Using the TPS92210EVM-613
User's Guide
Literature Number: SLUU436A
August 2010–Revised November 2010
User's Guide
SLUU436A–August 2010–Revised November 2010
Natural PFC LED Lighting Driver Controller
1 Introduction
The TPS92210EVM-613 evaluation module is a constant current TRIAC dimmable LED driver. It can drive
9 to 10 LEDs at 350 mA and is rated for an AC input of 184 VRMS to 265 VRMS.
2 Description
The TPS92210EVM-613 uses the TPS92210 in a Discontinuous Conduction Mode (DCM) flyback
topology. The controller uses cascode configuration which allows for faster start-up times as well as
eliminates the need for an external sense resistor for primary-side current sense. Additionally, the
controller employs a max on-time modulation scheme that allows it to be used in a Power Factor
Correction (PFC) circuit. This results in a compact LED driver design that achieves greater than 0.95
power factor (PF) driven by a single controller.
The TPS92210EVM-613 is also compatible with a wide variety of TRIAC dimmers. Secondary-side
feedback responds to the conduction time of the sinusoidal wave, as governed by the TRIAC, and
appropriately lowers the LED current to dim the LEDs. The secondary side also includes an adaptive
supplemental load that sinks current when LED current becomes too low, therefore ensuring conduction of
the TRIAC during very low dimming.
2.1 Typical Applications
• Commercial/Household LED Lighting
2.2 Features
• Single Stage Power Factor Correction Achieves PF Greater than 0.95
• TRIAC Dimming to Zero LED Current
• Test Points for Output Voltage/Current
• Cascoded Configuration for Fully Integrated Current Control with No External Sense Resistor
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Electrical Performance Specifications
3 Electrical Performance Specifications
Table 1. Electrical Performance Specifications
PARAMETER TEST CONDITIONS MIN TYP MAX UNITS
Input Characteristics
Voltage range 184 265 VAC
Maximum input current 45 mA
Output Characteristics
Output voltage, VOUT 19 32 V
Output load current, IOUT 330 350 370 mA
Output current ripple At VIN = 230 VAC 127 mApp
Output over voltage 36 V
Systems Characteristics
Switching frequency ~115 kHz
Peak efficiency 87.3%
Full load efficiency VIN = 230 VAC 87%
Power Factor > 0.95
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AC Power
Supply
Ammeter
1
Voltmeter 1
Ammeter
2
Voltmeter 2
Loop injection point
(TP8 and TP11)
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Test Setup
5 Test Setup
5.1 Test Equipment
Voltage Source: 265-VRMS AC source capable of at least 12 W
Multimeters: 4 Voltmeters
Network Analyzer: To measure loop response (phase/magnitude measurements)
Output Load: 9 LEDs in series (VF = 3.5 V at 350 mA per LED) or 80-Ω, 12-W resistor
Oscilloscope: 4 channel 100 MHz, high voltage probe rated for at least 600 V
Recommended Wire Gauge: 18 AWG
5.2 Recommended Test Setup
Figure 2. Recommended Test Setup
5.3 List of Test Points
Table 2. Test Points Functions
TEST POINTS NAME DESCRIPTION
TP1 Input AC + AC line input
TP2 LED + LED output
TP3 Input AC - AC line input
TP4 Dummy load Dummy load test point
TP5 LED - LED return point
TP6 Switch node Flyback switch node
TP7 N/A Recreated primary side sinusoidal voltage
TP8 TRIAC conduction angle Scaled TRIAC conduction angle
TP9 VDD VDD of TPS92210
TP10 TZE Transformer Zero Energy detection
TP11 Loop response Loop injection point for phase/gain measurement
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Test Procedure
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6 Test Procedure
CAUTION
CAUTION: High voltages exist on this EVM. Please handle with care. Do not
touch EVM when powered.
An external load MUST be used to power up this EVM. No load on the output will trigger the over-voltage
protection and shut down the EVM.
6.1 Line Regulation and Efficiency Measurement Procedure
1. Connect EVM per Figure 2 above. An external LED load must be used to start up the EVM.
NOTE: Frequency analyzer not required for this procedure.
2. Set AC source to 184 VRMS.
3. Turn on AC source.
4. Record output voltage reading from Voltmeter 2 and output current reading from Ammeter 2 and input
voltage reading from Voltmeter 1 and Ammeter 1.
