Buck Solution_10W LED Driver for Bulb LD7835_10W_R01_TEST. Size 55mm(L)ⅹ28mm(W)ⅹ18mm(H) Key Features

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1 Subject LD7835 Demo Board Manual Model Name (40V/250mA) TOP VIEW BOTTOM VIEW Key Features Size 55mm(L)ⅹ28mm(W)ⅹ18mm(H) Buck Topology Current Ripple Reduction (CRR) Current Accuracy < 5% Fast Start-up < 0.5 sec Single Stage PFC > 0.9 w/o Normal Line Efficiency > 90% LED Short/ Open protection Meet EN55015 EMI Test - Conduction Meet IEC Surge Test 1

2 Lighting Power Design Check List MODEL NAME LD7835_DB-01.a TOTAL PAGE: 25(Page) P.M. Scott Lin DATE: 2014(Y)/ 01 (M)/ 03(D) NO. TEST ITEM SPEC. NAME. PAGE RESULT 1 Input Characteristics - Efficiency >90% Hunter 10 ~ 10 PASS 2 Input Characteristics - Power Factor TBD Hunter 11 ~ 11 NA 3 Input Characteristics - THD of Input Current TBD Hunter 12 ~ 12 NA 4 Output Characteristics - Current Accuracy <5% Hunter 13 ~ 13 PASS 5 Output Characteristics Current Ripple TBD Hunter 14 ~ 14 NA 6 Turn On Delay Time <0.5 sec Hunter 15 ~ 15 PASS 7 Abnormal Test - LED Open Voltage Test Function Hunter 16 ~ 16 PASS 8 Abnormal Test - LED Short Dissipation Test <0.8W Hunter 17 ~ 17 PASS 9 Abnormal Test - Over Temp. Protection Test Function Hunter 17 ~ 17 PASS 10 Power Component Stress Voltage <Derating Hunter 18 ~ 18 PASS 11 AC On/Off Test TBD Hunter 21 ~ 21 NA 12 EMI Test - Conduction 13 EMS Test - Surge Meet EN55015 Meet EN Hunter 22 ~ 23 PASS Hunter 24 ~ 24 PASS 14 Thermal Test <100 o C Hunter 25 ~ 25 PASS 2

3 Contents Index 1. LED DRIVER MODULE SPECIFICATION INPUT CONDITION OUTPUT CONDITION PROTECTION CONDITION AMBIENT TEMPERATURE LED DRIVER APPLICATION CIRCUIT SCHEMATIC BOM LIST PCB GERBER FILE INDUCTOR SPECIFICATION EXECUTIVE SUMMARY INPUT CHARACTERISTICS Efficiency Power Factor THD of Input Current OUTPUT CHARACTERISTICS Current Accuracy Current Ripple TURN ON DELAY TIME ABNORMAL TEST LED Open Voltage Test LED Short Dissipation Test Over Temp. Protection Test POWER COMPONENT STRESS VOLTAGE MOSFET VOLTAGE AND INDUCTOR CURRENT WAVEFORMS AC ON/OFF TEST EMI TEST SURGE TEST THERMAL TEST

