AL9910EV6 User Guide Issue 4

WARNING: DANGER – HIGH VOLTAGES ARE PRESENT ON THIS EVALUATION BOARD
AL9910EV6 ISOLATED LED DRIVER USER GUIDE
Fig. 1 AL9910EV6 evaluation board connection diagram
Issue 4 – June 2011
© Diodes Incorporated, 2011
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AL9910EV6
DESCRIPTION
The AL9910EV6 is an offline isolated LED driver evaluation board designed to work on 110V AC line voltage.
It provides four constant LED current outputs which drive four seperate strings of between 8 and 14 LEDs, with
a LED current of 75mA per string.
It will provide a total LED power ranging from 8W to 15W.
AL9910EV6 SETUP AND TESTING PROCEDURE
Prerequiste
1. AL9910EV6 evaluation board.
2. Four sets of LEDs strings with 8 to 14 series-connected LEDs. Please note that the number of LEDs in
each string must be equal. The LEDs should be mounted on a heatsink capable of a power dissipation of
8 to 15W.
3. For safety reasons during testing, please use an isolated 110V AC source from the output of an isolation
tranformer. For public demonstration, the evaluation board and LEDs should be fitted into a transparent
case with sufficient insulation to meet the local safety requirements.
Connections and Power up
1.
2.
3.
4.
Preset the isolated AC source to either 110VAC.
ENSURE THAT THE AC SOURCE IS SWITCHED OFF OR DISCONNECTED.
Solder the anode wires of all LED strings to the LED+ terminal.
Solder the cathode wires of the four LED strings individually to the LED1-, LED2-, LED3- and LED4terminals. Connect ammeters in series with the cathode wires if LED current measurements are required.
5. Connect the two AC line wires to the AC1 and AC2 terminals which are located at the bottom left hand
corner of the evaluation board.
6. Ensure that the area around the board is clear and safe, and preferably that the board and LEDs are
enclosed in a transparent safety cover.
7. Turn on the mains switch. LED string should light up. DO NOT TOUCH THE BOARD, LEDs OR BARE
WIRING.
Caution: The input terminals carry high voltage during
operation!
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AL9910EV6
OPERATION
The AL9910A device is a PWM high-efficiency LED driver control IC. It allows efficient operation of High
Brightness (HB) LEDs from voltage sources ranging from 85VAC up to 265VAC. The AL9910A can be
configured to work in either fixed frequency or constant OFF-time mode. In fixed frequency mode, the
AL9910A controls an external MOSFET at a fixed switching frequency up to 300kHz, which can be
programmed using a single resistor. The LED string is driven at a constant current rather than at a constant
voltage, thus providing constant light output and enhanced reliability. The output current can be programmed
between a few milliamps and more than 1.0A.
Input filter and Rectifier section
In order to meet the EMI requirement, CX1, CX2, CX3, CX4, L1 and L2 are used to provide sufficient filtering
for both differential-mode and common-mode noise generated from the switching converter circuit after the
bridge rectifier.
The rectified line voltage from the bridge rectifier DB1 is fed into a valley-filled passive power factor correction
stage to provide a high power factor for the AC line input. The passive PFC stage comprises of C1, C2, D1,
D2, D3 and R1. This design gives power factors of greater than 0.9.
Constant Current Flyback Converter section
The isolated Flyback converter section consists of LED controller AL9910A (U1), ultra-fast free-wheeling
rectifier ES2G (D6), transformer (T8) and a high voltage MOSFET switch (Q1). On this evaluation board, the
AL9910A is configured to operate in the constant frequency mode to provide the best LED current regulation.
The switching frequency of the AL9910A is set to 100kHz using resistor R2. Please refer to the product
datasheet for more details on how to configure the constant frequency mode.
The Flyback converter have been designed to provide an total output current of 300mA. The LED current is
regulated with an isolated secondary side feedback, consisting of an opto coupler (U2), sense resistors (R1,
R2) and voltage reference (U3). The LED current level is set by resistors R1 and R2.
The voltage regulator network consisting of Q2, R9 and Z2 provides stable voltage to the AL9910A from the
transformer auxillary winding. Zener diode Z4 and resistor R13 provides protection to the power stage under
open LED condition.
Multi-channel LED Current Balancing section
In this section of the evaluation board, bipolar transistors Q4-Q7 are connected as current mirror to provide an
effective LED current balancing function to drive up to 4 strings of LEDs with minimal losses. The transistors
are mounted as close to one another on the PCB to achieve the best possible thermal coupling. R16, R17,
R22 and R23 are the transistor’s emitter resistors added to improve the LED current balancing.
