www.fairchildsemi.com
FEB157-001 User’s Guide
Offline High Brightness
LED Driver Evaluation Board
Featured Fairchild Product: FAN7554
© 2007 Fairchild Semiconductor
Page 1 of 17
Rev 1.1 April 2007
1. Introduction
1.1 Product Description
A high brightness LED evaluation board has been developed using the Fairchild Semiconductor
FAN7554D PWM controller. The board has the capability of driving one, two or three Lumiled,
or similar LEDs. The output current is user selectable at 350mA, 700mA, or 1A. The current is
selectable by inserting or removing jumpers JP1 and JP2 on the evaluation board. The board is
designed to operate over the universal AC line range of 90Vac to 270Vac. A picture of the board is
shown in Figure 1.
Figure 1: Offline High Brightness LED Driver Board
1.2 Circuit Description
The FEB157 evaluation board is an offline flyback converter utilizing the PWM controller,
FAN7554D. Rather than controlling the output voltage, it is designed to control the LED load
current. This is the preferred technique to drive high brightness LEDs. Controlling the LED current
allows for a constant brightness as well as long life of the LEDs. The schematic of the FEB157 is
shown in Figure 3 below.
Referring to Figure 3, the input AC line voltage comes in through J1. Capacitor C1, and common
mode line choke, LF1, form the conducted EMI filter. The dc resistance of LF1 and R1 limit the
inrush current at turn on. Diode bridge BD1 and filter capacitor C2 convert the ac voltage to an
unregulated dc voltage. Resistors R5 and R6 provide the initial startup current for the FAN7554D.
Capacitor C8 off of pin 2 of the FAN7554D provides for soft start in that the pulse width will
gradually increase slowly at turn on thereby decreasing the stress on Q1. Once the converter is up and
running the operating bias voltage will come from the auxiliary winding (pins 4–5) on transformer T1.
The oscillator frequency of the FAN7554D is set by an RC network, R10 and C9. In this board the
frequency is set to 100kHz. However, the FAN7554D can be operated as high as 500kHz.
The FAN7554D is a current mode PWM controller. Current mode operation implies that there are
two control loops. An inside loop that controls the current through the primary winding of the
transformer and an outer loop that controls the output voltage. However, as previously stated, in this
application the outer loop will actually provide feedback information regarding the LED load current
instead of the output voltage.
© 2007 Fairchild Semiconductor
Page 3 of 17
Rev 1.1 April 2007
Since the output current is being controlled instead of the output voltage, the output voltage will
actually vary with the number of LEDs on the output. The same applies to the auxiliary winding that
provides the bias supply to the FAN7554D. Consequently, the transformer had to be designed to
provide enough bias when powering one LED. Then when powering three LEDs, the bias voltage is
significantly higher. In order to maintain reliable operation, a regulator circuit consisting of R20, ZD1
and Q3 is implemented. This circuit will regulate the voltage to the Vcc pin of the FAN7554 to 18V
when there are multiple LEDs on the output. Please note that this circuit would not be needed in a
conventional application where the number of LEDs on the output is known and fixed. In such an
application, the transformer would then be designed to provide the required Vcc voltage for that
particular number of LEDs.
The FAN7554D will take feedback information from the sense resistor, R12, and from the feedback
pin, pin 1, and generate a PWM signal that is applied to the FET at location Q1. This FET,
FDQ2N80, is a 2A, 800V, N-channel MOSFET in a DPAK package. As with any flyback converter,
energy is stored in the transformer while the FET is on, and released to the secondary when the FET
is turned off. Since no transformer can be constructed with perfect coupling, the network consisting
of resistors R2, R3, R4, diode D1 and capacitor C3 clamp the resulting leakage inductance spike so
that it does not endanger Q1.
The transformer, T1, is constructed on an EFD20 core/bobbin. The energy stored in the transformer
during the on time of Q1 is delivered to the secondary during the off time of Q1. Diode D4, and
C11 rectify and filter the resulting secondary waveform to form a dc voltage. Inductor L1 and
capacitor C12 provide additional attenuation of any residual switching spikes on the output voltage.
Connector J2 is a Tyco six position connector (p/n 535676-5) that will mate with Future Electronics
LED “Emitter” boards to carry the dc power to the LEDs. A picture of a three LED assembly is shown
in Figure 2.
