6.5w led driver using upsr100 - unisonicrevision history: revised date: version: ... led driver demo...

1

UNISONIC TECHNOLOGIES CO., LTD

6.5W LED Driver Using UPSR100

Subject

Key features:

●AC Input Range180Vac/50Hz~264Vac/50Hz

●DC Output 19Vdc / 0.35A

●Average Efficiency >79%

●Short Circuit Protection and Open Loop

Revision History

Revised Date Version Reason/Issue

2013/12/27 A

UNISONIC TECHNOLOGIES CO., LTDwww.unisonic.com.tw

UPSR100 6 LED Driver Demo Board Manual- Hi Line Version

Protection.

http://www.unisonic.com.tw/

2


Contents Index Page

1 LED Driver Demo Board Specification 31.1. Input Characteristics 31.2. Output Characteristics 31.3. Performance Specifications 31.4. Protection Function 31.5. Environment 3

2 LED Driver Demo Board Information 42.1. Schematic 42.2. BOM 4,52.3. Module Dimension 52.4 Tranformer Design 62.4.1 Transformer Specification. 62.4.2 Transformer Diagram. 6

3 Performance Evaluation 73.1. Input Characteristics 83.1.1 Input Current 83.1.2 Efficiency at Full Load 83.2. Output Characteristics 93.2.1. Output Current Regulation 93.2.2. Ripple & Noise 93.2.3. Start-Up Time and Hold-Up Time 103.2.3.1 Start-Up Time 103.2.3.2 Hold-Up Time 103.3. Protection 113.3. Open Loop Protection 113.4. Short Circuit Protection 113.5. Thermal Testing 113.6 EMI Testing 123.6.1 Conduction EMI Testing 123.6.1.1 12,133.6.1.2 133.6.2 Radiation EMI Testing: 143.6.2.1 Radiation EMI Testing :Vertical Direction 143.6.2.2 Radiation EMI Testing :Horizontal Direction 14

4 Other Important Waveforms-Full Load 6 LED 154.1.1 Waveform Vce;Ice;Vcc,Vfb @180Vac/50Hz, Full Load-6 LED 154.1.2 Waveform Vce;Ice;Vcc,Vfb @230Vac/50Hz, Full Load-6 LED 154.1.3 Waveform Vce;Ice;Vcc,Vfb @264Vac/50Hz, Full Load-6 LED 154.2. 164.2.1 164.2.2 16

17

UNISONIC TECHNOLOGIES CO., LTD www.unisonic.com.tw

Start up at Full Load-6 LED Waveform :Vce ;Ice; VakNormal Operation at Full Load Waveform :Vce ;Ice; Vak

Vce(max) ;Ice; Vak(max) Operating@Start / Normal / Output Short

4.2.3 Output Short to Ground Waveform :Vce ;Ice; Vak

Line 1Line 2

3


1. LED Driver Demo Board Specification1.1. Input Characteristics● AC input voltage range 180Vac~264Vac● AC input frequency 50Hz

1.2. Output Characteristics● Output Voltage 19V● Max. load current 0.35A

1.3. Performance Specifications● Maximum Output Power 6.5W● Average Efficiency

● Current Line Regulation <3%● Current Load Regulation <5%● Current Ripple & Noise < 15mA

1.4. Protection Function● Short Circuit Protection Shut down and Auto Recover● Open Loop Protection Limit to 21V Output and Auto Recover

1.5. 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


>79%

4


2. LED Driver Demo Board Information2.1. Schematic

2.2. BOMNo.

1

2

3

4

5

6

7

8

9

10

11

12

13

14


C5

C6,C8

C7

Capacitor aluminum electrolytic 10uF/50V/DIP,105℃,±20%.Capacitor Ceramic 222pF/50V/X7R /0805, ±10%

C9

D3 Diode SB3200/DIP/DO_102 ,Schottky Diode 3A/200V.

Position Description

C10

Capacitor Ceramic 102pF/X7R /0805, ±10%

Capacitor, Y1, 102pF/400V, 105℃,±20%

D1

CY1

C2,C1

C3Capacitor aluminum electrolytic 6.8uF/400V, 105℃ ,±20%.

Quantity2

1

1

Diode FR107/DIP, Fast Diode, 1A/1000V.

Capacitor Ceramic104pF/50V/Y5V /0805,+80%;-20%

Capacitor aluminum electrolytic 470uF/50V/DIP,105℃,±20%.

2

1

1

1

1

1

1

Capacitor Ceramic 103pF/1KV/1206, ±10%

Diode RS1D/SMD/SMA, Fast Diode, 1A/200V.

