AN204 AP3983 (PSR Switcher) + AL1794 (4-Channel Linear CCR LED Driver) 3-Channel Warm Dimming (WD) / 3-Channel Tunable Color (TC) Smart Connected Light Bulb (SCL) Reference Design GENERAL DESCRIPTION The emerging Smart Connected Light (SCL) Bulbs, as Internet Of Things (IoT) devices in Smart Home environment, are characterized by integration of wireless-connectivity microcontroller (MCU) in LED light bulbs. Users can manage LED light bulbs through smart phone APPs to achieve the following needs: Energy saving (through dimming of brightness) - 1-channel Dimmable White (1-ch DW) Light quality management – 2-channel Tunable White (2-ch TW) Entertainment lighting – 3-channel Tunable Color (3-ch TC) or 4-channel White+RGB (4-ch W+RGB) Typical functional block diagram of SCL bulbs consists of: AC-DC Power Conversion LED Driver Emitter Module Wireless MCU Connectivity This application note describes the complete reference design of a 6.5W PAR16 ZigBee-Enabled 3channel Warm Dimming (WD) and Tunable Color (TC) SCL bulbs for both commercial and residential lighting applications. It serves as a good starting point for system designers to further customize SCL bulb design to their desired performance and cost consideration for similar products. KEY SPECIFICATION Model_#1: Model_#2: P16-DD-LE-LO-LD-3WD P16-DD-LE-LO-LD-3TC Lamp Shape: PAR16 Operating Power: 6.5W Operating Voltage: 100V-240V Frequency: 50/60Hz Average Lifetime: 25,000Hrs Bulb Base: E26/E27 Lumen: > 250 lumens CCT Range: Warm Dimming Tunable Color 1,900K to 3,000K (WD) 2,000K to 5,500K (TC) CRI: 90Ra Wireless: Dimension (L*D): ZigBee (Atmel SAM R21) 50mm x 73.5mm AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 1 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 FUNCTIONAL BLOCK DIAGRAM LED Emitter AC AC-DC Power Conversion and Power Management Constant Voltage LED Driver Circuit Constant Current and PWM Controller Constant Current Module < PWM Control Status > 3.3V DC Wireless Command Input Wireless Connectivity Module q ACDC Controller – AP3983C q LED Driver and PWM Dimming – AL1794 q ULDO Regulator – AP2204K Figure 1 - Functional Block Diagram for Smart Connected Light Bulb A typical SCL bulb (Figure 1) consists of four major functional blocks: 1) AC-DC Power Conversion - It converts AC input to one or multiple desired output DC Constant Voltages (CV). For a SCL bulb, two or more CVs might be required to better support various DC power requirements from Emitters and Wireless Connectivity MCU. 2) LED Driver - Taking CV inputs to relevant LED driver channels, the LED driver circuitry generates one or more Constant Current (CC) to drive associated LED emitters. 3) Wireless Connectivity Module - The Wireless Connectivity Module consists of an intelligent MCU and RF circuitry to connect a SCL bulb either directly with smartphones or indirectly through WiFi/ZigBee hub, based on a communication protocol (e.g. Bluetooth/BLE, ZigBee, etc.) 4) LED Emitter Module - This is the light source for the SCL bulb. Driven by PWM dimming signal(s) from Wireless Connectivity MCU, emitters on the LED Emitter Module are properly mixed to generate desired light output - either brightness adjustment, Corellated Color Temperature (CCT) tuning, or color mixing. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 2 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 APPLICATION DESCRIPTION Power Board (PB) Application Description The PB design (Figure 2) is based on AP3983C PSR AC/DC Switcher IC (with integrated MOSFET referred in the Key Component Section) to be capable of power rating up to 7.5W (SO-7 Package). To support both emitter strings and attached MCU power, the PB outputs two CVs: Warm Dimming (WD) Lamp 1) VLED1 - 8.2V for for driving emitter strings of RED, 3-die- in-serial 2) VLED2 – 7.4V for driving emitter strings of GW (Green-ish White), 2-die-in-seiral and BW (Blue-ish White), 2-die-in-serial, Emitters Tunable Color (TC) Lamp 1) VLED1 - 11.0V for driving emitter strings of G (Lime-Green White), 3-die-in-serial 2) VLED2 – 7.4V for driving emitter strings of RED, 2-die- in-serial, and for emitter stings of Blue, 2die-in-serial. Note that VLED1 and VLED2 supply constant voltages to attached emitter strings with sufficient voltage headroom (LEDx) for voltage regulation of