fairchild reference design rd-400 · fairchild reference design ... c7 150 nf ecq-e6154kf cap, x...

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© 2013 Fairchild Semiconductor Corporation 1 RD-400 • Rev. 1.0.0

Fairchild Reference Design

This reference design supports inclusion of the FL7930C, FAN6300H, FAN7346,

FSL138MRT, FAN7382, and FAN3111C devices in the design of an offline, 100 W,

CCCV, LED power supply intended for industrial lighting applications. The RD-400

reference design leverages several advanced Fairchild technologies to offer a complete

LED driver solution suitable for wide-range, AC-input voltage, high Power Factor (PF),

and high efficiency up to 100 W output power. The overall power architecture consists of

an EMI filter stage, a PFC boost converter, a dual-switch flyback converter, and two

control options for configuring the output to operate a single LED string or up to four

independent LED strings. It should be used in conjunction with the FL7930C,

FAN6300H, FAN7346, FSL138MRT, FAN7382, and FAN3111C datasheets as well as

Fairchild’s application notes and technical support team. Please visit Fairchild’s website

at http://www.fairchildsemi.com.

Application Fairchild Devices

Input Voltage Range

Rated Output Power

Output Voltage (Rated Current)

Industrial LED Lighting

FL7930C, FAN6300H, FAN7346,

FSL138MRT, FAN7382, FAN3111C

80-310 VAC 100 W

Single-Channel: 30 V - 50 V, (2 A)

4-Channel: 30 V - 62 V, (1.4 A)

Key Features

Wide Input Voltage Range from 80 VAC<VIN(AC)<310 VAC

Wide Range, High Efficiency

Inrush Current Limiting

Dedicated On-Board Flyback Bias Regulator

PFC-Ready (RDY) Function

BCM PFC Boost Pre-Regulator Can Operate as Boost Follower

Simple 2-Switch QRC Flyback Power Topology

Configurable for Single-Channel or 4-Channel LED Operation

4-Channel, 1.5% LED Current Accuracy

Supports LED Voltage up to 100 V per Channel

0 V - 10 V, On-Board, Analog Dimming

1% - 100%, On-Board, PWM Dimming

Individual Channel Dimming when Operating in 4-Channel Mode

Protection Functions: Open LED, Short LED, Error Flag Output, Over-Voltage,

Over-Current, and Thermal Shutdown

Low 25 mm Cross-Section Profile

http://www.fairchildsemi.com/



1. Schematics

Figure 1. PFC, Boost Follower Enable, Inrush Limit; Power Board Schematic



Figure 2. 2-Switch Flyback, PWM Dimmers, 5 V Secondary Bias



Figure 3. High-Voltage, Flyback Bias Regulator

Figure 4. Controller Daughter Card Schematic – Single Channel, CCCV LED Controller



Figure 5. Controller Daughter Card Schematic – 4-Channel, LED Controller



2. Custom Magnetics

2.1. BCM PFC Coupled Inductor (Wurth 750313579)

6

1

10

9

2.2. Winding Specification

Winding Pins (S→F) Wire Layers Turns

Main, N(6-1) 6→1 40 / 40, Served Litz 2 40

ZCD, NZCD(9-10) 9→10 #32 1 3

Core: EFD30 (Ae=69 mm2)

Bobbin: EFD30, 12 Pin, Horizontal

Gap: 1.2 mm

2.3. Electrical Characteristics

Pin Specification Remark

Inductance 6→1 175 µH ±10% 500 kHz, 100 mVAC

RDC(6-1) 6→1 <120 mΩ

RDC(9-10) 9→10 <80 mΩ



2.4. Quasi-Resonant Flyback Transformer (EV30 Custom)

1

4

3

11,12

9,10

2

5

6



½ Primary, NP(2-3) 2→3 18/38, Served Litz 1 36

Secondary, NS(9,10-11,12) 9, 10→11, 12 30/38, Served Litz 1 19

½ Primary, NP(3-4) 3→4 18/38, Served Litz 1 35

Detect, NDET(6-5) 6→5 2/38, Bifilar 1 4

High-Side, NHS(2-1) 2→1 2/38, Bifilar 1 3

Core: EV30 (Ae=99 mm2)

