor and low THD, constant on-time control is utilized with an external capacitor connected to the COMI pin. Precise constant-current control regulates accurate output current versus changes in input voltage and output voltage. The operating frequency is proportionally adjusted by the output voltage to guarantee DCM operation with higher efficiency and simpler design. FL6632 provides open-LED, short-LED, and overtemperature protection features. The current limit level is automatically reduced to minimize output current and protect external components in a short-LED condition. The FL6632 controller is available in an 8-pin SmallOutline Package (SOP). SOP-8 Package Application Voltage Range: 80 VAC ~ 308 VAC Applications LED Lighting System Ordering Information Part Number Operating Temperature Range Package Packing Method FL6632MX -40C to +125C 8-Lead, Small Outline Integrated Circuit Package (SOIC) Tape & Reel (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 www.fairchildsemi.com FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction May 2015 DC Output AC Input 2 8 GND GATE 3 GND CS 1 VDD 4 7 COMI NC VS 6 5 Figure 1. Typical Application Block Diagram Shutdown Max. Duty Controller GND 8 Gate Driver S VDD 4 + LEB OSC 3 Error Amp. R DCM Controller VDD Good OTP VS OVP 5 VS OVP 3V Figure 2. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 6 VS VREF tDIS Detector TRUECURRENT(R) Calculation EAV + NC COMI EAI Q + GND S 7 Sawtooth Generator + Internal Bias CS VCS-CL - + VDD OVP 1 Current Limit Control + VOVP GATE EAV Q R VDD Good 2 Sample & Hold Functional Block Diagram www.fairchildsemi.com 2 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Application Diagram 4 3 F: Z: X: Y: TT: T: M: 4 3 ZXYTT 6632 TM Fairchild Logo Plant Code 1-Digit Year Code 1-Digit Week Code 2-Digit Die Run Code Package Type (M=SOP) Manufacture Flow Code Figure 3. Top Mark Pin Configuration CS 1 8 GND GATE 2 7 COMI GND 3 6 3 VS VDD 4 5 4 NC Figure 4. Pin Configuration (Top View) Pin Descriptions Pin # Name Description 1 CS 2 GATE PWM Signal Output. This pin uses the internal totem-pole output driver to drive the power MOSFET. 3 GND Ground 4 VDD Power Supply. IC operating current and MOSFET driving current are supplied using this pin. 5 NC No Connect 6 VS Voltage Sense. This pin detects the output voltage information and discharge time for maximum frequency control and constant current regulation. This pin is connected to an auxiliary winding of the transformer via resistors of the divider. 7 COMI Constant Current Loop Compensation. This pin is connected to a capacitor between the COMI and GND pin for compensation current loop gain. 8 GND Ground Current Sense. This pin connects a current-sense resistor to detect the MOSFET current for the output-current regulation in constant-current regulation. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 www.fairchildsemi.com 3 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Marking Information Stresses exceeding the absolute maximum ratings may damage the device. The device may not function or be operable above the recommended operating conditions and stressing the parts to these levels is not recommended. In addition, extended exposure to stresses above the recommended operating conditions may affect device reliability. The absolute maximum ratings are stress ratings only. Symbol Parameter Min. Max. Unit 30 V (1,2) VVDD DC Supply Voltage VVS VS Pin Voltage -0.3 7 V VCS CS Pin Input Voltage -0.3 7 V VCOMI COMI Pin Input Voltage -0.3 7 V VGATE GATE Pin Input Voltage -0.3 30 V 633 mW 150 C 150 C 260 C PD Power Dissipation (TA50C) TJ Maximum Junction Temperature TSTG TL Storage Temperature Range -55 Lead Temperature (Soldering 10s) Notes: 1. Stresses beyond those listed under Absolute Maximum Ratings may cause permanent damage to the device. 