User's Guide SNVA631A - February 2012 - Revised May 2013 AN-2214 TPS92310 Evaluation Module 1 Introduction The TPS92310 EVM-8W evaluation module is a constant current output LED driver supporting 5W to 8W applications. The design focuses on applications that require small form factor and minimal number of external components. The actual PCB dimension of the module is only 22mm x 55mm x 19mm (L x W x H). The module can work with AC line input from 90 to 132VRMS or 180 to 264VRMS and supplying 350mA current into a single string of LEDs, typically 6-7 LEDs in series. The evaluation board is carefully designed to comply with major industrial EMC and safety requirements. The user can make use of the information provided in this document, Dual Hot-Swap Power Controllers with Interdependent Circuit Breaker and Power-Good Reporting (SLVS275) data sheet and application notes to design its specific end product easily. 2 Description The TPS92310 EVM-8W is developed with the TPS92310 controller IC. The TPS92310 is a single-stage AC/DC controller dedicated for LED Lighting applications. The controller uses a primary-side current sense configuration to control the LED current at secondly side. The system works in Critical Conduction Mode (CRM) with flyback topology and it employs a constant on time modulation scheme. Inherently, systems with this configuration can achieve greater than 0.90 Power Factor (PF) easily. The Power Factor (PF) and line current harmonic performances of the evaluation board are tested and reported in this document. The TPS92310 also integrated various protection features: Over-Voltage Protection (OVP), Thermal Shut Down (TSD) and cycle-by-cycle Over-Current Protection (OCP). With these features in place, the system is well protected against open and short circuit of the LEDs string. Considering with the EMI problem, the TPS92310 integrates an internal delay timer to improve it. The delay time can be programmed through an external resistor, it can ensures the controller switch ON the MOSFET only when the MOSFET's drain voltage at its lowest point. The Quasi-resonant switching operation improves the EMI and system efficiency significantly. 3 Typical Applications LED Lamps: * A19 (E26/27, E14) * PAR30/38 * GU10 Domestic and Office SSL solutions: * Down Light * LED Panel Light * Ceiling Lamp Troffer * T8 Tube SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 1 Electrical Performance Specifications www.ti.com Features * Application input voltage: 90VRMS-132VRMS or 180VRMS-264VRMS * Primary side Fly-back LED current regulation * Adaptive ON-time control with inherent PFC * Critcal-Conduction-Mode (CRM) with Zero-Current Detect (ZCD) for valley switching * Quasi-resonant switching to benefit the EMI and efficiency * Programmable FET Switch-On-Delay * Constant ON-Time (COT) and Peak Current Mode (PCM) * LED current setting with external sense resistor 4 Electrical Performance Specifications Table 1. 230VAC Evaluation Board (TPS92310 230V EVM) PARAMETER TEST CONDITIONS Min Voltage range 180 Typ Max Units 264 VRMS - mA Input Characteristics Input current when VAC =220VRMS, VLED=20V - 38 330 350 370 mA - 26 - V % Output Characteristics Output voltage, VLED Output load current, ILED 21 Output over voltage V Systems Characteristics Full load efficiency (PIN = 8W) 83 85 - Full load Power Factor (PIN = 8W) - >0.9 - Table 2. 