Buck Solution_10W LED Driver for Bulb LD7835_10W_R00_TEST (74V/125mA) Size 55mm(L)ⅹ28mm(W)ⅹ18mm(H) Key Features

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1 Subject LD7835 Demo Board Manual Model Name (74V/125mA) TOP VIEW BOTTOM VIEW Key Features Size 55mm(L)ⅹ28mm(W)ⅹ18mm(H) Buck Topology Current Ripple Reduction (CRR) Current Accuracy < 5% Single Stage PFC > Normal Line Efficiency > 92% LED Short/ Open protection Meet EN55015 EMI Test - Conduction Meet IEC Surge Test, October

2 Lighting Power Design Check List MODEL NAME LD7835_DB-00.a TOTAL PAGE: 23(Page) P.M. Scott Lin DATE: 2013(Y)/ 10(M)/ 28(D) NO. TEST ITEM SPEC. NAME. PAGE RESULT 1 Input Characteristics - Efficiency >92% Scott Lin 10 ~ 10 PASS 2 Input Characteristics - Power Factor >0.9 Scott Lin 11 ~ 11 PASS 3 Input Characteristics - THD of Input Current TBD Scott Lin 12 ~ 12 NA 4 Output Characteristics - Current Accuracy <5% Scott Lin 13 ~ 13 PASS Output Characteristics 5 TBD Scott Lin 14 ~ 14 NA Current Ripple & Voltage Ripple ( - ) 6 Turn On Delay Time TBD Scott Lin 15 ~ 15 NA 7 Abnormal Test - LED Open Voltage Test <100V Scott Lin 15 ~ 15 PASS 8 Abnormal Test - LED Short Dissipation Test <0.5W Scott Lin 16 ~ 16 PASS 9 Abnormal Test - Over Temp. Protection Test Function Scott Lin 16 ~ 16 PASS 10 Power Component Stress Voltage <Derating Scott Lin 17 ~ 17 PASS 11 AC On/Off Test TBD Scott Lin 19 ~ 19 NA 12 EMI Test - Conduction 13 EMS Test - Surge Meet EN55015 Meet EN Scott Lin 21 ~ 22 PASS Scott Lin 23 ~ 23 PASS 14 Thermal Test <100 o C Scott Lin 24 ~ 24 PASS, October

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 & Voltage 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... 23, October

4 Table Index Table 1 CV Load = 74V Table 2 LED Load = 74V Table 3 Power Factor Table 4 THD of Input Current Table 5 Output Current (ma) Table 6 Current Ripple LED Load = 74V Table 7 Voltage Ripple LED Load = 74V Table 8 Turn On Delay Time Table 9 Over Voltage Level Table 10 Input Power during LED short Table 11 MOS and Diode Stress Steady State (90V/ 60Hz) Table 12 MOS and Diode Stress Transient State (90V/ 60Hz) Table 13 MOS and Diode Stress Steady State (264V/ 60Hz) Table 14 MOS and Diode Stress Transient State (264V/ 60Hz) Table 15 Turn on delay time Table 16 Max. Drain 264Vac/60Hz 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 15 Fig. 7 LED Short 90Vac/60Hz Fig. 8 LED Short 264Vac/60Hz Fig. 9 Over Temp. 90Vac/60Hz Fig. 10 Over Temp. 264Vac/60Hz Fig. 11 Drain & I L 90Vac/60Hz Fig. 12 Drain & I L 90Vac/60Hz/Zoom-In Fig. 13 Drain & I L 115Vac/60Hz Fig. 14 Drain & I L 115Vac/60Hz/Zoom-In Fig. 15 Drain & I L 230Vac/60Hz Fig. 16 Drain & I L 230Vac/60Hz/Zoom-In Fig. 17 Drain & I L 264Vac/60Hz Fig. 18 Drain & I L 264Vac/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... 22, October

5 Fig VAC Line EMI test Fig VAC Neutral EMI test LED Driver Module 1.1. Input Condition AC Input Voltage : 90VAC ~ 264VAC AC Input Frequency : 47Hz ~ 63Hz 1.2. Output Condition Output Voltage : 74V (24 pcs LED) Output Current : Typical 125mA 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, October