Bobbin: EV30/12-1, 12 Pin, THT, Horizontal

Gap: 1.2 mm



Inductance 2→4 1 mH ±10% 500 kHz, 100 mVAC

Leakage 2→4 15 µH ±10% 1, 2, 5, 6, 9, 10, 11, 12 Shorted

RDC(2-4) 2→4 <500 mΩ 465 mΩ, Typical

RDC(9,10-11,12) 9, 10→11, 12 <150 mΩ 135 mΩ, Typical



2.7. Flyback Bias Transformer (Wurth 750313584)

1

2

5

3

4

7

8



½ Primary, NP(2-3) 2→3 #32 2 59

Secondary Bias, NSBIAS(8-7) 8→7 #32 1 20

½ Primary, NP(1-2) 1→2 #32 3 75

Primary Bias, NPBIAS(5-4) 5→4 #32 1 25

Core: EE16/7/5 (Ae=18.4 mm2)

Bobbin: EE16, 10 Pin, THT, Vertical

Gap: 0.57 mm



Inductance 1→3 1.1 mH ±10% 300 kHz, 100 mVAC

Leakage 1→3 15 µH, Typical

30 µH, Maximum 4, 5, 7, 8 Shorted

RDC(2-4) 1→3 <1.82 Ω

RDC(5-4) 5→4 <420 mΩ

RDC(8-7) 8→7 <325 mΩ



3. Bill of Materials

Table 1. Main Power Board BOM

Item Qty. Reference Value Part Number Description Manufacturer Package

1 2 C1, C6 470 pF FK26C0G2J471J Cap, Ceramic, 630 V, 10%,

COG, TDK Thru-Hole

2 2 C2, C7 150 nF ECQ-E6154KF Cap, X Type, 630 V, 10%,

Poly Metalized Panasonic Thru-Hole

3 2 C3-4 330 nF B32922C3334M Cap, X Type, 630 V, 10%,

Poly EPCOS Thru-Hole

4 2 C5, C8 330 µF UVR2E331MRD Cap, 250 V, Alum Elect. Nichicon Thru-Hole

5 9 C9, C11, C13 C19, C26,

C29 C33, C36, C43 100 nF

CAP, SMD, CERAMIC, 25 V, X7R

STD 805

6 1 C10 15 nF


STD 805

7 3 C12, C20, C25 2.2 µF


STD 805

8 1 C14 1.2 µF

CAP, SMD, CERAMIC, 10 V

STD 805

9 2 C15, C30 10 pF


STD 805

10 1 C16 120 nF


STD 805

11 6 C17, C27-28 C34-35,

C47 10 nF

CAP, SMD, CERAMIC, 25V, X7R

STD 805

12 1 C18 1 µF


STD 805

13 2 C21-22 470 µF UPW1J471MHD3 Cap, 63 V, Alum, Elect. Nichicon

14 3 C23-24, C40 100 nF


STD 805

15 1 C31 39 nF

CAP, SMD, CERAMIC, 25V, X7R

STD 1206

16 1 C32 470 pF


STD 805

17 2 C37, C44 10 µF C3216X7R1E106K160AB CAP, SMD,

CERAMIC,25 V, X7R STD 1206

18 1 C38 10 nF ECQ-E6103KF CAP, 630 V, 10 nF, 10%,

Poly Panasonic

19 4 C39, C41,

C45-46 47 µF F931C476MNC

CAP, SMD, TANT, 16 V, 20%

Nichicon

20 1 C42 22 nF


STD 805

22 1 C48 10 µF


STD 805

23 4 D1-2, D9-10

ES3J Diode, 600 V, 3 A, Fast

Recovery Fairchild

Semiconductor SMC

24 1 D3

GBU6J Diode Bridge, 6 A, 1000V Fairchild

Semiconductor Thru-Hole

25 4 D4, D8, D15, D23

MBR0540 Diode, Schottky,40 V,

500 mA Fairchild

Semiconductor SOD-123

26 1 D5 5.1 V MMBZ5231B Diode, Zener, 10 V,

350 mW Fairchild

Semiconductor SOT-23

27 8 D6-7, D17-22

1N4148WS Diode, 300 mA, 100 V Std.

