Innovative PowerTM ACT364 DESIGN GUIDE Jun 2014 Innovative LED Solutions AC/DC LED Lighting PRODUCT SELECTION GUIDE LED Lighting Reference Rev3.1 Apr 2011 Designs June 2014 Copyright © 2014 Active-Semi International, Inc. - - www.active-semi.com www.active-semi.com LED DESIGN GUIDE Innovative PowerTM Jun 2014 Table of Contents ACT364 1W 350mA(3.5V) E27.……………………………………………………………..…………….………3 ACT364 1W 350mA(3.5V) E27 Non-isolated…….………...…….……………………………..…….…...…...5 ACT364 3W 700mA(4V) GU10..…………………………………….…………………………………...………..7 ACT364 3W 700mA(4V) GU10 Non-isolated…………….………………………………….………………….9 ACT364 3W 350mA(12V) GU10………………………….……….………………………………….………11 ACT364 3W 350mA(12V) GU10 Non-isolated..……….……….……………………………………………..13 ACT365 7.8W 350mA(26V) PAR30 ………………….….………………...…………………….……………...15 ACT365 7.8W 350mA(26V) PAR30 Non-isolated…….………….……….….………………….….………...17 ACT512 16.8W 700mA(24V) PAR38 ………………….….………………...………………………….…….19 ACT111A 4.8-30VDC (up to 1.5A) MR16……………………………...………………………………………..21 Copyright © 2014 Active-Semi International, Inc. -2- www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 E27 1x1W LED Lighting Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 1 3.5V 1W Flyback can provide drivers for one (min), or two (max) LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NS), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/NS/NAUX (160/10/23) must be designed correctly to make sure it operates in DCM mode and it can supply either one to two LEDs in same circuit. A design value VOUTCV equal to 3.5V and IOUTCC-MIN equal to 350mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 3.5V, 350mA. This circuit is a typical flyback type power supply which includes the AC rectified circuit (BD1, C1), power drive circuit (BD pin, Q1), secondary rectified circuit (D3, C4) and the IC(ACT364) control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base driver for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Through a patented PSR technology, this circuit 2 IOUTCC 0.396 0.9 1 FSW LP V 2 R CS OUTCV (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC-R is the rectifier diode forward drop voltage at approximately 0.1A bias. VREF ( 1 VOUTCV NS R5 ) VSEC _ R R6 N AUX (1.2) The peak current limit is set by (0.396×0.9) /RCS. Figure 1: Schematic of LED Lighting Driver L1 FR1 10Ω/1W T1 EE10 L 1.5mH *R1 300kΩ 1 4 2 3 BD1 MB6S V+ *C2 100pF C1 4.7µF 400V D3 SB240 R8 3kΩ *D1 GS1M GND D2 LL4148 R2 10MΩ Q1 D13003X TO-92 N R3 22Ω 3 R4 22Ω C3 4.7µF 25V VDD R5 52.3kΩ 1 BD 4 Note: The *R1,*C2,*D1 is optional Copyright © 2014 Active-Semi International, Inc. C4 47µF/ 10V SW U1 ACT364 SOT23-6 GND 2 FB CS 6 R7 2.8Ω -3- 5 R6 9.2kΩ www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials PCB Top and Bottom Layers 26mm DESCRIPTION MFTR. C1 Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,47µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/10V,1206,SMD POE BD1 Bridge Rectifier,600V/0.5A, MBS06, SDIP PANJIT D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT D2 General Rectifier, LL4148, 100V/1A PANJIT D3 Diode,schottky,40V/2A,S240,SMA PANJIT L1 Axial Inductor,1.5mH,0410,Dip 14mm REF. Jintong FR1 Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Q1 Transistor,HFE 15-25,NPN,D13003,TO-92 Huawai R1 Chip Resistor, 00K ohm,0805,5% TY-OHM R5 Chip Resistor,52.3K ohm,0805,1% TY-OHM R6 Chip Resistor,9.2K ohm,0805,1% TY-OHM R7 Chip Resistor,2.8 ohm,1206,5% TY-OHM R8 Chip Resistor, 3K ohm, 0805, 5% TY-OHM T1 Transformer, Lp=4.2mH, EE10 U1 IC, ACT364US-T, SOT23-6 3kVAC Electrical Strength 50Hz, 1 minute, from Primary and Secondary 2 P1 Inductance Inductance between pin 4 4.2mH ± and pin 1 at 1VAC & 1kHz 7% 3 P1 Leakage Inductance Inductance between pin 4 and pin 1 with pins 3-2 and 8-5 shorted 75µH Typical performance Characteristics Efficiency vs. Input Voltage 70.00 69.20 Efficiency (%) Chip Resistor,22 ohm,0805,5% LIMITS ACT364-001 TY-OHM CONDITION 1 TY-OHM Chip Resistor,10M ohm,1206,5% R3,4 ITEM DESCRIPTION SoKa PCB1 PCB,L*W*T=25.5×14×1.6mm,Rev:A R2 Electrical Specifications 68.40 67.60 66.80 115VAC 230VAC 66.00 90 ACT 110 130 150 170 190 230 210 250 Input Voltage Transformer Specification Pin4 Pin8 Pin7 S1 NC Pin2 SH1 P1 Pin4 Pin1 P2 340 Reverse SH1 8 2 S1 1 7 P1 4 Build Up TERMINAL WINDING START FINISH Core(SH2) WIRE TURNS TYPE SIZE × QTY ACT364-002 Pin2 Pin3 P2 Output Current (mA) Pin4 Output Current vs. Input Voltage NC 3 INSULATION LAYER THICK/WIDE LAY ER 330 320 310 300 VIN 85VAC VIN 115VAC VIN 230VAC VIN 264VAC 290 P1 1 4 160 2UEW 0.1Φ×1 3 25µ/8.5mm 2 SH2 2 Open 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 S1 8 7 10 TEXE 0.35Φ×1 Reverse 1 25µ/8.5mm 2 P2 3 2 23 2UEW 0.1Φ×2 2 25µ/8.5mm 2 EVALUATION KITS 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-LED01 SH2 Core 4 280 90 110 130 150 170 190 210 230 250 270 Input Voltage VIN I0 85-264VAC 300-350mA LED(s) 1 or 2 Note: P1 and P2 are Primary, S1 is Secondary (Bobbin: EE-10 Horizontal). Copyright © 2014 Active-Semi International, Inc. -4- www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 E27 1x1W LED Lighting Non-isolated Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 1 3.5V 1W buck drivers for one (min), or two (max) LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NS), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/NAUX (160/23) must be designed correctly to make sure it operates in DCM mode and it can supply either one