6 2. LED Driver Application Circuit Buck Solution_10W LED Driver for Bulb 2.1. Schematic F1 1A/250V RL3 NC L2 4.7mH R2 300K/1206 R1 300K/ COMP ZCD 3 CS 6 5 OUT VCC N L 1 1 TVR1 7D C4 10uF/35V/1206 C3 1uF/ IC1 LD7835 LD7835 GND 470pF C5 R8 51R/0805 R9 47K/0805 R3 0/0805 R5 R4 180K/ K/0805 R6 16K/0805 R7 18K/ R/1206 R10 R11 3.3R/1206 C6 100uF/100V 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 L3 NC RL5 0R C2 104J/4050V/P7.5 Q1 4A/600V/251 C D2 US1006FL/SOD123 L4 EE13 /1.6MH D1 ER2G/SMB N1=160T N2=36T -, October

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 180KΩ,0805, 1% YAGEO R5 180KΩ,0805, 1% YAGEO R6 16KΩ,0805, ±1% YAGEO R7 18KΩ,0805, ±1% YAGEO R8 0Ω, 0805, 5% YAGEO R9 47KΩ,0805, 1% YAGEO R10 2.4Ω,1206, 1% YAGEO R11 3.3Ω,1206, 1% YAGEO R12 82KΩ,1206, ±5% YAGEO L1 NC L2 L3 2mH MCD KU NC MAG. laters L4 1.6mH, EE13 LD design L5 NC P/N Component Value Note C1 0.1uF, 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 100uF, 100V, E-cap KYS C7 NC, 1206 D1 ER2G Panjit D2 US1006FL Panjit D6 2A/400V(ER2G) Panjit BD1 TB8S Panjit V1 7D431 SFI F1 1A/250V Fuse Walter Q1 4A/600V PO460AI Niko-sem IC1 LD7835 Leadtrend, October

8 2.3. PCB Gerber File Buck Solution_10W LED Driver for Bulb TOP VIEW BOTTOM VIEW, September

9 2.4. Inductor Buck Solution_10W LED Driver for Bulb Bobbin : EE13, 10PIN Core : EE13, PC40 Inductance(PIN 1-6) : 1640uH NP/ NVcc: 160/36 Pin1 Pin2 NV cc NP BOBBIN 1 0.3mm 36Ts 2 Pin mm 124Ts 6 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, September

10 3.1. Input Characteristics Efficiency Buck Solution_10W LED Driver for Bulb >92% PASS Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 1 CV Load = 74V Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 2 LED Load = 74V Fig. 1 Vac vs. Efficiency, September

11 Power Factor with Current Ripple Reduction (CRR) Buck Solution_10W LED Driver for Bulb Normal Lin PASS PF CV:66V CV:74V CV:82V LED:74V 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 3 Power Factor Fig. 2 Vac vs. PF, September

12 THD of Input Current with Current Ripple Reduction (CRR) Buck Solution_10W LED Driver for Bulb NA NA i THD (%) CV:66V CV:74V CV:82V LED: 74V 90Vac/60Hz Vac/60Hz Vac/60Hz Vac/60Hz Table 4 THD of Input Current Fig. 3 Vac vs. THDi, September

13 3.2. Output Characteristics Current Accuracy Buck Solution_10W LED Driver for Bulb <5% PASS Output Current (ma) 90Vac/ 60Hz 115Vac/ 60Hz 230Vac /60Hz 264Vac /60Hz Line Regulation(%) CV=82V % CV=78V % CV=74V % CV=70V % CV=66V % Load Regulation(%) 3.06% 0.67% 0.20% 0.16% 4.33% LED=74V % Table 5 Output Current (ma) LED ACC% = (Max-Min)/ (Max+Min) = 2.23%, September

14 3.2.2 Current Ripple & Voltage Ripple with Current Ripple Reduction (CRR) NA 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 CR(%) w/o CRR NA Table 6 Current Ripple LED Load = 74V Definition of Voltage Ripple (%): V PK-PK / V o * 100 VR(%) 90 V/ 60Hz 115 V/ 60Hz 230 V /60Hz 264 V /60Hz V o (V) V PK-PK (V) VR(%)w/i CRR VR(%)w/o CRR NA Table 7 Voltage Ripple LED Load = 74V Note: Current ripple depends on output capacitance. If the need of CR(%) < 50%, the capacitance must be greater than 220uF and enable CRR function in this case., September