2. All voltage values, except differential voltages, are given with respect to GND pin. Thermal Impedance TA=25C, unless otherwise specified. Symbol Parameter Value Unit JA Junction-to-Ambient Thermal Impedance 158 C/W JC Junction-to-Case Thermal Impedance 39 C/W Note: 3. Referenced the JEDEC recommended environment, JESD51-2, and test board, JESD51-3, 1S1P with minimum land pattern. ESD Capability Symbol ESD Parameter Value Human Body Model, ANSI/ESDA/JEDEC JS-001-2012 4 Charged Device Model, JESD22-C101 2 Unit kV Note: 4. Meets JEDEC standards JESD22-A114 and JESD 22-C101. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 www.fairchildsemi.com 4 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Absolute Maximum Ratings VDD=15 V, TJ=-40 to +125C, unless otherwise specified. Currents are defined as positive into the device and negative out of device. Symbol Parameter Conditions Min. Typ. Max. Unit 14.5 16.0 17.5 V 6.75 7.75 8.75 V 3 4 5 mA 2 20 A 22.0 23.5 25.0 V 1.5 V VDD SECTION VDD-ON Turn-On Threshold Voltage VDD-OFF Turn-Off Threshold Voltage IDD-OP Operating Current At Maximum Frequency CL=1 nF IDD-ST Startup Current VDD=VDD-ON - 0.16 V VOVP VDD Over-Voltage-Protection Level GATE SECTION VOL Output Voltage Low VDD=20 V, IGATE= -1 mA VOH Output Voltage High VDD=10 V, IGATE= +1 mA Peak Sourcing Current VDD=10 ~ 20 V Isource Isink 5 V 60 mA Peak Sinking Current VDD=10 ~ 20 V tr Rising Time CL=1 nF 100 150 200 ns tf Falling Time CL=1 nF 20 60 100 ns 12 15 18 V VCLAMP Output Clamp Voltage 180 mA Oscillator SECTION fMAX-CC Maximum Frequency in CC VDD=10 V, 20 V 60 65 70 kHz fMIN-CC Minimum Frequency in CC VDD=10 V, 20 V 21.0 23.5 26.0 kHz tON(MAX) Maximum Turn-On Time 12 14 16 s 2.475 2.500 2.525 V 2.38 2.43 2.48 V CURRENT-ERROR-AMPLIFIER SECTION VRV Reference Voltage VCCR EAI Voltage for CC Regulation tLEB Leading-Edge Blanking Time tMIN Minimum On Time in CC tPD Propagation Delay to GATE tDIS-BNK tDIS Blanking Time of VS IVS-BNK VS Current for VS Blanking VCS=0.44 V VCOMI=0 V 50 300 ns 600 ns 100 150 ns 1.5 s -100 A 85 mho Current-Error-Amplifier SECTION Gm Transconductance ICOMI-SINK COMI Sink Current VEAI=3 V, VCOMI=5 V 25 38 A 38 A |COMI Source Current| VEAI=2 V, VCOMI=0 V 25 VCOMI-HGH COMI High Voltage VEAI=2 V 4.9 VCOMI-LOW COMI Low Voltage VEAI=3 V ICOMI-SOURCE (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 V 0.1 V www.fairchildsemi.com 5 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Electrical Characteristics VDD=15 V, TJ=-40 to +125C, unless otherwise specified. Currents are defined as positive into the device and negative out of device. Symbol Parameter Conditions Min. Typ. Max. Unit VCS Threshold Voltage for OCP 0.63 0.70 0.77 V VLowOCP VCS Threshold Voltage for Low OCP 0.15 0.20 0.25 V VLowOCP-EN VS Threshold Voltage to Enable Low OCP Level 0.4 V VLowOCP-DIS VS Threshold Voltage to Disable Low OCP Level 0.6 V VVS-OVP VS Level for Output Over-Voltage Protection VOLTAGE-SENSE SECTION VOCP 2.9 3.0 3.1 140 150 160 V OVER-TEMPERATURE-PROTECTION SECTION TOTP TOTP-HYS (5) Threshold Temperature for OTP Restart Junction Temperature Hysteresis 10 o C o C Note: 5. The Ensured by design. Not tested in production. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 www.fairchildsemi.com 6 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Electrical Characteristics (Continued) 1.5 1.3 1.3 Normalized to 25 C Normalized to 25 C 1.5 1.1 0.9 0.7 1.1 0.9 0.7 0.5 0.5 -40 -30 -15 0 25 50 75 85 100 -40 125 -30 -15 0 VDD-ON vs. Temperature Figure 6. 1.5 1.5 1.3 1.3 Normalized to 25 C Normalized to 25 C Figure 5. 1.1 0.9 0.7 50 75 85 100 125 VDD-OFF vs. Temperature 1.1 0.9 0.7 0.5 0.5 -40 -30 -15 0 25 50 75 85 100 -40 125 -30 -15 0 Figure 7. 25 50 75 85 100 125 Temp [C] Temp [C] IDD-OP vs. Temperature Figure 8. 