AL179X (LED Driver IC) to properly function. The maximum VF (Forward Voltage) for Red, Green-ish White and Blue-ish White emitters is 3.5V for 350mA maximum channel current. The maximum VF for RED emitters is 2.6V for 350mA maximum channel current. For 350mA channel current, the maximum LEDx (voltage headroom) is 0.4V. The rqeuired constant voltage to drive wireless MCU (3.3V) is generated from an LDO (AL2204) with input from VLED2 (7.4V). Figure 2 - AP3983C Power Board (42mm x 30mm, Power Boards) For the design principles and design examples of AP3983C power board (e.g. Swithcing Frequency, Transformer Design, Feedback Resistors Nework Design), please refer to Diodes' Application Note of AP3983. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 3 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Emitter Module Board (EMB) Application Description Two types of Emitters matching specific needs of WD and TC applications: WD EMB (Figure 3.a) - Suitable for CCT range 3,000K to 1,900K. Emitter Structure - R (3 dies in serial), GW (2 dies in serial ) and BW (2 dies in serial) in parallel strings Figure 3.a - 3-Ch WD Emitter Module TC EMB (Figure 3.b) - Suitable for CCT range 6,500K to 2,000K. Emitter Structure - R (2 dies in serial), G (3 dies in serial ) and B (2 dies in serial) in parallel strings Figure 3.b - 3-Ch TC Emitter Module For detailed emitter specification, please refer to Appendix II (LED Engin Emitters) Lens Application Description PAR16 lamps feature dierctional lighting with narrow beam angle. To create a narrow beam angle as well as to provide much superior color mixing, a Lens is used for achieving both goals (Figure 4). The key parameters of the lens are as shown below: FWHM CBCP - Full Width at Half Maximum Center Beam Candlepower FWHM FW10% Efficiency CBCP (cd/lm) 27° 57° 94% 2.6 Figure 4 - Lens for PAR16 Lamp AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 4 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 LED Driver and ZigBee Board (LZB) Application Description A ZigBee IC, Antenna as well as LED driver (AL1794, 4-Channel Linear CCR LED driver) co-exist in the same PCB (Figure 5). In this 3-Ch WD/TC SCL bulb design, the REF (reference current setting resistor) for LED Driver circuit is 8.5KΩ to regulate a total channel current around 350mA for both Channel 1 and Channel 2 and 262.5mA for Channel 3. Figure 5 - Wireless & LED Driver Board (41.2mm Outside Ring, 18mm Inside Ring) AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 5 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 PERFORMANCE TESTING Though with different target CCT Ranges and quality of white light, the PAR16 3-ch WD is comparable to OSRAM's PAR16 2-Channel Tunable White Lightify lamp (http://led.osram.com/led_com/lightify/index.jsp?mkturl=lightify). The key feature competitive analysis is summarized in Table 1a. Similarly, the PAR16 3-ch TC is comparable to Philips' HUE Tunable Color lamp (http://www2.meethue.com/en-us/the-range/hue/). A key feature competitive analysis is summarized in Table 1b. PAR16 WARM DIMMING LAMP COMPETITIVE ANALYSIS NO Benchmark Item LIGHTIFY TUNABLE WHITE LiteON PAR16 (Warm Dimming) 1 Input AC Voltage (V) 220 - 240 90 - 260 2 Power (W) 6 6.5 3 Power Factor 0.56 (230Vac) 0.85 (120Vac) 0.77 (230Vac) 5 Standby Power (W) 0.44W (230Vac) 0.15W (120Vac) 0.4W (230Vac) 6 Start-Up Time (Second) N/A from Wall Switch 0.4 second from Standby Mode 1.2 second from Wall Switch 0.4 second from Standby Mode 7 Emitter Module Individual Emitters (2,700K W + 6,500K W) 7mm x 7mm 7-die single Emitter 8 CCT Range (°K) 2,700K - 6,500K 1,900K - 3,000K 9 CCT White 10 CRI 81 @ 2,800K 90 @ 3,000K 11 Luminous Flux Φv (lm) 481lm @ 2,800K (RT) 428lm @ 2,800K (hot) 300lm (RT) 12 Beam Angle (°) 32 27 13 Iluminance Ev (Flux 2 lm/m ) 966 @ 2,800K 884 14 Efficacy (lm/W) 80 lm/W @ 2,800K 46 lm/W @ 3,000K 15 Wireless Connectivity ZigBee ZigBee 16 Dimension (L x D in mm) 58x50 73.5x50 Mixing 2,700K+ 6,500K White - Linear Warm Dimming - True White by Mixing Approximation Wg-Wb-R Table 1a - Competitive Analysis Summary of PAR16 3-ch WD SCL Bulbs AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 6 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 PAR16 TUNABLE COLOR LAMP COMPETITIVE ANALYSIS NO Benchmark Item HUE Tunable Color