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AL9910A
AL9910EV6
Fig. 2 AL9910EV6 Schematic Diagram
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AL9910EV6
PARTS LIST
Ref
U1
U2
U3
Q1
Q2
Q3
Q4, Q5,
Q6, Q7
D1, D2,
D3
D4
D5
D6
DB1
Z1
Z2
Z3
Z4
R1
R2
R3,R4
R5
R6
R7
R8, R10
R9
R11
R13
R14
R15, R20
R16, R17,
R22, R23
R18, R19,
R24, R25
R21
F1
C1,C2
C4,C11
C5
C7,C8
C10
CX1,CX2,
CX3, CX4
MOV1
L1
L2
T1
Description
Universal high brightness LED driver
Opto coupler CTR 80-160%
Shunt regulator
N-ch 600V MOSFET 3.2A, QG(max) =
16nC
NPN Transistor
60V NPN Transistor
P/N
AL9910A
FOD817A300
ZTLV431
Package
SO8
SPB03N60S5
MMBT2222A
MMBTA06
TO252
SOT23
SOT23
60V NPN Transistor
FZT853
SOT223
1A 1KV diode tRR=1.8µs
400V 1A ultrafast recovery diode
150V 400mA switching diode
400V 2A ultrafast recovery diode
1A, 600V bridge rectifier
100V 1W Zener
9.1V 50mW Zener
16V 500mW Zener
56V 500mW Zener
10R 3W resistor, +/-50ppm/C, +/-1%
generic
226K 0.125W +/-1% generic
0R 0.125W +/-5% generic
0R5 0.25W +/-1% generic
5K6 0.125W +/-5% generic
100K 0.125W +/-5% generic
5K1 0.125W +/-5% generic
1K 0.125W +/-5% generic
10K 0.25W +/-5% generic
20K 0.125W +/-5% generic
470R 0.125W +/-5% generic
8R2 0.33W +/-1% generic
S1M-13-F
MUR140
BAV20W-7
ES2G
DF06S
1N4764ADO41
BZT52C9V1-7
DDZ9703
MMSZ5263B
SMA
DO-41
SOD123
SMB
SOT23
Manufacturer
Diodes Inc
Fairchild
Diodes Inc
Infineon
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
DO-41
SOD123
SOD123
SOD123
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
Diodes Inc
Wire wound
0805
0805
1206
0805
0805
0805
0805
1206
0805
0805
1206
2R2 0.25W +/-1% generic
1206
0R 0.25W +/-1% generic
1R 0.25W +/-1% generic
10R 1W fusible resistor +/-200ppm
generic
33µF 450V electrolytic capacitor
4.7µF 25V X7R
1µF 50V X7R
33µF 63V
100nF 16V X7R
1206
1206
Panasonic
EEUED2E330
1206
1206
0805
Panasonic
100nF 275VAC, Film, X2, 20%
275V Varistor, 21J
6.8mH 290mA
30mH 300mA common mode choke
800µH Flyback transformer turn ratio =
1.76:1
ECQU2A104ML
B72207S0271K101
19R685C
B82791G2301N001
OWTR-PT25C774
Issue 4 – June 2011
5mm pitch
EER25
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Epcos
Murata
Epcos
Olewoff
AL9910EV6
PERFORMANCE
Efficiency vs Input Voltage
90
.
12 LEDs
10 LEDs
8 LEDs
Efficiency (%)
85
80
75
70
85
90
95
100 105 110 115 120 125 130
Input Voltage (V)
.
Power Factor vs Input Voltage
1.00
12 LEDs
10 LEDs
8 LEDs
Power Factor
0.95
0.90
0.85
0.80
0.75
0.70
85
90
95
100 105 110 115 120 125 130
Input Voltage (V)
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AL9910EV6
.
LED Current vs Input Voltage (12 LEDs)
100.00
LED1LED2LED3LED4-
LED Current (mA)
90.00
80.00
70.00
60.00
50.00
85
90
95 100 105 110 115 120 125 130
Input Voltage (V)
Operating waveforms during normal operation (Orange: AL9910A’s gate output voltage; Green: Q1’s
Drain current; Blue: Q1’s Drain voltage)
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AL9910EV6
Operating waveforms during start up condition (Orange: AL9910A’s gate output voltage; Green: Q1’s
Drain current; Blue: Q1’s Drain voltage)
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AL9910EV6
INTENTIONALLY BLANK
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AL9910EV6
INTENTIONALLY BLANK
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AL9910EV6
INTENTIONALLY BLANK
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AL9910EV6
IMPORTANT NOTICE
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DOCUMENT, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND
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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
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systems without the express written approval of the Chief Executive Officer of Diodes Incorporated. As used herein:
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