4 Table Index Table 1 CV Load = 40V w/i CRR Table 2 LED Load = 40V w/i CRR Table 3 LED Load = 40V w/o CRR Table 4 Power Factor Table 5 THD of Input Current Table 6 Output Current (ma) Table 7 Current Ripple LED Load = 40V w/i CRR Table 8 Current Ripple LED Load = 40V w/o CRR Table 9 Turn On Delay Time Table 10 Over Voltage Level Table 11 Input Power during LED short Table 12 MOS and Diode Stress Steady State (90V/ 60Hz) Table 13 MOS and Diode Stress Transient State (90V/ 60Hz) Table 14 MOS and Diode Stress Steady State (264V/ 60Hz) Table 15 MOS and Diode Stress Transient State (264V/ 60Hz) Table 16 Max. Drain 264Vac/60Hz AC On/Off Table 17 Surge Test Table 18 Thermal Test Figure Index Fig. 1 Vac vs. Efficiency Fig. 2 Vac vs. PF Fig. 3 Vac vs. THD Fig. 4 Start-up 90Vac/60Hz Fig. 5 LED Open 90Vac/60Hz Fig. 6 LED Open 16 Fig. 7 LED Short 90Vac/60Hz Fig. 8 LED Short 264Vac/60Hz...17 Fig. 9 Over Temp. 90Vac/60Hz Fig. 10 Over Temp. 264Vac/60Hz...17 Fig. 11 Drain & I L waveforms w/i CRR@ 115Vac/60Hz Fig. 12 Drain & I L waveforms w/i CRR@ 115Vac/60Hz/Zoom-In Fig. 13 Drain & I L waveforms w/o 115Vac/60Hz Fig. 14 Drain & I L waveforms w/o 115Vac/60Hz/Zoom-In Fig. 15 Drain & I L waveforms w/i 230Vac/60Hz Fig. 16 Drain & I L waveforms w/i 230Vac/60Hz/Zoom-In Fig. 17 Drain & I L waveforms w/o 230Vac/60Hz Fig. 18 Drain & I L waveforms w/o 230Vac/60Hz/Zoom-In Fig. 19 AC On/Off 115Vac/60Hz Fig. 20 AC On/Off 230Vac/60Hz Fig. 21 Max. Drain 264Vac/60Hz On/Off Test Fig VAC Line EMI test Fig VAC Neutral EMI test Fig VAC Line EMI test Fig VAC Neutral EMI test

5 1. LED Driver Module 1.1. Input Condition AC Input Voltage : 90VAC ~ 264VAC AC Input Frequency : 47Hz ~ 63Hz 1.2. Output Condition Output Voltage : 40V (13 pcs LED) Output Current : Typical 250mA 1.3. Protection Condition LED Open Protection Auto-recovery, Hiccup 1 times LED short Protection Auto-recovery, Hiccup 1 times Over Current Protection Cycle-by-cycle limit Over Temp. Protection Auto-recovery, Hiccup 1 time 1.4. Ambient Temperature Ambient Temperature 25 o C 5

6 2. LED Driver Application Circuit 2.1. Schematic F1 1A/250V R2 300K/1206 R1 300K/1206 RL3 NC L2 4.7mH 1 COMP ZCD 3 CS 6 5 OUT VCC N L 1 1 TVR1 7D C4 10uF/35V/1206 C3 1uF/ IC1 LD7835 LD7835 GND C5 470pF R8 0R/0805 R9 47K/0805 R3 0/0805 R5 91K/0805 R6 16K/0805 R7 18K/ R/1206 R10 R11 3.3R//3.3R /1206 R4 91K/0805 C6 220uF/50V R12 82K/ LED+ 1 1 LED- 2 AC AC 1 RL2 0R L1 NC L5 NC RL4 0R 4 BD1 ABS8 TVR2 NC C1 104J/4050V/P7.5 C2 104J/400V/P7.5 L3 NC RL5 0R Q1 4A/600V/251 C D2 US1006FL/SOD123 L4 EE13 /770uH N1=128T N2=56T D1 ER2J/SMB - 6

7 2.2. BOM List P/N Component Value Note RL2 0Ω,0805, ±5% YAGEO RL3 NC, 0805 YAGEO RL4 0Ω,0805, ±5% YAGEO RL5 0Ω, 0805, ±5% YAGEO R1 300KΩ, 1206, ±5% YAGEO R2 300KΩ, 1206, ±5% YAGEO R3 0Ω,0805, ±5% YAGEO R4 91KΩ,0805, 1% YAGEO R5 91KΩ,0805, 1% YAGEO R6 16KΩ,0805, ±1% YAGEO R7 18KΩ,0805, ±1% YAGEO R8 0Ω, 0805, 5% YAGEO R9 47KΩ,0805, 1% YAGEO R10 1.3Ω,1206, 1% YAGEO R11 3.3//3.3Ω,1206, 1% YAGEO P/N Component Value Note C1 0.1uF, DC 400V, X7T NA C2 0.1uF, DC 400V, X7T NA C3 1uF, 10V, 0603 YAGEO C4 10uF,35V,1206,X7R GRM32ER7YA106KA12 Murata C5 470pF, 10V, 0603 YAGEO C6 220uF, 50V, E-cap Ltec C7 NC, 1206 D1 ER2J Panjit D2 US1006FL Panjit BD1 ABS8 Panjit V1 7D431 SFI F1 1A/250V Fuse Walter Q1 4A/600V U4N60 AOS IC1 LD7835 Leadtrend R12 82KΩ,1206, ±5% YAGEO L1 NC L2 L3 4.7mH MAG. laters MCD KU NC L4 770uH, EE13 LD design L5 NC 7