Rec. Fairchild

Semiconductor SOD-323F

28 2 D11, D29 17 V MMSZ5247B Diode, Zener, 17 V,

500 mW Fairchild

Semiconductor SOD-123




29 4 D12-13, D24, D26

RGF1M Diode, Fast, 600 V, 1 A Fairchild

Semiconductor SMA

30 1 D14

EGP30D Diode, 200 V, 3 A Fairchild

Semiconductor Axial

31 1 D16

S1J Diode, General Purpose

1 A, 600 V Fairchild

Semiconductor SMA

32 3 D25, D27-28

S100 Diode, Schottky, 100 V,

1 A Fairchild

Semiconductor SMA

33 1 F1 3 A 0447003.YXP Fuse, 3 A, 350 VAC Littlefuse Thru-Hole

34 8 J1, J3, J5, J8-9 J14, J26-

27 3103-2-00-21-00-00-08-0 Test Pin, Gold, 40 mil, Mill-Max Thru-Hole

35 1 J2

640445-5 Header, 3 Pin, 0.312

Spacing TE Connectivity Thru-Hole

36 3 J4, J17, J21

Header, 3 Pin, 100 mil Spacing

STD Thru-Hole

37 5 J6-7, J22,

J24-25 1625854-4 Test Pin, SMD, 1206 Te Connectivity 1206

39 4 J15-16, J18, J20

OSTTA024163 Header, 2 Pin, 100 mil

Spacing, 15 A OST Inc. Thru-Hole

40 1 J19

SS-132-TT-2 Connector, Header, 8 Pin,

100 Mil Samtec inc. Thru-Hole

41 1 J23

SS-132-TT-2 Connector, Header, 10 Pin,

100 Mil Samtec Inc. Thru-Hole

42 1 K1

G5CA-1A DC12 RELAY PWR SPST-NO

10 A 12 VDC Omeron

Electronics Thru-Hole

43 1 L1 175 µH 750313579 BCM PFC Inductor, EFD30 Wurth Thru-Hole

44 1 L2 9 mH 750311795 Common Mode Choke,

9 mH Wurth Thru-Hole

45 2 L3-4 4.7 µH 744028004 Inductor, Power, 4.7 µH,

0.85 A Wurth SMD

46 1 Q1

FCP190N60E MOSFET, NCH,

SuperFET2, 600 V, 60 A Fairchild

Semiconductor TO-220

47 3 Q2, Q7, Q10

ZXTP25020DFL Transistor, PNP, 20 V,

1.5 A Zetex SOT-23

48 1 Q3

2N7002K MOSFET N-CH 60 V

300 mA Fairchild


49 2 Q4-5

MMBT2222A Transistor, NPN, 40 V,

1.0 A Fairchild


50 2 Q6, Q9

FDP22N50N MOSFET, NCH, UniFET,

500 V, 22 A Fairchild

Semiconductor TO-220

51 2 Q8, Q11

KA431ADTF Adjustable Shunt

Regulator Fairchild

Semiconductor SO-8

52 1 R1 0

RES, SMD, 1/2 W STD 2010

53 1 R2 0


54 2 R3, R5 604 kΩ


55 10 R4, R16, R21, R24-25, R29, R35, R40, R50,

R68 10 kΩ


56 3 R6, R31, R37 47.5Ω

RES, SMD, 1/8W STD 805

57 2 R7, R12 33Ω B57237S0330M000 THERMISTOR EPCOS Thru-Hole

58 1 R8 590 kΩ


59 2 R9, R11 1 kΩ


60 1 R10 24.9Ω


61 2 R13-14 0.28Ω





62 1 R15 150 kΩ


63 3 R17, R32, R38 DNP


64 2 R18, R20 118 kΩ


65 1 R19 18.2 kΩ


66 1 R22 162 kΩ


67 1 R23 34Ω


68 1 R26 1.74 kΩ


69 3 R27, R42, R46 100 kΩ


70 1 R28 6.34 kΩ


71 2 R30, R36 12Ω


72 1 R33 590Ω


73 1 R34 10.5 kΩ


74 1 R39 0.4Ω


75 4 R41, R43, R47, R49 24.9 kΩ


76 7 R44, R52-54 R58, R62-

63 0


77 2 R45, R55 500 kΩ 63M-T607-504 Potentiometer, 1 - Turn Murata Thru-Hole

78 1 R48 34.0 kΩ


79 1 R51 100Ω


80 1 R56 150 kΩ

2W RES BODY:340 CENTERS:1000

STD Thru-hole

81 4 R57, R59, R61, R67 20 kΩ


82 1 R64 499Ω


83 1 R65 12 kΩ


84 1 R66 48.7 kΩ


85 1 R69 22.1 kΩ


86 1 T1

Fairchild Custom XFMR, Flyback, EV30 EPCOS Thru-Hole

87 1 T2

750313584 XFMR, Flyback, Bias Wurth Thru-Hole

