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 > 0.9 @ Normal Line Efficiency > 92% LED Short/ Open protection Meet EN55015 EMI Test - Conduction Meet IEC61000-4-5 Surge Test, October 2013 1
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 EN6100-4-5 Scott Lin 21 ~ 22 PASS Scott Lin 23 ~ 23 PASS 14 Thermal Test <100 o C Scott Lin 24 ~ 24 PASS, October 2013 2
Contents Index 1. LED DRIVER MODULE SPECIFICATION... 5 1.1. INPUT CONDITION... 5 1.2. OUTPUT CONDITION... 5 1.3. PROTECTION CONDITION... 5 1.4. AMBIENT TEMPERATURE... 5 2. LED DRIVER APPLICATION CIRCUIT... 6 2.1. SCHEMATIC... 6 2.2. BOM LIST... 7 2.3. PCB GERBER FILE... 8 2.4. INDUCTOR SPECIFICATION... 9 3. EXECUTIVE SUMMARY... 9 3.1. INPUT CHARACTERISTICS... 10 3.1.1. Efficiency... 10 3.1.2. Power Factor... 11 3.1.3. THD of Input Current... 12 3.2. OUTPUT CHARACTERISTICS... 13 3.2.1 Current Accuracy... 13 3.2.2 Current Ripple & Voltage Ripple... 14 3.3. TURN ON DELAY TIME... 15 3.4. ABNORMAL TEST... 15 3.4.1. LED Open Voltage Test... 15 3.4.2. LED Short Dissipation Test... 16 3.4.3. Over Temp. Protection Test... 16 3.5. POWER COMPONENT STRESS VOLTAGE... 17 3.6. MOSFET VOLTAGE AND INDUCTOR CURRENT WAVEFORMS... 18 3.7. AC ON/OFF TEST... 20 3.8. EMI TEST... 21 3.9. SURGE TEST... 23 3.11. THERMAL TEST... 23, October 2013 3
Table Index Table 1 Efficiency @ CV Load = 74V... 10 Table 2 Efficiency @ LED Load = 74V... 10 Table 3 Power Factor... 11 Table 4 THD of Input Current... 12 Table 5 Output Current (ma)... 13 Table 6 Current Ripple (%) @ LED Load = 74V... 14 Table 7 Voltage Ripple (%) @ LED Load = 74V... 14 Table 8 Turn On Delay Time... 15 Table 9 Over Voltage Level... 15 Table 10 Input Power during LED short... 16 Table 11 MOS and Diode Stress Voltage @ Steady State (90V/ 60Hz)... 17 Table 12 MOS and Diode Stress Voltage @ Transient State (90V/ 60Hz)... 17 Table 13 MOS and Diode Stress Voltage @ Steady State (264V/ 60Hz)... 17 Table 14 MOS and Diode Stress Voltage @ Transient State (264V/ 60Hz)... 17 Table 15 Turn on delay time... 20 Table 16 Max. Drain Voltage @ 264Vac/60Hz... 20 Table 17 Surge Test... 23 Table 18 Thermal Test... 23 Figure Index Fig. 1 Vac vs. Efficiency... 10 Fig. 2 Vac vs. PF... 11 Fig. 3 Vac vs. THD... 12 Fig. 4 Start-up Waveforms @ 90Vac/60Hz... 15 Fig. 5 LED Open Test @ 90Vac/60Hz Fig. 6 LED Open Test @264Vac/60Hz... 15 Fig. 7 LED Short Test @ 90Vac/60Hz Fig. 8 LED Short Test @ 264Vac/60Hz... 16 Fig. 9 Over Temp. Protection @ 90Vac/60Hz Fig. 10 Over Temp. Protection @ 264Vac/60Hz... 16 Fig. 11 Drain & I L waveforms @ 90Vac/60Hz Fig. 12 Drain & I L waveforms @ 90Vac/60Hz/Zoom-In... 18 Fig. 13 Drain & I L waveforms @ 115Vac/60Hz Fig. 14 Drain & I L waveforms @ 115Vac/60Hz/Zoom-In... 18 Fig. 15 Drain & I L waveforms @ 230Vac/60Hz Fig. 16 Drain & I L waveforms @ 230Vac/60Hz/Zoom-In... 19 Fig. 17 Drain & I L waveforms @ 264Vac/60Hz Fig. 18 Drain & I L waveforms @ 264Vac/60Hz/Zoom-In... 19 Fig. 19 AC On/Off Test @ 115Vac/60Hz Fig. 20 AC On/Off Test @ 230Vac/60Hz... 20 Fig. 21 Max. Drain Voltage @ 264Vac/60Hz On/Off Test... 20 Fig. 22 110VAC Line EMI test... 21 Fig. 23 110VAC Neutral EMI test... 22, October 2013 4
Fig. 24 220VAC Line EMI test... 22 Fig. 25 220VAC Neutral EMI test... 23 1. 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 2013 5
