23W LED Driver Using UPSL101

Transcription

1 3W LED Driver Using UPSL0 Subject UPSL0 LED Driver Demo Board Manual Key features: Primary-side control with single stage PFC for LED driver Minimum BOM component Power factor > 0.9 THD meet IEC Class C LED open/ short protection Revision History Revise Date Version Reason/Issue 04//7 A first release 04//4 B Update PCB size

2 3W LED Driver Using UPSL0 Contents Index Page LED Driver Demo Board Specification 3.. Input Characteristics 3.. Output Characteristics 3.3. Performance Specifications 3.4. Protection Function 3.5. Environment 3 LED Driver Demo Board Information 4. Schematic 4. BOM 5.3 Module Dimension 6.4 Tranformer Design 7.4. Transformer Specification Transformer Diagram. 7 3 Performance Evaluation 8 3. Input Characteristics Input Current Efficiency Operation at Full Load Power Factor & THD 9 3. Output Characteristics Output Current Regulation Ripple & Noise Time Sequence Protection 3.3. Open Loop Protection 3.3. Short Circuit Protection 3.4 Thermal Testing 4 Other Important Waveforms 3 4. MOSFET Vds & Rectifier Output Start/ Normal/ Short 3 4. MOSFET Voltage & Current Waveform 4

3 3W LED Driver Using UPSL0. LED Driver Demo Board Specification.. Input Characteristics AC input voltage rating AC input voltage range AC input frequency.. Output Characteristics Output Voltage 00Vac~40Vac 90Vac~77Vac 47~63Hz 53V Output Current 0.435A.3. Performance Specifications Maximum Output Power 3W Input Current 0.35A max Power Factor >0.9 Efficiency >8% Current Line Regulation +/- 3% max Current Load Regulation +/- 3% max.4. Protection Function Short Circuit Protection Open Loop Protection Shut down and Auto Recover Shut down and Auto Recover.5. Environment Operation Temperature 0 to 70 Operation Humidity 0% to 90% R.H Storage Temperature -40 to 60 Storage Humidity 0% to 90% R.H 3

4 3W LED Driver Using UPSL0. LED Driver Demo Board Information.. Schematic 4

5 3W LED Driver Using UPSL0.. BOM No. Position Description Quantity F FUSE, TA/50V MOV Varistor, T Transformer, RM8, 900uH 4 LF Common Choke, Core6*0*8mm, Φ0.3*9Ts*,.7mH 5 LF Common Choke, UU-9, 4mH 6 LF3 Common Choke, Core8*4*3mm, Φ0.4*0Ts*, 60uH 7 L Inductor,.0mH 8 CX Capacitor, X, 04pF, ±0%, 75Vac 9 CY Capacitor, Y, pf, ±0%, 75Vac 0 C MPP, 3pF, 630V C NC 0 C3 MPP, 04pF, 630V 3 C4 Capacitor, Ceramic, 0pF/000V, ±0%, SMD 06 4 C5 Capacitor, Ceramic, 04pF/50V, ±0%, SMD C6 Capacitor, Ceramic, pf/50v, ±0%, SMD C7 Capacitor, Ceramic, 05pF/50V, ±0%, SMD C8 Capacitor, aluminum electrolytic, 33uF/50V, ±0%, C9 Capacitor, Ceramic, 0pF/000V, ±0%, SMD 06 9 C0,C,C Capacitor, aluminum electrolytic, 00uF/00V, ±0%, R Resistor, chip, 0K, SMD0805,/8W,±5% R Resistor, DIP, 9K*,/W,±5% R4 Resistor, DIP, M5*, /W,±5% 3 R5 Resistor, chip, 33K, SMD0805,/8W,±5% 4 R6 Resistor, chip, K, SMD0805,/8W,±5% 5 R7 Resistor, chip, 00K, SMD06,/4W,±5% 6 R8,R9 Resistor, chip, 50K, SMD06,/4W,±5% 7 R0 Resistor, chip, 68R, SMD0805,/8W,±5% 8 R Resistor, chip, 0K, SMD0805,/8W,±5% 9 RA,RB Resistor, chip, 3R6, SMD06,/4W,±5% 30 RC Resistor, chip, 4R7, SMD0805,/8W,±5% 3 R3 Resistor, chip, 0R, SMD06,/4W,±5% 3 R4,R5 Resistor, chip, 47K, SMD06,/4W,±5% 33 R6 Resistor, chip, 0K, SMD0805,/8W,±5% 34 R7 Resistor, chip, 390R, SMD0805,/8W,±5% 35 R8A,R8B Resistor, chip, 47R, SMD06,/4W,±5% 36 R9A,R9B NC 0 37 R0 Resistor, chip, 33K, SMD06,/4W,±5% 38 R,R Resistor, chip, 330K, SMD06,/4W,±5% 5

