RED W 1000mA LED Driver Design Report

Transcription

1 ed i RED W 1000mA LED Dive Deign Repot Low-cot Flicke-fee CC LED dive Efficiency 90.7% High Powe Facto > A 32-40V output Low EMI no CM choke Optimized fo COB/Panel No CM Choke Single Stage LLC convete EE19 Tanfome No ceen Ripple-Fee DC output 35mm 22mm Nea inewave AC input Paive PFC Low Cot Bipola Tanito PSR Cuent contol & PSR Voltage Limiting RED W 1000mA Deign Repot Rev01 Augut 2017

2 Specification Specification Value Tet condition Input voltage 50Hz VAC Functional pecification Input functional ange VAC 5 minute uvival Output votlage 32-40V VAC Output cuent 1A ± 5% VAC LF Ripple (Flicke) <2% - ee page VAC, 40VDC Hamonic compliance IEC VAC 32-39V DC Total Ripple < 20% 230VAC, 40VDC Time to light < 200m 230VAC, 40VDC Efficiency > 90% 230VAC, 40VDC Powe facto > VAC, 40VDC THD < 10% 230VAC, 40VDC No-load voltage < 60V 264VAC Potection Ovetpeatue, hot cicuit, open cicuit EMI tet 6dB magin LED eathed, Dive floating Suge Ambient Tpeatue 1kV DM, 2kV CM -20 to 50 C Page 2

3 Schatic Page 3

4 BOM Code Value Deciption Qty Supplie C1 220n X2 MKP 20% 275VAC 1 C2 150n X2 MKP 20% 275VAC 1 C3 15n MKP 5% 400VDC 1 Faatonic C4 3n NPO 5% 500VDC 1 Muata C6 27n MKP 5% 400VDC 1 Faatonic C9 1n NPO 5% 500VDC 1 Muata C10 10u ELEC 20% 450VDC 1 C11 47u ELEC 20% 50VDC 1 C12 1n 0805 X7R 10% 50VDC 1 C19 10n 0805 X7R 10% 100VDC 1 C18 1u 0805 X7R 10% 16VDC 1 C n 0805 X7R 10% 16VDC 2 C32 2n2 Y-CAP 1 D1,2,3,4,5,14,15 RS1J SMA Fat Diode 600VDC 7 TSC D12,D13 STPS3H100 Schottky Diode, 100V 3A 2 D16 BAV21W MiniMELF 1 L1 4m7H 8x10 Dum Coe 1 L2 705uH Main Inducto EE/19/16/10 1 R1 2R2 Fue eito 2R2 1 R3,4 0R W 1.0% 2 R5 1R W 1.0% 1 R6 0R W 1.0% 1 R11,R14,26,27 750k W 1.0% 4 R10 68k W 1.0% 1 R16 20k W 1.0% 1 R17 100k W 1.0% 1 R18 1M W 1.0% 1 R19 75k W 1.0% 1 P1,P2 Teminal 2 Pin 2 Q1,Q2 3DD4244DM NPN (T=2-2.5u) TO126 3A 2 Huawei T1 T9x5x4 Bae Dive: 18:6:6:1 tun 1 Fenghua T2 EE19 Output Tanfome 1 U1 RED2422 Low Ripple LED contolle IC 1 RediS TOTAL 47 Page 4

5 33mm PCB layout Top Side Bottom Side 87mm Single ided PCB 1mm thick 1 Oz coppe Page 5

6 Tanfome Contuction Tanfome Coe type EE19 PC47 Bobbin Type EE19 SELV 5+4 Pi 51t x1 x 0.32mm ECW Pi Inductance 3.4mH ±25% Sec1&2 29t x 1 x 0.35mm TEXE 2 laye W1 Finih Stat 1 laye Tape Stat 2 laye W2a Finih 2 laye W2b Finih Stat 1 laye Tape Page 6

7 Tet Reult Output Voltage 32V 40V Input voltage 198V 215V 230V 245V 264V 198V 215V 230V 245V 264V Output cuent 990mA 991mA 992mA 992mA 992mA 991mA 993mA 994mA 995mA 995mA Input Powe Output Powe Efficiency 89.4% 89.4% 89.3% 89.2% 89.0% 90.7% 90.8% 90.7% 90.4% 90.1% Powe Facto THD 10.0% 16.6% 22.2% 27.1% 32.4% 16.4% 15.2% 16.5% 19.4% 24.0% Ripple 1.60% 1.28% 1.11% 1.00% 0.90% Tet Reult Condition Peak no-load Voltage 45.00V 230VAC Time To light 140m 230VAC Hamonic Input Voltage 230Vac Output Voltage 40V Page 7