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/1206 1 COMP ZCD 3 CS 6 5 OUT VCC 4 1 1 N L 1 1 TVR1 7D471 + 3 C4 10uF/35V/1206 C3 1uF/0805 2 IC1 LD7835 LD7835 GND 470pF C5 R8 51R/0805 R9 47K/0805 R3 0/0805 R5 R4 180K/0805 180K/0805 R6 16K/0805 R7 18K/0805 2.4R/1206 R10 R11 3.3R/1206 C6 100uF/100V R12 82K/1206 1 1 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 C7 1206 D2 US1006FL/SOD123 L4 EE13 /1.6MH D1 ER2G/SMB N1=160T N2=36T -, October 2013 6
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-0808-472KU 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 2013 7
2.3. PCB Gerber File Buck Solution_10W LED Driver for Bulb TOP VIEW BOTTOM VIEW, September 2013 8
2.4. Inductor Buck Solution_10W LED Driver for Bulb Bobbin : EE13, 10PIN Core : EE13, PC40 Inductance(PIN 1-6) : 1640uH ±5% @1KHZ/1V NP/ NVcc: 160/36 Pin1 Pin2 NV cc NP BOBBIN 1 0.3mm 36Ts 2 Pin6 2 0.3mm 124Ts 6 3. Executive Summary Test Equipment Equipment Equipment Model No. Electrical Load Chroma 63030 Power Meter WT210 AC power source Chroma 61602 Scope TDS3014 Multi-function Meter Fluke 187 Thermal Hunter PT-3S, September 2013 9
3.1. Input Characteristics 3.1.1. Efficiency Buck Solution_10W LED Driver for Bulb >92% PASS Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz 10.39 130.3 74.04 92.85 115Vac/60Hz 9.93 126.0 74.04 93.94 230Vac/60Hz 9.89 125.0 74.04 93.58 264Vac/60Hz 9.95 125.0 74.04 93.02 Table 1 Efficiency @ CV Load = 74V Eff.(%) P in I o V o Efficiency (W) (ma) (V) (%) 90Vac/60Hz 10.62 130.5 74.87 92.0 115Vac/60Hz 10.07 126.1 74.77 93.6 230Vac/60Hz 10.00 125.1 74.80 93.6 264Vac/60Hz 10.06 125.1 74.82 93.0 Table 2 Efficiency @ LED Load = 74V Fig. 1 Vac vs. Efficiency, September 2013 10
3.1.2. Power Factor with Current Ripple Reduction (CRR) Buck Solution_10W LED Driver for Bulb >0.9 @ Normal Lin PASS PF CV:66V CV:74V CV:82V LED:74V 90Vac/60Hz 0.953 0.932 0.877 0.926 115Vac/60Hz 0.975 0.970 0.958 0.968 230Vac/60Hz 0.891 0.910 0.923 0.913 264Vac/60Hz 0.843 0.872 0.890 0.872 Table 3 Power Factor Fig. 2 Vac vs. PF, September 2013 11
3.1.3. 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 34.3 41.0 55.5 43.2 115Vac/60Hz 24.7 28.1 32.0 27.9 230Vac/60Hz 38.4 36.5 34.4 36.0 264Vac/60Hz 41.8 40.0 38.3 39.6 Table 4 THD of Input Current Fig. 3 Vac vs. THDi, September 2013 12
3.2. Output Characteristics 3.2.1 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 136.2 127.7 124.9 125.0 4.33% CV=78V 133.5 126.3 125.1 125.0 3.29% CV=74V 130.3 126 125.0 125.0 2.08% CV=70V 128.8 126.1 125.1 125.2 1.46% CV=66V 128.1 126.2 125.4 125.4 1.07% Load Regulation(%) 3.06% 0.67% 0.20% 0.16% 4.33% LED=74V 130.6 126.1 125.1 124.9 2.23% Table 5 Output Current (ma) LED ACC% = (Max-Min)/ (Max+Min) = 2.23%, September 2013 13
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) 130.5 126.1 125.1 125.0 I PK-PK (ma) 152.9 119.0 83.0 76 CR(%) w/i CRR 117.16 94.37 66.35 60.80 CR(%) w/o CRR NA 110 84.1 80 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) 74.78 74.73 74.79 74.79 V PK-PK (V) 6.2 5.3 3.8 3.4 VR(%)w/i CRR 8.29 7.09 5.08 4.55 VR(%)w/o CRR NA 7.72 5.84 5.71 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 2013 14
3.3. Turn On Delay Time Input Turn on delay Time 90Vac Table 8 Turn On Delay Time 840ms Fig. 4 Start-up Waveforms @ 90Vac/60Hz CH1:V ac, CH4:I o 3.4. Abnormal Test 3.4.1. 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 Test @ 90Vac/60Hz Fig. 6 LED Open Test @264Vac/60Hz, September 2013 15
