onsemi EVBUM2823/D 150 W Lighting Solution User Manual

EVAL BOARD USER’S MANUAL
www.onsemi.com
150 W Lighting Solution with
NCL2801+NCP13992+NCP58920
Evaluation Board User’s Manual
EVBUM2823/D

SPECIFICATION

on semi’s Device| Application| Input Voltage| Output Power| Topology| I/O Isolation
---|---|---|---|---|---
NCL2801
NCP13992
FUSB15101| Lighting| 90 Vac to 264 Vac| 150 W| BOOST PFC, LLC| Isolated
No.| Description| Symbol| Min| Type| Max| Unit| Test Condition
---|---|---|---|---|---|---|---
1| Input Voltage Range| Vin (min/max)| 90| 115/230| 264| Vac|
2| Input Current| Terms| | | 2| A| Full load
3| Rated Input Frequency| fin| 50| | 60| Hz|
4| Input Frequency Range| Fin (min/max)| 47| | 63| Hz|
5| Rated Output Power| Pout| | 150| | W|
6| Efficiency at Full Load| 11| | >94

92| | %| Tested at board end, 230 Vac
Tested at board end, 115 Vac
7| Output Voltage and
Current| Vout/lout| | 24 V/6 A| | V/A| 90 Vac – 264 Vac
8| No Load Power| Pstandby| | | <0.3| W|

Circuit Description

This design was used on semi’s PFC controller NCL2801CDA and LLC controller NCP13992, with a high PF and low THD performance. Thanks to on semi’s current- mode PFC controller, the reference design easy to maintain a high PF and Low THD performance. The NCP13992 is a high Specifications and Features

• High Working Frequency for GaN, with a 235 mm x 30 mm x 21 mm size

• Low STBY power consumption

• Protections: performance current mode controller for half-bridge resonant converters. This controller implements 600 V gate drivers, simplifying layout and reducing external component count.
  ♦ Over Voltage Protection
  ♦ Over Current Protection

• High PF and Low THD

• High Efficiency

EVBUM2823/D

Figure 1. Demo Board Pictures

Figure 2. Main Board PCB

Circuit Schematic

Figure 3. Circuit Schematic

LLC Transformer Design

Table 1. LLC TRANSFORMER

Pos.| Identification| Material| Turns| Turns
in Total| Size| Winding
Allowance| Tensile
Force
Required| Speed| Winding Point| Remarks
---|---|---|---|---|---|---|---|---|---|---
Beginning| End
1| NP1| copper
w.| 13| 13| 0.5 mm| | | | 6| 5|
2| Z1| tape| 1| 1| 11 mm| | | | | |
3| Vcc| TIW| 2| 2| 0.4 mm| | | | 2| 1|
4| Z2| tape| 2| 2| 11 mm| | | | | |
5| NS| copper
wire| 2| 2| 0.1 x 80 mm| | | | start 9, end 7
start 10, end 8|
6| Z3| tape| 1| 1| 11 mm| | | | | |
7| NP2| copper
w.| 5| 5| | | | | 5| 4|
8| Z4| tape| 2| 2| 8 mm| | | | | |
| Bobbin: PQ2616
| Cores: TPW33B from TDG
| LH = 280 that Lk = 5 that

PFC Choke Design

Table 2. PFC CHOKE

Pos.| Identification| Material| Turns| Turns
in Total| Size| Winding
Allowance| Tensile
Force
Required| Speed| Winding Point| Remarks
---|---|---|---|---|---|---|---|---|---|---
Beginning| End
1| NP| Litz wire| 30| 30| 0.1 x 30 mm| | | | 6| 4|
2| Z1| tape| 1| 1| 14 mm| | | | | |
3| Ns| copper
wire| 3| 3| 0.2 mm| | | | 11| 12|
4| Z2| tape| 1| 1| 14 mm| | | | | |
5| Z3| tape| 1| 1| 22 mm| | | | | pack the core
| Bobbin: PQ2616-1
| Cores: PQ2616 from TDG
| LH = 250 off ±7% (10 kHz)

LLC Resonant Choke 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 x 50| | | | 6| 14|
2| Z1| tape| 1| 1| 14 mm| | | | | |
| Bobbin: RM8
| Cores: RM8 from WE
| LH = 20 .tH ±7% (10 kHz)

Standby Power vs. Input Voltage

Test condition: all efficiency is tested at the board ends.