8 2.3. PCB Gerber File TOP VIEW BOTTOM VIEW 8

9 2.4. Inductor Bobbin : EE13, 10PIN Core : EE13, PC40 Inductance(PIN 1-6) : 770uH NP/ NVcc: 128/56 3. Executive Summary Test Equipment Equipment Equipment Model No. Electrical Load Chroma Power Meter WT210 AC power source Chroma Scope TDS3014 Multi-function Meter Fluke 187 Thermal Hunter PT-3S 9

10 3.1. Input Characteristics Efficiency >90% PASS Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 1 CV Load = 40V w/i CRR Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 2 LED Load = 40V w/i CRR Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 3 LED Load = 40V w/o CRR Fig. 1 Vac vs. Efficiency 10

11 Power Factor TBD NA PF CV:40V (w/i CRR ) LED:40V (w/i CRR ) CV:40V (w/o CRR ) LED:40V (w/o CRR ) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 4 Power Factor Fig. 2 Vac vs. PF 11

12 THD of Input Current TBD NA i THD (%) LED:40V (w/i CRR) LED:40V (w/o CRR) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 5 THD of Input Current Fig. 3 Vac vs. THD 12

13 3.2. Output Characteristics Current Accuracy <5% PASS Output Current (ma) 90Vac/ 60Hz 115Vac/ 60Hz 230Vac /60Hz 264Vac /60Hz Line Regulation CV=44V % CV=40V % CV=36V % Load Regulation 0% 0.07% 0.1% 0.11% 0.33% LED=40V % Table 6 Output Current (ma) LED ACC% = (Max-Min)/ (Max+Min) = +/- 0.23% 13

14 3.2.2 Current Ripple TBD NA Definition of Current Ripple (%): I PK-PK / I o * 100 CR(%) 90Vac/ 60Hz 115Vac/ 60Hz 230Vac/ 60Hz 264Vac/ 60Hz I o (ma) I PK-PK (ma) CR(%) w/i CRR Table 7 Current Ripple LED Load = 40V w/i CRR Definition of Current Ripple (%): I PK-PK / I o * 100 CR(%) 90Vac/ 60Hz 115Vac/ 60Hz 230Vac/ 60Hz 264Vac/ 60Hz I o (ma) I PK-PK (ma) CR(%) w/o CRR Table 8 Current Ripple LED Load = 40V w/o CRR 14

15 3.3. Turn On Delay Time <0.5 sec PASS Input T turn on delay 90Vac 405ms Table 9 Turn On Delay Time Fig. 4 Start-up 90Vac/60Hz CH1:V ac, CH4:I o 15

16 3.4. Abnormal Test LED Open Voltage Test Function PASS Input Voltage 115VAC/60Hz 230VAC/60Hz Output Voltage 51.2V 51.4V Table 10 Over Voltage Level Fig. 5 LED Open 90Vac/60Hz CH1: Gate, CH2:V cc, CH4:Vout Fig. 6 LED Open CH1: Gate, CH2:V cc, CH4:Vout 16