Figure 2: Offline LED Driver and LED Assembly
As previously mentioned, when driving high brightness LEDs the objective is to control the LED
current. There are different ways of controlling the current. In this evaluation board a method utilizing
sense resistors and an NPN transistor is used. Referring to the schematic in Figure 3, resistors R14,
R15, and R16 are the resistors that sense the return current from the LED load. Jumpers JP1 and JP2
allow the selection of the output current. Table 1 describes the jumper status for particular output
currents.
© 2007 Fairchild Semiconductor
Page 4 of 17
Rev 1.1 April 2007
Table 1: Jumper JP1/JP2 Status and LED Current
LED Current
350mA
JP1 Status
JP2 Status
Out
In
Out
Out
In
700mA
1A
In
Refer to the schematic in Figure 3. As the LED current returns back to the power supply, it develops a
voltage across the sense resistor(s). Once this voltage reaches the base-emitter junction voltage of the
NPN Q2, typically about 650mV, the transistor will conduct collector current. This current also flows
through the photodiode inside the optocoupler, IC2. The optocoupler will transfer this feedback
information optically across the primary-secondary boundary to the primary side of the supply
thereby maintaining the necessary isolation. Thermistor RTH1, is a negative temperature coefficient
device and compensates for changes in base-emitter voltage due to temperature change.
© 2007 Fairchild Semiconductor
Page 5 of 17
Rev 1.1 April 2007
2. Electrical Requirements
2.1 Input Requirements
Voltage range: 90Vrms to 270Vrms
Frequency: 47Hz to 63Hz
2.2 Output Requirements
The FEB157 board will power one, two, or three high brightness LEDs (Lumiled or similar) at user
selectable load currents of 350mA, 700mA, or 1A.
© 2007 Fairchild Semiconductor
Page 6 of 17
Rev 1.1 April 2007
3. Designed Solution
3.1 Schematic
LF1
2
R2
T1
22kΩ
2010
C2
C3
EFD20 Core/Bobbin
1
47µF
450V
1000pF
1kV
R1
5.6Ω
1W
3
BD1
R3
DF10S
22kΩ
2010
C1
Lm = 610µH
2
3
0.1µF
D1
RS1M
R4
F1
C14
R19 Prov. for 0805
Prov. for 2010
10Ω
1206
1A, 250V
TP1
1
R5
R6
L1
2.2µH
150kΩ
2010
150kΩ
2010
2
TP4
D4
Q1
C15
SS39
R7
8
FQD2N80
100pF
5
6
22Ω
0805
C11
C12
1000µF
16V
47µF
50V
R21
R14
R8
J2
47Ω
1.8Ω, 2010
JP1
JP2
10kΩ
0603
2010
D2
R15
Prov. for MMBD4148
ZD2
2Ω, 2010
Prov. for SOD-123
TP3
Q3
MMBT2222A
4
TP5
R9
D3
R18
100Ω
0603
R16
1.8Ω
2010
4.7Ω
0805
BAS21
C5
0.1µF
C4
47µF
50V
R20
5
TP6
1kΩ
RTH1
10kΩ
0805
ZD1
18 V
2010
TP2
8
7
6
5
IC2
FOD817A
C13
Vref Vcc Drive GND
2200pF
Y-cap
R10
10kΩ
1%
C6
FAN7554D
IC1
R17
0.01µF
Q2
MMBT2222AK
510Ω
0603
0603
FB
S/S
IS
Rt/Ct
4
1
2
3
R11
1kΩ
R12
0805
R13
1.2Ω
2512
IC2
C7
C8
C9
C10
Prov. for 2512
FOD817A
0.1µF
1µF
1800pF
470pF
Figure 3: Schematic of the FEB157 Offline High Brightness LED Driver Board
© 2007 Fairchild Semiconductor
Page 7 of 17
Rev 1.1 April 2007
3.2 Transformer
Required Components
Schematic
Winding Stackup
1
Core = EFD20
Vcc 25 T
1/2 Pri - 36 T
Bobbin = 10 pin; SMD; Horizontal
2
1/2 Primary - 36 T
Secondary - 10T
1/2 Primary - 36 T
8
1/2 Pri - 36 T
Output - 10 T
3
4
6
Vcc - 25 T
5
Electrical Specifications
Pin
Spec.
