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Flyback Solution_40W LED Driver for Tube LD7831 _DB_01a 1 Leadtrend Technology Corporation LD7831_DB_01a, April 2015 TOP VIEW BOTTOM VIEW Size 111.45mm(L) x 70.93mm(W) x 30.76mm(H) Key Features Fly-back Topology Single Stage PFC > 0.9 Efficiency > 86% LED Short / Open protection Meet IEC55015 EMI Test - Conduction Meet IEC61000-4-5 Surge Test Meet IEC61000-3-2 Class C THD Test Subject Model Name LD7831 Demo Board LD7831_DB_01a (36V/1.0A)

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Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

1 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

TOP VIEW BOTTOM VIEW

Size 111.45mm(L) x 70.93mm(W) x 30.76mm(H)

Key Features

Fly-back Topology

Single Stage PFC > 0.9

Efficiency > 86%

LED Short / Open protection

Meet IEC55015 EMI Test - Conduction

Meet IEC61000-4-5 Surge Test

Meet IEC61000-3-2 Class C THD Test

Subject Model Name

LD7831 Demo Board LD7831_DB_01a (36V/1.0A)

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

2 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

Design Check List

MODEL NAME

(機種名稱) LD7831_DB_01a

TOTAL PAGE

(共) 24 (頁)

P.M.

(機種負責人) Scott Lin, Leo Li

DATE

(日期) 2015(年)/04(月)/30(日)

NO.

(項目)

TEST ITEM

(測試項目)

SPEC

(規格)

NAME

(擔當者)

PAGE

(頁數)

RESULT

(結果)

1 Input Characteristics – Efficiency Test > 86% Hunter 10~11 PASS

2 Input Characteristics – Power Factor (@ Normal Line)

> 0.9 Hunter 11~11 PASS

3 Input Characteristics – THD of Input Current IEC61000-3-2

Class C Hunter 12~12 PASS

4 Output Characteristics – Current Accuracy < ±10% Hunter 13~13 PASS

5 Output Characteristics – Current Ripple < 10% Hunter 13~14 PASS

6 Turn On Delay Time < 1S@100VAC Hunter 15~15 PASS

7 Abnormal Test – LED Open Voltage Test < 55V Hunter 15~16 PASS

8 Abnormal Test – LED Short Dissipation Test < 1W Hunter 16~16 PASS

9 Abnormal Test – Over Temp. Protection Test Function Hunter 17~17 PASS

10 Power Component Stress Voltage < 100% Hunter 18~18 PASS

11 Drain Voltage and Inductor Current Waveforms De-rating <90% Hunter 19~19 PASS

12 AC On/Off Test De-rating <100% Hunter 20~20 PASS

13 EMI Test – Conduction IEC55015, < -3db Hunter 21~22 PASS

14 EMS Test – Surge IEC61000-4-5

@>2KV Hunter 23~23 PASS

15 Thermal Test Base on de-rating

90% at Ta=40°C

Hunter 23~23 PASS

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

3 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

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 DIRVER APPLICATION CIRCUIT ................................................................................ 6

2.1 Schematic ............................................................................................................................ 6

2.2 BOM List............................................................................................................................... 7

2.3 PCB Gerber File .................................................................................................................. 8

2.4 Transformer Specification .................................................................................................. 9

3. EXECUTIVE SUMMARY ....................................................................................................... 10

3.1 Input Characteristics......................................................................................................... 10

3.1.1 Efficiency Test ........................................................................................................ 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 ........................................................................................................ 13

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 .................................................................................. 17

3.5 Power Component Stress Voltage ................................................................................. 18

3.6 Drain Voltage and Inductor Current Waveforms .......................................................... 19

3.7 AC On/Off Test .................................................................................................................. 20

3.8 EMI Test - Conduction ...................................................................................................... 21

3.9 Surge Test .......................................................................................................................... 23

3.10 Thermal Test .................................................................................................................... 23

Revision History ............................................................................................................................ 24

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

4 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

Table Index

Table 1. Efficiency @ LED Load = 36V ........................................................................ 10

Table 2. Power Factor ..................................................................................................... 11

Table 3. THD of Input Current ....................................................................................... 12

Table 4. Output Current (mA) ........................................................................................ 13