6 3W LED Driver Using UPSL0 39 BD Bridge Diode, KBP06, A/600V. 40 D NC 0 4 D Diode, FR07/DIP, Fast Diode, A/000V. 4 D3 Diode, MURH840CT, Ultra Fast Diode, 8A/400V. 43 D4 Diode, RSD/SMA, Fast Diode, A/00V. 44 U PFC controller, UTC UPSL0, SOP-8 45 Q MOSFET, UTC 6N65, TO-0F 46 PCB 9mm(L) *4mm(W) *.6mm(T).3. Module Dimension 4mm 9mm mm 6

7 3W LED Driver Using UPSL0.4. Transformer Design.4.. Transformer Specification ) Bobbin: RM8 - Pin ) Core material : PC40 (TDK) or equivalent. 3) Lm -: 900uH,±5% (KHz ).4.. Transformer Diagram 3T Tape N4 T Tape N3 T Tape N T Tape Shielding T Tape N T Tape Shielding Bottom Transformer Winding Data Layer Winding Material Start Turns Finish Shielding 0.Φ* UEW 9 NC Tape Tape 3 N 0.7Φ UEW 0 30 F 4 Tape Tape 5 Shielding 0.Φ* UEW 9 NC 6 Tape Tape 7 N Triple Insulated Wire 0.5Φ Tape Tape 9 N3 0.7Φ* UEW Tape Tape N4 0.7Φ UEW F 30 Tape Tape 3 7

8 3W LED Driver Using UPSL0 3. Performance Evaluation This document presented here is to describe the LED driver module performance. The measuring data are tested at the board end.unless otherwise specified. The Summarized : Item. Input Characteristics Efficiency. Output characteristics Output Typical Power Output Typical Voltage Output Typical Current Current Line Regulation Ripple & Nnoise 3. Protection Short Circuit Protection Open Loop Protection Test result 87.9%@5Vac/60Hz & 86.9@30Vac/50Hz 3W 53V 430mA +-.% <50mA Shut Down and Auto Recovery Shut Down and Auto Recovery Test Equipment: Item.AC Source.Digital Power meter 3.Electronic Load 4.Digital Oscilloscope 5.Multi-meter 6.Thermal meter Vendor Chroma Chroma Chroma Tektronics Keithley Opex Model No: A DPO PT-3S 8

9 3W LED Driver Using UPSL0 3. Input Characteristics 3.. Input Current Table Input Full Load Output 40V 90Vac/60Hz 5Vac/60Hz 30Vac/50Hz 77Vac/50Hz SPEC 0.300A 0.7A 0.7A 0.03A 0.35A PASS 3.. Efficiency Operation at Full Load Table Full Load 90Vac/60Hz Output 40V 86.45% 5Vac/60Hz 30Vac/50Hz 87.9% 86.9% 77Vac/50Hz 84.57% SPEC >8% PASS 89% 88% 87% 86% 85% 84% 83% 8% 8% 80% 90Vac/60Hz 5Vac/60Hz 30Vac/50Hz 77Vac/50Hz Fig. full load 3..3 Power Factor & THD Table 3 Power Full Load Output 40V 90Vac/60Hz Vac/60Hz Vac/50Hz Vac/50Hz 0.95 SPEC >0.9 PASS Table 4 Full Load Output 40V 90Vac/60Hz 3.0% 5Vac/60Hz.9% 30Vac/50Hz 0.8% 77Vac/50Hz 9.9% SPEC <5% PASS 9

