6.5W LED Driver Using UPSR100

Transcription

1 6.5W LED Driver Using UPSR00 Subject UPSR00 6 LED Driver Demo Board Manual- Hi Line Version Key features: AC Input Range80Vac/50Hz~264Vac/50Hz DC Output 9Vdc / 0.35A Average Efficiency >79% Short Circuit Protection and Open Loop Protection. Revision History Revised Date Version Reason/Issue 203/2/27 A

2 6.5W LED Driver Using UPSR00 Contents Index Page LED Driver Demo Board Specification 3.. Input Characteristics 3.2. Output Characteristics 3.3. Performance Specifications 3.4. Protection Function 3.5. Environment 3 2 LED Driver Demo Board Information Schematic BOM 4, Module Dimension Tranformer Design Transformer Specification Transformer Diagram. 6 3 Performance Evaluation Input Characteristics Input Current Efficiency at Full Load Output Characteristics Output Current Regulation Ripple & Noise Start-Up Time and Hold-Up Time Start-Up Time Hold-Up Time Protection 3.3. Open Loop Protection 3.4. Short Circuit Protection 3.5. Thermal Testing 3.6 EMI Testing Conduction EMI Testing Line 2, Line Radiation EMI Testing: Radiation EMI Testing :Vertical Direction Radiation EMI Testing :Horizontal Direction 4 4 Other Important Waveforms-Full Load 6 LED Waveform Full Load-6 LED Waveform Full Load-6 LED Waveform Full Load-6 LED Vce(max) ;Ice; Vak(max) Operating@Start / Normal / Output Short Start up at Full Load-6 LED Waveform :Vce ;Ice; Vak Normal Operation at Full Load Waveform :Vce ;Ice; Vak Output Short to Ground Waveform :Vce ;Ice; Vak 6 7 2

3 6.5W LED Driver Using UPSR00. LED Driver Demo Board Specification.. Input Characteristics AC input voltage range AC input frequency.2. Output Characteristics Output Voltage 80Vac~264Vac 50Hz 9V Max. load current 0.35A.3. Performance Specifications Maximum Output Power 6.5W Average Efficiency Current Line Regulation <3% Current Load Regulation <5% Current Ripple & Noise >79% < 5mA.4. Protection Function Short Circuit Protection Open Loop Protection Shut down and Auto Recover Limit to 2V Output and Auto Recover.5. Environment Operation Temperature 0 to 70 Operation Humidity 20% to 90% R.H Storage Temperature -40 to 60 Storage Humidity 0% to 90% R.H 3

4 6.5W LED Driver Using UPSR00 2. LED Driver Demo Board Information 2.. Schematic 2.2. BOM No Position C2,C C3 C5 C6,C8 C7 C9 C0 CY D D2 D3 BD F L Description Capacitor aluminum electrolytic 6.8uF/400V, 05,±20%. Capacitor Ceramic 03pF/KV/206, ±0% Capacitor aluminum electrolytic 0uF/50V/DIP,05,±20%. Capacitor Ceramic 222pF/50V/X7R /0805, ±0% Capacitor Ceramic04pF/50V/Y5V /0805,+80%;-20% Capacitor Ceramic 02pF/X7R /0805, ±0% Capacitor aluminum electrolytic 470uF/50V/DIP,05,±20%. Capacitor, Y, 02pF/400V, 05,±20% Diode FR07/DIP, Fast Diode, A/000V. Diode RSD/SMD/SMA, Fast Diode, A/200V. Diode SB3200/DIP/DO_02,Schottky Diode 3A/200V. Bridge Diode B6S /SMD 0.5A/600V. Fuse TA/250V Inductor mh/dip Quantity 2 2 4

5 6.5W LED Driver Using UPSR Q Bipolar Transistor ;UTC MJE3003G-D-T6C-K/DIP/TO26C/RankD R Resistor 390K/206,/4W,±5% R2 Resistor 374K/206,/4W,±% R3 Resistor 5M6/0805,/8W,±5% R4 Resistor 200K/206,/4W,±5% R5 Resistor chip, 9R/0805,/8W,±5% R7 Resistor chip, 0R/0805,/8W,±5% R8,R6 Resistor chip 3R3/206,/4W,±5% 2 R9 Resistor chip 3K/0805,/8W,±5% R0 Resistor chip 30K/0805,/8W,±5% R Resistor chipk/0805,/8w,±5% R2 Resistor chip 68R/0805,/8W,±5% R3 Resistor chip 200K/0805,/8W,±5% R5 Resistor chip 24K/0805,/8W,±5% R6 Resistor chip 3R3/206,/4W,±5% U IC UTC UPSR 00-SOP-8 PCB : 25mm x 58.5mmx.6mm 2.3. Module Dimension 3.5mm 2mm 8mm 25mm 58mm 20mm 5