PAR16 PAR16 (Tunable Color) 1 Input AC Voltage (V) 120 90 - 260 2 Power (W) 6.5 6.5 3 Power Factor 0.55 0.856 (120Vac) 0.772 (230Vac) 5 Standby Power (W) 0.45W 0.31W (120Vac) 0.47W (230Vac) 6 Start-Up Time (Second) 2.0second from Wall Switch 0.5 second from Standby Mode 1.2 second from Wall Switch 0.4 second from Standby Mode 7 Emitter Module Individual Emitters (G3-R2-B2) 7mm x 7mm 7-die single Emitter 8 CCT Range (°K) 2,000K - 6,500K 2,000K - 5,500K 9 CCT White Mixing RGB Mixing RGB 10 CRI >80 CRI, 2,000K - 4,000K 90 @ 2,000K 89 @ 2,700K 85 @ 3,000K 77 @ 4,000K 71 @ 5,500K 11 Luminous Flux Φv (lm) *1 195 lm @ 2,700K (Default StartUp) *2 145 lm @ 2,000K, *3 210 lm @ 3,000K, *4 300 lm @ 4,000K, *5 230 lm @ 6,500K (estimate) (6.5W) *1 228 lm @ 2,700K *2 190 lm @ 2,000K, *3 233 lm @ 3,000K, *4 245 lm @ 4,000K, *5 255 lm @ 5,500K (measured) 175lm @ 4000K (4.5W) 12 Beam Angle (°) 38 27 13 Efficacy (lm/W) 38 lm/W @ 4,000K 38 lm/W @ 4,000K (estimate) 14 Wireless Connectivity ZigBee ZigBee 15 Dimension (L x D in mm) 50.8x50.8 73.5x50 Table 1b - Competitive Analysis Summary of PAR16 3-ch TC SCL Bulbs AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 7 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 SYSTEM DESIGN CONSIDERATIONS AND TRADE-OFFS When design a production-worthy SCL bulb, the system designers have many considerations: 1) Input Voltage Range 2) Power Factor (PF) 3) Efficiency 4) Standby Power 5) Start-Up Time 6) Improving Lumen Output 7) Thermal Management While 3-ch WD/TC SCL bulbs are designed for full range voltage input, system designs could optimize components for single voltage application (e.g. 120V or 230V). For example, more cost-effective components could be used for 120V-only SCL bulb, including: 1) BD201 (MB06S, see Figure 9 on Page 11) 2) Passive Valley Fill (PVF) Circuit: C201, C202, D201, D202 and D203 (see Figure 9 on Page 11). + C201 AC D203 BD201 D202 D201 + C202 Figure 6 - Bridge and Valley Fill Circuit AP3983C (SO-8), with integrated MOSFET switch, has its advantages of supporting a cost-effective power board design. The relative small ripple of output voltage for CVs of AP3983C (Vpeak-to-peak ripple < 2.9% of the CV of Emitter Strings) is ideal to support linear Constant Current Regulation (CCR) based LED driver, such as AL1792, with optimal voltage headroom for attached LED emitter strings. Per Energy Star Compliance requirement, the Power Factor (PF) for over 5W light bulb need to be over 0.7. As the AP3983C does not have built-in Active Power Factor circuitry, a PVF Circuit, consists of C201, C202. D201, D202 and D203 is designed to achieve desired PF over 0.7. A high PF value could be achieved by using larger capacitors (C201 and C202), but at the expenses of longer start-up time, PCB space and cost. The system designers need to select the right balance for the PF value and other considerations. The system efficiency of 6.5W typical 3-ch PAR16 WD/TC bulbs need to be above 70% based on the proposed two-stage designs. For the Power stage (first stage) efficiency, it is designed to achieve over 75%. While fixedCCT on-off LED light bulb will have no power consumption when turned off at standby mode, a SCL bulb consumes non-trivial standby power due to constant-on for wireless module connectivity. To save energy consumed during the standby mode, it recommded to stay within 0.5W when in the standby mode for the entire SCL bulb. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 8 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Key relevant circuitry which impact efficiency and standby power consuption include: 1) CV Output Voltages (PV1, PV2 - used to generate 3.3V for MCU Power). 2) Pre-loading circuit (R213, R214 and R216, see Figure 9 on Page 11) to prevent spurious output voltage at no load situation for one CV output, but sudden current is drawn by the other CV output. 