17 LED Short Dissipation Test <0.8W PASS Input Voltage 90VAC/60Hz 115VAC/60Hz 230VAC/60Hz 264VAC/60Hz Input Power 112.9mW 187.2mW 658.2mW 767.7mW Table 11 Input Power during LED short Fig. 7 LED Short 90Vac/60Hz CH1: Gate, CH2:V cc, CH4:I L Fig. 8 LED Short 264Vac/60Hz CH1: Gate, CH2:V cc, CH4:I L Note: The dissipation depends on start-up resistance Over Temp. Protection Test Function PASS Fig. 9 Over Temp. 90Vac/60Hz CH1: Gate, CH2:V cc, CH4:V out Fig. 10 Over Temp. 264Vac/60Hz CH1: Gate, CH2:V cc, CH4:V out 17

18 3.5. Power Component Stress Voltage <Derating PASS NO. Location Max. Rating(V) Steady State (90V / 60HZ) Measurement Derating(%) V V 1 Q % 2 D % Table 12 MOS and Diode Stress Steady State (90V/ 60Hz) NO. Location Max. Rating(V) Transient State (90V / 60HZ) Measurement Derating(%) V V 1 Q % 2 D % Table 13 MOS and Diode Stress Transient State (90V/ 60Hz) NO. Location Max. Rating(V) Steady State (90V / 60HZ) Measurement Derating(%) V V 1 Q % 2 D Table 14 MOS and Diode Stress Steady State (264V/ 60Hz) NO. Location Max. Rating(V) Transient State (90V / 60HZ) Measurement Derating(%) V V 1 Q % 2 D % Table 15 MOS and Diode Stress Transient State (264V/ 60Hz) 18

19 3.6. MOSFET Voltage and Inductor Current Waveforms Fig. 11 Drain & I L 115Vac/60Hz CH1: Drain, CH4: I L w/i CRR Fig. 12 Drain & I L 115Vac/60Hz/Zoom-In CH1: Drain, CH4: I L w/i CRR Fig. 13 Drain & I L 115Vac/60Hz CH1: Drain, CH4: I L w/o CRR Fig. 14 Drain & I L 115Vac/60Hz/Zoom-In CH1: Drain, CH4: I L w/o CRR 19

20 Fig. 15 Drain & I L 230Vac/60Hz CH1: Drain, CH4: I L w/i CRR Fig. 16 Drain & I L 230Vac/60Hz/Zoom-In CH1: Drain, CH4: I L w/i CRR Fig. 17 Drain & I L 230Vac/60Hz CH1: Drain, CH4: I L w/o CRR Fig. 18 Drain & I L 230Vac/60Hz/Zoom-In CH1: Drain, CH4: I L w/o CRR 20

21 3.7. AC On/Off Test TBD NA Power On: 1000ms & Power Off 1000ms Fig. 19 AC On/Off 115Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o Input Voltage Drain voltage Fig. 20 AC On/Off 230Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o 264VAC/60Hz 550V Table 16 Max. Drain 264Vac/60Hz AC On/Off Fig. 21 Max. Drain 264Vac/60Hz On/Off Test Note: The voltage spike of MOSFET is induced from inrush current at power on instantaneously. It s easy to be observed while phase of AC input is 90 o or 270 o. 21

22 3.8. EMI Test Meet EN55015 PASS Fig VAC Line EMI test Fig VAC Neutral EMI test 22

23 Fig VAC Line EMI test Fig VAC Neutral EMI test 23

24 3.9. Surge Test Meet IEC PASS EUT Line: 220Vac 2PIN 3PIN System Spec.: 24V/ 0.7A Waveform 1.2/50 10/700 Ring Impedance 12ohm 2ohm Repetition Once each 20 second period with 5 transients per test NOTE: LD7835 Real Demo Board Test Mode Phase & Level (V) Test Result L/N K -0.5K K -0.5K PASS PASS NOTE: Table 17 Surge Test 24

25 3.10. Thermal Test < 100 o C PASS No. Location Max. Derating(%) 90V/60Hz(.) 115V/60Hz(.) 230V/60Hz(.) 264/60Hz(.) Rating(.) 90V/60Hz 264/60Hz 1 L Q C IC D1 150 Ambient % 63.46% % 56.40% % 70.24% % 65.40% % 55.00% Table 18 Thermal Test BOTTOM VIEW TOP VIEW FULL VIEW 25