AL6562EV1 User Guide

AL6562EV1 User Guide
Universal input - High PFC PAR38 LED Driver
General Description
This AL6562 is a popular universal AC input,
high power factor correction (PFC) IC, its
output is “constant voltage mode” and can
be used for Boost & Flyback converter. This
driver board or regular general power EV
board provides 3 separate voltage outputs
(VLED1, 25V/600mA, VLED2, 12V/400mA,
and 9V/200mA) that can be used to drive
WiFi compatible RGB+White bulbs. The
total output power should be less than
15W. It can be used for LED and Power
Supply applications.
Key Features










Single Stage Fly-Back PFC Controller
Transition Discontinuous Conduction
Mode Operation
Low Start-Up, Operating and Quiescent
Currents
Zero Current Detection
Internal Start-Up Timer
PFC >0.95 & low THD
90 ~265VAC input range
~85% Efficiency
Adjustable Output Voltage through the
CN1 connector (pin 1)
Over Power Protection
AL6562 EV1 Specifications (CV mode)
Parameter
Value
Input Voltage
PFC
LED 1 Voltage
LED 1 Current
LED 2 Voltage
LED 2 Current
3rd Output
Efficiency
90 to 265VAC
> 0.95
25V
0 - 600mA (max.)
12V
0 - 400mA (max.)
9V/200mA (max.)
~85%
3 combined voltage
outputs <15W
70 x 40 x 24 mm
Yes
Total Output Power
XYZ Dimension
ROHS Compliance
Evaluation Board
Figure 1: Top View
Applications





Electronic Single-Stage LED Driver
High-End AC-DC adaptor/Charger
WiFi compatible RGB+White Bulbs
Regular Power Applications required
high PFC
PFC Pre-Regulators to Meet
IEC61000-3-2
AL6562EV1 Rev2
January 2016
www.diodes.com
Figure 2: Bottom View
Connection Instructions
Input Voltage: 90 - 230VAC (AC+, AC-)
Outputs: CN1 (pin3, 12V/400mA, pin4,
25V/600mA, pin6, 9V/200mA, pin2 and 5,
GND)
Page 1 of 11
AL6562EV1 User Guide
Universal input - High PFC PAR38 LED Driver
DIODES TAPPED TRANSFORMER DESIGN
AL6562 (90 VAC ~ 230VAC 3 outputs 18W Transformer Spec.)
1) C o r e & Bobbin
EE19
5+5 pin
2) Transformer Parameters
1. Primary Inductance (Pin1-Pin2, all other windings are open)
Lp = 0.8mH ± [email protected]
2. Primary Winding Turns (Pin2-Pin3 + Pin3 – Pin1): NP=110Ts
3. A Shielding Winding full layers
4. Secondary Winding Turns (Pin6- Pin8): NS1= 12Ts
5. Secondary Winding Turns (Pin8- Pin9): NS2= 3Ts
6. Secondary Winding Turns (Pin9- Pin10): NS3= 8Ts
7. Auxiliary Winding Turns (Pin4- Pin5): NA= 16Ts
AL6562EV1 Rev2
January 2016
www.diodes.com
Page 2 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
3) Transformer Winding Construction Diagram
Item
Windings
Winding Specification
1
W5-Primary
Winding
Start from Pin 2, 30# AWG*1, Two layers, end at Pin 3.
2
Insulation
1 Layer of insulation tape
3
Shielding
Winding
Start from Pin 1, 34# AWG*1 with full layer winding, end flowing wire.
4
5
Insulation
W4 NS1
Secondary
Winding
6
W3 NS2
Secondary
Winding
Start from Pin 8, double of insulation 26# AWG*1, 3Ts, same layer
above, end at Pin 9.
7
W2 NS3
Secondary
Winding
Start from Pin 9, double of insulation 26# AWG*1, 8Ts, same layer
above, end at Pin 10.
8
Insulation
2 Layers of insulation tape
9
W1-Primary
Winding
Start from Pin 3, 30# AWG*1, 50Ts, Two layers, end at Pin 1.