CH1: Gate, CH2:V cc, CH3:Vout Buck Solution_10W LED Driver for Bulb CH1: Gate, CH2:V cc, CH3:Vout 3.4.2. 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 Test @ 90Vac/60Hz CH1: Gate, CH2:V cc, CH4:I L Fig. 8 LED Short Test @ 264Vac/60Hz CH1: Gate, CH2:V cc, CH4:I L 3.4.3. Over Temp. Protection Test Function PASS Fig. 9 Over Temp. Protection @ 90Vac/60Hz CH1: Gate, CH2:V cc, CH3:V out Fig. 10 Over Temp. Protection @ 264Vac/60Hz CH1: Gate, CH2:V cc, CH3:V out, September 2013 16
3.5. Power Component Stress Voltage <Derating PASS No. Location Steady State(90V / 60HZ) Max. Rating(V) Measurement Derating(%) V V 1 Q1 600 136 22.67% 2 D1 400 146 36.50% Table 11 MOS and Diode Stress Voltage @ Steady State (90V/ 60Hz) No. Location Transient State(90V / 60HZ) Max. Rating(V) Measurement Derating(%) V V 1 Q1 600 192 32.00% 2 D1 400 166 41.50% Table 12 MOS and Diode Stress Voltage @ Transient State (90V/ 60Hz) No. Location Max. Rating(V) Steady State(264V / 60HZ) Measurement Derating(%) V 1 Q1 600 388 64.67% 2 D1 400 392 98.00% Table 13 MOS and Diode Stress Voltage @ Steady State (264V/ 60Hz) No. Location Max. Rating(V) Transient State(264V / 60HZ) Measurement Derating(%) V 1 Q1 600 584 97.33% 2 D1 400 392 98.00% Table 14 MOS and Diode Stress Voltage @ Transient State (264V/ 60Hz), September 2013 17
3.6. MOSFET Voltage and Inductor Current Waveforms Fig. 11 Drain & I L waveforms @ 90Vac/60Hz CH1: Drain, CH4: I L Fig. 12 Drain & I L waveforms @ 90Vac/60Hz/Zoom-In CH1: Drain, CH4: I L Fig. 13 Drain & I L waveforms @ 115Vac/60Hz CH1: Drain, CH4: I L Fig. 14 Drain & I L waveforms @ 115Vac/60Hz/Zoom-In CH1: Drain, CH4: I L, September 2013 18
Fig. 15 Drain & I L waveforms @ 230Vac/60Hz CH1: Drain, CH4: I L Fig. 16 Drain & I L waveforms @ 230Vac/60Hz/Zoom-In CH1: Drain, CH4: I L Fig. 17 Drain & I L waveforms @ 264Vac/60Hz CH1: Drain, CH4: I L Fig. 18 Drain & I L waveforms @ 264Vac/60Hz/Zoom-In CH1: Drain, CH4: I L, September 2013 19
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 Test @ 115Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o Fig. 20 AC On/Off Test @ 230Vac/60Hz CH1: Drain, CH2:Vac, CH4:I o Input Voltage 264VAC/60Hz Max. Drain voltage 584V Table 16 Max. Drain Voltage @ 264Vac/60Hz Fig. 21 Max. Drain Voltage @ 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 2013 20
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. 22 110VAC Line EMI test, September 2013 21
Fig. 23 110VAC Neutral EMI test Fig. 24 220VAC Line EMI test, September 2013 22
Fig. 25 220VAC Neutral EMI test 3.9. Surge Test Meet IEC 6100-4-5 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 90 +0.5K -0.5K 270 +0.5K -0.5K PASS PASS NOTE: Table 17 Surge Test 3.11. Thermal Test < 100 o C PASS No. Location Max. Derating(%) 90V/60Hz(.) 115V/60Hz(.) 230V/60Hz(.) 264/60Hz(.) Rating(.) 90V/60Hz 264/60Hz 1 L4 150 69.1 66.6 68.5 70 46.07% 46.67% 2 Q1 150 71.3 65.3 65.9 68.4 47.53% 45.60% 3 C6 125 65.7 63.9 65.4 66.6 52.56% 53.28% 4 IC1 150 72 70.6 74.6 76.6 48.00% 51.07% 5 D1 150 70.5 67.2 68.8 70.5 47.00% 47.00% Ambient 25.0 25.0 25.0 25.0 -- -- Table 18 Thermal Test, September 2013 23
4 5 3 1 2 BOTTOM VIEW TOP VIEW FULL VIEW, September 2013 24