88 1 U1

LM393M Dual, Differential

Comparator Fairchild

Semiconductor SOIC-8

89 1 U2

FL7930C FL7930 PFC LED

Controller Fairchild


90 1 U3

FAN3111C Gate Driver, Low-Side,

Single, 1 A Fairchild

Semiconductor SOT-23-5

91 1 U4

FAN7382 High-and Low-Side Gate

Driver Fairchild


92 2 U5-6

LM555 Timer, 555 Fairchild


93 1 U7

FAN6300H Quasi-Resonant, Current

Mode PWM Controller Fairchild


94 2 U8, U10

FOD817A Opto-Isolator Fairchild

Semiconductor SMD

95 1 U9

FSL138MRT PWM Controller, High

Input Voltage Fairchild

Semiconductor To-220F-

6L



Table 2. Multi-Channel, LED Controller, BOM


1 6 C101, C104-106, C108,

C110 100 nF

CAP, SMD, CERAMIC, 25 V, X7R STD 805

2 1 C102 DNP


3 1 C103 33 nF


4 1 C107 1 µF


5 1 C109 1.5 µF


6 1 D100

LTST-C170KRKT

LED, Red, SMD, 20 mA, 2 V Lite-On 805

7 1 J100

4-102972-0 Connector, 8-Pin, Header, 100 mil TE Connectivity Thru-Hole

8 5 J101-105

4-102972-0 Connector, Header, 100 mil TE Connectivity Thru-Hole

9 1 J106

4-102972-0 Connector, 10-Pin, Header,

100 mil TE Connectivity Thru-Hole

10 4 Q100-103

FDT86256 MOSFET,N Ch, Power Trench,

150V , 1.2 A Fairchild


11 1 R1 20 kΩ 3266W-1-203LF Potentiometer, 12turn precision Murata Thru-Hole

12 1 R2 6.98 kΩ


13 2 R3, R121 4.99 kΩ


14 4 R101, R103-105 100Ω


15 4 R106-109 10Ω


16 1 R110 100 kΩ


17 4 R111-114 2.26Ω

RES, SMD, 1/4W STD 1206

18 1 R115 47.5 kΩ


19 1 R116 2.87 kΩ


20 4 R117-120 2.32Ω


21 1 R122 2 kΩ


22 4 R123-126 10 kΩ


23 1 U100

FAN7346 4-Channel LED Current Balance

Controller Fairchild


Table 3. Single-Channel, CCCV LED Controller, BOM

Item Qty Reference Value Part Number Description Manufacturer Package

1 2 C200, C202 220 nF


2 2 C201, C203 100 nF


3 2 D200-201

1N4148WS Diode, 300 mA, 100 V Std. Rec. Fairchild Semiconductor SOD-323F

4 1 J200


5 1 J201

4-102972-0 Header, 3-Pin, 100 mil TE Connectivity Thru-Hole

6 1 J202


7 1 R200 649Ω


8 1 R201 10 kΩ


9 2 R202, R205 4.75 kΩ


10 2 R203-204 0.2Ω

RES, SMD, 1 W STD 2512

11 1 R206 150 kΩ


12 1 R207 100 kΩ


13 1 R208 47 kΩ


14 1 R209 280 kΩ


15 1 R210 14.7 kΩ


16 1 R211 0.4Ω

RES, SMD, 1 W STD 2512

17 1 U200

KA431A Adjustable Shunt Regulator Fairchild Semiconductor SO-8

18 1 U201

FAN4274 OPAMP, Dual, CMOS, 200 µA Fairchild Semiconductor MSOP-8



4. Electrical Performance

80%

85%

90%

95%

100%

80 100 120 140 160 180 200 220 240 260 280 300

Effi

cie

ncy

(%

)

Input Voltage (VAC)

RD-400, System Efficiency

70W, 50V, 4x350mA

85W, 60V, 4x350mA

Figure 6. Efficiency

0.850

0.900

0.950

1.000

80 100 120 140 160 180 200 220 240 260 280 300

Effi

cie

ncy

(%

)

Input Voltage (VAC)

RD-400, System Power Factor

70W, 50V, 4x350mA

85W, 60V, 4x350mA

Figure 7. Power Factor



0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Pe

rce

nt

Max

LED

Cu

rre

nt

(%)

PWM Dimming Duty Cycle (%)