3) Low VF Drop Super Barrier Rectifier (D211 and D212, see Figure 9 on Page 11) 4) Start-Up Circuit R201 (see Figure 9 on Page 11). An alternative quick dynsmic startup circuit can be used to replace the resistor start-up circuit to shorten start-up time without static standby power consumptino (Figure 7). During the AC power initial input, Transistor Q1 is turned ON to charge VCC input to AP3983C. Q1 will be shut off after initial start-up time until shut off by returning path from the auxiliary winding when VCC is highter than one threshold voltage below 18V where the Zener diode is clamped at. HV R2 R1 Q1 BSS127 ZD1 DFLZ18 VCC Figure 7 - Dynamic Fast Start-Up Circuit Improve Lumen Output with Unused Channel 4 AL1794, a 4-channel LED driver, has a fixed channel current ratio of 1:1:0.75:0.25 for Channel 1, 2, 3 and 4 respectively. In the current reference design of PAR16 lamps, only the first 3 LED driver channels of AL1794 are used. The Channel 4 LED driver can be used in parallel to Channel 1, 2 or 3 to enhance lumen output to desired effects. For example, enhancing GREEN channel with Channel 4 driver will enhance the overall lumen output of the TC lamp. Adding Channel 4 to the RED channel will result in stronger warm light output. Thermal Management Design Suggestion Thermal management is a critical design consieration as it impacts safety and reliability of the SCL bulbs. Among many good practices used in the power board design for managing thermal issues of SCL bulbs, system designers also need to fine tune the CV output to compensate for VF fluctuation due to temperature effect. Depending on thermal characteristics of emitters, V F drops around 5% to 10% range when temperature is increased from 25°C to 125°C. The proposed design is based on a low-cost open-loop CV fine tuning approach by adopting a Negative Temperature Coeffient (NTC) resistor 10K (RT201, Figure 9). Pin4 of Transformer T201 AP3983C R209 FB R205 RT201 R210 R206 Figure 8 - Thermal Management Circuit AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 9 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Also, VF matching resistors are used to help matching VF matching between strings attached to a CV source (R3 and R4, see Figure 11.b Page 13). The main purpose is to distribute unused LED power between the resistor and AL1794 less the unused LED power is all absorbed by AL1794 only. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 10 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 COMPLETE DESIGN SCHEMATICS R211 C211 L F201 L201 D211 10R,1WS C203 1 1 MOV1 CX201 4 - ~ R203 + C201 + 7 D203 C213 3 R213 PV1 9 D202 2 BD201 R201 GND R212 C212 3 2 N J1A 1 2 ~ R216 D204 R204 D205 PV2 4 VADJ + C202 D201 D212 4 10 5 6 CON4*1_2mm + C204 C214 R209 CS R205 CPC RT201 2 R210 7 GND R208 R206 1 R207 C251 5,6 D FB 4 R214 3 VCC U201 AP3983C/SO-7 T201 EE13/5P+5P CY 201 C205 Figure 9 - AP3983C Power Board Schematics PV2 GND PV2 VADJ C3 C4 VIN 1 3 2 3 EN U1 VOUT GND C1 PV1 2 1 J1 ADJ/NC 5 4 P3V3 PV1 C5 AP2204K-3.3TRG1 R1 P3V3 4 PV1ADC 2417SJ-04 R2 LEDPG NTC FAULTB R3 U2 AL1794AFE-13 1 LEDEN 2 PWM4 3 PWM3 R4 C6 4 PWM2 5 PWM1 6 R5 C7 VIN PWM4 REF PWM3 FAULTB PWM2 LEDPG PWM1 LED4 LED1 LED3 LED2 GND 14 13 J2 12 8 R6 C2 11 7 10 6 9 5 8 4 15 7 EN PGND LEDPG R7 3 2 1 NTC GND LED4 LED3 LED2 LED1 PV2 PV1 A2002WV2-8P Figure 10.a - LED Driver - AL1794 Schematics AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 11 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Xtal XTAL2 XTAL1 U3 P3V3 C10 C11 0.022 nF/50 V 2.2 uF/10 V GNDA GNDA 8 PWM1 11 PWM2 12 6 C23 100 nF/16 VGND 14 PWM3 15 PWM4 16 G Q C20 C21 @0.022 nF/50 V @0.022 nF/50 V 2 RF50B 1 2 G R G 1 7 13 CON1 MS-156C 3 4 2 0.022 nF/50 V 6 AVDD R80 10 Kohm 10 T1 3 GND G ANT1 @SC-251B C19 5 P3V3A P3V3 5 GNDA 1 RF50A GNDA R79 10 Kohm 9 C14 C15 0.022 nF/50 V 100 nF/16 V ANT 4 U G6 G2 G5 BA BB 6 5 GNDA 4 RFP 2450BM15A0015E RFN GNDA 17 18 19 20 R81 10 Kohm 21 R82 10 Kohm 22 GNDA GNDA GNDA GNDA GNDA GNDA R83 10 Kohm 23 R84 10 Kohm 24 49 GNDA AIN10/Y8/SC5_0PB02 XTAL2 SC1_3/TCC1_1PA31 XTAL1 SC1_2/TCC1_0/SWCLKPA30 GNDANA5 VDDIN VDDANA VDDCORE AVDD GND42 GNDANA8 SC3_1 PA28 VREFB/AIN4/AIN0/Y2/SC0_0/TCC0_0 PA04 RESET_ AIN5/AIN1/Y3/SC0_1/TCC0_1 PA05 AIN6/AIN2/Y4/SC0_2/TCC1_0 PA06 AIN7/AIN3/Y5/SC0_3/TCC1_1 PA07 VDDIO13 SC3_0 PA27 SC5_3 PB23 SC5_2 PB22 VDDIO36 GND14 GND35 AIN16/X0/SC0_0/SC2_0/TCC0_0/FEC0 SC3_3/SC5_3/TC5_1/TCC1_3/USB_DPPA25 AIN17/X1/SC0_1/SC2_1/TCC0_1/FEC1 PA09 SC3_2/SC5_2/TC5_0/TCC1_2/USB_DMPA24 PA08 GNDANA17X11/SC3_1/SC5_1/TC4_1/TCC0_5PA23 RFP X10/SC3_0/SC5_0/TC4_0/TCC0_4PA22 RFN DVDD GNDANA20 GND29 SC2_0/TCC2_0/FEC2 PA12 X7/SC1_3/SC3_3/TC3_1/TCC0_3PA19 SC2_1/TCC2_1/FEC3 PA13 X6/SC1_2/SC3_2/SC3_0/TCC0_2PA18 SC2_2/TC3_0/FEC4 PA14 