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LED Driver Design with iW3620
Summary and Features :
1. LED driver, 40V, 350mA ; Wide AC input range: 90Vac-264Vac
2. For Isolated Applications
3. High Efficiency, High Power Factor and Least Parts Solution
4. Meet EMI Requirement (EN55015BQP&AV scan)
5. Fully Protection Against AC input UV/OV,O/P Short &Open, Component single fault
2iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
1. Specification
Description Symbol Min Typ Max Units Comment
Input
Voltage VIN 90 264 VAC 2 Wire
Frequency fLINE 47 50 63 Hz
Open-load Input Power (264VAC)
W
Output
Const Voltage
Output Voltage VOUT_CV 40 V Measured at the PCB connector
Output Current IOUT_CV A
Const Current
Output Voltage VOUT_CV V Min Vout is depend on Vcc
Output Current IOUT_CV 0.35 A
Total Output Power
Continuous Output Power POUT 14 W
Over Current Protection IOUT_MAX A Auto-restart
Efficiency 83 % Measured at end of PCB
Power Fact PF 0.9 Harmonic meet IEC61000-3-2
Turn on Delay Time Sec
Conducted EMI Meets EN55015B
Hi-pot test 3 KV
Operation temperature Topr Free convection, sea level40 °C
3iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
2. Schematic
4iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
3.Circuit Board Photograph
Top side
5iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
core
7(F)
SECPRI
2UEW 0.21mm*1*17T – Primary (Clockwise)
6(S)
MATERIALS:1. Core : EC28(Ferrite Material TDK PC40 or equivalent)2. Bobbin :EC28. Primary=5, Secondary=53. Magnet Wires (Pri) : Type 2-UEW 4. Magnet Wire (Sec) : Triple Insulated Wires 5. Layer Insulation Tape :3M1298 or equivalent.
SCHEMATIC
51T
10T
ELECTRICAL SPECIFICATIONS:1. Primary Inductance (Lp) = 0.9mH @10KHz2. Primary Leakage Inductance (Lk)< = 30uH @10KHz3. Electrical Strength = 3KV, 50/60Hz,1Min
FINISHED :1. Cut remained of Pin after wires termination2. Core is connected to PRI-GND pin7.3. Varnish the complete assembly
4
56
7
Primary
Bias/sense
2UEW 0.17mm*2*10T Bias (clockwise)
4. Transformer Design
A(S)
5(S)
Cuffing Tape 40(L)x15(W)mmSmall solder Joint with fine wire
Finished Assembly
Fold up both side of Tape
Cut Copper Foil (4x20x0.05)mm
2UEW 0.21mm*1*17T – Primary (Clockwise)
Triple Insulated wire 0.28mm*1*8T Secondary
7(S) Copper foil 4(W)*20(L)mm shielding
32T
A
B
Secondary
4(F)
Triple Insulated wire 0.28mm*1*8T Secondary
2UEW 0.21mm*1*17T – Primary (Clockwise)
X(S)
Triple Insulated wire 0.28mm*1*8T Secondary
Triple Insulated wire 0.28mm*1*8T Secondary
B(F)
X(F)
6iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
5. Differential Mode Inductor L1
Ferrite core size : AxB 8x10mm
Wire gauge: 0.26mm, 150 Turns
Inductance @10kHz, 1V: 7500uH +/-20%
ICR: 0.8 OHM +/-20%
Differential Mode Inductor L2
Ferrite core size : AxB 8x10mm
Wire gauge: 0.3mm, 120 Turns
Inductance @10kHz, 1V: 450H +/-20%
ICR: 0.5 OHM +/-20%
7iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
