infineon公司的ICL5102是130W调光恒流LED驱动器,DSO-16封装内集成半桥控制器和PFC级,通用AC和DC输入,输入电压范围85-305VAC,功率因素大于99%,THD小于10%,效率高达95%.采用无铁芯变压器技术,PFC + LLC或LCC恒压抑CV)或恒流(CC)输出,输出功率高达300W,工作温度-40℃ 到+125℃,主要用在LED照明,高顶灯或办公室照明,街灯照明/智能街灯.本文介绍了ICL5102主要优势和特性,典型应用电路,以及130W LLC恒流评估板主要特性,电路图,材料清单和PCB设计图.

The ICL5102 integrates a half-bridge controller with a PFC stage in a single DSO-16 package.

ICL5102主要优势:

Small form factor LED driver and low bill-of-material

The high level of integration assures a low component count of external components, enabling small form factor designs ideal for compact and slim line power supplies for lighting, such as LED driver for indoor and outdoor applications. All parameters are specified for an extended temperature range from -40℃ up to +125℃. Configuration of the IC can be adjusted by simple resistors, cheap and reliable.

High performance, digital PFC and advanced HB driver

The high performance digital PFC stage achieves power factor of 99% and a THD < 10%, through operation in CrCM and DCM mode, in a frequency range of 22 kHz to 500 kHz, over a very wide load range. This supports stable operation even at low load conditions down to 0.1% of the nominal power without audible noise. The half-bridge resonant stage comes with integrated high- and low-side gate driver for discrete MOSFETs rated up to 650 V. Its non-overlap dead time is self adaptive from 500 ns ... 1.0 μs. A coreless transformer tech­nology connects the high side stage.

Fast time-to-light and low standby

With startup current of less than 100 μA the controller provides very fast time-to-light within less than 300 ms.While standby the controller changes into active burst mode which reduces power consumption to less than 300 mW.

Safety first

The controller has a comprehensive set of protection features built in to increase the system safety. It monitors in the run mode the complete system regarding bus over- and undervoltage, open loop, overcurrent of PFC and/or inverter, output overvoltage, over temperature and capacitive load regulation.

ICL5102主要特性:

PFC + LLC or LCC with Constant Voltage (CV) or Constant Current (CC) output

Up to 300 W

Universal AC and DC input

Coreless transformer technology

Input voltage range 85–305 V AC

Integrated high-voltage gate driver

Power factor > 99%

Outstanding THD < 10%

High efficiency up to 95%

Short startup time < 300 ms

3 state self-adapting soft start

Cap load regulation

Start-up frequency up to 1.3 MHz

Active burst mode less than 300 mW standby

Stable low load operation mode

Comprehensive protection mode with auto restart:Surge protection

Output overvoltage

Overcurrent

Brown-in/brown-out

Open loop

Overtemperature using NTC

-40°... +125℃

目标应用:

LED Lighting

Highbay or office lighting

Street Lighting /Smart Street Lamp

图1.ICL5102典型应用电路

图2.ICL5102 130W LLC恒流评估板外形图

This Application Note (AN) describes the characteristics and features of a 130 W SMPS LED demonstration board with dimmable constant current output in a voltage range from 76 V down to 38 V. High efficiency, high PF, low THD and a stable output current over the whole output voltage range makes it very suitable for high-quality LED lighting such as street lights, high-bay lighting or office lighting. With the highly integrated ICL5102 (combo controller with Critical Conduction Mode (CrCM)/Discontinuous Conduction Mode (DCM) PFC and half-bridge LLC integrated), the circuit design is considerably simplified, which results in space and Bill of Materials (BOM) cost savings. Furthermore, numerous monitoring and protection features ensure the highest reliability.

This reference design consists of a CrCM/DCM PFC and a half-bridge LLC, with dimmable constant current output from 38 V (minimum dimming voltage at VDIM = 1 V) up to 76 V LED forward voltage. The demo board is designed for 1–10 V dimming and a non-dimming constant current operation over the whole output voltage range.

The PFC stage of this reference design is controlled by the PFC block of the ICL5102. The PFC stage has an integrated digital PFC control loop. The improved adjustable (via resistor) THD compensation is designed especially for light-load condition at 25 percent load for THD less than 10 percent at 230 V. It operates in CrCM to achieve a good PF and very low THD over a wide load range. When the load decreases to the minimum level, the IC controls the PFC to operate in DCM. The PFC BUS voltage will be sensed highly accurately (± 1.6 percent) so there is no need for a compensation network. For PFC protection, an open-loop, BUS Over Voltage (OV) and Under Voltage (UV) and surge will be also detected.