537.0 - 656.0 uH
Remarks
Inductance
Leakage
1 - 3
1 - 3
100 kHz, 0.10 Vrms
All other windings shorted
3.3 Bill of Materials
Sch Ref
Vendor
Part Number
Description
BD1
Fairchild
DF10S
1.5A, 1000 V Bridge
C1
C2
NIC Components or Equivalent
NIC Components
NPX104M275VX2M
0.1µF, X2 cap
NREH470M450V18X36F
ESMH451ESN470MN25S
C4520X7R3A102KT
47µF, 450V
UCC
47µF, 450V
C3
TDK
1000 pF, 1kV, SMD
47µF, 50V, SMD
0.1µF, 50V, 0603
0.01µF, 50V, 0603
0.1µF, 50V, 0603
1.0µF, 16V, 0603
1800 pF, 25V, 0603, NPO
470 pF, 50V, 0603
1000µF, 16V, Leaded
47µF, 50V, SMD
2200pF, Y-rated cap
Prov. for 0805
C4
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
Panasonic
NACK470M50V6.3X8TR
NMC0603X7R104K50TRP
NMC0603X7R103K50TRP
NMC0603X7R104K50TRP
NMC0603X7R105K16TRP
NMC0603NPO182F25TRP
NMC0603X7R471K50TRP
NRSJ102M16V10X16TB
NACK470M50V6.3X8TR
ECK-NVS222ME
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
TDK
C4520CH3F101K
100 pF, 3kV, SMD
© 2007 Fairchild Semiconductor
Page 8 of 17
Rev 1.1 April 2007
3.3 Bill of Materials (Continued)
Sch Ref
Conn1
Conn2
D1
Vendor
Part Number
Description
Phoenix Contact
1729018
2 position terminal block
Tyco
535676-5
6 position connector
1A, 1000V, SMA
Fairchild
RS1M
D2
Fairchild
Prov. for MMBD4148
BAS21
D3
Fairchild
0.2A, 250V, SOT-23
3A, 90V, SMC
D4
Fairchild
SS39
F1
Littlefuse
3721100
1A, 250V, Slo-Blo
PWM Controller, SO-8
Optocoupler
IC1
IC2
JP1
Fairchild
FAN7554D
Fairchild
FOD817A
Sullins
PRPN021PAEN-RC
PRPN021PAEN-RC
STN02SYBN-RC
STN02SYBN-RC
DO1608C-222
UU9LFBNP-B322
FQD2N80
2 pin header (2mm)
2 pin header (2mm)
2 pin shunt
JP2
Sullins
JP1
Sullins
JP2
Sullins
2 pin shunt
L1
Coilcraft
2.2µH
LF1
Q1
Q2
Q3
R1
Sumida
3.2mH
Fairchild
2A, 800V, N-channel, DPAK
0.6A, 40V, NPN
0.6A, 40V, NPN
5.6Ω, 1 W
Fairchild
MMBT2222AK
MMBT2222AK
NCF100J5R6TR
NRC50J223TR
NRC50J223TR
NRC12J100TR
NRC50J154TR
NRC50J154TR
NRC10J220TR
NRC06J103TR
NRC10J4R7TR
NRC06F1002TR
NRC10J102TR
NRC100J1R2TR
Fairchild
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
R2
22kΩ, 1/2 W, 2010
22kΩ, 1/2 W, 2010
10Ω, 1/4 W, 1206
150kΩ, 1/2 W, 2010
150kΩ, 1/2 W, 2010
22Ω, 1/8 W, 0805
10kΩ, 1/10 W, 0603
4.7Ω, 1/8 W, 0805
10kΩ, 1/10 W, 1%, 0603
1kΩ, 1/8 W, 0805
1.2Ω, 1 W, 2512
Prov. for 2512
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
NIC Components or Equivalent
NIC Components or Equivalent
NIC Components or Equivalent
NRC50J1R8TR
NRC50J2R0TR
NRC50J1R8TR
1.8Ω, 3/4 W, 2010
2.0Ω, 3/4 W, 2010
1.8Ω, 3/4 W, 2010
© 2007 Fairchild Semiconductor
Page 9 of 17
Rev 1.1 April 2007
3.3 Bill of Materials (Continued)
Sch Ref
Vendor
Part Number
Description
R17
NIC Components or Equivalent
NIC Components or Equivalent
NRC06J511TR
510Ω, 1/10 W, 0603
R18
R19
R20
R21
RTH1
T1
NRC06J101TR
100Ω, 1/10 W, 0603
Prov. for 2010
NIC Components or Equivalent
NRC50J102TR
NRC50J470TR
NCT08AJ104334TR
CTX0117893
5002
1kΩ, 3/4 W, 2010
47Ω, 3/4 W, 2010
10kΩ, NTC Thermistor, Beta = 3340
EFD20 Core/Bobbin Transformer
PC Test Point-White
NIC Components or Equivalent
NIC Components or Equivalent
Cooper
TP1
TP2
TP3
TP4
TP5
TP6
ZD1
ZD2
Keystone
Keystone
5001
PC Test Point-Black
Keystone
5000
PC Test Point-Red
Keystone
5000
PC Test Point-Red
Keystone
5001
PC Test Point-Black
Keystone
5003
PC Test Point-Orange
18V, 1/2W, SOD-123
Prov. for SOD-123
Fairchild
MMSZ5248B
3.4 Printed Circuit Board
The PCB is a double sided board made of FR4 with 1oz copper.
