AL9910 B10 Refence Design Report »

Reference Design
AL9910EV8
Non-Dimmable 120VAC
Evaluation Board
Case #1:
(Input=120VAC; Output=48V/90mA)
Case #2:
(Input=120VAC; Output=96V/45mA)
Applications: B10 Light Bulbs
-Customer: CreeDate: October 27, 2011
This document contains Diodes confidential and proprietary information
AL9910EV8 120VAC ND Ref Design Report
October 2011
Table of Contents
1.
2.
2.1
2.2
2.3
2.4
2.5
3.
4.
4.1
4.2
5.
PURPOSE ................................................................................................................... 3
EVALUATION BOARD INFORMATION .............................................................................. 4
AL9910 Pin Assignment and Description ..................................................... 4
Evaluation Board Schematic.......................................................................... 5
Evaluation Board BOM List ............................................................................ 6
Evaluation Board Layouts .............................................................................. 8
Evaluation Board Snapshots ......................................................................... 9
LED OUTPUT ........................................................................................................... 10
EVALUATION BOARD TESTING SUMMARY ................................................................... 11
Testing Results (case #1): ............................................................................ 11
Testing Results (case #2): ............................................................................ 12
CONCLUSION ............................................................................................................ 13
AL9910-EV8 (10/27/2011)
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AL9910EV8 120VAC ND Ref Design Report
October 2011
1. PURPOSE
Introduction
We are using our AL9910 Non-Dimmable board to evaluate two test condition requirements using highpower LEDs from Cree for functional performance.
1) Test condition requirement #1: VIN=120VAC; OUT=48V/90mA.
2) Test condition requirement #2: VIN=120VAC; OUT=96V/45mA.
Customer: Cree
Features
Non-Dimmable
Selectable 5W-8W output power
Active PFC with power factor >0.9
No electrolytic capacitor
High temperature operation
Long operating life
Typical Applications: Retrofit B10/E27 LED Light Bulbs
Specifications
Parameter
AC Input Voltage
DC Output Voltage
Output Current
Output Power
Power Factor
Efficiency
Operating Ambient temperature
Operating Junction Temperature
ROHS Compliance
Units
V, AC
V, DC
mA
W
NA
%
C
C
NA
Value
90 - 140
40 – 98
45 - 90
3–6
>0.9
87%-90%
-40 to +85
-40 to +125
Yes
Test conditions:
Input Voltage:
120VAC, 60Hz
Output Voltage:
40VDC - 98VDC
Operating Ambient Temperature: -40°C to 85°C
Connection Instructions:
AC+ Input: Red – Hot
AC- Input: Black - Neutral
DC LED+ Output: LED+ (Red)
DC LED- Output: LED- (Black)
Board Dimension (components included):
WxLxH (in mm) = 18mm x 25mm x 13mm
AL9910-EV8 (10/27/2011)
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AL9910EV8 120VAC ND Ref Design Report
October 2011
2. EVALUATION BOARD INFORMATION
2.1
AL9910 Pin Assignment and Description
AL9910 Pin Assignment
(Top View)
VIN
1
CS
GND
2
Gate
8
Rosc
3
7
6
LD
VDD
4
5
PWM_D
AL9910
SO-8
AL9910 Pin Description
Pin Name
Pin Number
VIN
CS
GND
Gate
1
2
3
4
PWM_D
5
VDD
6
LD
7
ROSC
8
AL9910-EV8 (10/27/2011)
Description
Input voltage
Senses LED string current
Device ground
Drives the gate of the external MOSFET
Low Frequency PWM Dimming pin, also Enable input. Internal 100kΩ pull-down to
GND
Internally regulated supply voltage. 7.5V nominal for AL9910. Can supply up to 1 mA
for external circuitry. A sufficient storage capacitor is used to provide storage when
the rectified AC input is near the zero crossings
Linear Dimming by changing the current limit threshold at current sense comparator
Oscillator control. A resistor connected between this pin and ground sets the PWM
frequency.