Table 5. Current Ripple (%) without LD6801@ LED Load = 36V ............................ 13

Table 6. Current Ripple (%) with LD6801@ LED Load = 36V ................................. 14

Table 7. Turn On Delay Time ......................................................................................... 15

Table 8. Over Voltage Level ........................................................................................... 15

Table 9. Input Power during LED short ........................................................................ 16

Table 10. Drain PIN and Diode Stress Voltage @ Steady State (90V / 60Hz) ...... 18

Table 11. Drain PIN and Diode Stress Voltage @ Transient State (90V / 60Hz) .. 18

Table 12. Drain PIN and Diode Stress Voltage @ Steady State (277V / 50Hz) .... 18

Table 13. Drain PIN and Diode Stress Voltage @ Transient State (277V / 50Hz) 18

Table 14. Surge Test ....................................................................................................... 23

Table 15. Thermal Test @ Open frame ........................................................................ 23

Figure Index

Figure 1. VAC vs. Efficiency ............................................................................................ 11

Figure 2. VAC vs. Efficiency ............................................................................................ 11

Figure 3. VAC vs. THDi .................................................................................................... 12

Figure 4. Start-up Waveforms @ 100VAC / 60Hz ....................................................... 15

Figure 5. Max. Drain Voltage @ 277VAC/50Hz On/Off Test ...................................... 20

Figure 6. 110VAC Line EMI Test ..................................................................................... 21

Figure 7. 110VAC Neutral EMI Test ............................................................................... 21

Figure 8. 220VAC Line EMI Test .................................................................................... 22

Figure 9. 220VAC Neutral EMI Test ............................................................................... 22

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

5 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

1. LED DRIVER MODULE SPECIFICATION

1.1 Input Condition

AC Input Voltage : 90VAC ~ 277VAC

AC Input Frequency : 50Hz ~ 60Hz

1.2 Output Condition

Output Voltage : 36V (12 pcs LED)

Output Current : Typical 1000mA

1.3 Protection Condition

LED Open Protection Auto-recovery, Hiccup 2 times

LED Short Protection Auto-recovery, Hiccup 4 times

Over Temp. Protection Auto-recovery, Hiccup 1 time

1.4 Ambient Temperature

Ambient Temperature 25oC

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

6 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

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2. LED DIRVER APPLICATION CIRCUIT