8 Tet Reult Cuent Regulation 996mA 994mA 992mA 990mA 32V 40V 988mA 190V 200V 210V 220V 230V 240V 250V 260V 270V PF V V V 200V 210V 220V 230V 240V 250V 260V 270V 1.8% Flicke 35% THD 1.6% 1.4% 1.2% 30% 25% 1.0% 20% 0.8% 0.6% 0.4% 0.2% 36V 0.0% 190V 200V 210V 220V 230V 240V 250V 260V 270V 15% 10% 5% 32V 40V 0% 190V 200V 210V 220V 230V 240V 250V 260V 270V Page 8

9 Tet Reult - Plot Collecto cuent and voltage Reonant tun-off Inducto cuent 230VAC, 40VDC Input cuent and output flicke cuent 1%/div Page 9

10 Tet Reult - Plot Output Voltage HT Voltage L2 cuent L2 Cuent Shot cicuit potection 264VAC (Wot cae) Open Cicuit Input Voltage 120m L2 Cuent Output cuent Time To light 230VAC, 40VDC Output Cuent Ripple L2 cuent Capacitive mode opeation - 180VAC, 40VDC Page 10

11 Tet Reult EMI Radiated Tet Setup Conducted Tet Setup >10dB Magin EMI Pa Radiated 30M~300MHz Conducted 9k~30MHz Page 11

12 Tet Reult - Suge 1kV uge pa with magin 6kV uge upgade with MOV Plot of HT bu voltage and midpoint cuent duing 1.2kV uge with fue eito Plot of HT bu voltage and midpoint cuent duing 6kV uge with Fue and MOV Fo 2kV to 6kV uge : Add MOV Change Fue-eito to T-type, 2 to 6A Page 12

13 Tet Reult - Themal Tet condition: In a box in a heated oven Ta = 50C Tet condition: Open on the bench Themal Reult 198V 264V (caed) 40V 32V Ta 51.0C 51.0C Q C 117.0C Q C 117.0C L2 coe 100.0C 121.0C L2 winding 100.0C 119.0C T2 coe 108.0C 117.0C T2 winding 116.0C 109.0C Top ide Themal Bottom ide Themal Page 13

14 Tet Reult AC tanient AC Main tanient 198Vac - 264Vac evey 1econd Reult: No flicke on LED AC Main 198Vac 264Vac Iout 198Vac 264Vac 264Vac 198Vac 14

15 Upgade Bette THD Tet unit Hamonic Range C3 C4 C6 THD at VHT at 264Vac 36Voutput 32Voutput Rak Simple modification fo bette THD Change the chage pump capacito A (oiginal) Oiginal 15n 3n3 27n 16.5% 398V Optimized highe efficiency deign B Bette 15n 8n2 22n 12.2% 403V Bette THD, not much ange impovent C E ven bette 15n 12n 22n 10.3% 407V Bette THD, wide ange, le efficient, o hotte D Bet 15n 15n 22n 8.8% 410V Bette THD, wide Range, even hotte, o conide lage cae & A B C D AC input 230VAC, 36V Page 15

16 Modify output cuent Only need to change boot capacito & CS eito to change output cuent fom 1000mA to 700mA Deign cuent C3 Change R5&6 264V & 36V 230V & 36V Output ange fo good Hamonic 32V & 264VAC 1000mA 15n 0R36 & 1R3 16.5% 90.2% 30-39V 400.7V Oiginal dive Rak 900mA 12n 0R36 & 2R2 15.7% 90.4% 29-41V 405.6V Efficiency ie a powe educe 800mA 10n 0R36 & 10R 17.0% 90.4% 30-41V 403.6V Can educe C10 to 8.2uF 700mA 8n2 0R47 & 2R7 18.9% 90.6% 31-40V 398.2V Can alo change L2 to EE16/10 & Q1,2 to TO92 Page 16

17 Upgade Bette EMI Fo impoved EMI magin at 150kHz to 5MHz, add an EF12.6 CM inducto Conducted EMI with LED eathed and Dive on an eathed goundplane (Wot Cae) Conducted 9k~30MHz Rove Link & Fit 30mH CM choke EF12.6 Page 17

18 Upgade Lowe flicke Change output cap(c11) to 330uF and Vdd cap(c18) to 2.2uF, Pk-Pk flicke educe by 40%, ingle tatup. Change output cap(c11) to 680uF and Vdd cap(c18) to 2.2uF, Pk-Pk flicke educe by 60%, twice tatup. Inceaing C18 and C11 inceae time to light to 400m Replaced with 680uF Twice tatup wavefom Output cuent ipple eduction (680uF) Page 18

19 Upgade 320VAC opeation Conide changing bulk capacito to 500V Efficiency at 320VAC = 90% Component tpeatue afte 1 hou on the bench Themal eult 320Vac Q1 70.0C Q2 68.0C Replace E-cap with 500V type Main inducto 90.0C Tanfome 82.0C Ta 30.0C Becaue of the half-bidge configuation the convete can withtand vey high input voltage Fo uvival up to 460VAC and 6kV uge, ee AN2114 Page 19

20 RED2422 Dataheet Page 20

21 Contact detail Appoved Ditibuto Page 21