The half-bridge LLC stage has a fixed duty cycle of D = 0.5 with a self-adapting dead-time from 250 ns to 750 ns. ICL5102 provides an extended operation frequency range up to a typical 330 kHz in order to provide a wide dimming range and support LCC topologies. The three-state self-adapting soft-start starts with HF and has a capacitive mode regulation implemented. The following protection functions are implemented: output short-circuit protection, LLC Over Current Protection (OCP), capacitive mode regulation, Over Temperature Protection (OTP), output Over Voltage Protection (OVP) and Brown Out (BO) detection. Active Burst Mode (ABM) provides standby power below 300 mW(board level) and can be disabled.

130 W SMPS LED演示板主要特性:

& Input voltage range: 90–305 V AC

& Input voltage frequency: 47–63 Hz

& Regulated nominal output current: IOUTnom_min = 1.75 AMIN in an output voltage range from 38 V DC up to 76 V DC

& IOUTMIN = 74–76 mA (5 percent of IOUTnom_min at VDIM = 1.0 V)

& Output current ripple at VOUT = 76 V/1.75 A: IOUTRipplemax = 110 mAP_P (± 3 percent)

& Dimming using an analog 1–10 V interface

& STB less than 300 mW

& Time to light: tT2L ~ 350 ms at 90 V AC/VDim = 1.0 V

& Efficiency at nominal load: ~ 92.0 percent at 230 V AC

& PF: greater than 90 percent at 50 percent load (230 V ACin)

& Input current THD: less than 10 percent at 25 percent load (230 V ACin)

& Low-temperature start-up at -40oC TA

& OTP at 95 ℃/auto-restart at 85℃

& Output OVP at VOUT = 90 V DC

& BO/Brown In (BI) detection: at 71 V ACIN/BI at 79 V ACIN

& Harmonics: according to EN 61000-3-2 Class C

& EMI: according to EN 55015

& Safety : according to EN 61347-2-13

& Board dimensions: 178 mm (L) × 52 mm (B) × 32 mm

图3.PFC和LLC调光恒流参考板外形图

图4.PFC和LLC调光恒流参考板电路图

图5.火线输入滤波器电路图

PFC和LLC调光恒流参考板材料清单:

图5.PFC和LLC调光恒流参考板PCB布局图:底视图

图6.PFC和LLC调光恒流参考板PCB装配区图:顶视图

ICL5102

High performance PFC + resonant controller for LCC and LLC

The ICL5102 integrates a half-bridge controller with a PFC stage in a single

DSO-16 package.

Small form factor LED driver and low bill-of-material

The high level of integration assures a low component count of external components,enabling small form factor designs ideal for compact and slim line power supplies for lighting, such as LED driver for indoor and outdoor applications. All parameters arespecified for an extended temperature range from -40°C up to +125°C. Configuration of the IC can be adjusted by simple resistors, cheap and reliable.

High performance, digital PFC and advanced HB driver

The high performance digital PFC stage achieves power factor of 99% and a THD < 10%,through operation in CrCM and DCM mode, in a frequency range of 22 kHz to 500 kHz, over

a very wide load range. This supports stable operation even at low load conditions down to 0.1% of the nominal power without audible noise. The half-bridge resonant stage comes

with integrated high- and low-side gate driver for discrete MOSFETs rated up to 650 V. Itsnon-overlap dead time is self adaptive from 500 ns ... 1.0 µs. A coreless transformer technology connects the high side stage.

Fast time-to-light and low standby

With startup current of less than 100 µA the controller provides very fast time-to-light within less than 300 ms. While standby the controller changes into active burst mode

which reduces power consumption to less than 300 mW.

Safety first

The controller has a comprehensive set of protection features built in to increase the

system safety.

It monitors in the run mode the complete system regarding bus over- and undervoltage,

open loop, overcurrent of PFC and/or inverter, output overvoltage, over temperature and

capacitive load regulation.

Key features

› PFC + LLC or LCC with Constant

Voltage (CV) or Constant Current (CC)

output

› Up to 300 W

› Universal AC and DC input

› Coreless transformer technology

› Input voltage range 85–305 V AC

› Integrated high-voltage gate driver

› Power factor > 99%

› Outstanding THD < 10%

› High efficiency up to 95%

› Short startup time < 300 ms

› 3 state self-adapting soft start

› Cap load regulation

› Start-up frequency up to 1.3 MHz

› Active burst mode

less than 300 mW standby

› Stable low load operation mode

› Comprehensive protection mode

with auto restart:

– Surge protection

– Output overvoltage

– Overcurrent

– Brown-in/brown-out

– Open loop

– Overtemperature using NTC

› -40° ... +125°C