X5/SC1_1/SC3_1/TCC2_1/TCC0_1PA17 SC2_3/TC3_1/FEC5 PA15 X4/SC1_0/SC3_0/TCC2_0/TCC0_0PA16 47 NTC 3 46 SWDIO 45 SWDCLK 44 P3V3 43 VDDCORE 42 Y1 E2SB16.0000F09G11 GND R86 10 Kohm 40 RESET_ 39 LEDEN 38 FAULTB 37 LEDPG C12 100 nF/16 V C16 100 nF/16 V P3V3 C13 2.2 uF/10 V Debug J3 GND 1 VTREF SWDIO 3 RXD 33 C22 100 nF/16 V TXD GND3 SWDCLK 5 7 32 VADJ 31 C9 GND GND GND 34 GND P3V3 36 35 GND C8 P3V3 GND 41 1 0.01 nF/50 V 0 ohm 3 XTAL1 SC1_1/TCC2_1 PA01 AIN11/Y9/SC5_1PB03 PV1ADC 0.01 nF/50 V R10 XTAL2 PA00 48 4 R78 10 Kohm 2 SC1_0/TCC2_0 2 R77 10 Kohm 1 9 GND R85 10 Kohm GND5 NC6 NC7 NC8 NC9 RESET_ 2 SWDIO 4 SWDCLK 6 R87 0 ohm RXD 8 R88 0 ohm TXD 10 RESET_ 222804-00205 30 Cortex Debug DVDD 29 GND 28 EESCLK 27 EEMOSI 26 EESS_ 25 EEMISO C18 100 nF/16 V R8 100 Kohm P3V3 GND GND PAD ATSAMR21G18A-MF GND P3V3 SPI Flash GND Connect all GND pins to center pad. Connections not in netlist, use plain lines. Connect all GNDA pins to center pad. GNDA P3V3 R9 100 Kohm GND EESS_ EEMISO 1 2 3 4 P3V3 C17 100 nF/16 V U4 MX25L4006EM1I-12G 8 GND /CS VCC 7 DO /HOLD 6 EESCLK /WP CLK 5 EEMOSI GND DI GND Figure 10.b - LED Driver - Atmel SAM R21 ZigBee Module Schematics JP3 5 5 6 7 8 D3K_R 25 D4A_B 19 20 NC19 D4K_B 21 D5A_R B G D7A_G NC13 NC7 t D3A_R R PAD 7 RT1 NTC 22 R R2 HDR200P8 NC22 NC16 R1 6 D2K_B D1K_R NC4 D6K_G 17 16 15 14 13 NC12 4 G B 18 12 NTC D2A_B D7K_G GND 4 11 LED4 3 NC10 LED3 JP5 3 JP2 NC18 R 10 LED2 2 D1A_R D5K_R PV2 LED1 1 9 2 PV1 D6A_G J1 NC1 8 1 24 E1 LZ7-WD322 23 JP4 JP6 JP7 JP1 Figure 11.a - 3-Ch Warm Dimming Emitter Module Schematics AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 12 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 JP3 J2 2 D2A_B 4 4 19 20 NC19 D4K_B 21 D3K_G 22 NC22 D2K_B R B 3 NC4 G D3A_G G 6 25 D4A_B B PAD NC13 R2 7 NC7 A2002WV2-8P RT1 NTC t D7K_R 17 16 15 14 13 NC12 8 D5K_G 18 12 6 7 R D7A_R 5 D6A_R NC16 R1 5 JP2 NC18 G 11 NTC D1K_G NC10 GND 3 10 LED4 JP6 D5A_G LED3 JP8 JP4 9 LED2 JP7 2 D6K_R PV2 LED1 1 NC1 8 PV1 D1A_G 1 24 E1 LZ7-CT232 23 JP5 R3 R4 JP1 Figure 11.b - 3-Ch Tunable Color Emitter Module Schematics AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 13 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 KEY COMPONENTS AP3983C - AC/DC Controller AP3983C IC PIN OUT ASSIGNMENT Primary Side control for Eliminating Opto-coupler and Secondary CV/CC Control Circuitry Built-In HV power MOSFET with 650V BVDSS Valley-turn on to reduce switching loss Up to 80KHz operating frequency at full load for compact size application Piece-wise frequency reduction to enhance conversion efficiency and suppress audio noise ±5% constant voltage accuracy ±7% constant current accuracy Open Circuit Protection (OCP), Overall Voltage Protection (OVP), Over Temperature Protection (OTP) Short Circuit Protection (SCP) with hiccup 3-Segment Drive Current for Radiative EMI Suppression Pin Name Symbol Descriptions SO-7 / PDIP-7 CPC 1 This pin is connected a capacitor to GND to serve as a cable compensation function. Additional resistor in parallel with the capacitor will weaken cable compensation to meet cable-less applications. FB 2 The voltage feedback is from Auxiliary winding. VCC 3 This pin receives rectified voltage from the Auxiliary winding of the transformer. CS 4 It is used for current sense from primary side of the transformer. D 5, 6 GND 7 AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 The pin is connected with an internal power MOSFET's drain. The pin is the signal reference ground. 14 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 AL1791/2/3/4 - LED Driver Controller AL1791/2/3/4 IC PIN OUT ASSIGNMENT EN 1 14 VIN PWM4/GND 2 13 REF PWM3/GND 3 12 FAULTB PWM2/GND 4 11 LEDPG PWM1 5 10 LED4/GND LED1 6 9 LED3/GND LED2/GND 7 8 GND Input Voltage Range: 6.5V to 30V 1/2/3/4-channel LED drivers: independent Analog or PWM dimming control for each channel Reference Current: Adjustable by an external reference resistor Ratio-optimized currents for 4 independent LED channels (AL1794 only): Suitable for Tunable White and Tunable Color Low Standby Power: With EN pin E-flicker free High Frequency PWM dimming with Deep Dimming Capability: Support 10KHz down to 1.0%, 4KHz down to 0.4%, or 1KHz down to 0.1% Internal Protections: Under Voltage Lockout (UVLO), LED string open/short protection Over temperature protection (OTP): Thermal shut down and auto thermal recovery Fault Reporting: UVLO, OTP, Open, and Short LED Power Good Reporting Low system BOM cost Ambient Temperature Range -40°C to +125°C (Automotive Grade) U-DFN4030-14: Available in “Green” Molding Compound (No Br, Sb) Totally Lead-Free & Fully RoHS Compliant Halogen and Antimony Free. “Green” Device AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 15 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 AL1791/2/3/4 Pin Descriptions Pin Number Pin Name Descriptions U-DFN4030-14 EN 1 Active-high to Enable, Internally Pulled Down PWM4/GND 2 PWM Signal Input for channel 4, Internally Pulled Down for AL1794. GND for AL1791, AL1792, and AL1793. PWM3/GND 3 PWM Signal Input for channel 3, Internally Pulled Down for AL1793 and AL1794. GND for AL1791 and AL1792. PWM2/GND 4 PWM Signal Input for channel 2, Internally Pulled Down for AL1792, AL1793, and AL1794. GND for AL1791. PWM1 5 PWM Signal Input for channel 1, Internally Pulled Down (Tied to GND when this channel is NOT used). LED1 6 Channel 1 LED Cathode LED2/GND 7 Channel 2 LED Cathode for AL1792, AL1793, and AL1794. GND for AL1791. GND 8 Ground LED3/GND 9 Channel 3 LED Cathode for AL1793 and AL1794. GND for AL1791 and AL1792. LED4/GND 10 Channel 4 LED Cathode for AL1794. GND for AL1791, AL1792, and AL1793. LEDPG 11 LED Power Good Indication. Asserted Low to report insufficient headroom. Needs an external pull-up resistor. FAULTB 12 Fault Report. Asserted Low to report faulty conditions. Needs an external pull-up resistor. REF 13 Reference Current Setting through External Resistor (RSET) VIN 14 Voltage Input Exposed pad. Internally connected to GND. Exposed PAD Exposed PAD It should be externally connected to GND and thermal mass for enhanced thermal impedance. It should not be used as electrical conduction path. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 16 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 BILL-OF-MATERIAL – ACDC Poweer Board Item QTY 1 1 2 Reference Part Package BD201 SMD RH06 1 CX201 DIP RP RP 0.1uF/450V 3 1 CY201 DIP Y-CAP Y1 102M/500V 4 2 C202, C201 DIP 8X10mm 5 1 C203 SMD C1206 1nF/1000V,NPO 6 1 C204 SMD C1206 10uF/25V,X7R 7 1 C205 SMD C0603 100nF/25V,X7R 8 1 C211, C212 SMD C0805 470pf /100V,X7R 9 1 C251 SMD C0805 NC 10 2 C213, C214 DIP 8X12mm 11 5 D201, D202, D203, D204, D205 SMD SOD-123F 12 2 D211, D212 SMD SOD-123 13 1 U201 SMD SO7 14 1 MOV1 DIP Varistor 07D471K 15 1 RT201 SMD R0603 NTC Resistor 10K,TSM1A103F34D1RZ 16 1 R201 SMD R1206 600K/500V, 1%,1/8W 17 1 R203 SMD R1206 150K, 5%, 1/4W 18 1 R204 SMD R0603 10R, 5%, 1/10W 19 1 R205 SMD R0603 45.3K, 1%,1/10W (49.2K for TC) 20 1 R206 SMD R0603 12.7K 1%,1/10W (14K for TC) 21 1 R209 SMD R0603 47K, 1%,1/10W 22 1 R210 SMD R0603 12.1K, 1%,1/10W (20K for TC) 23 1 R207 SMD R0805 2.7R, 1%,1/8W 24 1 R208 SMD R0805 1.54R, 1%,1/8W 25 2 R211, R212 SMD R0805 22R, 5%,1/8W 26 1 R213 SMD R0805 3.9K, 5%,1/8W 27 1 R214 SMD R0805 8.2K, 5%,1/8W 28 1 R216 SMD R0805 15K, 5%,1/8W (20K for TC) 29 1 T201 DIP EE13 5+5Pin EE13 30 1 L201 DIP (Color-coded inductor) 3.3mH,120mA 31 1 F201 DIP Fuse 10R,1WS,5% 32 - PCB FR4 PCB TOTAL 39 AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 Description Supplier Bridge,600V/0.5A,MB6S Diodes, Inc. E.C,CD11GD,105°C,6000H,10uF/200V, 8X9mm E.C,RS,105°C,7000H,470uF/16V, 8X12mm S1MWF 1A-1000V Diodes, Inc. SBR2A40P1,40V/2A Diodes, Inc. AP3983C IC Diodes, Inc. 30.5*42*1mm 2Layers 1oz by Lead free tin Power Board Electronic Parts 17 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 BILL-OF-MATERIAL – LED Drive Board (LED Driver and ZigBee) LED Driver System BOM # Name QTY Part Number Manufacturer 1 U1 1 AP2204K-3.3TRG1 Diodes, Inc. 2 U2 1 AL1794AFE-13 Diodes, Inc. 3 R1 1 100K Wide input voltage range, 150mA ULDO regulator, SOT23-5 Quad Channel Current-Ratio-Optimized LED Driver with Analog and PWM Dimming U-DFN4030-14 Voltage Divider Resistor, Full Voltage input 11.0V 4 R2 1 10K Voltage Divider Resistor, feedback 1.0V to PV1ADC 5 R3 1 10K Voltage Divider Resistor, for Adjusting CV Output from Power Stage 6 R4 1 10K Voltage Divider Resistor, for Adjusting CV Output from Power Stage 7 R5 1 100K Pull-down Resistor to EN Pin from GPIO of MCU 8 R6 1 6.04K Reference Channel Current Resistor, to generate 500mA (Maximum Channel current) 