PFC Value in Different Load

Test condition: test in different load conditions.

THD in Different Load

Test condition: test in different load conditions.

Efficiency Curve:

Test condition: all efficiency is tested at the board ends.

PFC MOSFET D−S Wave−form:

PFC MOSFET D−S Wave−form:

LLC MOSFET Wave−form:

Output Short Circuit Protection:

SR Part Wave Form:

Output Voltage & Vcc:

Output Voltage Ripple:

BOX

Table 4. BILL OF MATERIALS

Designator (Main Board)| Qty| Description| Value| Tolerance| Footprint| Manufacturer| Manufacturer Part Number| Substitution Allowed| ****

Lead-Free

---|---|---|---|---|---|---|---|---|---
NTC1| 1| NTC| 1.5 Ω| 1%| 7 mm| SUNLORD| SPNL09D1R5MBI| Yes| Yes
F1| 1| FUSE| Micro Fuse

3.15 A/250 Vac

| NC| Axial Lead| Littelfuse| Micro Fuse

3.15 A/250 Vac

| Yes| Yes
L1| 1| Filter| 90 µH/4 A| 20%| 10 mm 20 mm| WE| 7447013| No| Yes
L4| 1| PFC choke| 250 µH| 10%| PQ2616| TDG| TPW33B From TDG| No| Yes
L2| 1| Filter| 2250 µH/3 A| 20%| | WE| 750344558| No| Yes
L3| 1| Filter| 24 mH/3 A| 20%| | WE| 750344559| No| Yes
L5| 1| Resonant choke| 20 µH| 7%| RM8| WE| 750345066| No| Yes
T1| 1| LLC Transformer| 280 µH| 7%| PQ2616| TDG| TPW33B From TDG| No| Yes
CX1, CX2| 2| Film Capacitor, X2, Radial| 474/275 Vac| 10%| LW: 18 * 6 cm, Pin distance 1.5 cm| WE| 890334025039CS| Yes| Yes
R1, R11| 2| Resistor| 1M5/0805| 1%| 0805| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R2, R48| 2| Resistor| 20K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R3| 1| Resistor| 15K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R14| 1| Resistor| 13K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R4| 1| Resistor| 56K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R5| 1| Resistor| 20K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K5FKEA| Yes| Yes
R6| 1| Resistor| 2M4/0805| 1%| 0805| StdVishay/Dale| CRCW080524M0FKEA| Yes| Yes
R7| 1| Resistor| 2M4/0805| 1%| 0805| StdVishay/Dale| CRCW080524M0FKEA| Yes| Yes
R21, R22, R27, R29, R47| 5| Resistor| 10/0603| 1%| 0603| StdVishay/Dale| CRCW060100FKEA| Yes| Yes