1

1

1

1

D2

Fuse T1A/250VF1

Bridge Diode B6S /SMD 0.5A/600V .BD1

Inductor 1mH/DIPL1


5


15

16

17

18

19

20

21

22

23

24

25

26

27

28

28

29

30

2.3. Module Dimension


1

R16 Resistor chip 3R3/1206 ,1/4W,±5%

U1 IC UTC UPSR 100-SOP-8

Q1

1

R2 Resistor 374K/1206 ,1/4W,±1% 1

1

1

Bipolar Transistor ;UTC MJE13003G-D-T6C-K/DIP/TO126C/RankD 1R1 Resistor 390K/1206 ,1/4W,±5%

R5 Resistor chip , 9R1/0805 ,1/8W,±5% 1

R7 Resistor chip , 0R/0805 ,1/8W,±5% 1

1

R8,R16 Resistor chip 3R3/1206 ,1/4W,±5% 2

R9 1

1

R15 Resistor chip 24K/0805 ,1/8W,±5% 1

R12


1

Resistor chip 68R/0805 ,1/8W,±5% 1


Resistor 5M6/0805 ,1/8W,±5%R3

PCB : 25mm x 58.5mmx1.6mm

R11 Resistor chip11K/0805,1/8W,±5%

Resistor chip 3K/0805 ,1/8W,±5%

Resistor 200K/1206 ,1/4W,±5%R4

58mm

18mm 25mm

3.5mm 21mm

20mm

6

6.5W LED Driver Using UPSR1002.4. Transformer Design2.4.1. Transformer Specification

1) Bobbin: EE16 -10 Pin2) Core material : PC40 (TDK) or equivalent.3) Lm 1-5: 3.75mH,±10% (1KHz )

2.4.2. Transformer DiagramN5 EMI /Shielding Layer 3Ts Tape

1 10 ○ ○ D 1T Tape

） ● ○ D 1T Tape

） ( A● ● ○ 1T Tape

4● ） ( ● ○ 1T Tape

） ( N4 ○ ○ E 1T Tape） ( ● ○ E 1T Tape

5● ） ( ○ ○ C 1T Tape

( ● ○ C 1T Tape

3● ( ● ○

） ( B

） BottomN6/EMI /Shielding Layer

Transformer Winding DataLayer Start

1 123 545 C6

8

1011 31213 21415 41617 D18


Tape Tape 1

N1(D-1)=0.21Φ X42Ts

1

N1

N2 0.21Φ 2 UEW 42

9

N184TsN284Ts

N325T

Tape Tape

N5 0.15Φ 2 UEW

7 N4

18E

Triple InsulatedWire 0.2Φ A 18

30

Tape 1

Triple InsulatedWire 0.2Φ

Tape Tape 1N3 0.21Φ 2 UEW 25



0.21Φ 2 UEW 42Tape Tape 3

36Ts N4(A-E)=0.2Φ X 18Ts N2(C-4)=0.21Φ X42TsN2(5-C)=0.21Φ X42Ts N5(1)=0.15Φ X30Ts

N3(3-2)=0.21Φ X25Ts N6(2)= 0.15Φ X30Ts N1(4-D)=0.21Φ X42Ts

N4

Material

Tape Tape 1

N4(E-B)=0.2Φ X18Ts

Tape Tape

TurnsWinding

2

42Tape

1

N2 0.21Φ 2 UEW

E

B

FinishEMI /Shielding

C

4

1

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. They are tested at full load 6 LEDs.

The Summarized Result :

Test Equipment:


6.Thermal meter

3.Electronic Load

Output Typical Voltage

Chroma

Opex PT-3S

1.AC Source

Tektronics

Chroma

4.Digital Oscilloscope

Shut Down and Auto RecoveryLimit to 21.16V and Auto Recover

Current Line Regulation 2.79%

<13.6mA3. Protection Short Circuit Protection Open Loop Protection

Test result

Current Load Regulation

>79.38%

4.63%

Efficiency- 6 LED

Item

6.5W

0.35A

1. Input Characteristics

Model No:

Ripple & Nnoise

2. Output characteristics Output Typical Power

19.2V

6310266202

VendorChroma

Item

Output Typical Current

2.Digital Power meter61602

2000Keithley5.Multi-meterDPO3014


8

6.5W LED Driver Using UPSR1003.1. Input Characteristics3.1.1 Input Current- Full Load

Table 1 Input Current @ Full Load 6 LED

Input

180Vac/50Hz

230Vac/50Hz

264Vac/50Hz

3.1.2 Efficiency Operation at Full Load 6 LED

6 LED 5 LED 3 LED 6LED 5LED 3 LED 6LED 5 LED 3LED 6LED 5LED 3 LED

Fig1 Input Voltage Vs Efficiency


Irms(mA)

103.10.3910.44

89.884.3

PF

0.365

Table 2 Efficiency :Operation at 6 LEDs;5 LEDs;3 LEDs each.