to two LEDs in same circuit. A design value VOUTCV equal to 3.5V and IOUTCC-MIN equal to 350mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 3.5V, 350mA. This circuit is tapped buck power supply which includes the AC rectified circuit (BD1, C1), power drive circuit (BD pin, Q1), secondary rectified circuit (D3, C4) and the IC(ACT364) control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base driver for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Through a patented PSR technology, this circuit can provide 2 0.396 0.9 1 FSW LP V 2 RCS OUTCV IOUTCC (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC-R is the rectifier diode forward drop voltage at approximately 0.1A bias. VREF ( 1 VOUTCV NS R5 ) VSEC _ R R6 N AUX (1.2) The peak current limit is set by (0.396×0.9) /RCS. Figure 1: Schematic of LED Lighting Driver L1 FR1 10Ω 1W V+ L 1.5mH *R1 300kΩ 1 4 2 3 BD1 MB6S *C2 100pF C1 4.7µF 400V R3 22Ω R2 10MΩ VDD R4 22Ω C3 4.7µF 25V Copyright © 2014 Active-Semi International, Inc. -5- GND R5 52.3kΩ 1 BD 4 C4 47µF 10V Q1 D13003X TO-92 3 Note: The *R1,*C2,*D1 is optional R8 3kΩ T1 EE10 *D1 GS1M D2 LL4148 N D2 SB240 SW U1 ACT364 SOT23-6 GND 2 FB 5 CS 6 R7 2.8Ω R6 9.2kΩ www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials PCB Top and Bottom Layers DESCRIPTION MFTR. C1 Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,47µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/10V,1206,SMD POE BD1 Bridge Rectifier,600V/0.5A, MBS06, SDIP PANJIT D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT D2 General Rectifier, LL4148, 100V/1A PANJIT D3 Diode,schottky,40V/2A,S240,SMA PANJIT L1 Axial Inductor,1.5mH,0410,Dip Electrical Specifications ITEM SoKa PCB1 PCB,L*W*T=25.5×14×1.6mm,Rev:A Jintong FR1 Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Q1 Transistor,HFE 15-25,NPN,D13003,TO-92 Huawai R1 Chip Resistor, 00K ohm,0805,5% TY-OHM R2 Chip Resistor,10M ohm,1206,5% TY-OHM Chip Resistor,22 ohm,0805,5% TY-OHM R5 Chip Resistor,52.3K ohm,0805,1% TY-OHM R6 Chip Resistor,9.2K ohm,0805,1% TY-OHM R7 Chip Resistor,2.8 ohm,1206,5% TY-OHM R8 Chip Resistor, 3K ohm, 0805, 5% TY-OHM T1 Transformer, Lp=4.2mH, EE10 U1 IC, ACT364US-T, SOT23-6 R3,4 26mm 14mm REF. DESCRIPTIO N CONDITION LIMITS 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary 3kVAC 2 P1+P2 Inductance Inductance between pin 8 and pin 1 at 1VAC & 1kHz 4.2mH ± 7% 3 P1+P2 Leakage Inductance Inductance between pin 4 and pin 8 with pins 3-2 . 75µH Typical performance Characteristics Figure 1 ACT Transformer Specification Pin4 NC 3 Pin4 Pin4(SH2) Pin2 Pin3 NC Pin2 2 P3 SH1 Pin8 Pin4 P2 P3 SH1 P1 P2 8 1 P1 Pin4 Pin1 4 Core(SH2) Build Up TERMINAL WINDING WIRE TURNS START FINISH TYPE SIZE × QTY INSULATION LAYER THICK/WIDE LAY ER Figure 2 P1 1 4 150 2UEW 0.1Φ×1 3 25µ/8.5mm 2 P2 4 8 10 2UEW 0.3Φ×1 1 25µ/8.5mm 2 SH1 2 NC 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 P3 3 2 23 2UEW 0.1Φ×2 2 25µ/8.5mm 2 EVALUATION KITS SH2 Core 4 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-LED02 VIN I0 85-264VAC 300-350mA LED(s) 1 or 2 Note: P1,P2 ,and P3 are Primary (Bobbin: EE-10 ;Vertical). Copyright © 2014 Active-Semi International, Inc. -6- www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 GU10 1x3W LED Lighting Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 1 4V 3W Flyback technology, this circuit can provide drivers one 3W LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NS), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/Ns/NAUX (160/7/22) must be designed correctly to make sure it operates in DCM mode and it can supply one LEDs in same circuit. A design value VOUTCV equal to 4V and IOUTCC_MIN equal to 650mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 4V, 650mA. This circuit is a typical flyback type power supply which includes the AC rectified circuit (BD1, L1, C1), primary snubber circuit (D1, R1, C2), power drive circuit (BD pin ,Q1), secondary rectified circuit (D3, C4) and the IC control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-couple. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Through a patented PSR 2 IOUTCC 0.396 0.9 1 FSW LP 2 RCS VOUTCV (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC-R is the rectifier diode forward drop voltage at approximately 0.1A bias. VREF ( 1 VOUTCV R5 NS ) VSEC _ R R6 NAUX (1.2) The peak current limit is set by (0.396×0.9) /RCS. Figure 1: Typical Application Circuit L1 FR1 10/1W T1 EE10 L 1.5mH 0410 BD1 MBS06 SMD 4 2 *C2 101/500V 1206 *R1 300K/ 0805 1 *D1 GS1M SMA C1 4.7µF/400V 8×12 3 V+ 5 8 3 1 D2 LL4148 R3 22R/0805 R4 22R/0805 C3 4.7µF/25V 1206 Copyright © 2014 Active-Semi International, Inc. R8 2K/0805 C4 47µF/10V GND Q1 2 D13003X TO-92 R2 10M/1206 N D3 S240 SMD 4 3 4 VDD R5 51.6K/0805 1 BD SW U1 ACT364 SOT23-6 GND FB 5 CS 6 2 R7 2R/1206 -7- R6 9.88K/0805 www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials PCB Top and Bottom Layers DESCRIPTION MFTR. C1 Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,4.7µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/10V,1206,SMD POE BD1 Bridge Rectifier,600V/0.5A,MBS06,SDIP PANJIT 26mm 14mm REF. Electrical Specifications ITEM DESCRIPTION CONDITION LIMITS 3kVAC D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary D2 General Rectifier,LL4148,100V/1A PANJIT 2 P1 Inductance Inductance between pin 1 and pin 4 at 1VAC & 1kHz 3.2mH ± 7% D3 Diode,schottky,40V/2A,S240,SMA PANJIT L1 Axial Inductor,1.5mH,0410,Dip 