1.5 1.5 1.3 1.3 Normalized to 25 C Normalized to 25 C 25 Temp [C] Temp [C] 1.1 0.9 0.7 VOVP vs. Temperature 1.1 0.9 0.7 0.5 0.5 -40 -30 -15 0 25 50 75 85 100 -40 125 -30 -15 Figure 9. fMAX_CC vs. Temperature (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 0 25 50 75 85 100 125 Temp [C] Temp [C] Figure 10. fMIN_CC vs. Temperature www.fairchildsemi.com 7 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Typical Performance Characteristics 1.5 1.3 1.3 Normalized to 25 C Normalized to 25 C 1.5 1.1 0.9 0.7 0.5 1.1 0.9 0.7 0.5 -40 -30 -15 0 25 50 75 85 100 125 -40 -30 -15 0 Temp [C] 50 75 85 100 125 Temp [C] VCCR vs. Temperature Figure 12. 1.5 1.5 1.3 1.3 Normalized to 25 C Normalized to 25 C Figure 11. 25 1.1 0.9 0.7 0.5 VVVR vs. Temperature 1.1 0.9 0.7 0.5 -40 -30 -15 0 25 50 75 85 100 125 -40 -30 -15 Temp [C] Figure 13. 25 50 75 85 100 125 Temp [C] VOCP vs. Temperature (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 0 Figure 14. VOCP_Low vs. Temperature www.fairchildsemi.com 8 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Typical Performance Characteristics (Continued) FL6632 is AC-DC PWM controller for LED lighting applications. TRUECURRENTTM techniques regulate accurate LED current independent of input voltage, output voltage, and magnetizing inductance variations. The linear frequency control in the oscillator reduces conduction loss and maintains DCM operation in the wide range of output voltage, which implements high power factor correction in a single-stage flyback topology. A variety of protections, such as short/openLED protection, over-temperature protection, and cycleby-cycle current limitation stabilize system operation and protect external components. PFC and THD In a conventional boost converter, Boundary Conduction Mode (BCM) is generally used to keep input current inphase with input voltage for PF and THD. In flyback/buck boost topology, constant turn-on time and constant frequency in Discontinuous Conduction Mode (DCM) can implement high PF and low THD, as shown in Figure 16. Constant turn-on time is maintained by the internal error amplifier and a large external capacitor (typically over 1 F) at the COMI pin. Constant frequency and DCM operation are managed by linear frequency control. Startup Powering at startup is slow due to the low feedback loop bandwidth in PFC converter. To boost powering during startup, an internal oscillator counts 12ms to define Startup Mode. During Startup Mode, turn-on time is determined by Current-Mode control with a 0.2 VCS voltage limit and transconductance becomes 14 times larger, as shown in Figure 15. After startup, turn-on time is controlled by Voltage Mode using COMI voltage and error amplifier transconductance is reduced to 85 mho. IIN IIN_AVG VDD = VDD_ON VIN GATE Constant Frequency VCS 0.2 V Figure 16. Input Current and Switching DCM Control VCOMI 14gm gm As mentioned above, DCM should be guaranteed for high power factor in flyback topology. To maintain DCM across a wide range of output voltage, the switching frequency is linearly adjusted by the output voltage in linear frequency control in the whole Vs range. Output voltage is detected by the auxiliary winding and the resistive divider connected to the VS pin, as shown in Figure 17. When the output voltage decreases, secondary diode conduction time is increased and the DCM control lengthens the switching period, which retains DCM operation over the wide output voltage range, as shown in Figure 18. The frequency control lowers the primary rms current with better power efficiency in full-load condition. Startup Mode: 12 ms ILED Time Figure 15. Startup Sequence Constant-Current Regulation The output current can be estimated using the peak drain current and inductor current discharge time since output current is same as the average of the diode current in steady state. The peak value of the drain current is determined by the CS pin and the inductor discharge time (tdis) is sensed by tdis detector. By using three points of information (peak drain current, inductor discharging time, and operating switching period); the TRUECURRENTTM calculation block estimates output current. The output of the calculation is compared with an internal precise reference to generate an error voltage (VCOMI), which determines turn-on time in Voltage-Mode control. With Fairchild's innovative TRUECURRENTTM technique, constant-current output can be precisely controlled. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 Gate Driver OSC 2 GATE CC Control VOUT tDIS Detector 5 VS DCM Controller S/H Figure 17. DCM and BCM Control www.fairchildsemi.com 9 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Functional Description Secondary Current nV O Lm VO = VO.NOM VIN t t DIS n VO = 75% VO.NOM 3 V 4 O Lm VCS 0.2V 4 t 3 4 t DIS 3 n VO = 60% VO.NOM 3 V 5 Lm VDD VDD_ON O 5 t DIS 3 VDD_OFF 5 t 3 Figure 20. Figure 18. Primary and Secondary Current Waveforms in Short-LED Condition Open-LED Protection BCM Control FL6632 protects external components, such as diode and capacitor, at secondary side in open-LED condition. During switch-off, the VDD capacitor is charged up to the auxiliary winding voltage, which is applied as the reflected output voltage. Because the VDD voltage has output voltage information, the internal voltage comparator on the VDD pin can trigger output OverVoltage Protection (OVP), as shown in Figure 21. When at least one LED is open-circuited, output load impedance becomes very high and output capacitor is quickly charged up to VOVP x NS / NA Then switching is shut down and the VDD block goes into Hiccup Mode until the open-LED condition is removed, as shown in Figure 22. The end of secondary diode conduction time could possibly be behind the end of a switching period set by DCM control. In this case, the next switching cycle starts at the end of secondary diode conduction time since FL6632 doesn't allow CCM. Consequently, the operation mode changes from DCM to Boundary Conduction Mode (BCM). Short-LED Protection In case of a short-LED condition, the switching MOSFET and secondary diode are stressed by the high powering current. However, FL6632 changes the OCP level in a short-LED condition. When VS voltage is lower than 0.4 V, OCP level becomes 0.2 V from 0.7 V, as shown in Figure 19, so powering is limited and external components current stress is reduced. Internal Bias VDD Good + - VDD 4 LEB 1 CS VOVP - + VOCP + - At VS < 0.4 V, VOCP = 0.2 V 6 VS S At VS > 0.6 V, VOCP = 0.7 V Figure 19. VDD Good Internal OCP Block (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 Shutdown Gate Driver R Figure 21. Figure 20 shows operational waveforms in short-LED condition. Output voltage is quickly lowered to 0 V right after a short-LED event. Then the reflected auxiliary voltage is also 0 V, making VS less than 0.4 V. 0.2 V OCP level limits primary-side current and VDD hiccups up and down between UVLO hysteresis. Q Internal OVP Block www.fairchildsemi.com 10 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction LED Short ! Primary Current The turn-on and turn-off thresholds are fixed internally at 16 V and 7.5 V, respectively. During startup, the VDD capacitor must be charged to 16 V through the startup resistor to enable the FL6632. The VDD capacitor continues to supply VDD until power can be delivered from the auxiliary winding of the main transformer. VDD must not drop below 7.5 V during this startup process. This UVLO hysteresis window ensures that the VDD capacitor is adequate to supply VDD during startup. VDD_OVP VDD_ON VDD_OFF VOUT VDD_OVP x Ns/Na Over-Temperature Protection (OTP) The FL6632 has a built-in temperature-sensing circuit to shut down PWM output if the junction temperature exceeds 150C. While PWM output is shut down, the VDD voltage gradually drops to the UVLO voltage. Some of the internal circuits are shut down and VDD gradually starts increasing again. When VDD reaches 16 V, all the internal circuits start operating. If the junction temperature is still higher than 140C, the PWM controller is shut down immediately. GATE Figure 22. Waveforms in Open-LED Condition (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 www.fairchildsemi.com 11 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction Under-Voltage Lockout (UVLO) LED Open ! VDD PCB layout for a power converter is as important as circuit design because PCB layout with high parasitic inductance or resistance can lead to severe switching noise with system instability. PCB should be designed to minimize switching noise into control signals. 