InputVoltage

Pin(mW) Vo(V) Io(mA) Efficiency(%)

180Vac/50Hz 8.20 6.98 4.57 19.31 16.06 9.85 349.40 353.37 363.90 82.28 81.31 78.43

230Vac/50Hz 8.16 7.01 4.63 19.27 16.05 9.84 343.51 348.30 359.24 81.12 79.75 76.35

264Vac/50Hz 8.18 7.12 4.69 19.12 16.03 74.669.84 339.61 345.10 355.86 79.38 77.70

70.00 71.00 72.00 73.00 74.00 75.00 76.00 77.00 78.00 79.00 80.00 81.00 82.00 83.00 84.00

180Vac/50Hz 230Vac/50Hz 264Vac/50Hz

Effic

ienc

y(%

)

Input Voltage

6LED

5LED

3 LED


9


3.2 Output Characteristics3.2.1 Output Current Regulation .

Table 3 Line Regulation and Load Regulation

180Vac/50Hz

230Vac/50Hz264Vac/50Hz

3.2.2 Ripple & Noise- Full LoadTable 4 Ripple & Noise

180Vac/50Hz

230Vac/50Hz

264Vac/50Hz

Fig.3 Ripple & Noise 132Vac/60Hz CH4 Current Waveform ,CH1 Voltage Waveform CH4 Current Waveform ,CH1 Voltage Waveform


2.79%

RemarkRipple &Noise(mA)

InputVoltage

12.80

12.0013.60

Fig.2 Ripple & Noise 90Vac/60Hz

LineRegulation

349.40 353.37 363.904.63%343.51 348.30 359.24

339.61 345.10 355.86

InputVoltage

Output Current(mA) LoadRegulation

19.2V(6 LED) 16.4V(5 LED) 9.8V(3 LED)


10


3.2.3.1 Start- up TimeTable 5 . Start- up Time

180Vac/50Hz

230Vac/50Hz

264Vac/50Hz

Fig.4 180Vac /50Hz,Start Up Fig.5 264Vac / 50Hz,Start Up CH4Current Waveform ,CH1 AC Voltage Waveform CH4 Current Waveform ,CH1 AC Voltage Waveform

3.2.3.2 Hold- up TimeTable 6 Hold- up Time

180Vac/50Hz

230Vac/50Hz

264Vac/50Hz

Fig.6 180Vac / 50Hz,Hold- Up Time Fig.7 264Vac /50Hz, Hold-Up TimeCH4 Current Waveform ,CH1 AC Voltage Waveform CH4 Current Waveform ,CH1 AC Voltage Waveform


143.00

3.2.3 Start- Up Time and Hold-Up Time-Full Load

InputVoltage

Start-Up Time(s)

1.68Fig.4─

1.32 Fig.5

─

Remark

Fig.6

Hold-Up Time(ms)

189.00

InputVoltage

Fig.7

Remark

84.00

2.74


11

6.5W LED Driver Using UPSR1003.3 Protection3.3 Open Loop Protection:Full Load When LED connection is opened , the Output will be limited to 21V.Once the condition is removed, and the power will be back to normal output Voltage .Table 7 Open Loop Protection

3.4 Short Circuit Protection:Full Load When Short Circuit Protection condition is removed and the power automatically recoverTable 8 Short Circuit Protection

180Vac/50Hz

230Vac/50Hz

264Vac/50Hz

3.5. Thermal Testing - Full Load Tested at Room temperature 34℃ in Plastic ABS Case. (Case Dimension 61mmX35mmX120mm).

Table 9 Thermal TestingInput

V lt180Vac/50Hz

230Vac/50Hz

264Vac/50Hz


Schottky

79.4

65℃62℃ 65℃

InputVoltage Pi(mW)

UPSR100

No Damage

67℃ 67℃

63℃60℃63℃62℃

56℃

66℃58℃

107.5

180Vac/50Hz

No Damage

230Vac/50Hz

No Damage

Board Status

Auto Recover48.8

264Vac/50Hz

Input Voltage

Transistor Transformer

Over Pen LoopProtection (V)

21.15

21.16

21.13

Remark

Remark


12

6.5W LED Driver Using UPSR1003.6 EMI Testing - Full Load

Fig.8 Line1

Frequency(MHz)

CorrectFactor(dB)

Reading Level(dBuV)

Measure Level(dBuV)

Margin(dB)

Limit(dBuV)

0.837 9.728 37.200 46.928 -9.072 56.000

Frequency(MHz)

CorrectFactor(dB)

Reading Level(dBuV)

Measure Level(dBuV)

Margin(dB)

Limit(dBuV)

0.653 9.719 32.350 42.069 -3.931 46.000


The Test conditions is one Shielding Layer to Ground .