9 R7 1 23.2K Pull-up resistor for NTC (3.3V) 10 C1, C3, C5 3 10uF/25V 11 C2, C4, C6, C7 4 100nF/16V 12 J1 1 Connector TOTAL 17 Description LD Board-Driver Electronic Parts ZigBee Module System BOM (Key Parts only) # Name QTY Part Number Manufacturer 1 U3 1 ATSAMR2118A-MF Atmel 2 T1 1 2450BM15A0015E 3 U4 1 MX25L4006EM1I12G 4 Y1 1 E2SB16.0000F09G1 1 5 TOTAL AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 ANT1 @SC-251B - - Description ZigBee 2.4GHz IC SPI Flash Crystal OSC Embedded Antenna LD Board-ZigBee Electronic Parts 18 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 BILL-OF-MATERIAL – Emitter Board Tunable Color Emitter Module System BOM # Name QTY Part Number Manufacturer Description 1 E1 1 LZ7-CT232 2 R1 1 0R/1206 Jumper to connected LED4 to LED1, for enhancing LED1 Channel Current by 25% 3 R2 0 - Not fitted. (For AL1794_LED4 pin grounding) 4 R3, R4 2 1R/1206 VF (Forward Voltage) Matching Resistor 5 JP1,JP2,JP4,JP5,JP8 5 0R/0603 Jumpers 6 JP3,JP6,JP7 3 0R/1206 Jumpers, JP3 and JP6 are also for VF matching resistors 7 J1 1 HDR200P8 Jumper from Emitter Module to Driver PCB 8 NTC1 1 10K/1%/0603/NTC Thermal management detector component TOTAL LED Engin 14 LZ7-07T200-0000 (Tunable Color) Tunable Color Emitter Board Electronic Parts Warm Dimming Emitter Module System BOM # Name QTY Part Number Manufacturer Description 1 E1 1 LZ7-CT322 2 R1 1 0R1206 Jumper to connected LED4 to LED2, for enhancing LED2 Channel Current by 25% 3 R2 0 - Not fitted. (For AL1794_LED4 pin grounding) 4 JP5,JP6,JP7 3 0R/1206 Jumpers and VF (Forward Voltage) matching resistors 5 JP1,JP2,JP4 3 0R/0603 Jumpers 6 JP3 1 0R/1206 Jumper 7 J1 1 HDR200P8 Jumper from Emitter Module to Driver PCB 8 NTC1 1 10K/1%/0603/NTC Thermal management detector component TOTAL AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 LED Engin 11 LZ7-07T100-0000 (Warm Dimming) Warm Dimming Emitter Board Electronic Parts 19 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 APPENDIX I - EE13 TRANSFORMER SPEC A. Transformer Pin & Wire Description (PAR16 WD) Circuit: Primary Cross sectional view: Secondary 3Ts 1 7 Over core L1 2Ts L3 L5 3 2Ts 9 L4 L4 2Ts 2 L2+L3 10 4 2Ts L2 F1 Wire Shilding L5 2Ts 6 5 Start Teflon Tube F1 5 L1 Pin definition (StartEnd) Wire (φ) Turn (Ts) Layers Layers of Tape L1 Pin3 to Pin1 2UEW-B 30#AWG x 1P 67 3 2Ts F1 Pin5 -- Floating 2UEW-B 36#AWG x 1P full layer 1 2Ts L2 Pin10 to Pin6 Triple wire-B 28#AWG x 1P 7 0.8 L3 Pin7 to Pin9 Triple wire-B 28#AWG x 1P 1 0.2 2Ts L4 Pin2 to Pin3 2UEW-B 30#AWG x 1P 51 2 2Ts L5 Pin4 to Pin5 2UEW-B 34#AWG x 1P 18 1 2Ts OVER CORE 3Ts Note. 1. 2. B. # EE13 Bobbin 5+5Pin Output for Warm Dimming (7.4V + 6.7V turn Ratio) Electrical Characteristic : Test Item Winding Pin Rating Tolerance Remark 2.1 Inductance L1+L4 #1 to #2 0.8mH +/-5% 1KHz / 0.4V 2.2 Leakage Inductance L1+L4 #1 to #2 100uH Max 10KHz / 0.4V AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 20 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 C. Transformer Pin & Wire Description (PAR16 CT) Circuit: Primary Cross sectional view: Secondary 1 3Ts 7 Over core L1 2Ts L3 3 L5 9 2Ts L4 L4 2Ts 2 L2+L3 10 2Ts 4 L2 F1 Wire Shilding L5 2Ts 6 5 L1 Start Teflon Tube F1 5 Pin definition (StartEnd) Wire (φ) Turn (Ts) Layers Layers of Tape L1 Pin3 to Pin1 2UEW-B 30#AWG x 1P 67 3 2Ts F1 Pin5 -- Floating 2UEW-B 36#AWG x 1P full layer 1 2Ts L2 Pin10 to Pin6 Triple wire-B 28#AWG x 1P 7 0.7 L3 Pin7 to Pin9 Triple wire-B 28#AWG x 1P 3 0.3 2Ts L4 Pin2 to Pin3 2UEW-B 30#AWG x 1P 51 2 2Ts L5 Pin4 to Pin5 2UEW-B 34#AWG x 1P 18 1 2Ts OVER CORE 3Ts Note. 1. EE13 Bobbin 5+5Pin 2. Output for Tunable Color (9.8V + 6.7V turn Ratio) D. # Electrical Characteristic : Test Item Winding Pin Rating Tolerance Remark 2.1 Inductance L1+L4 #1 to #2 0.8mH +/-5% 1KHz / 0.4V 2.2 Leakage Inductance L1+L4 #1 to #2 100uH Max 10KHz / 0.4V AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 21 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 APPENDIX II - LED ENGIN 3-CHANNEL WD and TC EMITTERS LZ7-07T100-0000 Tunable White (Warm Dimming) LED Emitter Key Features Ultra-bright, ultra-compact tunable white emitter Capable of high quality, high CRI white light Typical emitter flux output 345lm@ 3000K, 6.4W Typical efficacy 54lm/W Based on LuxiGen LZ7-series 7-die high power density product