120VAC Evaluation Board (TPS92310 120V EVM) PARAMETER TEST CONDITIONS Min Typ Max Units 132 VRMS - mA Input Characteristics Voltage range Input current when VAC = 220VRMS, VLED=20V 90 - 75 330 350 370 mA - 26 - V Full load efficiency (PIN = 8W) 82 85 - % Full load Power Factor (PIN = 8W) - >0.9 - Output Characteristics Output voltage, VLED Output load current, ILED Output over voltage 21 V Systems Characteristics 2 AN-2214 TPS92310 Evaluation Module SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated Schematic ( TPS92310 120V EVM / TPS92310 230V EVM ) www.ti.com 5 Schematic ( TPS92310 120V EVM / TPS92310 230V EVM ) *L1 D2 *R16 LED+ *C2 *R15 T1 R11 *C5 D1 *R3 C3 *C6 C9 *F1 *CN1 AC R1 D3 *VR1 C4 6 7 LED *R12 *CN2 D4 R6 *R2 *D7 VZCD R4 *R5 C11 LED- R7 CY1 U1 1 C8 2 D6 C7 * Optional R10 VCC ZCD 3 AGND 4 COMP 5 DLY GATE 10 ISNS 9 PGND 8 *R13 MODE1 7 6 MODE2 *R14 Q1 R8 *R9 TPS92310 Figure 1. Standard Schematic for the TPS92310 Evaluation Board 5.1 Test Equipment Voltage Source: Start at 90VRMS-140VRMS or 180VRMS-264VRMS; AC source: PCR500LA (KIKUSUI) Multimeter: Agilent 34401A Power meter: WT210 Digital Power Meter (YOKOGAWA) Output Load: 7 LEDs in series ( LED forward voltage =3.0 V at 350 mA ) or VLED = 21V Oscilloscope:TDS3054C (TEKTRONIX ) Operation temperature : 25C SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 3 Board Connection 6 www.ti.com Board Connection Current Meter AC LINE LED+ Current Meter AC TPS92310 EVM / LM3440 EVM Voltage Meter AC Neutral 7 x LED Voltage Meter LED- Figure 2. Typical Connection Block Diagram Figure 3. TPS92310EVM_8W 4 Terminal Designation Description AC Live AC Neutral Connect 230VAC or 120VAC to the board ( TPS92310 120V EVM = 120VAC , TPS92310 230V EVM = 230VAC ) LED+ Connect to the LED + of the LED string LED- Connect to the LED - of the LED string AN-2214 TPS92310 Evaluation Module SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated TPS92310 Evaluation Board Test Procedure www.ti.com 7 TPS92310 Evaluation Board Test Procedure CAUTION High voltage levels are present on the evaluation module whenever it is energized. Proper precautions must be taken when working with the EVM. Serious injury can occur if proper safety precautions are not followed. Table 3. Connections Step Operation Remarks 1 Confirm the demo boards version. (120VACTPS92310 120V EVM or 230VACTPS92310 230V EVM) Check the demo board. 2 Connect the AC source to AC line AC source voltage is 230VACTPS92310 230V EVM /120VACTPS92310 120V EVM 3 Connect the LED light or electronic load to connecter LED+ and LED-. (Figure 3) If use electronic load, set the electronic load is 20V with CV mode. And make sure the LED + connect to electronic load + and LED- connection electronic load GND. Table 4. Functional AC Input Test Step Operation Remarks 4 Switch the power switch on the setup to ON position. Please confirm the AC1 and AC2 connection are correct. 