5. Increase output voltage by 5 VRMS.
6. Repeat steps 4 and 5 until you reach 265 VRMS.
7. Turn off the AC source.
6.2 TRIAC Dimmer Measurement Procedure
Figure 3. TRIAC Dimmer Test Setup
1. Set up the EVM per Figure 2.
2. Add TRIAC dimmer to the input per Figure 3.
3. Set AC source to 230 VRMS (or 220 VRMS depending on the TRIAC).
4. Set line frequency to 50 Hz.
5. Set TRIAC to maximum output.
6. Measure output current.
7. Slowly slide TRIAC dimmer to minimum output.
8. Observe output current reduces.
6.3 Equipment Shutdown
1. Turn off the AC source.
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180 190 210 230 250 260 270
VAC - Input Voltage - V
85.0
86.0
87.0
88.0
89.0
90.0
220
85.5
86.5
87.5
88.5
89.5
h- Efficiency - %
EFFICIENCY
vs
INPUT VOLTAGE
240200
180 190 210 230 250 260 270
VAC - Input Voltage - V
350
352
354
356
358
360
220
IOUT - Output Current - mA
OUTPUT CURRENT
vs
INPUT VOLTAGE
240200
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Performance Data and Typical Characteristic Curves
7 Performance Data and Typical Characteristic Curves
Figure 4 through Figure 15 present typical performance curves for TPS92210EVM-613.
7.1 Efficiency
Figure 4. Efficiency
7.2 Line Regulation
Figure 5. Line Regulation
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180 190 210 230 250 260 270
VAC - Input Voltage - V
0.950
0.960
0.970
0.975
0.985
0.995
220
PF - Power Factor
POWER FACTOR
vs
INPUT VOLTAGE
240200
0.955
0.965
0.980
0.990
18 20 22 26 28 30 32
VOUT - Output Voltage - V
350
352
354
360
24
IOUT - Output Current - mA
OUTPUT CURRENT
vs
OUTPUT VOLTAGE
356
358
Performance Data and Typical Characteristic Curves
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7.3 Power Factor
Figure 6. Power Factor Performance
7.4 Load Regulation
Figure 7. Load Regulation
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1 10 100
Frequency - Hz
-100
-60
-20
100
Magnitude- dB
MAGNITUDE/PHASE
vs
FREQUENCY
20
60
-200
-150
-50
200
Phase - degrees
50
150
-100
0
100
Phase
Magnitude
80
40
0
-40
-80
0 20 40 80 100 140 160
Turn-On Angle - degrees
0
100
150
400
60
IOUT - Output Current - mA
OUTPUT CURRENT
vs
TURN-ON ANGLE
250
300
350
200
50
120
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Performance Data and Typical Characteristic Curves
7.5 Bode Plot
Figure 8. Loop Response Gain and Phase (crossover: 1.8 Hz, 86 degrees phase margin)
7.6 TRIAC Dimmer Performance
Figure 9. TRIAC Dimmer Performance
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Performance Data and Typical Characteristic Curves
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7.7 Output Ripple
Figure 10. Output Ripple (CH4 – 200 mA/10 mV)
7.8 Switch-Node Voltage
Figure 11. Switching-Node Waveform (CH4 – 200 mA/10 mV)
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Performance Data and Typical Characteristic Curves
7.9 Turn On Waveform
Figure 12. Turn-On Waveform (CH4 – 500 mA/10 mV)
7.10 Turn Off Waveform
Figure 13. Turn-Off Waveform (CH4 – 500 mA/10 mV)
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Performance Data and Typical Characteristic Curves
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7.11 TRIAC Dimming Waveform
Figure 14. TRIAC Triggering at 100% (CH4 – 500 mA/10 mV)
Figure 15. TRIAC Triggering at 50% (CH4 – 500 mA/10 mV)
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EVM Assembly Drawing and PCB layout
8 EVM Assembly Drawing and PCB layout
The following figures (Figure 16 through Figure 19) show the design of the TPS92210EVM-613 printed
circuit board.