2.1 Schematic

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

7 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

2.2 BOM List

P/N Component Value Vender P/N Component Value Vender

R1, R3 51Ω, 1206, ±1% RALEC C7 222K/1000V, 1206 HEC

R5 200Ω, 1206, ±1% RALEC C11 33pF/1000V, 1206 HEC

R6, R9, R31 1MΩ, 1206, ±1% RALEC C12 104K/50V, 0805 HEC

R21, R23 1MΩ, 1206, ±1% RALEC C15 684K/50V, 0805 HEC

R7,R10 120KΩ, 1206, ±1% RALEC C17 105K/35V, 1206 HEC

R8 51KΩ, 1206, ±1% RALEC C18 10uF/50V, E-CAP

R11 NC RALEC C19 680pF/50V, 0603 HEC

R12 51Ω/2W, DIP RALEC C21 224K/50V, 0805 HEC

R13 300KΩ, 0805, ±1% RALEC C201 105K/50V, 1206 HEC

R14, R15 1.2Ω, 1206, ±1% RALEC C202 474K/10V, 0805 HEC

R16, R17, R20 510KΩ, 1206, ±1% RALEC C203 224K/50V, 0805 HEC

R19, R26, R35 5.1KΩ, 1206, ±1% RALEC CX1 224K/310V HJC

R22 51KΩ, 0805, ±1% RALEC CY1 NC

R25 22Ω, 0805, ±1% RALEC CY2 NC

R27 300Ω, 0805, ±1% RALEC CY3 2200pF/250Vac MURATA

R30 51KΩ, 0805, ±1% RALEC L1 1mH, DR1016 3L

R32 2KΩ, 0805, ±1% RALEC L2 UU-9.8/0.35Ф, 15mH Elytone

R33, R37 0.9Ω, 1206, ±1% RALEC LC1 530uH Elytone

R34 1KΩ, 1206, ±1% RALEC TR1 SCK10053 TKS

R48, R49 7.5Ω, 0805, ±1% RALEC ZNR1 07D561 Wendell

R201, R202 39KΩ, 1206, ±1% RALEC ZNR2 07D561 Wendell

R203 2.2MΩ, 1206, ±1% RALEC ZNR3 07D511 Wendell

R204, R205 0Ω, 1206, ±1% RALEC BD1 SBU106 NA

R206 1KΩ, 0805, ±1% RALEC T1 0.7mH, PQ2625 LD design

R207 510KΩ, 1206, ±1% RALEC F1 1.6A/250V Fuse NA

R208 100Ω, 0805, ±1% RALEC Q1 10A/730V ICE10N73 ICEMOS

R209 0.2Ω, 1206, ±1% RALEC U1 LD7831 Leadtrend

R210 0.39Ω, 1206, ±1% RALEC U201 LD6801 Leadtrend

C1 221K/1KV, 1206 HEC D1 20A/200V, TO220 Sirect

C2, C3 1000uF/50V, E-CAP HURMEI D3 RS1M, SMB Sirect

C4 224K/100V, 1206 HEC D4 1N4148, SOD123 Panjit

C5 224J/450V, Film-CAP D8 US1M, SMB Sirect

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

8 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

2.3 PCB Gerber File

TOP VIEW

BOTTOM VIEW

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

9 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

2.4 Transformer Specification

Bobbin : PQ-2625

Core : PQ-2625

Inductance(PIN 1 - 3) : 770uH ± 5% @ 1kHz/1V

NP/NS/NAUX : 43/11/5

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

10 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

3. EXECUTIVE SUMMARY

Test Equipment

Equipment Equipment Model No.

Electrical Load Chroma 63030

Power Analyzer PM100

Power Meter WT210

AC power source Chroma 61602

Scope TDS3014

Multi-function Meter Fluke 187

Thermal Hunter PT-3S

3.1 Input Characteristics

3.1.1 Efficiency Test

Specification Result

> 86% PASS

Input Voltage PIN (W) IO (A) VO (V) Efficiency (%)

90VAC / 60Hz 41.08 1.0027 35.588 86.86

100VAC / 60Hz 41.27 1.0126 35.619 87.40

115VAC / 60Hz 41.23 1.0184 35.631 88.01

230VAC / 50Hz 40.28 1.0086 35.595 89.12

264VAC / 50Hz 39.91 0.9988 35.558 88.98

277VAC / 50Hz 39.76 0.9949 35.539 88.92

Table 1. Efficiency @ LED Load = 36V

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

11 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

Figure 1. VAC vs. Efficiency

3.1.2 Power Factor

Specification Result

> 0.9 PASS

PF CV=30V CV=36V CV=42V LED=36V

90VAC / 60Hz 0.9984 0.9990 0.9993 0.9989

100VAC / 60Hz 0.9975 0.9984 0.9989 0.9981

115VAC / 60Hz 0.9958 0.9972 0.9980 0.9968

230VAC / 50Hz 0.9763 0.9819 0.9854 0.9803

264VAC / 50Hz 0.9654 0.9735 0.9788 0.9712

277VAC / 50Hz 0.9602 0.9695 0.9757 0.9669

Table 2. Power Factor

Figure 2. VAC vs. Efficiency

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

12 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

3.1.3 THD of Input Current

Specification Result

IEC 61000-3-2 Class C PASS

THDi(%) CV=30V

(%)

CV=36V

(%)

CV=42V

(%)

LED=36V

(%)

90VAC / 60Hz 4.322 2.838 2.205 3.585

100VAC / 60Hz 6.695 4.030 2.842 4.690

115VAC / 60Hz 7.655 6.844 4.173 7.418

230VAC / 50Hz 11.922 10.620 9.611 11.512

264VAC / 50Hz 12.062 10.268 9.734 11.405

277VAC / 50Hz 12.082 10.651 9.644 11.418

Table 3. THD of Input Current

Figure 3. VAC vs. THDi

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

13 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

3.2 Output Characteristics

3.2.1 Current Accuracy

Specification Result

< ±10% PASS

Output

Current

(mA)

90VAC / 60Hz

100VAC / 60Hz

115VAC / 60Hz

230VAC / 50Hz

264VAC / 50Hz

277VAC / 50Hz

Line Regulation

(%)