Page 4 of 14
AL9910EV8 120VAC ND Ref Design Report
2.2
October 2011
Evaluation Board Schematic
2.1.1 Case #1 => Test conditions: VIN=120VAC; OUT=48V/90mA
Figure 1: Evaluation Board Schematic (Case#1)
2.1.2 Case #2 => Test conditions: VIN=120VAC; OUT=96V/45mA
Figure 2: Evaluation Board Schematic (Case#2)
AL9910-EV8 (10/27/2011)
Page 5 of 14
AL9910EV8 120VAC ND Ref Design Report
2.3
October 2011
Evaluation Board BOM List
Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA
#
2
3
4
5
6
7
8
9
10
11
12
13
Name
U1
D1,2,3,
4
D6
Q1
C4
C3
R1
R3
R2
R4
R6
R9
R7
14
16
16
17
C1, C2
C5
L1
L2
1
Quantity Part number
1 AL9910S-13
Manufacturer
Diodes
Description
Universal High Voltage LED Driver
1
1
1
1
1
1
1
1
1
1
1
1
HD02-T
MUR160-T
STD7NK40ZT4
C0402X7R1A221K
C1608X7R1A105K
CRCW0402330KFKTD
CRCW04021K00FKED
CRCW040222R0FKED
CRCW08051R50FKEA
CRCW120616R0FKEA
CRCW1206510KJNEA
CRCW0402787RFKED
Diodes
Diodes
ST
Vishay
TDK
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
RECT BRIDGE GP 200V 0.8A MINIDIP
DIODE ULTRA FAST 1A 600V DO-41
MOSFET N-CH 400V 5.4A DPAK
CAP CER 220PF 10V X7R 01005
CAP CER 1.0UF 10V X7R 0603
RES 330K OHM 1/16W 1% 0402 SMD
RES 1.0K OHM 1/16W 1% 0402 SMD
RES 22.0 OHM 1/16W 1% 0402 SMD
RES 1.5 OHM 1/8W 1% 0805 SMD
RES 16.0 OHM 1/4W 1% 1206 SMD
RES 510K OHM 1/4W 5% 1206 SMD
RES 787 OHM 1/16W 1% 0402 SMD
2
2
1
1
VJ1812Y104KXETW1BC
UMK325C7106MM-T
LPS5015-225ML
13R475C
Vishay
Taiyo
Coilcraft
Murata
CAP Multilayer Cer (MLCC) – SMD /
SMT 1812 0.1uF 500volts X7R 10%
CAP CER 4.7uF//4.7uF 100V X7R 1210
Inductor 2.2mH 64mA
Inductor Radial 4.7mH 0.16A
AL9910-EV8 (10/27/2011)
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AL9910EV8 120VAC ND Ref Design Report
October 2011
Case #2 => Test conditions: VIN=120VAC; OUT=96V/45mA
#
2
3
4
5
6
7
8
9
10
11
12
13
Name
U1
D1,2,3,
4
D6
Q1
C4
C3
R1
R3
R2
R4
R6
R9
R7
14
16
16
17
C1, C2
C5
L1
L2
1
Quantity Part number
1 AL9910S-13
Manufacturer
Diodes
Description
Universal High Voltage LED Driver
1
1
1
1
1
1
1
1
1
1
1
1
HD02-T
MUR160-T
STD7NK40ZT4
C0402X7R1A221K
C1608X7R1A105K
CRCW0402330KFKTD
CRCW04021K00FKED
CRCW040222R0FKED
CRCW08052R94FKEA
CRCW120616R0FKEA
CRCW1206510KJNEA
CRCW0402787RFKED
Diodes
Diodes
ST
Vishay
TDK
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
Vishay
RECT BRIDGE GP 200V 0.8A MINIDIP
DIODE ULTRA FAST 1A 600V DO-41
MOSFET N-CH 400V 5.4A DPAK
CAP CER 220PF 10V X7R 01005
CAP CER 1.0UF 10V X7R 0603
RES 330K OHM 1/16W 1% 0402 SMD
RES 1.0K OHM 1/16W 1% 0402 SMD
RES 22.0 OHM 1/16W 1% 0402 SMD
RES 2.94 OHM 1/8W 1% 0805 SMD
RES 16.0 OHM 1/4W 1% 1206 SMD
RES 510K OHM 1/4W 5% 1206 SMD
RES 787 OHM 1/16W 1% 0402 SMD
2
2
1
1
VJ1812Y104KXETW1BC
C3225X7S2A475K
LPS5015-225ML
13R476C
Vishay
TDK
Coilcraft
Murata
CAP Multilayer Cer (MLCC) – SMD /
SMT 1812 0.1uF 500volts X7R 10%
CAP CER 4.7uF//4.7uF 100V 1210
Inductor 2.2mH 64mA
Inductor Radial 47mH 0.045A
AL9910-EV8 (10/27/2011)
Page 7 of 14
AL9910EV8 120VAC ND Ref Design Report
2.4
October 2011
Evaluation Board Layouts
Figure 3: Top-View PCB Layout