R10| 1| Resistor| 150R/0603| 1%| 0603| StdVishay/Dale| CRCW0603150FKEA| Yes| Yes
R13| 1| Resistor| 0R15| 1%| 2512| Panasonic| ERJ1TRSJR15U| Yes| Yes
R20, R24| 2| Resistor| 6.8K/0603| 1%| 0603| StdVishay/Dale| CRCW06036K8FKEA| Yes| Yes
R18, R23| 2| Resistor| 1.1K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K1FKEA| Yes| Yes
R42| 1| Resistor| 510/0603| 1%| 0603| StdVishay/Dale| CRCW0603510FKEA| Yes| Yes
R17| 1| Resistor| 7.5K/0603| 1%| 0603| StdVishay/Dale| CRCW06037K5FKEA| Yes| Yes
R19, R25| 2| Resistor| 27K/0603| 1%| 0603| StdVishay/Dale| CRCW060327K0FKEA| Yes| Yes
R15, R16| 2| Resistor| 2K7/0805| 1%| 0805| StdVishay/Dale| CRCW06032K7FKEA| Yes| Yes
R8, R9, R12, R28| 4| Resistor| 1K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K0FKEA| Yes| Yes
R38, R50, R51| 3| Resistor| 33/0603| 1%| 0603| StdVishay/Dale| CRCW0603330FKEA| Yes| Yes
R31| 1| Resistor| 100/1206| 1%| 1206| StdVishay/Dale| CRCW1206100FKEA| Yes| Yes
R30| 1| Resistor| 2K4/0603| 1%| 0603| StdVishay/Dale| CRCW06032K4FKEA| Yes| Yes
R43| 1| Resistor| 2K/0603| 1%| 0603| StdVishay/Dale| CRCW06031K0FKEA| Yes| Yes
R39| 1| Resistor| 12K/0603| 1%| 0603| StdVishay/Dale| CRCW060375K0FKEA| Yes| Yes
R40| 1| Resistor| 75K/0603| 1%| 0603| StdVishay/Dale| CRCW060312K0FKEA| Yes| Yes
R41, R52| 2| Resistor| 10K/0603| 1%| 0603| StdVishay/Dale| CRCW060310K0FKEA| Yes| Yes
R26, R32, R46, R49| 4| Resistor| 47/0805| 1%| 0603| StdVishay/Dale| CRCW0603470FKEA| Yes| Yes
R44| 1| Resistor| 68K/0603| 1%| 0603| StdVishay/Dale| CRCW060368K0FKEA| Yes| Yes
R33| 1| Resistor| 100K/0603| 1%| 0603| StdVishay/Dale| CRCW0603100K0FKEA| Yes| Yes
C1, C22| 2| Film Capacitor, X2, Radial| 450 V/474| 10%| Film capacitor| WE| 890334025039CS| Yes| Yes
EC1, EC2, EC7| 3| Aluminum Electrolytic Capacitor| 450 V/33 µF| 10%| E−cap| WE| 860241481006| Yes| Yes
C9, C10, C21, C24| 4| Ceramic Capacitor, NPO, SMD| 102/25 V| 10%| 0603| AVX| 06035C102K4Z2A| Yes| Yes
C3, C13| 2| Ceramic Capacitor, NPO, SMD| 103/25 V| 10%| 0603| AVX| 06035C103K4Z2A| Yes| Yes