10
Insulation
2 Layers of insulation tape
11
W6-Primary
Winding
Start from Pin 4, 34# AWG*1, 16Ts, One layer, end at Pin 5.
12
Insulation
2 Layers of insulation tape
AL6562EV1 Rev2
January 2016
www.diodes.com
2 Layers of insulation tape
Start from Pin 6, double of insulation 26# AWG*1, 12Ts, one layer, end
at Pin 8.
Page 3 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
Evaluation Board Schematic
Figure 3: Evaluation Board Schematic
Evaluation Board Layout
Figure 4: PCB Board Layout Top View
Figure 5: PCB Board Layout Bottom View
Quick Start Guide
1. By default, the evaluation board is preset at 25V/600mA for VLED1 (pin 4 of the CN1),
12V/400mA for VLED2 (pin 3 of the CN1), and 9V/200mA (pin 6 of the CN1). Total output
power should be less than 15W.
2. Ensure that the AC source is switched OFF or disconnected.
3. Connect the AC line wires of power supply to “L and N” on the left side of the board.
4. Connect the 25V load to VLED1 (pin 4 of the CN1).
5. Connect the load GND to pin 2 and pin 5 of the CN1.
6. Turn on the main switch.
AL6562EV1 Rev2
January 2016
www.diodes.com
Page 4 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
Bill of Material
#
Name
QTY
Part number
Manufacturer
Description
1
IC1
1
AL6562S-13
Diodes Inc
Current Mode PFC LED Controller,
SO-8
2
T1
1
EE19
Elite Electronics
EE19, Transformer
3
BD1
1
DF06S-T
Diodes Inc
Bridge Rectifiers 1A 600V
4
D1
1
S1JA-13-F-1A600V
Vishay
Rectifier 1A/600V, DO-214AC (SMA)
5
D2,D3
2
1N4148W
Diodes Inc
Rectifier 150mA/100V (SOD-123)
6
D51
1
SBR3150SB-13
Diodes Inc
Schottky Diode, 3A/150V (SMB)
7
D52,D53
2
B160/B
Diodes Inc
Schottky Diode, 1A/60V (SMA)
8
D55
1
BAT43W
Diodes Inc
Rectifier 200mA/30V (SOD-123)
9
F1
1
39211250000
Littelfuse
Fuse, 1A/250V
10
LF1
1
744821110
Wurth
Common Mode Choke 11mH 0.9A
11
Q1
1
DMG4N65CTI
Diodes Inc
MOSFET N-CH 650V 4A T0-220
12
Q2
1
FMMT459
Diodes Inc
MOSFET N-CH 500V 120mA SOT-23
13
L1,L2
7447728102
Wurth
Inductor 1mH/300mA Dia 8.7mm
14
U1
PS2561DL-1
CEL
Photocoupler, SO-4
15
U3
AZ431BN
Diodes Inc
Shunt Regulator, 1% 2.5VZ
16
Z1
MOV-07D471KTR
Bourns
Varistor 11.5x5.5-P7.5
17
ZD1
MMSZ5245B
MCC
Zener Diodes, 15VZ
18
CX1
B32921C3104M
TDK
CAP 0.1µF 275V (12mm x 5mm-P10)
19
CY1
WY0222MCMBF0KR
Vishay
CAP 2.2nF 275V (11mm x 6mm-P10)
20
C2
-
Generic
CAP CER 0.1µF 500V 1210
21
C3
-
Generic
CAP CER 1nF 500V 1206
22
C5
Wurth
E-CAP 10µF 20% 35V (5mm x 8mm)
23
C6
-
Generic
CAP CER 1000pF 25V 0603
24
C8
-
Generic
CAP CER 220pF 25V 0603
25
C9,C10
-
Generic
CAP CER 10nF 500V 1206
26
C11
-
Generic
CAP CER 0.47µF 25V 0805
27
C12
-
Generic
CAP CER 100pF 25V 0603