6 6.5W LED Driver Using UPSR Transformer Design Transformer Specification ) Bobbin: EE6-0 Pin 2) Core material : PC40 (TDK) or equivalent. 3) Lm -5: 3.75mH,±0% (KHz ) Transformer Diagram N 84T s N2 84T s N3 25T N5 EMI /Shielding Layer 3Ts Tape N(D-)=0.2Φ X42Ts ) N(4-D)=0.2Φ X42Ts D T Tape ) ( A N6(2)= 0.5Φ X30Ts T Tape N3(3-2)=0.2Φ X25Ts ) ( N4 N4(E-B)=0.2Φ X8Ts E T Tape ) ( 36Ts N4(A-E)=0.2Φ X 8Ts E T Tape N2(C-4)=0.2Φ X42Ts ( N2(5-C)=0.2Φ X42Ts C T Tape N5()=0.5Φ X30Ts 0 D T Tape 4 ) ( T Tape 5 ) ( C T Tape 3 ( ) ( B 2 ) Bottom N6/EMI /Shielding Layer Transformer Winding Data Layer Winding Material Start Turns N5 0.5Φ 2 UEW 30 2 Tape Tape 3 N2 0.2Φ 2 UEW Tape Tape 5 N2 0.2Φ 2 UEW C 42 6 Tape Tape Finish EMI /Shielding C 4 7 N4 Triple Insulated Wire 0.2Φ A 8 E 8 Tape Tape 9 N4 Triple Insulated Wire 0.2Φ E 8 B 0 Tape Tape N3 0.2Φ 2 UEW Tape Tape 3 N6 0.5Φ 2 UEW Tape Tape 5 N 0.2Φ 2 UEW Tape Tape 7 N 0.2Φ 2 UEW D 42 8 Tape Tape 3 2 EMI /Shielding D 6

7 6.5W LED Driver Using UPSR00 3. Performance Evaluation This document presented here is to describe the Demo Board Module performance. The measuring data are tested at the board end. They are tested at full load 6 LEDs. The Summarized Result : Item Test result. Input Characteristics Efficiency- 6 LED >79.38% 2. Output characteristics Output Typical Power 6.5W Output Typical Voltage 9.2V Output Typical Current 0.35A Current Line Regulation 2.79% Current Load Regulation 4.63% Ripple & Nnoise <3.6mA 3. Protection Short Circuit Protection Shut Down and Auto Recovery Open Loop Protection Limit to 2.6V and Auto Recover Test Equipment: Item.AC Source 2.Digital Power meter 3.Electronic Load 4.Digital Oscilloscope 5.Multi-meter 6.Thermal meter Vendor Chroma Chroma Chroma Tektronics Keithley Opex Model No: DPO PT-3S 7

8 6.5W LED Driver Using UPSR Input Characteristics 3.. Input Current- Full Load Table Input Full Load 6 LED Input 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Irms(mA) PF Efficiency Operation at Full Load 6 LED Table 2 Efficiency :Operation at 6 LEDs;5 LEDs;3 LEDs each. Input Pin(mW) Vo(V) Io(mA) Efficiency(%) Voltage 6 LED 5 LED 3 LED 6LED 5LED 3 LED 6LED 5 LED 3LED 6LED 5LED 3 LED 80Vac/50Hz Vac/50Hz Vac/50Hz Efficiency(%) Fig 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Input Voltage Input Voltage Vs Efficiency 6LED 5LED 3 LED 8

9 6.5W LED Driver Using UPSR Output Characteristics 3.2. Output Current Regulation. Table 3 Line Regulation and Load Regulation Input Voltage 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Line Regulation Output Current(mA) 9.2V(6 LED) 6.4V(5 LED) 9.8V(3 LED) % Load Regulation 4.63% Ripple & Noise- Full Load Table 4 Ripple & Noise Input Voltage 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Ripple & Noise(mA) Remark Fig.2 Ripple & Noise 90Vac/60Hz CH4 Current Waveform,CH Voltage Waveform Fig.3 Ripple & Noise 32Vac/60Hz CH4 Current Waveform,CH Voltage Waveform 9

10 6.5W LED Driver Using UPSR Start- Up Time and Hold-Up Time-Full Load Start- up Time Table 5. Start- up Time Input Voltage 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Start-Up Time Remark (s) 2.74 Fig Fig.5 Fig.4 80Vac /50Hz,Start Up Fig.5 264Vac / 50Hz,Start Up CH4Current Waveform,CH AC Voltage Waveform CH4 Current Waveform,CH AC Voltage Waveform Hold- up Time Table 6 Hold- up Time Input Hold-Up Time Voltage (ms) 80Vac/50Hz Vac/50Hz Vac/50Hz Remark Fig.6 Fig.7 Fig.6 80Vac / 50Hz,Hold- Up Time Fig.7 264Vac /50Hz, Hold-Up Time CH4 Current Waveform,CH AC Voltage Waveform CH4 Current Waveform,CH AC Voltage Waveform 0

