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