Figure 16. Top Layer Assembly Drawing (top view)
Figure 17. Bottom Assembly Drawing (bottom view)
13
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List of Materials
9 List of Materials
The EVM components list according to the schematic shown in Figure 1
Table 3. List of Materials
COUNT REFDES DESCRIPTION PART NUMBER MFR
Capacitor, metal polyester, 0.01 µF, 630 V, 85°C, +/-10%,
2 C1, C2 ECQ-E6103KF Panasonic
12 mm x 4.5 mm
Capacitor, polyester film, 22 nF, 630 V, ±10%, 0.260 inch
1 C3 ECQ-E6223KZ Panasonic
x 0.470 inch
Capacitor, polypropylene film, 200 nF, 630 V, ±10%, 0.256
1 C4 ECW-F6204JL Panasonic
inch x 0.650 inch
2 C5, C6 Capacitor, ceramic, 10 µF, 50 V, X7R, ±10%, 1210 Std Std
Capacitor, alumninum electrolytic, 560 µF, 50 V, ±20%,
2 C7, C8 UPW1H561MHD Rubycon/Nichicon
12.5 mm x 25 mm GRM3291X2A222JZ0
2 C9, C10 Capacitor, ceramic, 0.015 µF, 100 V, ±5%, 1210 Murata
1
1 C11 Capacitor, ceramic, 220 pF, 50 V, X7R, ±10%, 0603 Std Std
1 C12 Capacitor, ceramic, 1.0 µF, 10 V, X7R, ±10%, 0805 Std Std
1 C13 Capacitor, ceramic, 220 pF, 100 V, 125°C, ±5%, 1206 12061A221JAT2A AVX
C14, C15,
6 C16, C19, Capacitor, ceramic, 0.01 µF, 50 V, X7R, ±10%, 0603 Std Std
C20, C21
1 C17 Capacitor, ceramic, 0.1 µF, 25 V, X7R, ±10%, 0603 Std Std
1 C18 Capacitor, aluminum, 100 µF, 25 V, ±20%, 0.200 inch EEU-FC1E101S Panasonic
1 C22 Capacitor, ceramic, 0.22 µF, 25 V, X7R, ±10%, 0603 Std Std
1 D1 Diode, utrafast, power rectifier, 1 A, 100 V, DO-201AD MUR220RLG On Semiconductor
1 D2 Diode, bridge rectifier, 0.5 A, 600 V, SO-4 MB6S Fairchild
1 D3 Diode, ultra fast rectifier, 1 A, 800 V, SMA RS1K-13-F Diodes, Inc.
1 D4 Diode, shunt voltage reference, SOT-23 LM4040C50 Texas Instruments
Diode, super fast rectifier, 1A, 200V, 0.220 inch x 0.115
1 D5 ES1D Diodes, Inc.
inch
1 D6 Diode, Zener, 18 V, 500 mW, SOD-123 MMSZ18T1G On Semiconductor
1 D7 Diode, switching, dual, 200 mA, 70 V, SOT-23 MMBD6100LT1G On Semiconductor
1 D8 Diode, Schottky, 1 A, 30 V, SOD-323 SDM100K30 Diodes, Inc
1 D9 Diode, ultra fast, 1 A, 200 V, SMA CSFA103-G On Semiconductor
1 F1 Fuse, axial, fast acting, 2.5 A, 250V, 0.160 x 0.400 inch 026302.5WRT1-L Littelfuse
Inductor, radial, 470 µH, 310 mA, +/-10%, 70°C, 0.315
2 L1, L2 22R474C Murata
inch Diameter
1 Q1 Bipolar, NPN, 100 V, 1 A, SOT-89 FCX493TA Zetex
Bipolar, complementary, NPN/PNP 60/40 V, 600 mA,
1 Q2 MMDT4413-7-F Diodes, Inc.
SOT-363
1 Q3 MOSFET, N-channel, 600 V, 0.4 A, 8.5 W, SOT-223 STN1HNK60 STMicroelectronics
1 Q4 MOSFET, N-channel, 60 V, 115 mA, SOT-23 2N7002 Std
1 Q5 Bipolar, NPN, 40 V, 200 mA, 350 mW, SOT-23 MMBT3904-TP Micro Commercial Co
1 Q6 MOSFET, N-channel, 650 V, 7.3 A, 0.6 W, TO-220 SPA07N60C3 Infineon
1 R1 Resistor, chip, 499 Ω, 1/4 W, ±1%, 1206 Std Std
1 R2 Resistor, metal oxide, 33 Ω, 1 W, ±5%, 2512 ERG-1SJ330 Panasonic
1 R3 Resistor, chip, 249 Ω, 1/4 W, ±1%, 1206 Std Std
1 R4 Resistor, chip, 75.0 kΩ, 1/4 W, ±1%, 1206 Std Std
2 R5, R12 Resistor, chip, 1.00 MΩ, 1/4 W, ±1%, 1206 Std Std
1 R6 Resistor, chip, 0.51 Ω, 1/2 W, ±1%, 2010 Std Std
1 R7 Resistor, chip, 1.00 kΩ, 1/4 W, ±5%, 1206 Std Std
1 R8 Resistor, metal film, 5.11 kΩ, 1/2 W, ±1%, RN55 Std Std
15
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List of Materials
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Table 3. List of Materials (continued)
COUNT REFDES DESCRIPTION PART NUMBER MFR
2 R9, R41 Resistor, chip, 200 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R10 Resistor, chip, 10.0 kΩ, 1/10 W, ±1%, 0603 Std Std