3 P1 Leakage Inductance Inductance between pin 1 and pin 4 with pins 3-2 and 7-8 shorted 75µH SoKa PCB,L*W*T=25.5×14×1.6mm,Rev:A FR1 Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Q1 Transistor,HFE 15-25,NPN,D13003,TO-92 Huawai R1 Chip Resistor,300K ohm,0805,5% TY-OHM R2 Chip Resistor,10M ohm,1206,5% TY-OHM Chip Resistor,22 ohm,0805,5% TY-OHM R5 Chip Resistor,51.6K ohm,0805,1% TY-OHM R6 Chip Resistor,9.88K ohm,0805,1% TY-OHM R7 Chip Resistor,2 ohm,1206,5% TY-OHM R8 Chip Resistor,2K ohm,0805,5% TY-OHM T1 Transformer,Lp=3.2mH,EE10 U1 IC,ACT364US-T,SOT23-6 Typical Performance Characteristics Efficiency vs. Input Voltage 70.00 69.20 Efficiency (%) R3,4 Jintong ACT364-001 PCB 1 68.40 67.60 66.80 66.00 115VAC 115VAC 230VAC 230VAC 3 LEDs 90 110 130 150 ACT 170 190 210 230 250 Input Voltage Transformer Specification Pin4 Pin8 Pin7 S1 NC Pin2 SH1 P1 Pin4 Pin1 P2 720 Reverse SH1 S1 1 7 P1 4 Build up TERMINAL WINDING START FINISH Core(SH2) WIRE TURNS TYPE SIZE × QTY VOUT1 = 1.8V 8 2 INSULATION LAYER THICK/WIDE LAY ER P1 1 4 160 2UEW 0.1Φ×1 3 25µ/8.5mm 2 SH2 2 NC 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 TEXE 0.35Φ×1 Reverse S1 8 7 7 1 25µ/8.5mm 2 P2 3 2 22 2UEW 0.1Φ×2 2 25µ/8.5mm 2 SH2 Core 4 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-002 Pin2 Pin3 P2 Output Current (mA) Pin4 Output Current vs. Input Voltage NC 3 700 680 660 85VAC 115VAC 230VAC 264VAC 640 620 90 110 130 150 170 190 210 230 250 270 Input Voltage EVALUATION KITS ACT364-LED03 VIN I0 85-264VAC 650-750mA LED(s) 1 P1 and P2 are Primary, S1 is Secondary (Bobbin: EE-10 Vertical) Copyright © 2014 Active-Semi International, Inc. -8- www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 GU10 1x3W LED Lighting Non-isolated Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 1 4V 3W buck technology, this circuit can provide drivers one 3W LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NS), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/NAUX (160/22) must be designed correctly to make sure it operates in DCM mode and it can supply one LEDs in same circuit. A design value VOUTCV equal to 4V and IOUTCC_MIN equal to 650mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 4V, 650mA. This circuit is tapped buck power supply which includes the AC rectified circuit (BD1, L1, C1), primary snubber circuit (D1, R1, C2), power drive circuit (BD pin ,Q1), secondary rectified circuit (D3, C4) and the IC control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-couple. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Through a patented PSR 2 0.396 0.9 1 FSW LP 2 RCS VOUTCV IOUTCC (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC-R is the rectifier diode forward drop voltage at approximately 0.1A bias. VREF ( 1 VOUTCV R5 NS ) VSEC _ R R6 NAUX (1.2) The peak current limit is set by (0.396×0.9) /RCS. Figure 1: Typical Application Circuit L1 FR1 10Ω/1W V+ L 1.5mH *R1 300kΩ 1 4 2 3 BD1 MB6S C1 4.7µF 400V Note: The *R1,*C2,*D1 is optional R3 22Ω R2 10MΩ R4 22Ω C3 4.7µF 25V Copyright © 2014 Active-Semi International, Inc. -9- GND R5 51.6kΩ 1 BD VDD C4 47µF 10V Q1 D13003X TO-92 3 4 R8 2kΩ T1 EE10 *D1 GS1M D2 LL4148 N D3 SB240 *C2 100pF SW U1 ACT364 SOT23-6 GND 2 FB 5 CS 6 R7 2Ω R6 9.88kΩ www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials PCB Top and Bottom Layers DESCRIPTION MFTR. C1 Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,4.7µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/10V,1206,SMD POE BD1 Bridge Rectifier,600V/0.5A,MBS06,SDIP PANJIT 26mm 14mm REF. Electrical Specifications ITEM DESCRIPTION CONDITION LIMITS 3kVAC D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary D2 General Rectifier,LL4148,100V/1A PANJIT 2 P1+P2 Inductance Inductance between pin 1 and pin 8 at 1VAC & 1kHz 3.2mH ± 7% D3 Diode,schottky,40V/2A,SB240,SMA PANJIT L1 Axial Inductor,1.5mH,0410,Dip SoKa 3 P1+P2 Leakage Inductance Inductance between pin 1 and pin 8 with pins 2-3 75µH PCB1 PCB,L*W*T=25.5×14×1.6mm,Rev:A Jintong Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Q1 Transistor,HFE 15-25,NPN,D13003,TO-92 Huawai R1 Chip Resistor,300K ohm,0805,5% TY-OHM R2 Chip Resistor,10M ohm,1206,5% TY-OHM Chip Resistor,22 ohm,0805,5% TY-OHM R5 Chip Resistor,51.6K ohm,0805,1% TY-OHM R6 Chip Resistor,9.88K ohm,0805,1% TY-OHM R7 Chip Resistor,2 ohm,1206,5% TY-OHM R8 Chip Resistor,2K ohm,0805,5% TY-OHM T1 Transformer,Lp=3.2mH,EE10 U1 IC,ACT364US-T,SOT23-6 R3,4 Typical Performance Characteristics Average Efficiency Vs Vin Efficiency FR1 NC P3 SH1 P1 P2 2 8 1 P2 Pin4 Pin1 4 Core(SH2) TERMINAL WIRE TURNS TYPE P1 1 4 153 2UEW 0.1Φ×1 3 25µ/8.5mm 2 LAYER THICK/WIDE P2 4 8 7 2UEW 0.35Φ×1 1 25µ/8.5mm 2 2 NC 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 P3 3 2 22 2UEW 0.1Φ×2 2 25µ/8.5mm 2 EVALUATION KITS 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-LED04 Core 4 160 230 264 Figure 2 LAY ER SH1 SH2 115 Input Voltage INSULATION SIZE × QTY START FINISH 235 740 735 730 725 720 715 710 705 700 695 690 685 680 90 Build up WINDING 210 Output Current VS.Load Pin4(SH2) Pin2 Pin3 NC Pin2 P1 185 Figure 1 Output Current(mA) Pin8 Pin4 160 Vin Pin4 SH1 135 ACT 3 P3 Efficiency Vs Vin 115V,230" 110 Transformer Specification Pin4 78.00% 76.00% 74.00% 72.00% 70.00% 68.00% 66.00% VIN I0 85-264VAC 650-750mA LED(s) 1 Note: P1,P2, and P3 are Primary (Bobbin: EE-10; Vertical). Copyright © 2014 Active-Semi International, Inc. - 10 - www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 GU10 3x1W LED Lighting Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 3 12V 3W Flyback peak current sense pin. Through a patented PSR technology, this circuit can provide drivers for two (min), or three (max) LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NS), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/NS/NAUX (160/20/24) must be designed correctly to make sure it operates in DCM mode and it can supply either two or three LEDs in same circuit. A design value VOUTCV equal to 12V and IOUTCC MIN equal to 300mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 12V, 350mA. This circuit is a typical flyback type power supply which includes the AC rectified circuit (BD1, C1, L1), primary snubber circuit (D1, R1, C2), power drive circuit (BD pin, Q1), secondary rectified circuit (D3, C4) and the IC control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the 2 IOUTCC 0.396 0.9 1 FSW LP 2 RCS VOUTCV (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC R is the rectifier diode forward drop voltage at approximately 0.1A bias. VREF ( 1 VOUTCV NS R5 ) VSEC R6 NAUX _R (1.2) The peak current limit is set by (0.396×0.9)/RCS. Figure 1: Schematic of LED Lighting Driver L1 FR1 10Ω/1W T1 EE10 L 1.5mH BD1 MB6S V+ *C2 100pF *R1 300kΩ 1 D3 SB2B0 2 4 R8 10kΩ *D1 GS1M 3 C5 2.2µF 400V C1 4.7µF 400V N Note: The *R1,*C2,*D1 is optional GND D2 LL4148 R3 22Ω R2 10MΩ Q1 D13003X TO-92 3 1 BD 4 R4 22Ω VDD - 11 - R5 52.3kΩ SW U1 ACT364 SOT23-6 GND C3 4.7µF 25V Copyright © 2014 Active-Semi International, Inc. C4 10µF 16V 2 FB 5 CS 6 R7 1.4Ω R6 9.2kΩ www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials REF. PCB Top and Bottom Layers DESCRIPTION 26mm MFTR. Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,4.7µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/16V,1206,SMD POE Electrical Specifications C5 Capacitor,Electrolytic,2.2µF/400V,6.2×12mm KSC ITEM DESCRIPTION 14mm C1 CONDITION LIMITS Bridge Rectifier,600V/0.5A,MBS06,SDIP PANJIT 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT 2 P1 Inductance Inductance between pin 1 and pin 4 at 1VAC & 1kHz D2 General Rectifier, LL4148, 100V/1A PANJIT 3 P1 Leakage Inductance Inductance between pin 1 and pin 4 with pins 2-3 and 7-8 shorted D3 Diode,schottky,100V/1A,S100,SMA L1 Axial Inductor,1.5mH,0410,Dip PANJIT SoKa PCB1 PCB,L*W*T=25.5×14×1.6mm,Rev:A FR1 2.1mH ± 7% 75µH Typical Performance Characteristics Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Transistor,HFE15-25,NPN,D13003,TO-92 R1 Chip Resistor,300K ohm,0805,5% TY-OHM R2 Chip Resistor,10M ohm,1206,5% TY-OHM Efficiency vs. Input Voltage 76 Huawai Chip Resistor,22 ohm,0805,5% TY-OHM R5 Chip Resistor,52.3K ohm,0805,1% TY-OHM R6 Chip Resistor,9.2K ohm,0805,1% TY-OHM R7 Chip Resistor,1.4 ohm,1206,5% TY-OHM R8 Chip Resistor,10K ohm,0805,5% TY-OHM T1 Transformer,Lp=2.1mH,EE10 U1 IC, ACT364US-T, SOT23-6 ACT364-001 Q1 R3,4 3kVAC Jintong Efficiency (%) BD1 74 72 70 230VAC 115VAC 115VAC 230VAC 68 90 110 130 150 170 190 230 210 250 Input Voltage ACT Transformer Specification Pin4 P2 Pin8 Pin7 S1 NC Pin2 SH1 P1 Pin4 Pin1 P2 360 Reverse SH1 S1 1 7 P1 4 Build Up TERMINAL WINDING START FINISH Core(SH2) WIRE TURNS 350 8 2 TYPE SIZE × QTY Output Current (mA) Pin2 Pin3 INSULATION LAYER THICK/WIDE ACT364-002 Pin4 Output Current vs. Load NC 3 LAY ER 340 330 320 310 300 264VAC 230VAC 115VAC 264VAC 230VAC 110VAC 85VAC 85VAC 290 P1 1 4 160 2UEW 0.1Φ×1 3 25µ/8.5mm 2 SH1 2 Open 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 S1 8 7 20 TEXE 0.25Φ×1 Reverse 1 25µ/8.5mm 2 P2 3 2 24 2UEW 0.1Φ×2 2 25µ/8.5mm 2 EVALUATION KITS 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-LED05 SH2 Core 4 280 90 110 130 150 170 190 210 230 250 270 Input Voltage VIN I0 85-264VAC 280-350mA LED(s) 2 or 3 Note: P1 and P2 are Primary, S1 is Secondary (Bobbin: EE-10 Vertical). Copyright © 2014 Active-Semi International, Inc. - 12 - www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 GU10 3x1W LED Lighting No-isolated Input Voltage Device LED(s) Output Voltage Power Output Topology 85 - 264VAC ACT364 3 12V 3W buck peak current sense pin. Through a patented PSR technology, this circuit can provide drivers for two (min), or three (max) LED lights in series due to the wide VDD operation ranges. Key Component Selection The turn ratio of the primary turn and the secondary turn (NP/NAUX), together with the R7 sets the maximum output current value as shown in formula (1.1). The voltage setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (1.2). NP/NAUX (160/24) must be designed correctly to make sure it operates in DCM mode and it can supply either two or three LEDs in same circuit. A design value VOUTCV equal to 12V and IOUTCC MIN equal to 300mA are used to do the design. Operation and Application Figure 1 is the schematic of an offline LED driver using ACT364 to provide a power output of 12V, 350mA. This circuit is tapped buck power supply which includes the AC rectified circuit (BD1, C1, L1), primary snubber circuit (D1, R1, C2), power drive circuit (BD pin, Q1), secondary rectified circuit (D3, C4) and the IC control circuit. ACT364 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the 2 IOUTCC 0.396 0.9 1 FSW LP 2 RCS VOUTCV (1.1) NS and NAUX are numbers of transformer secondary and auxiliary turns, and VSEC R is the rectifier diode forward drop voltage at approximately 0.1A bias. VOUTCV VREF (1 NS R5 ) VSEC _ R R6 NAUX (1.2) The peak current limit is set by (0.396×0.9)/RCS. Figure 1: Schematic of LED Lighting Driver L1 FR1 10Ω/1W V+ L 1.5mH BD1 MB6S *C2 100pF *R1 300kΩ 1 D3 SB2B0 R8 10kΩ 2 4 T1 EE10 *D1 GS1M 3 C5 2.2µF 400V C1 4.7µF 400V N Note: The *R1,*C2,*D1 is optional D2 LL4148 R2 10MΩ R3 22Ω R4 22Ω C3 4.7µF 25V Copyright © 2014 Active-Semi International, Inc. - 13 - R5 52.3kΩ 1 BD VDD GND Q1 D13003X TO-92 3 4 C4 10µF 16V SW U1 ACT364 SOT23-6 GND 2 FB 5 CS 6 R7 1.4Ω R6 9.2kΩ www.active-semi.com ACT364 DESIGN GUIDE Innovative PowerTM Jun 2014 Bill of Materials PCB Top and Bottom Layers REF. DESCRIPTION Capacitor,Electrolytic,4.7µF/400V,8×12mm KSC C2 Capacitor,Ceramic,100pF/500V,1206,SMD POE C3 Capacitor,Ceramic,4.7µF/25V,1206,SMD POE C4 Capacitor,Ceramic,10µF/16V,1206,SMD POE C5 Capacitor,Electrolytic,2.2µF/400V,6.2×12mm KSC Bridge Rectifier,600V/0.5A,MBS06,SDIP 14mm C1 BD1 26mm MFTR. Electrical Specifications ITEM DESCRIPTION PANJIT CONDITION LIMITS D1 Diode,U1tra Fast,GS1M,1000V/1.0A,SMA PANJIT 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary D2 General Rectifier, LL4148, 100V/1A PANJIT 2 P1+P2 Inductance Inductance between pin 1 and pin 8 at 1VAC & 1kHz 2.1mH ± 7% D3 Diode,schottky,200V/1A,SB2B0,SMA PANJIT 3 P1+P2 Leakage Inductance Inductance between pin 1 and pin 8 with pins 2-3 . shorted 75µH L1 Axial Inductor,1.5mH,0410,Dip SoKa PCB1 PCB,L*W*T=25.5×14×1.6mm,Rev:A Jintong FR1 Wire Round Resistor,1W,10ohm,KNP,5% TY-OHM Q1 Transistor,HFE15-25,NPN,D13003,TO-92 Huawai Typical Performance Characteristics Average Efficiency Vs Vin 86.00% 84.00% 82.00% 80.00% 78.00% 76.00% 74.00% 72.00% 70.00% Chip Resistor,300K ohm,0805,5% TY-OHM R2 Chip Resistor,10M ohm,1206,5% TY-OHM Chip Resistor,22 ohm,0805,5% TY-OHM R5 Chip Resistor,52.3K ohm,0805,1% TY-OHM R6 Chip Resistor,9.2K ohm,0805,1% TY-OHM R7 Chip Resistor,1.4 ohm,1206,5% TY-OHM Vin R8 Chip Resistor,10K ohm,0805,5% TY-OHM Figure 1 T1 Transformer,Lp=2.1mH,EE10 U1 IC, ACT364US-T, SOT23-6 Pin4(SH2) Pin2 Pin3 NC Pin2 SH1 Pin8 Pin4 P3 SH1 2 8 1 P2 P1 P1 Pin4 Pin1 P2 Output Current(mA) Pin4 P3 135 90 4 WINDING START FINISH TURNS TYPE SIZE × QTY 235 115 160 230 264 Figure 2 INSULATION LAYER THICK/WIDE 210 Input Voltage Build Up WIRE 185 350 345 340 335 330 325 320 315 310 305 300 Core(SH2) TERMINAL 160 Output Current VS.Load NC 3 Efficiency Vs Vin 115V,230" 110 ACT Transformer Specification Pin4 Efficiency R1 R3,4 3kVAC LAY ER P1 1 4 140 2UEW 0.1Φ×1 3 25µ/8.5mm 2 P2 4 8 20 2UEW 0.3Φ×1 1 25µ/8.5mm 2 SH1 2 NC 16 2UEW 0.1Φ×3 1 25µ/8.5mm 2 P3 3 2 24 2UEW 0.1Φ×2 2 25µ/8.5mm 2 EVALUATION KITS SH2 Core 4 1 Copper 0.18Φ×1 Wire 1 25µ/8.5mm 2 ACT364-LED06 VIN I0 85-264VAC 280-350mA LED(s) 2 or 3 Note: P1 and P2 and P3 are Primary (Bobbin: EE-10 ;Vertical). Copyright © 2014 Active-Semi International, Inc. - 14 - www.active-semi.com ACT365 DESIGN GUIDE Innovative PowerTM Jun 2014 PAR30 7x1W LED Lighting Input Voltage Device LED(s) 85 - 264VAC ACT365 7 Output Voltage Power Output Transformer 26V 7.8W Topology EE16 Flyback Key Component Selection The maximum output current is decided by formula (1). 1 0.9 * 0.396 2 FSW LP ( ) ( ) 2 RCS VOUTCC IOUTCC (1) Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. η is Operation and Application Figure 1 is the schematic of LED lighting using ACT365 to provide output power of 26V300mA with PF>0.77.This circuit is a typical flyback power supply which includes the AC rectified circuit(BD1,C2, C3),power drive circuit (BD pin, Q1),power factor rectified circuit (D1D3,C2,C3),secondary rectified circuit (D6, C7,C8) and the IC control circuit. ACT365 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. Through a patented PSR technology, this circuit can provide drivers for five(min), or seven (max) LED lights in series due to the wide VDD operation ranges. the overall system efficiency, which value is approximately equal to 75%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). VOUTCC VREF (1 R5 NS ) VSEC _ R R6 NAUX (2) Np/Ns/Naux (102/23/13) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 26V and Ioutcc_min equal to 300mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of LED Lighting Driver 2 D4 FR107 R11 C6 10Ω 1000pF 10 9 D6 HER104 V+ R13 10kΩ 1 R7 5MΩ R8 5MΩ 4 C9 102/400VAC C8 47µF/50V D3 1N4007 5 C4 1000pF/ 1KV Q1 13003 D2 1N4007 R4 22Ω N DB1 B6S R3 300kΩ D5 FR102 L2 680µH C1-2 0.1µF C1-1 0.1µF L1 1.5mH C3 22uF/400V C2 22µF/400V T1 EE16 C7 47µF/50V R12 4k D1 1N4007 F1 1A 250V L LED1 LED7 GND R10 330kΩ 8 1 BD 6 VDD R5 51.1kΩ SW U1 ACT365 FB 5 R1 22Ω GND 2,4,7 C5 10µF/ 35V Copyright © 2014 Active-Semi International, Inc. CS 3 R9 0.67Ω - 15 - R6 8.66kΩ www.active-semi.com ACT365 DESIGN GUIDE Innovative PowerTM Jun 2014 Electrical Specifications Bill of Materials REF DESCRIPTION MFTR C1-1/2 X1 Capacitor,0.1µF/400V,13x6x11mm USE C2,C3 Capacitor,Electrolytic, 22µF/250V, 10x14mm KSC C4 Capacitor,Ceramic,1000pF/1KV, DIP POE C5 Capacitor,Electrolytic,10µF/35V, 5x11mm KSC C6 Capacitor,Ceramic,1000pF/50V,1206 POE Capacitor,Electrolytic, 47µF/50V, 6.3x12mm KSC C7,C8 C9 Y cap,1000pF/275V,Dip BD1 USE Bridge,B6S,600V/0.5A,MDI,SMD Fast Recovery Rectifiers,1N4007, DO-41 Good-Ark Fast Recovery Rectifier ,FR107,DO-41 Good-Ark D5 Fast Recovery Rectifier ,FR102,DO-41 Good-Ark D6 Efficiency Rectifiers, 300V/1A ,HER104, DO-41 Good-Ark L1 Axial Inductor,1.5mH, ¢5x7mm,Dip L2 I-shaped Inductor,680µH,0410,Dip Q1 Transistor, HFE 20-25 NPN, D13003, TO-126 