15 3.3. Turn On Delay Time Input Turn on delay Time 90Vac Table 8 Turn On Delay Time 840ms Fig. 4 Start-up 90Vac/60Hz CH1:V ac, CH4:I o 3.4. Abnormal Test LED Open Voltage Test <100V PASS Input Voltage 115VAC/60Hz 230VAC/60Hz Output Voltage 87.6V 87.2V Table 9 Over Voltage Level Fig. 5 LED Open 90Vac/60Hz Fig. 6 LED Open September

16 CH1: Gate, CH2:V cc, CH3:Vout Buck Solution_10W LED Driver for Bulb CH1: Gate, CH2:V cc, CH3:Vout LED Short Dissipation Test <0.5W PASS Input Voltage 90VAC/60Hz 115VAC/60Hz 230VAC/60Hz 264VAC/60Hz Input Power 61mW 112mW 315mW 408mW Table 10 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 Over Temp. Protection Test Function PASS Fig. 9 Over Temp. 90Vac/60Hz CH1: Gate, CH2:V cc, CH3:V out Fig. 10 Over Temp. 264Vac/60Hz CH1: Gate, CH2:V cc, CH3:V out, September

17 3.5. Power Component Stress Voltage <Derating PASS No. Location Steady State(90V / 60HZ) Max. Rating(V) Measurement Derating(%) V V 1 Q % 2 D % Table 11 MOS and Diode Stress Steady State (90V/ 60Hz) No. Location Transient State(90V / 60HZ) Max. Rating(V) Measurement Derating(%) V V 1 Q % 2 D % Table 12 MOS and Diode Stress Transient State (90V/ 60Hz) No. Location Max. Rating(V) Steady State(264V / 60HZ) Measurement Derating(%) V 1 Q % 2 D % Table 13 MOS and Diode Stress Steady State (264V/ 60Hz) No. Location Max. Rating(V) Transient State(264V / 60HZ) Measurement Derating(%) V 1 Q % 2 D % Table 14 MOS and Diode Stress Transient State (264V/ 60Hz), September

18 3.6. MOSFET Voltage and Inductor Current Waveforms Fig. 11 Drain & I L 90Vac/60Hz CH1: Drain, CH4: I L Fig. 12 Drain & I L 90Vac/60Hz/Zoom-In CH1: Drain, CH4: I L Fig. 13 Drain & I L 115Vac/60Hz CH1: Drain, CH4: I L Fig. 14 Drain & I L 115Vac/60Hz/Zoom-In CH1: Drain, CH4: I L, September

19 Fig. 15 Drain & I L 230Vac/60Hz CH1: Drain, CH4: I L Fig. 16 Drain & I L 230Vac/60Hz/Zoom-In CH1: Drain, CH4: I L Fig. 17 Drain & I L 264Vac/60Hz CH1: Drain, CH4: I L Fig. 18 Drain & I L 264Vac/60Hz/Zoom-In CH1: Drain, CH4: I L, September

20 3.7. AC On/Off Test NA NA Input Voltage 115VAC/60Hz 230VAC/60Hz Turn on delay 520ms 190ms Table 15 Turn on delay time Power On: 900ms & Power Off 1000ms Fig. 19 AC On/Off 115Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o Fig. 20 AC On/Off 230Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o Input Voltage 264VAC/60Hz Max. Drain voltage 584V Table 16 Max. Drain 264Vac/60Hz 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, September

21 phase of AC input is 90 o or 270 o. Buck Solution_10W LED Driver for Bulb 3.8. EMI Test Meet EN55015, < 6db PASS Fig VAC Line EMI test, September

22 Fig VAC Neutral EMI test Fig VAC Line EMI test, September

23 Fig VAC Neutral EMI test 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 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 % 46.67% 2 Q % 45.60% 3 C % 53.28% 4 IC % 51.07% 5 D % 47.00% Ambient Table 18 Thermal Test, September

24 BOTTOM VIEW TOP VIEW FULL VIEW, September

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