6.5W LED Driver Using UPSR100

Transcription

1 6.5W LED Driver Using UPSR00 Subject UPSR00 LED Driver Demo Board Manual- Low Line Key features: AC Input Range 90Vac/60Hz~32Vac60/Hz DC Output 2Vdc / 0.3A Average Efficiency > 76% Short Circuit Protection and Open Loop Protection. Revision History Revised Date Version Reason/Issue 203/2/27 A

2 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 Open Loop Protection Short Circuit Protection 3.4. Thermal Testing 4 Other Important Waveforms-Full Load 7 LED Waveform Full Load-7 LED Waveform Full Load-7 LED Waveform Full Load-7 LED Vce(max) ;Ice; Vak(max) Operating@Start / Normal / Output Short Start up at Full Load-7 LED Waveform :Vce ;Ice; Vak Normal Operation at Full Load Waveform :Vce ;Ice; Vak Output Short to Ground Waveform :Vce ;Ice; Vak 3 4 2

3 . LED Driver Demo Board Specification.. Input Characteristics AC input voltage range AC input frequency 90Vac~32Vac 60Hz.2. Output Characteristics Output Voltage 2.8V Max. load current 0.3A.3. Performance Specifications Maximum Output Power 6.5W Average Efficiency Current Line Regulation <% Current Load Regulation <5% Current Ripple & Noise >76% < 40mA.4. Protection Function Short Circuit Protection Open Loop Protection Shut down and Auto Recover Limit to 28V 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 2. LED Driver Demo Board Information 2.. Schematic 2.2. BOM No Position Description C2,C C3 Capacitor aluminum electrolytic 6.8uF/400V, 05,±20%. Capacitor Ceramic 03pF/KV/206, ±0% C5 C6,C8 Capacitor aluminum electrolytic 0uF/50V/DIP,05,±20%. Capacitor Ceramic 222pF/50V/X7R /0805, ±0% C7 Capacitor Ceramic04pF/50V/Y5V /0805,+80%;-20% C9 C0 Capacitor Ceramic 02pF/X7R /0805, ±0% Capacitor aluminum electrolytic 470uF/50V/DIP,05,±20%. CY Capacitor, Y, 02pF/400V, 05,±20% D Diode FR07/DIP, Fast Diode, A/000V. Quantity 2 2 D2 Diode RSD/SMD/SMA, Fast Diode, A/200V. D3 Diode SB3200/DIP/DO_02,Schottky Diode 3A/200V. BD Bridge Diode B6S /SMD, 0.5A/600V. F Fuse TA/250V L Inductor mh/dip 4

5 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 Resistor DIP, R/DIP,0.5W,±5% 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 5R/0805,/8W,±5% U IC UTC UPSR 00-SOP Module Dimension 3.5mm 2mm 8mm 25mm 58mm 20mm 5

6 2.4. Transformer Design Transformer Specification ) Bobbin: EE6-0 Pin 2) Core material : PC40 (TDK) or equivalent. 3) Lm -5:.2mH,±0% (KHz ) Transformer Diagram N 53T s N2 53T s N3 27T 2 N5 EMI /Shielding Layer 6 3Ts Tape 0 D T Tape ) N(4-D)=0.2Φ X27Ts D T Tape ) ( A N6(2)= 0.5Φ X30Ts T Tape 4 ) ( N3(3-2)=0.2Φ X27Ts T Tape ) ( N4 N4(E-B)=0.2Φ X22Ts E T Tape ) ( 44Ts N4(A-E)=0.2Φ X 22Ts E T Tape 5 ) ( N2(C-4)=0.2Φ X26Ts C T Tape ( N2(5-C)=0.2Φ X27Ts C T Tape 3 ( N5()=0.5Φ X30Ts ) ( B ) 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 26 6 Tape Tape 7 N4 8 9 N4 Triple Insulated Wire 0.2Φ Tape Tape Triple Insulated Wire 0.2Φ A 22 E 22 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 26 8 Tape Tape 3 N(D-)=0.2Φ X26Ts Finish EMI /Shielding C 4 E B 2 EMI /Shielding D

7 3. Performance Evaluation This document presented here is to describe the Demo Board Module performance. The measuring data are tested at the board end. The Summarized Result : Item Test result. Input Characteristics Efficiency- 7 LED >76% 2. Output characteristics Output Typical Power 6.5W Output Typical Voltage 2.83V Output Typical Current 0.30A Current Line Regulation 0.97% Current Load Regulation 4.50% Ripple & Nnoise 37.6mA 3. Protection Short Circuit Protection Shut Down and Auto Recovery Open Loop Protection Limit to 23.9V 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 3.. Input Characteristics 3.. Input Current- 7LED Table Input Full Load 7 LED Input 90Vac/60Hz 5Vac/60Hz 32Vac/60Hz Irms(mA) PF Efficiency Operation at Full Load 7 LED Table 2 Efficiency :Operation at 7 LEDs;6 LEDs;5 LEDs each. Input Voltage Pin(mW) Vo(V) Io(mA) Efficiency(%) 7 LED 6 LED 5 LED 7LED 6LED 5 LED 7 LED 6 LED 5 LED 7LED 6LED 5 LED 90Vac/60Hz Vac/60Hz Vac/60Hz Efficiency(%) LED 6LED 5 LED 90Vac/60Hz 5Vac/60Hz 32Vac/60Hz Input Voltage Fig Input Voltage Vs Efficiency 8