CV=30V 1.0103 1.0162 1.0206 1.0072 0.9989 0.9954 1.25

CV=36V 0.9970 1.0098 1.0162 1.0084 0.9992 0.9966 0.97

CV=42V 0.9767 1.0018 1.0103 1.0089 1.0009 0.9974 1.69

Load

Regulation

(%)

1.69 0.71 0.50 0.08 0.1 0.1 2.20

LED=36V 1.0027 1.0126 1.0184 1.0086 0.9988 0.9949 1.16

Table 4. Output Current (mA)

LED ACC(%) = (Max-Min) / (Max+Min)

=2.20%

3.2.2 Current Ripple

Specification Result

< 10% (w/i LD6801) PASS

Definition of Current Ripple (%): IPK-PK / Io * 100

CR(%) 90VAC / 60Hz

100VAC / 60Hz

115VAC / 60Hz

230VAC / 50Hz

264VAC / 50Hz

277VAC / 50Hz

Io(mA) 1004.9 1013.3 1018.3 1001.6 991.5 987.7

IPK-PK(mA) 294 294 288 310 308 308

CR(%) 29.25 29.01 28.28 30.95 31.06 31.18

Table 5. Current Ripple (%) without LD6801@ LED Load = 36V

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

14 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

CR(%) 90VAC / 60Hz

100VAC / 60Hz

115VAC / 60Hz

230VAC / 50Hz

264VAC / 50Hz

277VAC / 50Hz

Io(mA) 1000.6 1012.0 1017.0 1000.8 990.3 986.9

IPK-PK(mA) 64.0 62.4 62.4 72.8 73.6 71.2

CR(%) 6.40 6.16 6.13 7.27 7.43 7.21

Table 6. Current Ripple (%) with LD6801@ LED Load = 36V

Without LD6801@ 90VAC / 60Hz

CH1:VOUT, CH4:IOUT

Without LD6801@ 277VAC / 50Hz

CH3:VOUT, CH4:IOUT

With LD6801@ 90VAC / 60Hz

CH3:VOUT, CH4:IOUT

With LD6801@ 277VAC / 50Hz

CH3:VOUT, CH4:IOUT

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

15 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

3.3 Turn On Delay Time

Specification Result

< 1S @ 100VAC PASS

Input Turn On Delay

100VAC 548mS

Table 7. Turn On Delay Time

CH1:VAC, CH4:IO

Figure 4. Start-up Waveforms @ 100VAC / 60Hz

3.4 Abnormal Test

3.4.1 LED Open Voltage Test

Specification Result

< 55V (OVP Threshold) PASS

Input Voltage 90VAC / 60Hz 277VAC / 50Hz

Output Voltage 52.2V 52.2V

Input Power 213mW 435mW

Table 8. Over Voltage Level

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

16 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

LED Open Test @ 90VAC / 60Hz

CH1: VCC, CH2:VGATE, CH3:VOUT

LED Open Test @ 277VAC / 50Hz

CH1: VCC, CH2:VGATE, CH3:VOUT

3.4.2 LED Short Dissipation Test

Specification Result

< 1W PASS

Input Voltge 90VAC / 60Hz 277VAC / 50Hz

Input Power 767mW 940mW

Table 9. Input Power during LED short

LED Short Test @ 90VAC / 60Hz

CH1: VCC, CH2:VGATE, CH3:VOUT, CH4:IOUT

LED Short Test @ 277VAC / 50Hz

CH1: VCC, CH2:VGATE, CH3:VOUT, CH4:IOUT

Flyback Solution_40W LED Driver for Tube

LD7831 _DB_01a

17 Leadtrend Technology Corporation

LD7831_DB_01a, April 2015

3.4.3 Over Temp. Protection Test

Specification Result

Function PASS

Over Temp. Protection @ 115VAC / 60Hz

CH1: VCC, CH2:VGATE, CH4:IOUT

Over Temp. Protection @ 230VAC / 50Hz

CH1: VCC, CH2:VGATE, CH4:IOUT

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3.5 Power Component Stress Voltage

Specification Result

< 100% PASS

No. Location Max. Rating (V)

Steady State(90V / 60Hz)