platform Small high density foot print – 7mm x 7mm High luminous flux density with LES 6mm Surface mount ceramic package Exceptionally low thermal resistance with electrically neutral thermal path Lead (Pb) free and RoHS compliant - reflow soldering (up to 6 cycles) Luminous Flux Typical Luminous Flux (ΦV) @ IF = 500mA 3 Red 2 GreenWhite 2 BlueWhite 210 lm 312 lm 294 lm Notes: Luminous flux performance guaranteed with in published operating conditions. LED Engin maintains a tolerance of +/- 10% on flux measurements. Forward Voltage Bin Typical Forward Voltage (VF) @ IF = 500mA 3 Red 2 GreenWhite 2 BlueWhite 6.9 V 6.2 V 6.2 V Notes: Forward Voltage is binned with all LED dies of a kind connected in series. LED Engin maintains a tolerance of +/-0.16V for forward voltage measurements for the LEDs. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 22 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Tunable Emitter Chromaticity Coordinates Plotted on excerpt from the CIE 1931 (2°) x-y Chromaticity Diagram. Chromaticity Bin Coordinates Typical CIEX @ IF = 500mA Red GreenWhite BlueWhite 0.681, 0.318 0.443, 0.533 0.342, 0.383 Notes: LED Engin maintains a tolerance of +/-0.002 on x, y coordinates. Dominant Wavelength Bins Typical Dominant Wavelength (λD) @ IF = 500mA Red GreenWhite BlueWhite 616 571 561 Notes: LED Engin maintains a tolerance of +/-1.0nm on dominant wavelength measurements AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 23 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Mechanical Dimensions (mm) AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 24 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 LZ7-07T200-0000 Tunable Color (TC) LED Emitter Key Features Ultra-bright, ultra-compact tunable color emitter Capable of simulating 16 million shades of color Typical emitter flux output 388 lm@3000K, 7.5W Typical efficacy 52 lm/w Based on LuxiGen LZ7-series 7-die high power density product platform Small high density foot print – 7mm x 7mm High luminous flux density with LES 6mm Surface mount ceramic package Exceptionally low thermal resistance with electrically neutral thermal path Lead (Pb) free and RoHS compliant – reflow soldering (up to 6 cycles) Emitter available on 3-channel MCPCB (optional) Luminous Flux Typical Luminous Flux (ΦV) @ IF = 500mA 2 Red 3 GreenWhite 2 BlueWhite 144 lm 480lm 63lm Notes: Luminous flux performance guaranteed with in published operating conditions. LED Engin maintains a tolerance of +/- 10% on flux measurements. Forward Voltage Bin Typical Forward Voltage (VF) @ IF = 500mA 2 Red 3 GreenWhite 2 BlueWhite 4.9 V 9.3 V 6.2 V Notes: Forward Voltage is binned with all LED dies of a kind connected in series. LED Engin maintains a tolerance of +/-0.16V for forward voltage measurements for the LEDs. AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 25 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Tunable Emitter Chromaticity Coordinates Plotted on excerpt from the CIE 1931 (2°) x-y Chromaticity Diagram Chromaticity Bin Coordinates Typical CIEX @ IF = 500mA Red GreenWhite BlueWhite 0.691, 0.308 0.445, 0.533 0.158, 0.040 Notes: LED Engin maintains a tolerance of +/-0.002 on x, y coordinates. Dominant Wavelength Bins Typical Dominant Wavelength (λD) @ IF = 500mA Red GreenWhite BlueWhite 620 571 457 Notes: LED Engin maintains a tolerance of +/-1.0nm on dominant wavelength measurements AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 26 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 Mechanical Dimensions (mm) Package Outline Drawing LED Engin Web Site: Contact: www.ledengin.com Cindy Xu ([email protected]) APPENDIX III - ZIGBEE MODULE Atmel SAM R21 Introduction and Specification ZigBee IC On board: Atmel SAM R21 http://www.atmel.com/images/45067a-sam-r21_brochure_e_a4_021214_web.pdf AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 27 of 28 www.diodes.com January 2016 © Diodes Incorporated AN204 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). 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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 systemsrelated 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 AN204 3-Ch WD/TC SCL Bulb Reference Design Document number: Rev 1.0 28 of 28 www.diodes.com January 2016 © Diodes Incorporated