5 The LEDs lights up within 2 sec. Measure the convertor output voltage. The LED voltage is 21V. ILED current is 350mA +/5% (electronic load loading value). If the VLED start up <2 sec, Power Factor >0.9 and ILED between 330mA to 370mA 6 Switch off the power source. Don't touching any connection within 2 sec after power off. SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 5 Typical Performance Characteristics (TPS92310 230V EVM (230VAC) / TPS92310 120V EVM (120VAC) Typical Performance Characteristics (TPS92310 230V EVM (230VAC) / TPS92310 120V EVM (120VAC) 100 100 95 95 EFFICIENCY (%) EFFICIENCY (%) 8 90 85 80 90 85 80 75 75 70 70 180 190 200 210 220 230 240 250 260 270 AC INPUT (VAC) 90 0.40 0.40 0.39 0.39 0.38 0.38 0.37 0.37 0.36 0.35 0.34 140 0.35 0.34 0.33 0.32 0.32 0.31 0.31 0.30 180 190 200 210 220 230 240 250 260 270 AC INPUT (VAC) 0.30 90 AN-2214 TPS92310 Evaluation Module 110 120 130 AC INPUT (VAC) 0.36 0.33 Figure 6. Line Regulation 100 Figure 5. Efficiency vs AC Input I LED (A) I LED (A) Figure 4. Efficiency vs AC Input 6 www.ti.com 100 110 120 130 AC INPUT (VAC) 140 Figure 7. Line Regulation SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated Typical Performance Characteristics (TPS92310 230V EVM (230VAC) / TPS92310 120V EVM (120VAC) 1.00 1.00 0.98 0.98 0.96 0.96 0.94 0.94 0.92 0.92 P.F P.F www.ti.com 0.90 0.90 0.88 0.88 0.86 0.86 0.84 0.84 0.82 0.82 0.80 180 190 200 210 220 230 240 250 260 270 AC INPUT (VAC) 0.80 90 100 380 380 370 370 360 360 350 350 340 340 330 330 320 320 14 15 16 17 18 19 VLED(V) 20 21 22 14 Figure 10. Load Regulation (230VAC) Ch1 > 140 Figure 9. Power Factor ILED(mA) ILED(mA) Figure 8. Power Factor 110 120 130 AC INPUT (VAC) VAC 15 16 17 18 19 VLED(V) 20 21 22 Figure 11. Load Regulation (120VAC) Ch1 > VAC Ch3 > Ch3 > IAC Ch1: 250V/div; Ch3: 50 mA/div; Time: 4 ms/div. Figure 12. Input Voltage and Input Current (230VAC) SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback IAC Ch1: 100V/div; Ch3: 100 mA/div; Time: 4 ms/div Figure 13. Input Voltage and Input Current (120VAC) AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 7 Typical Performance Characteristics (TPS92310 230V EVM (230VAC) / TPS92310 120V EVM (120VAC) www.ti.com VAC VAC Ch1 > Ch1 > ILED VLED Ch3 > Ch4 Ch1: 250V/div; Ch3: 200 mA/div; Ch4: 5V/div; Time: 200 ms/div ILED VLED Ch3 > Ch4 Ch1: 100V/div; Ch3: 200 mA/div; Ch4: 5V/div; Time: 200 ms/div. Figure 14. Power Up Output Voltage and Current (230VAC) Figure 15. Power Up Output Voltage and Current (120VAC) VAC Ch1 > VAC Ch1 > VLED VLED ILED ILED Ch3 > Ch4 Ch1: 250V/div; Ch3: 200 mA/div; Ch4: 5V/div; Time: 4 ms/div. Figure 16. Output Current and Voltage Waveforms (230VAC) 8 AN-2214 TPS92310 Evaluation Module Ch3 > Ch4 Ch1: 100V/div; Ch3: 200 mA/div; Ch4: 5V/div; Time: 4 ms/div Figure 17. Output Current and Voltage Waveforms (120VAC) SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated Current Harmonic Information www.ti.com 9 Current Harmonic Information Eval Board Figure 18. TPS92310 120V EVM Current Harmonic vs IEC61000-3-2 Class C Limits Eval Board Figure 19. TPS92310 230V EVM Current Harmonic vs IEC61000-3-2 Class C Limits SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 9 Electromagnetic Interference (EMI) 10 www.ti.com Electromagnetic Interference (EMI) In order to get quick estimation of the EMI filter performance, only PEAK conductive EMI scan was measured and the data was compared with the EN 55022 Class B conducted EMI Limits. All test conditions are under PIN=8W full load. Figure 20. Peak Conductive EMI per EN55022, Class