Figure 4: Bottom-View PCB Layout
AL9910-EV8 (10/27/2011)
Page 8 of 14
AL9910EV8 120VAC ND Ref Design Report
2.5
October 2011
Evaluation Board Snapshots
Figure 5: Top-View PCB Board
Figure 6: Top-View PCB Board in Bulb Module
AL9910-EV8 (10/27/2011)
Page 9 of 14
AL9910EV8 120VAC ND Ref Design Report
October 2011
3. LED OUTPUT
3.1
LED P/N: Cree XM-L T6
LED Output: ~+48V (ideal)
3.2
LED P/N: Cree XPSTAR103
LED Output: ~+96V (ideal)
AL9910-EV8 (10/27/2011)
Page 10 of 14
AL9910EV8 120VAC ND Ref Design Report
October 2011
4. EVALUATION BOARD TESTING SUMMARY
4.1
Testing Results (case #1):
(Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA):
(Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA):
Board
#
1
2
Cree
LED
48V
48V
VRMS
(V)
120.52
120.62
AL9910-EV8 (10/27/2011)
IRMS
(mA)
34.45
35.32
PIN
(W)
PFC
4.032
4.125
0.969
0.966
VLED
(V)
41.35
41.4
ILED
(mA)
91.14
91.95
Efficiency
(%)
POUT
(W)
3.566
3.625
88.44
87.88
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AL9910EV8 120VAC ND Ref Design Report
4.2
October 2011
Testing Results (case #2):
(Case #2 = > Test conditions: VIN=120VAC; OUT=96V/45mA):
(Case #2 = > Test conditions: VIN=120VAC; OUT=96V/45mA):
Board
#
1
Cree
LED
96
VRMS
(V)
120.02
AL9910-EV8 (10/27/2011)
IRMS
(mA)
37.03
PIN
(W)
PFC
4.227
0.962
VLED
(V)
94.43
ILED
(mA)
POUT
(W)
46.17
3.704
Efficiency
(%)
87.63
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AL9910EV8 120VAC ND Ref Design Report
October 2011
5. CONCLUSION
It is concluded that the new circuit implementation of replacing the inductor (L2) and changing
the RSENSE (R4) fully function as expected. As configured in a high-power 48V LED module,
the efficiency is about ~88% and PFC is ~0.969. As configured in a high-power 96V LED
module, the efficiency is about ~87.6% and PFC is ~0.962.
Main benefits are achieved in the high-power LED evaluation:
1) High Efficiency
2) High PFC (>0.9)
3) No electrolytic capacitor
4) Correct average LED output current
5) Suitable for E27 LED Light Bulbs
AL9910-EV8 (10/27/2011)
Page 13 of 14
AL9910EV8 120VAC ND Ref Design Report
October 2011
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
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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
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convey any license under its patent or trademark rights, nor the rights of others. Any Customer or user of this document or products
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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:
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A critical component is any component in a life support device or system whose failure to perform can be reasonably expected
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Incorporated products in such safety-critical, life support devices or systems.
Copyright © 2011, Diodes Incorporated
www.diodes.com
AL9910-EV8 (10/27/2011)
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