1. 2. The signal ground and power ground should be separated and connected only at one position (GND pin) to avoid ground loop noise. The power ground path from the bridge diode to the sensing resistors should be short and wide. Gate-driving current path (GATE - RGATE - MOSFET - RCS - GND) must be as short as possible. 3. Control pin components; such as CCOMI, CVS, and RVS2; should be placed close to the assigned pin and signal ground. 4. High-voltage traces related to the drain of MOSFET and RCD snubber should be kept far way from control circuits to avoid unnecessary interference. 5. If a heat sink is used for the MOSFET, connect this heat sink to power ground. 6. The auxiliary winding ground should be connected closer to the GND pin than the control pin components' ground. DC Output AC Input Power ground 5 RCS 2 RGATE 4 FL6632 CS GND CCOMI GATE COMI CVS 1 GND VS VDD NC 3 RVS2 CVDD 6 RVS1 Figure 23. (c) 2015 Fairchild Semiconductor Corporation FL6632 * Rev. 1.0 Signal ground Layout Example www.fairchildsemi.com 12 FL6632 -- Primary-Side-Regulated LED Driver with Power Factor Correction PCB Layout Guidance ON Semiconductor and are trademarks of Semiconductor Components Industries, LLC dba ON Semiconductor or its subsidiaries in the United States and/or other countries. ON Semiconductor owns the rights to a number of patents, trademarks, copyrights, trade secrets, and other intellectual property. A listing of ON Semiconductor's product/patent coverage may be accessed at www.onsemi.com/site/pdf/Patent-Marking.pdf. ON Semiconductor reserves the right to make changes without further notice to any products herein. ON Semiconductor makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does ON Semiconductor assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation special, consequential or incidental damages. Buyer is responsible for its products and applications using ON Semiconductor products, including compliance with all laws, regulations and safety requirements or standards, regardless of any support or applications information provided by ON Semiconductor. "Typical" parameters which may be provided in ON Semiconductor data sheets and/or specifications can and do vary in different applications and actual performance may vary over time. All operating parameters, including "Typicals" must be validated for each customer application by customer's technical experts. ON Semiconductor does not convey any license under its patent rights nor the rights of others. ON Semiconductor products are not designed, intended, or authorized for use as a critical component in life support systems or any FDA Class 3 medical devices or medical devices with a same or similar classification in a foreign jurisdiction or any devices intended for implantation in the human body. Should Buyer purchase or use ON Semiconductor products for any such unintended or unauthorized application, Buyer shall indemnify and hold ON Semiconductor and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges that ON Semiconductor was negligent regarding the design or manufacture of the part. ON Semiconductor is an Equal Opportunity/Affirmative Action Employer. This literature is subject to all applicable copyright laws and is not for resale in any manner. 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