Huawei PCB, ACT365_LED_01,Rev:A Jintong F1 R3 Chip Resistor, 300kΩ, 1W, 5% TY-OHM R5 Chip Resistor, 51.1kΩ, 0805,1% TY-OHM R6 Chip Resistor, 8.66kΩ, 0805, 1% TY-OHM R7,R8 Chip Resistor, 5MΩ, 0805 , 5% TY-OHM R9 Chip Resistor, 0.67Ω, 1206,1% TY-OHM R10 Chip Resistor, 330kΩ, 1/4W, 5% TY-OHM R11 Chip Resistor, 10Ω, 0805, 5% TY-OHM R12 Chip Resistor, 4.0kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10kΩ, 0805, 5% TY-OHM T1 Transformer, Lp=1.0mH, EE16, Vertical U1 IC, ACT365SH-T ,SOP-8 P1 Inductance Inductance between pin 2 1.0mH ± and pin 5 at 1VAC & 1kHz 7% 3 P1 Leakage Inductance Inductance between pins 2 and pin 5 with pins 4-1 and 8-10 shorted 75µH EFFICIENCY CV Regulation 380 360 340 320 300 280 260 240 220 200 115 230 264 Input voltage(V) Pin4 5 LINE AND LOAD REGULATION Core Reverse P1 10 10 8 S1 2 90 Transformer Specifica- SH2 50Hz, 1 minute, from Primary and Secondary walter TY-OHM NC Pin4 Pin5 Electrical Strength Typical performance Characteristics Chip Resistor, 22Ω, 0805, 5% P2 3kVAC 1 SoKa Fuse:3.15A 250V 3.6*10mm With Pigtail Pin4 Pin1 LIMITS SoKa R1,R4 Pin4 CONDITION PCB Layout PANJIT D4 PCB1 DESCRIPTION Io(mA) D1~D3 ITEM 2 NC 1 S1 NC P2 SH1 8 SH2 Pin2 NC Pin4 SH1 P1 4 Build up Core SH3 TERMINAL WINDING WIRE TURNS START FINISH SH1 4 NC P1 2 5 INSULATION TYPE SIZE × QTY LAYER THICK/WIDE LAYE R 14 2UEW 0.12Φ*4 1 0.025*8.5W 2 102 2UEW 0.23Φ*1 3 0.025*8.5W 2 0.12Φ*4 1 0.025*8.5W 2 SH2 4 NC 14 2UEW Reverse S1 8 10 23 TEX-E 0.35Φ*1 1 0.025*8.5W 2 P2 1 4 13 2UEW 0.12Φ*2 1 0.025*8.5W 2 SH3 core 4 3 conductor 0.15Φ*1 1 0.025*10 8 Note: SH1,SH2,and SH3 are shielding; P1 and P2 are Primary, S1 is Secondary (Bobbin: EE-16, Vertical). Copyright © 2014 Active-Semi International, Inc. - 16 - PFC TEST HARMONIC CURRENT EVALUATION KITS VIN ACT365-LED01 85-264VAC VO Io 26V 300-400mA www.active-semi.com Innovative PowerTM ACT365 DESIGN GUIDE Jun 2014 PAR30 7x1W LED Lighting Non-isolated Input Voltage Device LED(s) 85 - 264VAC ACT365 7 Output Voltage Power Output Transformer 26V 7.8W Topology EE16 Flyback Key Component Selection The maximum output current is decided by formula (1). 1 0.9 * 0.396 2 FSW IOUTCC LP ( ) ( ) (1) 2 RCS VOUTCC Lp is the transformer inductance value, Rcs is the current sense resistor, which is shown as R9 in the schematic. Fsw is the switching frequency, which design value is 75kHz. η is Operation and Application Figure 1 is the schematic of LED lighting using ACT365 to provide output power of 26V300mA with PF>0.77.This circuit is a typical flyback power supply which includes the AC rectified circuit(BD1,C2, C3),power drive circuit (BD pin, Q1),power factor rectified circuit (D1D3,C2,C3),secondary rectified circuit (D6, C7,C8) and the IC control circuit. ACT365 is a Primary Side Regulator (PSR) so that the power supply unit can regulate current and voltage without Opto-coupler. Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the base drive for the NPN transistor. Pin 1 is the switching pin. Pin 5 is the feedback pin that senses the output current and output voltage. Pin 6 is the peak current sense pin. Resistance of R10 determines the output DC cord compensation percentage. Through a patented PSR technology, this circuit can provide drivers for five(min), or seven (max) LED lights in series due to the wide VDD operation ranges. the overall system efficiency, which value is approximately equal to 75%. Voutcc is the output voltage, which setting is through the flyback voltage of auxiliary winding and the feedback resistor R5, R6 as shown in formula (2). VOUTCC VREF (1 R5 N ) S VSEC _ R R6 NAUX (2) Np/Ns/Naux (102/23/13) must be designed correctly to ensure it operates in DCM in all conditions. A design value Voutcc equal to 26V and Ioutcc_min equal to 300mA are used to do the design. Ns and Naux are number of turns of secondary and auxiliary of the transformer. VSEC_R is the forward voltage drop of the output rectifier diode at approximately 0.1A bias. The peak current limit is set by (0.396×0.9)/Rcs. Figure 1: Schematic of LED Lighting Driver R12 4k D3 1N4007 C7 47µF 50V R13 10kΩ C8 47µF 50V LED7 GND D4 FR107 T1 EE16 R7 5MΩ R8 5MΩ R10 330kΩ 8 1 BD 6 R1 22R C5 10µF/ 35V Copyright © 2014 Active-Semi International, Inc. D6 SB2B0 C4 1000pF/ 1kV Q1 13003 D2 1N4007 R4 22Ω N DB1 B6S LED1 R3 300kΩ D5 FR102 L2 680µH C1-2 0.1µF C1-1 0.1µF L1 1.5mH C3 22uF/400V C2 22µF/400V V+ D1 1N4007 F1 1A 250V L - 17 - VDD R5 51.1kΩ SW U1 ACT365 GND 2,4,7 FB 5 CS 3 R9 0.67Ω R6 8.66kΩ www.active-semi.com Innovative PowerTM ACT365 DESIGN GUIDE Jun 2014 Electrical Specifications Bill of Materials REF DESCRIPTION MFTR C1-1/2 X1 Capacitor,0.1µF/400V,13x6x11mm USE C2,C3 Capacitor,Electrolytic, 22µF/250V, 10x14mm KSC C4 Capacitor,Ceramic,1000pF/1KV, DIP POE C5 Capacitor,Electrolytic,10µF/35V, 5x11mm KSC C6 Capacitor,Ceramic,1000pF/50V,1206 POE Capacitor,Electrolytic, 47µF/50V, 6.3x12mm KSC C7,C8 C9 BD1 Y cap,1000pF/275V,Dip ITEM USE PANJIT D1~D3 Fast Recovery Rectifiers,1N4007, DO-41 Good-Ark D4 Fast Recovery Rectifier ,FR107,DO-41 Good-Ark D5 Fast Recovery Rectifier ,FR102,DO-41 Good-Ark D6 Efficiency Rectifiers, 300V/1A ,HER104, DO-41 Good-Ark L1 Axial Inductor,1.5mH, ¢5x7mm,Dip L2 I-shaped Inductor,680µH,0410,Dip Q1 Transistor, HFE 20-25 NPN, D13003, TO-126 Huawei PCB, ACT365_LED_01,Rev:A Jintong F1 CONDITION LIMITS 3kVAC 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary 2 P1+P2 Inductance Inductance between pin 2 2.0mH ± and pin 8 at 1VAC & 1kHz 7% 3 P1+P2 Leakage Inductance Inductance between pins 2 and pin8 with pins 4-1 shorted 75µH PCB Layout Bridge,B6S,600V/0.5A,MDI,SMD PCB1 DESCRIPTION SoKa SoKa Fuse:3.15A 250V 3.6*10mm With Pigtail walter R1,R4 Chip Resistor, 22Ω, 0805, 5% TY-OHM R3 Chip Resistor, 300kΩ, 1W, 5% TY-OHM R5 Chip Resistor, 51.1kΩ, 0805,1% TY-OHM R6 Chip Resistor, 8.66kΩ, 0805, 1% TY-OHM R7,R8 Chip Resistor, 5MΩ, 0805 , 5% TY-OHM R9 Chip Resistor, 0.67Ω, 1206,1% TY-OHM R10 Chip Resistor, 330kΩ, 1/4W, 5% TY-OHM R11 Chip Resistor, 10Ω, 0805, 5% TY-OHM R12 Chip Resistor, 4.0kΩ, 0805, 5% TY-OHM R13 Chip Resistor, 10kΩ, 0805, 5% TY-OHM T1 Transformer, Lp=1.0mH, EE16, Vertical U1 IC, ACT365SH-T ,SOP-8 Typical performance Characteristics Transformer Specification EFFICIENCY Pin4 5 LINE AND LOAD REGULATION Core Pin4 Pin4 Pin1 NC Pin4 P1 P3 P2 2 1 8 NC NC SH2 8 5 P2 SH1 SH2 Pin5 P1 Pin2 NC Pin4 P3 SH1 4 Core Build up SH3 TERMINAL WINDING WIRE TURNS PFC TEST INSULATION TYPE SIZE × QTY LAYER THICK/WIDE LAYE R 14 2UEW 0.12Φ*4 1 0.025*8.5W 2 5 80 2UEW 0.2Φ*1 2 0.025*8.5W 2 8 23 2UEW 0.35Φ*1 1 0.025*8.5W 2 4 NC 14 2UEW 0.12Φ*4 1 0.025*8.5W 2 S1 8 10 23 2UEW 0.35Φ*1 1 0.025*8.5W 2 P3 1 4 13 2UEW 0.12Φ*2 1 0.025*8.5W 2 SH3 core 4 3 conductor 0.15Φ*1 1 0.025*10 8 START FINISH SH1 4 NC P1 2 P2 5 SH2 Note: SH1,SH2,and SH3 are shielding; P1,P2 and P3 are Primary, (Bobbin: EE-16, Vertical). Copyright © 2014 Active-Semi International, Inc. - 18 - HARMONIC CURRENT EVALUATION KITS VIN ACT365-LED02 85-264VAC VO Io 26V 300-400mA www.active-semi.com ACT512 DESIGN GUIDE Innovative PowerTM Jun 2014 PAR38 7x3W LED Lighting Input Voltage Device LED(s) 85 - 264VAC ACT512 7 Output Voltage Power Output Transformer 24V 16.8W Topology EF20 Flyback Key Component Selection The maximum output current is decided by formula (1). Ioutcc 2.5 R16 R15 R12 // R13 (1) Its output voltage or number of LED is roughly decided by formula (2). Operation and Application Figure 1 is the schematic of LED lighting using ACT512 to provide output power of 24V700mA with PF>0.9.This circuit is a typical flyback power supply which includes the AC rectified circuit(D1D4,C1A, C1),power drive circuit (GATE pin, Q1),power factor rectified circuit (D9D11,C1A,C1),secondary rectified circuit (D8, C9,C10) and the IC control circuit. ACT512 is a CCM & Quasi-Resonant PWM Controller . Pin 4 and Pin 2 are the VDD and ground pins to provide power for the IC. Pin 3 is the gate drive pin for the MOSFET. Pin 1 is the Current Sense Pin. Pin 5 is the Valley Detector Pin. Pin 6 is the Feedback Pin. R21 R20 R21 Voutcv 2.5 * * Io * R12 // R13 R 20 R 20 (2) The transformer design procedure can refer to the design example section of ACT512 DS. In this design, Np/Ns/Naux is set as 80/36/25 to ensure it operates in CCM to improve efficiency. Independent Output Short Protection, OTP, OVP, Brown Out Protection, Rcs Short/Open Protection, Transformer Winding Short Protection, Output Diode Short/Open Protection, Open Loop Protection, are integrated to protect damage on circuits and LED die itself. This circuit can provide drivers for five (min), or seven (max) LED lights in series due to the wide VDD operation ranges. Accurate current control is through R12/R13 and LM358 control circuit. Figure 1: Schematic of LED Lighting Driver D10 D9 D1-D4 C1 22µF 250V C3 R2 510kΩ 1000pF C8 1000pF/200V R24 10Ω Bead T3.5*9 D5 RS1M R4 100Ω D8 SB10200 V+ D11 C1A 22µF 250V L1 UU9.8 30mH R6 1.1Ω R1 1MΩ Q1 4N65 3 1 TVS 10471 F1 2A 250Vac NTC 5RS5C 4 GATE C9 470µF 35V D6 RS1M R2 1MΩ D7 L4148 R9 330Ω CX1 0.1uF 400V LF2 200µH L2 3uH R11 3.3kΩ U1 5 CS ACT512US-T VDET SOT23-6 FB GND 6 2 C4 6.8µF 35V U2B L N Copyright © 2014 Active-Semi International, Inc. U2A R14 18kΩ D9 C7 100pF 50V R21 88.7kΩ R20 10kΩ R8 8.25kΩ CY1 2200pF 400Vac - 19 - GND U4 TL431A C11 0.1µF R7 54.9kΩ VDD R12 0.22Ω R13 0.22Ω R17 5KΩ R5 4.7Ω R10 22Ω C10 470µF 35V 8 7 6 5 R23 R19 20kΩ 1kΩ C12 0.1µF 50V R18 20kΩ 1 OUT1 2 IN1OUT2 VCC IN2- IN1+ IN2+ GND 3 4 R22 510Ω R15 14KΩ R16 470Ω U3 LM358 www.active-semi.com Innovative PowerTM ACT512 DESIGN GUIDE Jun 2014 Electrical Specifications Bill of Materials REF DESCRIPTION MFTR IC1 IC, ACT512, SOT23-6 Active-Semi C1A Capacitor, Electrolytic, 22µF/250V, 10 × 16mm KSC C1 Capacitor, Electrolytic,22µF/250V, 10 × 16mm KSC C3 Capacitor, Ceramic,1000pF/0.5KV,SMD POE C4 Capacitor, Electrolytic,6.8µF/35V,5*11mm KSC C7 Capacitor, Ceramic, 1000PF/50V,0805,SMD POE C8 Capacitor, Ceramic, 1000PF/100V,0805,SMD POE C9,C10 Capacitor, Electrolytic,470µF/35V,8*16mm POE C11,C12 Capacitor, Ceramic,0.1uF/50V,0805,SMD POE D1-D4,D9-D11 Diode, 1N4007,1A1000V DO-41 Good-Ark D5,D6 RS1M SMD Good-Ark D7 Diode L4148 SMD Good-Ark D8 Diode, Schottky, 200V/10A, SBR10200, DO-220 Good-Ark LF1 CM Inductor, 20mH, UU9.8 SoKa LF2 Axial Inductor, 0.55*5T, 5*7,Dip 200uH SoKa L2 DM Inductor, 3µH, R5 SoKa Q1 Mosfet Transisor, 04N65, TO-220 ST PCB1 PCB, L*W*T =49x68x1.6mm, Cem-1, Rev:A Jintong F1 Fusible, 2A/250V TY-OHM R1,R2 Chip Resistor,1M, SMD 0805, 5% TY-OHM R3 metal Resistor,400K Ω,1206,5% TY-OHM R4 Chip Resistor, 100Ω, 0805, 5% TY-OHM R5 Chip Resistor,4.7Ω, 0805, 5% TY-OHM R6 Chip Resistor,1Ω,1206, 1% TY-OHM R7 Chip Resistor, 78KΩ, 0805, 1% TY-OHM R8 Chip Resistor, 11.7KΩ, 0805, 1% TY-OHM R9 Chip Resistor, 330Ω,0805, 5% TY-OHM R10 Chip Resistor, 22Ω,0805, 5% TY-OHM R11 Chip Resistor, 6KΩ,0805, 5% TY-OHM R12,R13 Chip Resistor, 0.22Ω, 1206, 5% TY-OHM R14 