RD-400, PWM Dimming(120VAC, 250Hz, 3.3VDIM, 50V, 4x350mA, 70W)

Figure 8. PWM. Dimming

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Pe

rce

nt

Max

LED

Cu

rre

nt

(%)

Dimming Voltage (VDC)

RD-400, Analog Dimming(120VAC, 50V, 4x350mA, 70W)

Figure 9. Analog Dimming



0

0.05

0.1

0.15

0.2

0.25

0.3

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Har

mo

nic

C

urr

en

t (A

)

Harmonic Number

RD-400, System THDEN61000-3-2, 115VAC, 85W (4x350mA)

Measured Harmonic Current

Class C (Lighting) Limit

Figure 10. Total Harmonic Discharge: VIN=115 VAC, POUT=85 W, THD=8.91%

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39

Har

mo

nic

C

urr

en

t (A

)

Harmonic Number

RD-400, System THDEN61000-3-2, 230VAC, 85W (4x350mA)

Measured Harmonic Current

Class C (Lighting) Limit

Figure 11. Total Harmonic Discharge: VIN=230 VAC, POUT=85 W, THD=21.52%



5. Related Resources

FL7930C − Single-Stage Flyback and Boundary Mode PFC Controller for Lighting

FAN6300H − Highly Integrated Quasi-Resonant Current Mode PWM Controller

FSL138MRT − Green-Mode Fairchild Power Switch (FPS™) for High Input Voltage

FAN7346 − 4-Channel LED Current Balance Controller for Lighting

FAN7382 − Half Bridge Gate Driver

FAN3111C − Single 1A High-Speed, Low-Side Gate Driver

http://www.fairchildsemi.com/referencedesign/

Reference Design Disclaimer Fairchild Semiconductor Corporation (“Fairchild”) provides these reference design services as a benefit to our customers. Fairchild has made a good faith attempt to build for the specifications provided or needed by the customer. Fairchild provides this product “as is” and without “recourse” and MAKES NO WARRANTY, EXPRESSED, IMPLIED OR OTHERWISE, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Customer agrees to do its own testing of any Fairchild reference designs in order to ensure design meets the customer needs. Neither Fairchild nor Customer shall be liable for incidental or consequential damages, including but not limited to, the cost of labor, requalifications, rework charges, delay, lost profits, or loss of goodwill arising out of the sale, installation or use of any Fairchild product.

Subject to the limitations herein, Fairchild will defend any suit or proceeding brought against Customer if it is based on a claim that any product furnished hereunder constitutes an infringement of any intellectual property rights. Fairchild must be notified promptly in writing and given full and complete authority, information and assistance (at Fairchild’s expense) for defense of the suit. Fairchild will pay damages and costs therein awarded against Customer but shall not be responsible for any compromise made without its consent. In no event shall Fairchild’s liability for all damages and costs (including the costs of the defense by Fairchild) exceed the contractual value of the products or services that are the subject of the lawsuit. In providing such defense, or in the event that such product is held to constitute infringement and the use of the product is enjoined, Fairchild, in its discretion, shall procure the right to continue using such product, or modify it so that it becomes noninfringing, or remove it and grant Customer a credit for the depreciated value thereof. Fairchild’s indemnity does not extend to claims of infringement arising from Fairchild’s compliance with Customer’s design, specifications and/or instructions, or the use of any product in combination with other products or in connection with a manufacturing or other process. The foregoing remedy is exclusive and constitutes Fairchild’s sole obligation for any claim of intellectual property infringement and Fairchild makes no warranty that products sold hereunder will not infringe any intellectual property rights. All solutions, designs, schematics, drawings, boards or other information provided by Fairchild to Customer are confidential and provided for Customer’s own use. Customer may not share any Fairchild materials with other semiconductor suppliers.

http://www.fairchildsemi.com/ds/FL/FL7930C.pdf

http://www.fairchildsemi.com/ds/FA/FAN6300H.pdf

http://www.fairchildsemi.com/ds/FS/FSL138MRT.pdf

http://www.fairchildsemi.com/ds/FA/FAN7346.pdf

http://www.fairchildsemi.com/ds/FA/FAN7382.pdf

http://www.fairchildsemi.com/ds/FA/FAN3111C.pdf

http://www.fairchildsemi.com/referencedesign/

fairchild reference design rd-400 · fairchild reference design ... c7 150 nf ecq-e6154kf cap, x...

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