10 3W LED Driver Using UPSL0 3. Output Characteristics 3.. Output Current Regulation. Table 5 Line Regulation and Load Regulation 90Vac/60Hz 5Vac/60Hz 30Vac/50Hz 77Vac/50Hz Regulation Output 53V 45mA 46mA 48mA 43mA Output 48V 43mA 43mA 436mA 439mA +-.% Output 4V 439mA 439mA 445mA 450mA Regulation +/-.% SPEC Load & Line Regulation < +/-3% PASS 3.. Ripple & Noise Table 6 Output LED current Ripple & Noise 90Vac/60Hz Ripple & Noise(mA) 4 SPEC 5Vac/60Hz 4 30Vac/50Hz 0 <50mA 77Vac/50Hz 0 PASS Remark Fig. Fig.3 Fig. Ripple & 90Vac/60Hz Fig.3 Ripple & 77Vac/50Hz 3..3 Time Sequence Table 7 Time sequence Item Start-up Time Meas. Data 90Vac/60Hz 0.55s Fig.4 (Note ) 80Vac/50Hz Remark 0.496s Fig.5 Note : When input voltage is 90Vac/60Hz, using R be 9K and the measured data is 0.55s. 0

11 3W LED Driver Using UPSL0 Fig.4 Start-up 90Vac/60Hz, full load Fig.5 Start-up 80Vac/50Hz, full load 3.3 Protection 3.3. Open Loop Protection When LED connection is opened, the output will be limited to 65.4V. Once the condition is removed, and the power will be back to normal output voltage. Table 8 OVP output voltage under no load Vout 90Vac/60Hz 5Vac/60Hz 30Vac/50Hz 77Vac/50Hz SPEC 64.4V 65.4V 65.4V 65.4V <00V PASS Fig.6 Vout & 90Vac/60Hz, no load Fig.7 Vout & 77Vac/50Hz, no load

12 3W LED Driver Using UPSL Short Circuit Protection When short circuit protection condition is removed and the power automatically recover. Table 9 Short circuit protection & input power SCP Pin(W) 90Vac/60Hz 5Vac/60Hz 30Vac/50Hz 77Vac/50Hz SPEC Shut down Shut down Shut down Shut down Shut down 0.53W 0.8W.0W.50W <3W PASS Fig.8 Vds, Ids & 90Vac/60Hz, output short Fig.9 Vds, Ids & 90Vac/60Hz, spread Fig.0 Vds, Ids & 77Vac/50Hz, output shor Fig. Vds, Ids & 77Vac/50Hz, spread 3.4 Thermal Testing Table 0 Thermal testing: Open fram 90Vac/60Hz UPSL0 6.4 MOSFET 73.5 Transformer 7.4 Rectifier Diode 50.9 LED driver enclosure: black, mm thickness, ABS, 08mmX8mmX3mm

13 3W LED Driver Using UPSL0 4 Other Important Waveforms 4. MOSFET Vds & Rectifier Output Start/ Normal/ Short Fig.0 Vds & 77Vac/50Hz, output start Fig. Vds & 77Vac/50Hz, output normal Fig. Vds & 77Vac/50Hz, output short Fig.3 Vds & Vak output short, spread Table output start/ normal / output short. Item Input voltage Vds(max) Start up at full load 77V/50HZ 57V Normal at full load 77V/50HZ 578V Short at full load 77V/50HZ 440V Vak(max) V 43V 3V Spec. Remark Vds<650V Vr<600V Pass Fig.0 Fig. Fig., 3 3

14 3W LED Driver Using UPSL0 4. MOSFET Voltage & Current Waveform Fig.4 Vds, Ids & 90Vac/60Hz, full load Fig.5 Vds, Ids & 90Vac/60Hz, spread Fig.6 Vds, Ids & 5Vac/60Hz, full load Fig.7 Vds, Ids & 5Vac/60Hz, spread Fig.8 Vds, Ids & 30Vac/50Hz, full load Fig.9 Vds, Ids & 30Vac/50Hz, spread 4

15 3W LED Driver Using UPSL0 Fig.0 Vds, Vcs & 77Vac/50Hz, full load Fig. Vds, Vcs & 77Vac/50Hz, spread 5