onsemi NCL2801 150 W Lighting Solution Instructions
- June 1, 2024
- onsemi
Table of Contents
EVAL BOARD USER’S MANUAL
www.onsemi.com
150 W Lighting Solution with NCL2801, NCL30159,
NCL38046 Inside
EVBUM2896/D
SPECIFICATIONS
onsemi’s Device| Application| Input Voltage| Output Power| Topology|
I/O Isolation
---|---|---|---|---|---
NCL2801 NCL30159 NCL38046| Lighting| 90 to 264 Vac| 150 W| BOOST PFC, LLC|
Isolated
No.| Description| Symbol| Min| Type| Max|
Unit|
Test Conditions
---|---|---|---|---|---|---|---
1| Input Voltage Range| Vin(min/max)| 90| 115/230| 264| Vac|
2| Input Current| Irms| | | 2| A| full load
3| Rated Input Frequency| fin| 50| | 60| Hz| Isolated
4| Input Frequency Range| Fin(min/max)| 47| | 63| Hz|
5| Rated Output Power| Pout| | 150| | W|
6| Efficiency At Full Load| | | >94| | %| Tested at board end, 230 Vac
92| Tested at board end, 115 Vac
7| Output Voltage and Current| Vout/Iout| | 50 V / 3 A| | V/A| 90 Vac−264 Vac
8| No load power| Pstandby| | | <0.3| W|
SPECIFICATIONS AND FEATURES
-
High Efficiency and Low Standby Power
-
An Easily Setting SKIP Mode
-
Protections
♦ Over Voltage Protection
♦ Over Current Protection
♦ Constant Power Protection by NCL30159 and NCL38046 -
High PF and Low THD
EVBUM2896/D
EVBUM2896/D
EVBUM2896/D
CIRCUIT DESCRIPTION
This design used onsemi’s PFC controller NCL2801CDA, LLC controller NCL30159
and CC/CV mode feedback loop controller NCL38046. Thanks to onsemi’s current
mode PFC controller NCL2801, the reference design PFC part easy to maintain a
High PF value and low THD even in very light load condition.
The NCL30159 is a high performance current mode controller for half bridge
resonant converters, which with an easily setting SKIP mode. This controller
implements 720 V gate drivers, simplifying layout and reducing external
component count.
The NCL30159 implements maximum power limit feature. This simple system
ignores the LLC stage efficiency shift at different operating points at high
power level, that’s why the input bulk voltage and input average current
flowing into LLC stage are sensed. It’s sometimes called as quasi constant
power feature.
The maximum power limit can be calculated easily by Eq.1:
(V osc_max is 3.325, Vref is selectable via different IC version in range
0.500 V to 1.700 V ).
As the same LLC controller in ONSEMI family, compare with NCP1399 and
NCP13992, NCL30159 have a big improvement at the OCP performance which
triggered by CS pin after adding the OCPRC circuit inside.
(CH2 – CS_stop_cmp_inv, CH3 – internal FB with RC, CH4 − Iprimary)
Figure 5. Resonant Choke Current when SS without OCPRC
Ramp compensation gain adjusted base on over−current event, this help to get a significantly reduced primary and secondary currents under stress conditions.
NCL30159 implements a simple SKIP MODE setting.
The SKIP_OUT level is fixed by IC IPT version (SKIP_OUT level is selectable
via different IC IPT version), and there is a constant current source inside
SKIP pin which is 50uA, so you can set R18 to set the SKIP_IN level.
SKIP_IN LEVEL 50 A*R18 (eq. 2)
SKIP_IN level should be lower than SKIP_OUT level which selected by IC IPT
version.
The NCL38046 is a high performance Constant Current and Constant Voltage
amplifier with low input offset voltage. It can enable to extend system
dimming range under 1%. Also can support programmable constant power
regulation to protect LED load and to provide wide output operating range.
NCL38046 have PA and AA version, when analog voltage signal at ADIM is used
for the maximum output current setting and PWM duty signal at PDIM is used for
dimming, PA version should be used. VCS(REF) is determined by (Eq. 3) which
corresponds to Figure 8.
When adim is used for dimming and pdim is to set the maximum output current, AA version should be used. V CS(REF) is set by (Eq. 4) corresponding to Figure 9.
CS(REF) dimming voltage range is limited by CS(REF−MAX) and V O / I O Sensing
CS(REF−MIN) .
Figure 10 shows how to set the CC and CV feedback loop.
The Io_max can be set by : RCS 100 mV Io.max (eq. 5)
Which RCS (= RCS1 || RCS2), and Max. VCS reference = 100 mV. The Vo_max can be
set by : RVS1 RVS2 ( Vo.max 2.5 V ) 2.5 V (eq. 6)
Which Max. V VS reference = 2.5 V.
At startup, 50 A I SET sources SET/REF pin and the external R SET and C are detected to set the internal parameters. Then, SET sequence is terminated and SET/REF pin out is 3.3 V by internal LDO. The dimming curve will be setting by C Table 1. SET SET :
C SET Function
CSET| Dimming Curve
0 nF| Linear
1.2 nF| Logarithm
For the dimming curve, the modulator input signal, mod , have an effective input range between 10% and 90%. When mod IN IN is 10%, mod clamped to 1% by mod OUT (MIN). When modI N OUT is lower than 3%, NCL38046 enters STBY mode.
LLC TRANSFORMER DESIGN
Table 2. LLC TRANSFORMER
PFC CHOKE DESIGN
LLC RESONANTCHOKE DESIGN
Table 3. RESONANT CHOKE
Pos.| Identification| Material| Turns| ****
Turns in Total
| Size| Winding Allowance| Tensile Force Required| Speed|
Winding Point| Remarks
---|---|---|---|---|---|---|---|---|---|---
Beginning| End
1| NP| litz wire| 20| 20| 0.1 mm ´ 25| | | | 6| 14|
2| Z1| tape| 1| 1| 14 mm| | | | | |
| Bobbin: RM8
| Cores:
| LH = 100 µH ±7% (10 kHz)
EVBUM2896/D
PFC MOSFET D−S Wave−Form: (CH2: DS, CH3: CS)
LLC MOSFET D−S Wave−Form:
(CH3: Mlow D−S, CH6: Resonant Current)
Output Voltage Ripple:
(CH1: Output Voltage Ripple)
BOM
REFERENCES
onsemi datasheet for NCL30159, NCL38046, NCL2801.
www.onsemi.com
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