Table 4. BILL OF MATERIALS (continued)

Designator (Main Board)|

Qty

|

Description

|

Value

|

Tolerance

|

Footprint

|

Manufacturer

| Manufacturer Part Number| Substitution Allowed|

Lead-Free

---|---|---|---|---|---|---|---|---|---
C5, C23| 2| Ceramic Capacitor, NPO, SMD| 105/50 V| 10%| 0603| AVX| 06035C105K4Z2A| Yes| Yes
C4| | Ceramic Capacitor, NPO, SMD| 224/25 V| 10%| 0603| AVX| 06035C224K4Z2A| Yes| Yes
C7, C6, C17, C19, C33, C34| 6| Ceramic Capacitor, NPO, SMD| 225/25 V| 10%| 0603| AVX| 06035C225K4Z2A| Yes| Yes
C8| 1| Ceramic Capacitor, NPO, SMD| 22 pF/25 V| 10%| 0603| AVX| 06035C332K4Z2A| Yes| Yes
C2, C11, C18, C14, C20| 5| Ceramic Capacitor, NPO, SMD| 104/25 V| 10%| 0603| AVX| 06035C332K4Z2A| Yes| Yes
C15| 1| Ceramic Capacitor, NPO, SMD| 57 pF/1 kV| 10%| 1206| AVX| | Yes| Yes
C25| 1| Resistor| 1.5 R| 1%| 1206| StdVishay/Dale| | Yes| Yes
C16| 1| Ceramic Capacitor, NPO, SMD| 153/50 V| 10%| 0603| AVX| 06035C102K4Z2A| Yes| Yes
C12, C26, C28| 3| Ceramic Capacitor, NPO, SMD| 471/25 V| 10%| 0603| AVX| 06035C152K4Z2A| Yes| Yes
C32| 1| Ceramic Capacitor, NPO, SMD| 152/35 V| 10%| 0603| AVX| 06035C101K4Z2A| Yes| Yes
C27, C30, D4, D6| 4| Ceramic Capacitor, NPO, SMD| 2.2 nF/1 kV| 5%| 1206| WE| 885342008007| Yes| Yes
C29, C31| 2| Ceramic Capacitor, NPO, SMD| 1 nF/1 kV| 5%| 1206| WE| 885342008005| Yes| Yes
C55, C56, C57, C58| 4| Ceramic Capacitor, NPO, SMD| 225/50 V| 5%| 0805| AVX| 08055C225K4Z2A| Yes| Yes
C37| 1| Ceramic Capacitor, NPO, SMD| 101/25 V| 5%| 0603| AVX| 06035C101K4Z2A| Yes| Yes
C42| 1| Ceramic Capacitor, NPO, SMD| 103/25 V| 5%| 0603| AVX| 06035C102K4Z2A| Yes| Yes
EC3| 1| Aluminum Electrolytic Capacitor| 35 V/68 µF| 20%| E−cap| WE| 860160573009| No| Yes
EC5| 1| Aluminum Electrolytic Capacitor| 35 V/100 µF| 20%| E−cap| WE| 860160574013| No| Yes
EC4, EC6| 2| Aluminum Electrolytic Capacitor| 35 V/1000 µF| 20%| E−cap| WE| 860160578032| No| Yes
M1, M2, M3| 3| GaN| 650 V/150 mR| NC| DFN26| onsemi| NCP58920| No| Yes
Q1, Q2| 2| N−Channel Power MOSFET| 60 V/100 A| NC| DFN5| onsemi| NTMFS5C645NL| No| Yes
Q3, Q5, Q6| 3| N−Channel Small−Signal MOSFET| 50 V/0.22 A| NC| SOT−23| onsemi| BSS138| No| Yes
U2, U4| 2| SR Controller| SR Controller| NC| SOIC−8| onsemi| NCP4306AAAZZZ| No| Yes
D2, D12, D13| 3| Super−Fast Recovery Diode| 1 kV/1 A| NC| SMA| onsemi| ES1J| No| Yes
D14| 1| Super−Fast Recovery Diode| 1 kV/1 A| NC| SOD−123| onsemi| ES1JFC| No| Yes
D7, D8| 2| Resistor| 0 R| NC| 0603| onsemi| CRCW060300FKEA| No| Yes
D1| 1| SiC Diode| 650 V/4 A| NC| TO252| onsemi| FFSD0465A| No| Yes
D9, D10, D15, D16| 4| Schottky Power Rectifier| 100 V/2 A| NC| SOD−123| onsemi| MBR2H100SF| No| Yes
D3, D5| 2| Diode bridge| 1000 V/2 A| NC| SDIP−4L| onsemi| DF10S2| No| Yes
D26, D27| 2| Zener diode| 2.4 V| NC| SOD−323| onsemi| MM2V4T1G| No| Yes
D17| 1| Zener diode| 15 V| NC| SOD−323| onsemi| MM15V1T1G| No| Yes
U1| 1| PFC controller| PFC controller| NC| SOIC−8| onsemi| NCL2801CDA| No| Yes
U3| 1| LLC controller| LLC controller| NC| SOIC−16| onsemi| NCP13992AR| No| Yes
U7| 1| NCP431| NCP431| NC| SOT−23| onsemi| NCP431| No| Yes
CY1| 1| Y CAP| | | | | 222/275V/CY1| No| Yes
OPT1| 1| Optical coupler| Optical coupler| NC| LSOP4| onsemi| FODM1007| No| Yes

References
onsemi datasheet for NCP13992, NCP58920, NCL2801

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