Measurement Derating

V %

1 Drain 730 410 56.16

2 D1 200 82.1 41.05

Table 10. Drain PIN and Diode Stress Voltage @ Steady State (90V / 60Hz)

No. Location Max. Rating (V)

Transient State(90V / 60Hz)

Measurement Derating

V %

1 Drain 730 450 61.64

2 D1 200 89.2 44.60

Table 11. Drain PIN and Diode Stress Voltage @ Transient State (90V / 60Hz)

No. Location Max. Rating (V)

Steady State(277V / 50Hz)

Measurement Derating

V %

1 Drain 730 672 92.06

2 D1 200 156.8 78.40

Table 12. Drain PIN and Diode Stress Voltage @ Steady State (277V / 50Hz)

No. Location Max. Rating (V)

Transient State(277V / 50Hz)

Measurement Derating

V %

1 Drain 730 716 98.05

2 D1 200 166 83.00

Table 13. Drain PIN and Diode Stress Voltage @ Transient State (277V / 50Hz)

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3.6 Drain Voltage and Inductor Current Waveforms

Specification Result

De-rating <90% PASS

Drain & IL waveforms @ 115VAC / 60Hz

CH1:VDrain, CH4:IL

Drain & IL waveforms @ 115VAC / 60Hz (Zoom-In)

CH1:VDrain, CH4:IL

Drain & IL waveforms @ 230VAC / 50Hz

CH1:VDrain, CH4:IL

Drain & IL waveforms @ 230VAC / 50Hz (Zoom-In)

CH1:VDrain, CH4:IL

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3.7 AC On/Off Test

Specification Result

De-rating <100% PASS

Input Voltge 115VAC / 60Hz 230VAC / 50Hz

Turn on delay 457mS 449mS

Power On: 1000mS & Power Off: 1000mS

AC On/Off Test @ 115VAC / 60Hz / 90

o

CH1:VAC, CH2:VDrain, CH4:IO

AC On/Off Test @ 230VAC / 50Hz / 90

o

CH1:VAC, CH2:VDrain, CH4:IO

Input Voltge 277VAC / 50Hz

Max. Drain voltage 716V

CH1:VAC, CH2:VDrain, CH4:IO

Figure 5. Max. Drain Voltage @ 277VAC/50Hz On/Off Test

Note: The voltage spike of Drain is induced from inrush current at power on instantaneously. It’s easy to be observed while phase of AC

input is 90o or 270

o.

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3.8 EMI Test - Conduction

Specification Result

IEC55015, < -3db PASS

Figure 6. 110VAC Line EMI Test

Figure 7. 110VAC Neutral EMI Test

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Figure 8. 220VAC Line EMI Test

Figure 9. 220VAC Neutral EMI Test

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3.9 Surge Test

Specification Result

IEC61000-4-5

@>1KV PASS

EUT Line: 220VAC ■ 2PIN □ 3PIN System Spec.: 36V /1.0A

Waveform

■ 1.2/50

□ 10/700

□ Ring

Impedance

□ 12ohm

Repetition

Once each 20

second period with

5 transients per test ■ 2ohm

Note: LD7831+LD6801 Real Demo Board

Test Mode Phase & Level (V) Test Result

L/N 90o ■+2K ■-2K 270

o ■+2K ■-2K PASS PASS

Note:

Table 14. Surge Test

3.10 Thermal Test

Specification Result

Base on de-rating 90% at Ta=40°C

PASS

No. Location Max Rating

(oC)

90V/

60Hz (oC)

115V/

60Hz (oC)

230V/

50Hz (oC)

277V/

50Hz (oC)

Derating(%)

90V/60Hz 277V/50Hz

1 T1 150 48.6 49.6 49.8 50.8 32.40 33.86

2 IC1 125 43.3 43.4 43.0 43.4 32.64 34.72

3 D1 150 53.1 54.0 53.4 53.3 35.40 35.53

4 Q1 150 48.1 47.2 49.6 52.3 32.06 34.86

5 Q201 150 62.6 64.3 63.3 63.3 41.73 42.20

Ambient 26.0 -- --

Table 15. Thermal Test @ Open frame

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Revision History

REV. Date Change Notice

DB_01a 04/30/2015 Original Specification