28
C13
-
Generic
CAP CER 47pF 1000V 1206
29
C14
-
Generic
CAP CER 100pF 0603
30
C51A,C51B
860020575014
Wurth
E-CAP 470µF/35V (10 x 16-P5)
31
C52
860020474014
Wurth
E-CAP 470µF/25V (8 x 15-P5)
32
C53,C54
Generic
CAP CER 1nF 200V 0805
33
C55
Wurth
E-CAP 220µF 16V 6.5x12
34
C58
-
Generic
CAP CER 1µF 25V 0603
35
C59
-
Generic
CAP CER 47pF 25V 0603
36
C60
2
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
2
1
2
1
1
1
1
-
Generic
CAP CER 0.1µF 25V 0603
AL6562EV1 Rev2
January 2016
www.diodes.com
860020572003
860020373010
Page 5 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
37
R1,R2
38
R3
39
R4,R5
40
R6
41
R7
42
R9A,R9
43
R10,R11
44
R12
45
R13
46
R14
47
R15
48
R16
49
R17A,R17B
50
R18
51
R19
52
R23,R24
53
R49
54
R50
55
R51,R52
56
R53
57
R54
58
R55
59
R56
60
R57
61
R58
62
R59
63
R60
64
R61
65
CN1
AL6562EV1 Rev2
January 2016
www.diodes.com
2
1
2
1
1
2
2
1
1
1
1
1
2
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
2306-6121-TG
-
Generic
RES 1MΩ 1/4W 5% 1206 SMD
-
Generic
RES 5.6KΩ 1/8W 1% 0805 SMD
-
Generic
RES 470KΩ 1/4W 5% 1206 SMD
-
Generic
RES 12.1KΩ 1/8W 1% 0805 SMD
-
Generic
RES 36KΩ 1/8W 1% 0603 SMD
-
Generic
RES 1.5Ω /2 Ω 1/4W 1% 1206 SMD
-
Generic
RES 2KΩ 1/8W 1% 0603 SMD
-
Generic
RES 51KΩ 1/8W 1% 0603 SMD
-
Generic
RES 15KΩ 1/8W 1% 0603 SMD
-
Generic
RES 100KΩ 1/8W 1% 0603 SMD
-
Generic
RES 560KΩ 1/8W 1% 0603 SMD
-
Generic
RES 33Ω 1/8W 1% 0805 SMD
-
Generic
RES 27KΩ 1/4W 1% 1206 SMD
-
Generic
RES 10KΩ 1/8W 1% 0603 SMD
-
Generic
RES 10Ω 1/8W 1% 0805 SMD
-
Generic
RES 100KΩ 1/4W 1% 1206 SMD
-
Generic
RES 4.7KΩ 1/8W 1% 0805 SMD
-
Generic
RES 9.1KΩ 1/8W 1% 0805 SMD
-
Generic
RES 22Ω 1/8W 1% 0805 SMD
-
Generic
RES 1KΩ 1/8W 1% 0603 SMD
-
Generic
RES 5.1KΩ 1/8W 1% 0603 SMD
-
Generic
RES 14KΩ 1/8W 1% 0603 SMD
-
Generic
RES 6.8KΩ 1/8W 1% 0603 SMD
-
Generic
RES 5.1KΩ 1/8W 1% 0805 SMD
-
Generic
RES 5.1KΩ 1/8W 1% 0603 SMD
-
Generic
RES 300KΩ 1/8W 1% 0603 SMD
-
Generic
RES 39KΩ 1/8W 1% 0805 SMD
-
Generic
RES 1.5KΩ 1/8W 1% 0805 SMD
3M
Pin Header 2x3-pin
Page 6 of 11
AL6562EV1 User Guide
Universal input - High PFC PAR38 LED Driver
Functional Performance (Single Output, VLED1 - 25V)
Manuf
Board Type
VIN
(VAC)
PFC
PIN
(W)
VLED
(V)
IOUT
(mA)
POUT
(W)
Efficiency
(%)
Athd
(%)
Ripple
(%)
Diodes
Inc
AL6562EV1
Module
Board
100
0.982
17.500
24.28
600
14.668
83.82
10.9
-
110
0.976
17.316
24.27
600
14.662
84.67
11.2
-
120
0.979
17.271
24.32
600
14.692
85.07
11.5
10.8
130
0.983
17.206
24.32
600
14.692
85.39
11.7
-
200
0.957
17.312
24.57
600
14.842
85.73
16.4
-
210
0.952
17.366
24.61
600
14.866
85.60
17.2
-
220
0.947
17.428
24.66