6.Common Choke L1 for EMI
core : UU8.5 (Ferrite Material TDK PC40 or equivalent)Bobbin : UU8.5
Turns:100T
Inductance 6.6mH +/-20%
SCHEMATIC
0.26*1*155 Ts
ELECTRICAL SPECIFICATIONS:
1.Inductance (Lp) = 900uH @10KHz 2.Core : EFD15 (Ferrite Material TDK PC40 or equivalent) 3.Bobbin : EFD15 Vertical 4.Ferrite core is connected to Pin 10 after assembling 5.Cut remained of Pin1,2,3,4,7,8,9 after wires termination 6.Varnish the complete assembly
7
3
PFC Inductor L4 Design
4
8iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
7. Bill of MaterialItem Qty. Ref. Description U/ P (RMB)
1 1 F1 1.25A/250Vac Fuse
2 1 CX1 0.1uF/250V X Capacitor
3 2 C2,C3 MPE 0.1uF,400V
4 1 C4 22uF/400V,E-CAP,1050C
5 1 C5 2.2nF,1KV
6 1 C6,C8 470pF,50V,NPO,SMD-0603
7 1 C7 68pF,50V,NPO,SMD-0603
8 1 C9 1nF,50V,NPO,SMD-0603
9 1 C11 220uF,50V,E-CAP,1050C
13 1 L1 750uH(8*10)
14 2 L2 470uH(8*10)
15 1 L3 EFD15 Transformer
16 1 L4 UU8.5
18 1 DBR1 DBR107
19 1 D1,D2,D3 HER107
20 2 D4 FR107
21 1 D5,D6 1N4148,SMD
23 2 D7 HER207
24 1 U1 IW3620,Off-line digital PWM controller,SOT-8
25 1 Q1 4N60,SMD
26 1 T1 EC28
27 3 R1 4.7KΩ +/-5%,SMD-0805
28 1 R2 4.7KΩ +/-5%,SMD-1206
29 2 R3,R4 560KΩ +/-5%,SMD-1206
30 1 R5 100KΩ +/-5%,SMD-1206
35 1 R6 47Ω +/-5%,SMD-0603
31 1 R7 22KΩ +/-5%,SMD-0603
32 1 R8,R9 1.8Ω +/-5%,SMD-0805
33 3 R10 1KΩ +/-1%,SMD-0603
34 1 R11 20KΩ +/-5%,SMD-0603
35 1 R12 10Ω +/-5%,SMD-0805
36 1 R13 22KΩ +/-5%,SMD-0603
37 1 R14 3KΩ +/-1%,SMD-0603
38 1 R15 22KΩ +/-1%,SMD-0805
9iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
VIN=264VAC, TAMB=25VIN=90VAC, TAMB=25
* Note: Output voltage measured at PCB end, TAMB=25
V- I Curve
20
22
24
26
28
30
32
34
36
38
40
42
0 100 200 300 400
I out
Vout
8. V-I Curve
V- I Curve
202224262830323436384042
0 100 200 300 400
I out
Vout
10iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
9. Efficiency Measurement
* Note: Output voltage measured at end of PCB.
0
10
20
30
40
50
60
70
80
90
80 100 120 140 160 180 200 220 240 260 280
Vin(Vac)
Eff
(%)
11iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
10. VDS waveform
Test Condition:
VIN=264VAC, VOUT_CV=40V
Result:
VDS_MAX=504V
Remark: Mosfet Spec__4A 600V
12iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
11. Start up and turn on delay time
110VAC,Full Load
TST_DELAY=1.83S
264VAC,Full Load
TST_DELAY=716mS
13iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
12. PF and harmonic current
Vin__110V PF=0.928 3rd <28% 5th_<13%
Vin__230V PF=0.933 3rd <27% 5th_<9%
___IEC61000-3-2 requirement---- 3rd <86% 5th_<61%
14iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
13.Conducted EMI ( Input 115Vac Full Load, output floating )
Peak scan N
Peak scan L
Peak ScanQP Limit line
Peak ScanQP Limit line
15iWatt Confidential – Do Not Copy 40V/350mA LED Driver 17 Jun 2009 Page:
14. Conducted EMI ( Input 230Vac Full Load, output floating )
Peak scan N
Peak scan L
Peak ScanQP Limit line
Peak ScanQP Limit line