2 R11, R18 Resistor, chip, 49.9 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R13 Resistor, carbon film, 510 Ω, 1/2 W, ±5%, RN55 Std Std
R14, R24, Resistor, chip, 100 kΩ, 1/10 W, ±1%, 0603 Std Std
3R40
1 R15 Resistor, chip, 3.01 Ω, 1/8 W, ±1%, 0805 Std Std
1 R16 Resistor, chip, 4.42 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R17 Resistor, chip, 71.5 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R19 Resistor, chip, 39.2 Ω, 1/8 W, ±1%, 0805 Std Std
1 R20 Resistor, chip, 681 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R21 Resistor, chip, 464 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R22 Resistor, chip, 100 Ω, 1/10 W, ±1%, 0603 Std Std
1 R23 Resistor, chip, 2.37 Ω, 1/8 W, ±1%, 0805 Std Std
1 R25 Resistor, chip, 511 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R26 Resistor, Chip, 274 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R27 Resistor, chip, 20.0 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R28 Resistor, chip, 634 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R29 Resistor, chip, 110 kΩ, 1/8 W, ±1%, 0805 Std Std
1 R30 Resistor, chip, 7.5 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R31 Resistor, chip, 1.0 MΩ, 1/8 W, ±1%, 0805 Std Std
1 R32 Resistor, chip, 4.99 Ω, 1/10 W, ±1%, 0603 Std Std
1 R33 Resistor, chip, 49.9 Ω1/10 W, ±1%, 0603 Std Std
1 R34 Resistor, chip, 1.00 MΩ, 1/10 W, ±1%, 0603 Std Std
1 R35 Resistor, chip, 604 kΩ, 1/10 W, ±1%, 0603 Std Std
2 R36, R43 Resistor, chip, 3.01 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R37 Resistor, carbon film, 10.0 kΩ, 1/2 W, ±5%, RN55 Std Std
1 R38 Resistor, chip, 33.2 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R39 Resistor, chip, 40.2 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R42 Resistor, chip, 2.00 kΩ, 1/10 W, ±1%, 0603 Std Std
1 R44 Resistor, chip, 23.7 kΩ, 1/10 W, ±1%, 0603 Std Std
1 T1 Transformer, 1200 µH, ±10%, 0.567 inch x 0.876 inch 750811145 Wurth Midcom
U1, U2, Op-Amp Low Voltage Rail-to-Rail Output, 130 µA Typical, LMV321IDBVR Texas Instruments
3U4 SOT-23-5
1 U3 PFC LED Lighting Driver Controller, SO-8 TPS92210D Texas Instruments
1 U5 Optocoupler, High Isolation Voltage, SOP4 Gull-Wing PS2561L-1-A NEC
1 VAR1 Varistor, Disk, 220 V, 8.5 mm Dia. ERZ-V07D221 Panansonic
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EVM Warnings and Restrictions
It is important to operate this EVM within the input voltage range of 184 VAC to 265 VAC and the output voltage range of 19 VDC
to 32 VDC .
Exceeding the specified input range may cause unexpected operation and/or irreversible damage to the EVM. If there are
questions concerning the input range, please contact a TI field representative prior to connecting the input power.
Applying loads outside of the specified output range may result in unintended operation and/or possible permanent damage to the
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specification, please contact a TI field representative.
During normal operation, some circuit components may have case temperatures greater than 50° C. The EVM is designed to
operate properly with certain components above 50° C as long as the input and output ranges are maintained. These components
include but are not limited to linear regulators, switching transistors, pass transistors, and current sense resistors. These types of
devices can be identified using the EVM schematic located in the EVM User's Guide. When placing measurement probes near
these devices during operation, please be aware that these devices may be very warm to the touch.
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