600
14.896
85.47
17.7
-
230
0.942
17.500
24.71
600
14.926
85.29
18.0
240
0.937
17.581
24.76
600
14.956
85.07
19.2
-
250
0.931
17.660
24.81
600
14.986
84.86
19.6
-
265
0.923
17.791
24.88
600
15.028
84.47
20.1
-
9.6
Functional Performance
Efficiency (%) vs Vin (VAC)
AL6562EV1
27
87
26
86
Efficiency [%]
Vout [V]
Vout (V) vs Vin (VAC)
25
24
85
84
83
23
82
22
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Vin [VAC]
Vin [VAC]
Figure 6. Efficiency (%) vs. Vin (VAC)
Figure 5. Vout (V) vs. Vin (VAC)
Athd (%) vs Vin (VAC)
PFC vs Vin (VAC)
AL6562EV1
20
1.00
18
0.90
16
AL6562EV1
0.80
PFC
Athd [%]
AL6562EV1
14
0.70
12
0.60
10
0.50
8
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Vin [VAC]
Vin [VAC]
Figure 7. Athd (%) vs. Vin (VAC)
AL6562EV1 Rev2
January 2016
www.diodes.com
Figure 8. PFC vs. Vin (VAC)
Page 7 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
Functional Performance (Three Outputs, VLED1 - 25V, VLED2 – 12V, and 9V)
rd
Manuf
Board
Type
VIN
(VAC)
PFC
PIN
(W)
VLED1
(V)
IOUT
(mA)
VLED2
(V)
3
Output
(V)
Total
POUT
(W)
Efficiency
(%)
Athd
(%)
Diodes
Inc
AL6562EV1
Module
Board
110
0.987
18.016
25.04
400
11.64
8.29
14.952
82.99
9.0
120
0.985
17.900
25.04
400
11.65
8.31
14.965
83.61
10.1
130
0.983
17.824
25.04
400
11.66
8.32
14.975
84.02
11.0
200
0.952
17.748
25.04
400
11.69
8.36
15.007
84.56
16.0
210
0.947
17.766
25.03
400
11.69
8.37
15.013
84.50
16.7
220
0.942
17.796
25.03
400
11.70
8.37
15.013
84.36
17.0
230
0.936
17.835
25.03
400
11.70
8.38
15.016
84.19
17.5
240
0.931
17.879
25.03
400
11.70
8.38
15.016
83.99
17.5
250
0.924
17.929
25.03
400
11.70
8.38
15.016
83.75
18.0
265
0.914
18.015
25.03
400
11.71
8.39
15.026
83.41
19.0
Functional Performance
3 Output Voltages (V) vs Vin (VAC)
25V_output
Efficiency (%) vs Vin (VAC)
12V_output
28
86
9V_output
85
Efficiency [%]
Vout [V]
24
20
16
12
84
83
82
8
81
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Vin [VAC]
Vin [VAC]
Figure 9. 3 Ouput Voltages (V) vs. Vin (VAC)
Athd (%) vs Vin (VAC)
Figure 10. Efficiency (%) vs. Vin (VAC)
PFC vs Vin (VAC)
AL6562EV1
20
1.00
17
0.90
14
0.80
AL6562EV1
PFC
Athd [%]
AL6562EV1
11
0.70
8
0.60
5
0.50
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250
Vin [VAC]
Vin [VAC]
Figure 11. Athd (%) vs. Vin (VAC)
AL6562EV1 Rev2
January 2016
www.diodes.com
Figure 12. PFC vs. Vin (VAC)
Page 8 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
Application Information
Adjusting the (3) Output Voltages (VLED1, VLED2, and 9V output):
1). The (3) output voltages can be adjusted to a lower value by applying a DC voltage to pin 1 of
the CN1 connector.