Figure 4: Silkscreen/Component Placement of PCB Layout
© 2007 Fairchild Semiconductor
Page 10 of 17
Rev 1.1 April 2007
Figure 5: Silkscreen/Component Placement of Top Side Layer
Figure 6: Silkscreen/Component Placement of Bottom Side Layer
© 2007 Fairchild Semiconductor
Page 11 of 17
Rev 1.1 April 2007
4. Test Results
4.1 Regulation
4.1.1 Line Regulation
This graph illustrates the regulation of the output current over line voltage for the three possible
settings, 350mA, 700mA, and 1A.
1200
1000
800
1 LED
2 LEDs
3 LEDs
600
400
200
0
90
120
270
Input Voltage (Vac)
Figure 7: LED Current vs. Line Voltage
© 2007 Fairchild Semiconductor
Page 12 of 17
Rev 1.1 April 2007
4.2 Efficiency
The efficiency data shown is for the converter with a load of one, two and three LEDs driven at 1A.
90
80
70
60
1 LED @ 1 A
50
2 LEDs @ 1 A
40
3 LEDs @ 1 A
30
20
10
0
90
120
270
Input Voltage (V)
Figure 8: Converter Efficiency Data Plotted Against Increasing Line Input
for LED Current of 1A.
© 2007 Fairchild Semiconductor
Page 13 of 17
Rev 1.1 April 2007
4.3 Steady State Operation
Figure 9: Steady State Waveforms at 90Vac with Three LEDs at 1A
Figure 10: Steady State Waveforms at 270Vac with One LED at 350mA
© 2007 Fairchild Semiconductor
Page 14 of 17
Rev 1.1 April 2007
4.4 Start up
The startup profile is captured at 90Vac and 270Vac with a load of three LEDs operating at a current
of 1A.
Figure 11: Startup Profile at 90 Vac with Three LEDs at 1A
Figure 12: Startup Profile at 270Vac with Three LEDs at 1A
© 2007 Fairchild Semiconductor
Page 15 of 17
Rev 1.1 April 2007
Warning and Disclaimer:
This Evaluation Board may employ high voltages so appropriate safety precautions should be used
when operating this board. Replace components on the Evaluation Board only with those parts shown
on the parts list in the User's Guide. Contact an authorized Fairchild representative with any
questions.
The Evaluation Board is for demonstration purposes only and neither the Board nor this User's Guide
constitute a sales contract or create any kind of warranty, whether express or implied, as to the
applications or products involved. Fairchild warranties that its products will meet Fairchild's published
specifications but does not guarantee that its products will work in any specific application. Fairchild
reserves the right to make changes without notice to any products described herein to improve
reliability, function or design. Either the applicable sales contract signed by Fairchild and Buyer, or if
no contract exists Fairchild's Standard Terms and Conditions on the back of Fairchild invoices, govern
the terms of sale of the products described herein.
© 2007 Fairchild Semiconductor
Page 16 of 17
Rev 1.1 April 2007
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© 2007 Fairchild Semiconductor
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Rev 1.1 April 2007
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