11 6.5W LED Driver Using UPSR Protection 3.3 Open Loop Protection:Full Load When LED connection is opened, the Output will be limited to 2V.Once the condition is removed, and the power will be back to normal output Voltage. Table 7 Open Loop Protection Over Pen Loop Input Voltage Remark Protection (V) 80Vac/50Hz 230Vac/50Hz 264Vac/50Hz Short Circuit Protection:Full Load When Short Circuit Protection condition is removed and the power automatically recover Table 8 Short Circuit Protection Input Voltage Pi(mW) Board Status Remark 80Vac/50Hz 48.8 No Damage 230Vac/50Hz 79.4 No Damage Auto Recover 264Vac/50Hz 07.5 No Damage 3.5. Thermal Testing - Full Load Tested at Room temperature 34 in Plastic ABS Case. (Case Dimension 6mmX35mmX20mm). Table 9 Thermal Testing Input 80Vac/50Hz V lt 230Vac/50Hz 264Vac/50Hz UPSR Transistor Transformer Schottky

12 6.5W LED Driver Using UPSR EMI Testing - Full Load 3.6. Conduction EMI Testing The Test result is under 3.93 db. The Test conditions is one Shielding Layer to Ground Line Frequency (MHz) Correct Factor (db) Readin g Level Fig.8 Line Table 0 Conduction Test Data- Quasipeak Type(Limit : CNS_45_00M_QP;) Measur e Level Margin (db) Limit Detector Type QUASIPEAK Table Conduction Test Data- Average Type ( Limit : CNS_45_00M_AV) Frequency (MHz) Correct Factor (db) Readin g Level Measur e Level Margin (db) Limit Detector Type AVERAGE 2

13 6.5W LED Driver Using UPSR Line2 Fig. 9 Line2 Table 2 Conduction Test Data- Quasipeak ( Type Limit : CNS_45_00M_QP) Frequency (MHz) Correct Factor (db) Readin g Level Measur e Level Margin (db) Limit Detector Type QUASIPEAK Table 3 Conduction Test Data- Average Type ( Limit : CNS_45_00M_AV) Frequency (MHz) Correct Factor (db) Readin g Level Measur e Level Margin (db) Limit Detector Type AVERAGE 3

14 6.5W LED Driver Using UPSR Radiation EMI Testing The test result are Vertical Under 0.5dB, Horizontal Under 5 db Radiation EMI Testing Vertical Direction Radiation EMI Testing Horizontal Direction 4

15 6.5W LED Driver Using UPSR00 4. Other Important Waveforms-Full Load 6 LED 4...Waveform Full Load-6 LED Measuring Data:Vce=396Vp-p; Ice=328mAp-p;Vcc=7.4V;Vfb=6V; Frequency:43.86KHz Fig.0 80Vac/50Hz, Full Load Fig. 80Vac/50Hz, Full Load Spread Waveform Full Load- 6 LED Measuring Data:Vce=468Vp-p; Ice=320mAp-p;Vcc=7V;Vfb=8.4V; Frequency:44.25KHz Fig.2 230Vac/50Hz, Full Load Fig.3 230Vac/50Hz, Full Load Spread 4..3.Waveform Full Load-6 LED Measuring Data:Vds=52Vp-p; Vsense=32mAp-p;Vcc=7.0V;Vfb=9.2V; Frequency:44.44KHz Fig Vac/50Hz, Full Load Fig.5.264Vac/50Hz, Full Load Spread 5

16 6.5W LED Driver Using UPSR Vce(max) ;Ice; Vak(max) / Normal / Output Short cocnditio Table 4 Measuring Data at Full Load-6 LED, Operating Start/ Normal / Output Short Test. Test Item Start up at full load Normal at full load Short at full load Input voltage Ice(mA) Vce(max) Vak(max) Spec. Remark 264V/50HZ Vcbo<70 Fig4 264V/50HZ V Fig5 2.Vak< V/50HZ V Fig Start up at Full Load Waveform :Vce ;Ice; Vak - 6 LED Fig.6 264Vac / 50Hz,Start up at Full load. Vds ;Ice; Vak Normal Operation at Full Load Waveform :Vce ;Ice; Vak - 6 LED Fig.7 264Vac / 50Hz,Normal Operation at Full load. Vds ;Ice; Vak 6

17 6.5W LED Driver Using UPSR Output Short to Ground Waveform :Vce ;Ice; Vak - 6 LED Fig Vac / 50Hz, Output Short to Ground Waveform Vce ;Ice; Vak 7