Pin 1_CN1 (VDC)
input voltage
VLED1
(25V)
VLED2
(12V)
9V
5.0V
22.00
11.43
8.76
4.0V
22.92
11.91
9.14
3.3V
23.63
12.26
9.41
2.8V
24.13
12.50
9.59
N/C
24.41
12.61
9.67
2). The (3) output voltages can also be adjusted to a lower value by changing R59 to a higher
value.
Change the R59 value
VLED1 VLED2
(25V) (12V)
9V
300k//500k
22.77
9.04
11.86
Adjusting the Over Power Protection Threshold:
The over power protection threshold can be adjusted by changing R9 to a higher value. Current
R9 default setting is at 2Ω.
Vin (VAC)
VLED1 (25V) R9 = 2Ω//R9A=1.5 Ω
120
24.44
100
24.40
90
24.25
80
22.80
70
20.42
AL6562EV1 Rev2
January 2016
www.diodes.com
Page 9 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
Performance Waveforms
All of the Channel 1 (VIN) measurement used a 100:1 differential probe shown in a 5V/division scale.
Figure 9. 120VAC input, IIN, and Vout waveform
0.19 sec
Figure 11. 120VAC vs. output startup time
Figure 10. 230VAC input, IIN, and Vout waveform
0.18 sec
Figure 12. 230VAC vs. output startup time
Thermal Test
Figure 13. Top Vin=120VAC, Testing time =30 mins
AL6562EV1 Rev2
January 2016
www.diodes.com
Figure 14. Bottom Vin=120VAC, Testing time =30 mins
Page 10 of 11
AL6562EV1 User Guide
Universal Power High PFC PAR38 LED Driver
IMPORTANT NOTICE
DIODES INCORPORATED MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, WITH REGARDS TO THIS
DOCUMENT, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION).
Diodes Incorporated and its subsidiaries reserve the right to make modifications, enhancements, improvements, corrections or other
changes without further notice to this document and any product described herein. Diodes Incorporated does not assume any
liability arising out of the application or use of this document or any product described herein; neither does Diodes Incorporated
convey any license under its patent or trademark rights, nor the rights of others. Any Customer or user of this document or products
described herein in such applications shall assume all risks of such use and will agree to hold Diodes Incorporated and all the
companies whose products are represented on Diodes Incorporated website, harmless against all damages.
Diodes Incorporated does not warrant or accept any liability whatsoever in respect of any products purchased through unauthorized
sales channel.
Should Customers purchase or use Diodes Incorporated products for any unintended or unauthorized application, Customers shall
indemnify and hold Diodes Incorporated and its representatives harmless against all claims, damages, expenses, and attorney fees
arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized
application.
Products described herein may be covered by one or more United States, international or foreign patents pending. Product names
and markings noted herein may also be covered by one or more United States, international or foreign trademarks.
This document is written in English but may be translated into multiple languages for reference. Only the English version of this
document is the final and determinative format released by Diodes Incorporated.
LIFE SUPPORT
Diodes Incorporated products are specifically not authorized for use as critical components in life support devices or systems
without the express written approval of the Chief Executive Officer of Diodes Incorporated. As used herein:
A. Life support devices or systems are devices or systems which:
1. are intended to implant into the body, or
2. support or sustain life and whose failure to perform when properly used in accordance with instructions for use provided
in the labeling can be reasonably expected to result in significant injury to the user.
B. A critical component is any component in a life support device or system whose failure to perform can be reasonably expected
to cause the failure of the life support device or to affect its safety or effectiveness.
Customers represent that they have all necessary expertise in the safety and regulatory ramifications of their life support devices or
systems, and acknowledge and agree that they are solely responsible for all legal, regulatory and safety-related requirements
concerning their products and any use of Diodes Incorporated products in such safety-critical, life support devices or systems,
notwithstanding any devices- or systems-related information or support that may be provided by Diodes Incorporated. Further,
Customers must fully indemnify Diodes Incorporated and its representatives against any damages arising out of the use of Diodes
Incorporated products in such safety-critical, life support devices or systems.
Copyright © 2016, Diodes Incorporated
www.diodes.com
AL6562EV1 Rev2
January 2016
www.diodes.com
Page 11 of 11
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