3.6.1 Conduction EMI Testing

3.6.1.1 Line1

Detector Type

QUASIPEAK

Table 11 Conduction Test Data- Average Type ( Limit : CNS_14115_00M_AV)

Detector Type

AVERAGE

The Test result is under 3.931 dB.

Table 10 Conduction Test Data- Quasipeak Type(Limit : CNS_14115_00M_QP;)


13

6.5W LED Driver Using UPSR1003.6.1.2 Line2

Fig. 9 Line2

Frequency(MHz)

CorrectFactor(dB)

Reading Level(dBuV)

Measure Level(dBuV)

Margin(dB)

Limit(dBuV)

0.652 9.699 34.300 43.999 -12.001 56.000

Frequency(MHz)

CorrectFactor(dB)

Reading Level(dBuV)

Measure Level(dBuV)

Margin(dB)

Limit(dBuV)

0.652 9.699 27.180 36.879 -9.121 46.000


Table 12 Conduction Test Data- Quasipeak ( Type Limit : CNS_14115_00M_QP)

Detector Type

AVERAGE

Table 13 Conduction Test Data- Average Type ( Limit : CNS_14115_00M_AV)

Detector Type

QUASIPEAK


14

6.5W LED Driver Using UPSR1003.6.2 Radiation EMI Testing

3.6.2.1 Radiation EMI Testing Vertical Direction

3.6.2.2 Radiation EMI Testing Horizontal Direction


The test result are Vertical Under 0.5dB, Horizontal Under 15 dB.


15


4. Other Important Waveforms-Full Load 6 LED4.1.1.Waveform Vce;Ice;Vcc,Vfb @180Vac/50Hz, Full Load-6 LED Measuring Data:Vce=396Vp-p; Ice=328mAp-p;Vcc=17.4V;Vfb=16V; Frequency:43.86KHz

Measuring Data:Vce=468Vp-p; Ice=320mAp-p;Vcc=17V;Vfb=18.4V; Frequency:44.25KHz

4.1.3.Waveform :Vds;Vsense @264Vac/50Hz, Full Load-6 LED Measuring Data:Vds=512Vp-p; Vsense=312mAp-p;Vcc=17.0V;Vfb=19.2V; Frequency:44.44KHz

Fig.14 . 264Vac/50Hz, Full Load Fig.15.264Vac/50Hz, Full Load Spread


4.1.2. Waveform :Vds;Ids @230Vac/50Hz, Full Load- 6 LED

Fig.10 180Vac/50Hz, Full Load Fig.11 180Vac/50Hz, Full Load Spread

Fig.12 230Vac/50Hz, Full Load Fig.13 230Vac/50Hz, Full Load Spread


16

6.5W LED Driver Using UPSR1004.2. Vce(max) ;Ice; Vak(max) Operating@Start / Normal / Output Short cocnditio Table 14 Measuring Data at Full Load-6 LED, Operating Start/ Normal / Output Short Test.

Input voltage Ice(mA) Vce(max) Vak(max) Spec. Remark264V/50HZ 312 520 120 Fig14264V/50HZ 302 504 120 Fig15264V/50HZ 304 424 98 Fig16

Fig.16 264Vac / 50Hz,Start up at Full load. Vds ;Ice; Vak

Fig.17 264Vac / 50Hz,Normal Operation at Full load. Vds ;Ice; Vak


4.2.1. Start up at Full Load Waveform :Vce ;Ice; Vak - 6 LED

4.2.2.Normal Operation at Full Load Waveform :Vce ;Ice; Vak - 6 LED

Short at full load

1.Vcbo<700V

2.Vak<200V

Test ItemStart up at full loadNormal at full load


17



Fig.18. 264Vac / 50Hz, Output Short to Ground Waveform Vce ;Ice; Vak

4.2.3 Output Short to Ground Waveform :Vce ;Ice; Vak - 6 LED


6.5w led driver using upsr100 - unisonicrevision history: revised date: version: ... led driver demo...

Documents