B Limits (110VAC Live) Figure 21. Peak Conductive EMI per EN55022, Class B Limits (110VAC Neutral) Figure 22. Peak Conductive EMI per EN55022, Class B Limits (230VAC Live) 10 AN-2214 TPS92310 Evaluation Module SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated Electromagnetic Interference (EMI) www.ti.com Figure 23. Peak Conductive EMI per EN55022, Class B Limits (230VAC Neutral) 10.1 EVM Assembly Drawing and PCB Layout Figure 24. Top Layer Assembly Drawing (Top View) SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 11 Electromagnetic Interference (EMI) www.ti.com Figure 25. Bottom Layer Assembly Drawing (Bottom View) Figure 26. Top Layer Copper (Top View) Figure 27. Bottom Layer Copper (Bottom View) 12 AN-2214 TPS92310 Evaluation Module SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated Bill of Materials TPS92310 Evaluation Board (TPS92310 230V EVM) www.ti.com 11 Bill of Materials TPS92310 Evaluation Board (TPS92310 230V EVM) Item Designator 1 PCB 2 U1 3 C3, C5 4 5 6 C6, C8 Description Manufacturer Printed Circuit Board Part Number 551600739-001 REV A TPS92310 TI TPS92310 CAP CER .1 F 630V 10% X7R 1812 Murata Electronics North America GRM43DR72J104KW01L C4 CAP 47000PF 310VAC EMI SUPPRESSN Vishay/BC Components BFC233920473 C9 CAP ALUM 470 F 35V 20% RADIAL Panasonic - ECG EEU-FR1V471L CAP, CERM, 10 F, 50V, XR7 ,[1210], CAP CER X7R 1210 Murata GRM32ER71H106KA12L 7 C7 CAP CER 2.2 F 50V X7R 0805 Murata GRM21BR71A225KA01L 8 C11 CAP CER 15p 50V 0603 Murata GRM1885C1H150JA01D 9 CY1 CAP CER 2200PF 250VAC X1Y1 RAD Murata DE1E3KX222MA4BL01 10 D1 RECT BRIDGE GP 600V 0.8A MINIDIP Diodes Inc HD06-T 11 D2 DIODE SCHOTTKY 100V 1A SMA Diodes Inc B1100-13-F 12 D3 DIODE GPP ULTRA FAST 1A 600V SMA Vishay/General Semiconductor US1J-E3/61T 13 D4 Default Diode Diodes Inc BAV20W-7-F 14 D5 Zener Diode Littelfuse Inc SMAJ250ALFCT-ND 15 D6 General Purpose diode Comchip Technology CDSU4148 16 Q1 MOSFET N-CH 800V 2.5A DPAK STMicroelectronics STD3NK80ZT4 17 R1 NC NC NC 18 R2 RES 47 OHM 1W 5% METAL FILM AX (230VAC) Yageo FMP100JR-52-47R 19 R3 RES, 1.00k ohm, 1%, 0.25W, 1206 Vishay/Dale CRCW12061K10FKEA 20 R4 RES, 66.5k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060366K5FKEA 21 R5 RES 0.0 OHM 1/8W 0805 SMD Vishay/Dale CRCW08050000Z0EA 22 R6 RES, 20.0 ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060320R0JNEA 23 R7 RES, 11.0k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060311K0FKEA 24 R8 3.3 Ohm (230VAC) Panasonic - ECG ERJ-8GEYJ3R3V 25 R9 51 Ohm (230VAC) Panasonic - ECG ERJ-8GEYJ510V 26 R10 RES, 18.0k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060318K0JNEA 27 R11 200KOhm, 5%. 0.25W 1206 Vishay/Dale CRCW1206200KJNEA 28 R12 200KOhm, 5%. 0.25W 1206 Vishay/Dale CRCW1206200KJNEA 29 R13 NC NC NC 30 R14 NC NC NC 31 R15 NC NC NC 32 R16 RES 0.0 OHM 1/8W 0805 SMD Vishay/Dale CRCW08050000Z0EA 33 VR1 VARISTOR 300V 30J 7MM EPCOS EPCOS Inc S07K300E2 34 L1 Inductor 4.7mH Sumida RCH895 00777-T048-332 35 T1 750341087 REV 2.0 Wurth 750341087 REV 2.0 36 F1 FUSE SLOW BLOW 0.5A Littelfuse Inc 0677.500MXE 37 H1, H2, H5, H6 Standoff, Hex, 0.5"L #4-40 Nylon Keystone 1902C 38 H3, H4, H7, H8 Machine Screw, Round, #4-40 x 1/4, Nylon, Philips panhead B&F Fastener Supply NY PMS 440 0025 PH Conn Term Block, 2POS, 5.08mm PCB Phoenix Contact 