Chip Resistor, 18KΩ, 0805, 5% TY-OHM R15 Chip Resistor,14KΩ, 0805,5% TY-OHM R16 Chip Resistor,510Ω, 0805,1% TY-OHM R17 Chip Resistor,5KΩ, 0805, 5% TY-OHM R18,R23 Chip Resistor,20KΩ, 0805, 5% TY-OHM R19 Chip Resistor,1KΩ, 0805, 5% TY-OHM R20 Chip Resistor,10KΩ, 0805,1% TY-OHM R21 Chip Resistor,86KΩ, 0805,1% TY-OHM R22 Chip Resistor,510Ω, 0805,5% TY-OHM R24 Chip Resistor,22Ω, 1206,5% TY-OHM T1 EF20 ACT CX1 X capacitance, 0.1µF/400V,X1 NTC Thermistor, SC053 TVS Varistor, 7D471 CY1 Y capacitance, 1000pF/400V,Y1 SEC IC2 Opto-coupler, PC817C CTR=200 dip-4 Sharp IC3 IC LM358 SOP-8 ST IC4 Voltage Regulator, TL431A, Vref=2.5V TO-92 ST ITEM DESCRIPTION CONDITION LIMITS 3kVAC 1 Electrical Strength 50Hz, 1 minute, from Primary and Secondary 2 P1 Inductance Inductance between pin 2 0.82mH and pin 3 at 1VAC & 1kHz ± 7% 3 P1 Leakage Inductance Inductance between pins 2 and pin3 with pins 4-1 shorted 75µH PCB Layout Typical performance Characteristics EFFICIENCY LINE AND LOAD REGULATION Transformer Specification 2 10 P3 5 2 5 1 4 3 9 10 NC SH1 9 NC 4 SH1 S1 1 5 3 S1 P1 P3 P2 P2 P1 1 PFC TEST Build up TERMINAL WINDING WIRE TURNS INSULATION TYPE SIZE × QTY LAYER THICK/WIDE LAYE R 0.28Φ*1 1 0.025*11W 2 START FINISH P1 3 5 40 2UEW SH1 NC 1 0.9 copper 10mm 1 0.025*11W S1 9 10 36 TEX-E 0.4Φ*1 2 0.025*11W 2 P2 4 1 25 2UEW 0.15Φ*2 1 0.025*11W 2 P3 5 2 40 2UEW 0.28Φ*1 1 0.025*11W 2 SH2 core 1 3 conductor 0.15Φ*1 1 0.025*10 8 Note: SH1,SH2are shielding; P1,P2 and P3 are Primary, (Bobbin: EF-20, level). Copyright © 2014 Active-Semi International, Inc. - 20 - HARMONIC CURRENT EVALUATION KITS VIN ACT512-LED01 85-264VAC VO Io 24V 700-720mA www.active-semi.com Innovative PowerTM ACT111A High Efficiency, Low Cost HB LED Lighting Input Voltage LED # Output Current VFB Topology 4.8 – 30VDC 1-6 1.5A 100mV Buck Circuit Bottom View Circuit Top View Key Component Selection An inductor with RMS rating greater than load current and its saturation current at least 30% higher should be used. Inductance value is selected to make its ripple current 20-30% of the load current. A Schottky diode (D5) is usually used for better efficiency as long as the breakdown voltage can withstand the maximum output voltage. The forward current rating of the diode must Design Features be at least equal to the maximum LED current. 95% Efficiency 4.8V to 30V Input and up to 1.5A Output 1.4 MHz Switching & Small SOT23-6 Package PWM (0-100%, 0.1-10kHz) Dimming Thermal Shutdown & Short Circuit Protection For AC input, if a conventional step-down line trans- former is used, a low cost IN4001can be used for D1-D4. However, if a high frequency electronic transformer is used, a Schottky diode such as SS14 should be used for Operation and Application high efficiency operation. For input and output capaci- The bridge rectifier is for AC input only. The DC input is directly connected to IN and ground. The ACT111A has an under-voltage lockout (UVLO) at 4.0V with 250mV hysteresis. When input voltage falls below 4.0V, SW stops tors, small size and low ESR ceramic capacitor is preferred. PC Board Layout Guidance switching. The device is activated as input voltage goes Place input capacitor (C1) to IN pin, inductor (L1) and higher than 4.2V. diode (D5) to SW pin as close as possible to reduce the The LED output current is sensed by a resistor in series voltage ringing at these pins. Place the current sense with the LED. The ACT111A precisely regulates the LED resistor (R2 ) close to FB pin. Minimize ground noise by current by the internal EA and 0.1V reference. The aver- connecting high current ground returns, the input capaci- age LED current is determined by the equation: ILED =0.1V/ tor ground lead, and the output filter ground lead to a RSENSE. single point (star ground configuration). There are two The ACT111A allows dimming with a PWM signal at the power loops in normal operation, one is formed when the DIM pin. A signal level above 1.5V enables switching and SW is high and the high current flows through input ca- turns LED on. To turn off the LED current, the signal level pacitor (C1), internal MOSFET, inductor(L1), LEDs, has to be below 1.52V. The dimming signal frequency RSENSE(R2) to ground. The other loop is through inductor range is from 100Hz to 10kHz.A 200kΩ resistor is needed (L1), LEDs, RSENSE(R2), ground to diode(D5). Make these to connect between FB pin RSENSE. A 100pF capacitor is loop areas as small as possible to minimize noise inter- recommended to connect from the FB pin to ground. action. Copyright © 2014 Active-Semi International, Inc. - 21 - www.active-semi.com Innovative PowerTM ACT111A High Efficiency, Low Cost HB LED Lighting Schematic ( VIN=12VDC or AC, 3x350mA LEDs ) Bill of Materials PCB Top Layer Ref. Description Mftr C1 Capacitor Tantalum,100uF/16V, D Case AVX C2 Capacitor, Ceramic,0.01uF/50V,0603 POE C3 Capacitor, Ceramic,100pF/25V,0603 POE C4 Capacitor Ceramic,10uF/16V,1206 AVX D1-D4 Diode shottoky, 40V/1A, SS14, SMA PANJIT D5 Schottky Barrier Rectifier,SR24,40V/2.0A,SMB PANJIT ZD1 Diode Zener,GLZ13A,13V, 0.5W, MINI-MELF PANJIT R1 Meter Film Resistor, 30KΩ,0603, 5% TY-OHM R2 Meter Film Resistor, 0.28Ω,1206, 1% TY-OHM R4 Meter Film Resistor, 510Ω,1206, 5% TY-OHM L1 SMD Power Inductor,SR0604220ML,10uH,±20% QianRu U1 IC,ACT111,SOT23-6 Active Typical performance characteristics PCB Bottom Layer Copyright © 2014 Active-Semi International, Inc. - 22 - www.active-semi.com