9 3.2 Output Characteristics 3.2. Output Current Regulation. Table 3 Line Regulation and Load Regulation Input Voltage 90Vac/60Hz 5Vac/60Hz 32Vac/60Hz Line Regulation Output Current(mA) 2.8V(7 LED) 8.8V(6 LED) 5.8V(5 LED) % Load Regulation 4.50% Ripple & Noise-7LED Table 4 Ripple & Noise Input Voltage 90Vac/60Hz 5Vac/60Hz 32Vac/60Hz Ripple & Noise(mA) Fig.2 Ripple & Noise 90Vac/60Hz CH Current Waveform,CH3 Voltage Waveform Fig.3 Ripple & Noise 32Vac/60Hz CH Current Waveform,CH3 Voltage Waveform 9

10 3.2.3 Start- Up Time and Hold-Up Time-7 LED Start- up Time Table 5. Start- up Time Input Start-Up Time Voltage (s) 90Vac/60Hz Vac/60Hz.74 32Vac/60Hz.37 Remark Fig.4 Fig.5 Fig.7 264Vac / 50Hz, Start Up Fig.4 90Vac / 60Hz,Start Up Fig.5 32Vac / 60Hz,Start Up CH Current Waveform,CH2 AC Voltage Waveform CH Current Waveform,CH2 AC Voltage Waveform Hold- up Time Table 6 Hold- up Time Input Hold-Up Time Voltage (ms) Remark 90Vac/60Hz 5Vac/60Hz 32Vac/60Hz Fig.6 Fig.7 Fig.6 90Vac / 60Hz,Hold- Up Time Fig.7 32Vac / 60Hz, Hold-Up Time CH Current Waveform,CH2 AC Voltage Waveform CH Current Waveform,CH2 AC Voltage Waveform 0

11 3.3 Protection 3.3. Open Loop Protection- 7 LED When LED connection is opened, the Output will be limited to 23.97V.Once the condition is removed, and the power will be back to normal output Voltage. Table 7 Open Loop Protection Voltage Input Voltage 90Vac/60Hz 5Vac/60Hz 32Vac/50Hz Open Loop Protection (V) Short Circuit Protection: 7 LED When Short Circuit Protection condition is removed and the power automatically recover Table 8 Short Circuit Protection Input Voltage Pi(mW) Board Status Remark 90Vac/60Hz 22 No Damage 5Vac/60Hz 33 No Damage 32Vac/50Hz 45 No Damage 3.4. Thermal Testing - 7 LED Plastic ABS Case measured Room Temperature 36. (Case Dimension 6mmX35mmX20mm). Table 9 Thermal Testing Input 90Vac/60Hz V lt 5Vac/60Hz 32Vac/50Hz UPSR Transistor Transformer Schottky

12 4. Other Important Waveforms-Full 7 LED 4...Waveform Full Load-7 LED Measuring Data:Vce=94Vp-p; Ice=50mAp-p;Vcc=4.6V;Vfb=V; Frequency:46.73KHz Fig.8 90Vac/60Hz, Full Load Fig.9 90Vac/60Hz, Full Load Spread Waveform Full Load- 7 LED Measuring Data:Vce=232Vp-p; Ice=500mAp-p;Vcc=4.6V;Vfb=2.4V; Frequency:46.73KHz Fig.0. 5Vac/60Hz, Full Load Fig.. 5Vac/60Hz, Full Load Spread 4..3.Waveform Full Load-7 LED Measuring Data:Vds=250Vp-p; Vsense=50mAp-p;Vcc=4.6V;Vfb=3.6V; Frequency:46.95KHz Fig.2. 32Vac/60Hz, Full Load Fig.3. 32Vac/60Hz, Full Load Spread 2

13 4.2. Vce(max) ;Ice; Vak(max) / Normal / Output Short cocnditio Table 0 Measuring Data at Full Load-7 LED, Operating Start/ Normal / Output Short Test. Test Item Start up at full load Normal at full load Short at full load nput voltage Ice(mA) Vce(max) Vak(max) Spec. Remark 32V/60HZ Vceo<40 Fig4 32V/60HZ V Fig5 2.Vak<200 32V/60HZ V Fig Start up at Full Load-7 LED Waveform :Vce ;Ice; Vak- 7 LED Fig.4 32Vac / 60Hz,Start up at Full load. Vds ;Ice; Vak Normal Operation at Full Load Waveform :Vce ;Ice; Vak - 7 LED Fig.5 32Vac / 60Hz,Normal Operation at Full load. Vds ;Ice; Vak 3

14 4.2.3 Output Short to Ground Waveform :Vce ;Ice; Vak - 7 LED Fig.6 32Vac / 60Hz, Output Short to Ground Waveform Vce ;Ice; Vak 4