1715721 Terminal, Turret, TH, Double Keystone Electronics 1502-2 39 CN1, CN2 40 TP1, TP2, TP3, TP4 SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback AN-2214 TPS92310 Evaluation Module Copyright (c) 2012-2013, Texas Instruments Incorporated 13 Bill of Materials TPS92310 Evaluation Board (TPS92310 120V EVM) 12 Bill of Materials TPS92310 Evaluation Board (TPS92310 120V EVM) Item Designator 1 PCB 2 U1 3 C3, C5 4 5 6 C6, C8 Description Manufacturer Printed Circuit Board PartNumber 551600739-001 REV A TPS92310 TI TPS92310 CAP CER .1F 630V 10% X7R 1812 Murata Electronics North America GRM43DR72J104KW01L C4 CAP 47000PF 310VAC EMI SUPPRESSN Vishay/BC Components BFC233920473 C9 CAP ALUM 470F 35V 20% RADIAL Panasonic - ECG EEU-FR1V471L CAP, CERM, 10F, 50V, XR7 ,[1210], CAP CER X7R 1210 Murata GRM32ER71H106KA12L 7 C7 CAP CER 2.2F 50V X7R 0805 Murata GRM21BR71A225KA01L 8 CY1 CAP CER 2200PF 250VAC X1Y1 RAD Murata DE1E3KX222MA4BL01 9 C11 CAP CER 15p 50V 0603 Murata GRM1885C1H150JA01D 10 D1 RECT BRIDGE GP 600V 0.8A MINIDIP Diodes Inc HD06-T 11 D2 DIODE SCHOTTKY 100V 1A SMA Diodes Inc B1100-13-F 12 D3 DIODE GPP ULTRA FAST 1A 600V SMA Vishay/General Semiconductor US1J-E3/61T 13 D4 Default Diode Diodes Inc BAV20W-7-F 14 D5 Zener Diode Littelfuse Inc SMAJ250ALFCT-ND 15 D6 General Purpose diode Comchip Technology CDSU4148 16 Q1 MOSFET N-CH 800V 2.5A DPAK STMicroelectronics STD3NK80ZT4 17 R1 NC NC NC 18 R2 RES 22 OHM 1W 5% METAL FILM AX Yageo FMP100JR-52-22R 19 R3 RES, 1.00k ohm, 1%, 0.25W, 1206 Vishay/Dale CRCW12061K10FKEA 20 R4 RES, 66.5k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060366K5FKEA 21 R5 RES 0.0 OHM 1/8W 0805 SMD Vishay/Dale CRCW08050000Z0EA 22 R6 RES, 20.0 ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060320R0JNEA 23 R7 RES, 11.0k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW060311K0FKEA 24 R8 1.5 Ohm 1206 Panasonic - ECG ERJ-8GEYJ1R5V 25 R9 36 Ohm 1206 NC ERJ-8GEYJ360V 26 R10* RES, 6.34k ohm, 1%, 0.1W, 0603 Vishay/Dale CRCW06036K34FKEA 27 R11 100KOhm, 5%. 0.25W 1206 Vishay/Dale CRCW1206100KJNEA 28 R12 100KOhm, 5%. 0.25W 1206 Vishay/Dale 'CRCW1206100KJNEA 29 R13 NC NC NC 30 R14 NC NC NC 31 R15 NC NC NC 32 R16 RES 0.0 OHM 1/8W 0805 SMD Vishay/Dale CRCW08050000Z0EA 33 VR1 VARISTOR 300V 30J 7MM EPCOS EPCOS Inc S07K300E2 34 L1 Inductor 3.3mH Sumida RCH895 00777-T048-332 35 T1 750341086 REV 2.0 Wurth 750341086 REV 2.0 36 F1 FUSE SLOW BLOW 0.5A Littelfuse Inc 0677.500MXE 37 H1, H2, H5, H6 Standoff, Hex, 0.5"L #4-40 Nylon Keystone 1902C 38 H3, H4, H7, H8 Machine Screw, Round, #4-40 x 1/4, Nylon, Philips panhead B&F Fastener Supply NY PMS 440 0025 PH Conn Term Block, 2POS, 5.08mm PCB Phoenix Contact 1715721 Keystone Electronics 1502-2 39 40 14 www.ti.com CN1, CN2 TP1, TP2, TP3, TP4 Terminal, Turret, TH, Double AN-2214 TPS92310 Evaluation Module SNVA631A - February 2012 - Revised May 2013 Submit Documentation Feedback Copyright (c) 2012-2013, Texas Instruments Incorporated IMPORTANT NOTICE Texas Instruments Incorporated and its subsidiaries (TI) reserve the right to make corrections, enhancements, improvements and other changes to its semiconductor products and services per JESD46, latest issue, and to discontinue any product or service per JESD48, latest issue. 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