Reference Design AL9910EV8 Non-Dimmable 120VAC Evaluation Board Case #1: (Input=120VAC; Output=48V/90mA) Case #2: (Input=120VAC; Output=96V/45mA) Applications: B10 Light Bulbs -Customer: CreeDate: October 27, 2011 This document contains Diodes confidential and proprietary information AL9910EV8 120VAC ND Ref Design Report October 2011 Table of Contents 1. 2. 2.1 2.2 2.3 2.4 2.5 3. 4. 4.1 4.2 5. PURPOSE ................................................................................................................... 3 EVALUATION BOARD INFORMATION .............................................................................. 4 AL9910 Pin Assignment and Description ..................................................... 4 Evaluation Board Schematic.......................................................................... 5 Evaluation Board BOM List ............................................................................ 6 Evaluation Board Layouts .............................................................................. 8 Evaluation Board Snapshots ......................................................................... 9 LED OUTPUT ........................................................................................................... 10 EVALUATION BOARD TESTING SUMMARY ................................................................... 11 Testing Results (case #1): ............................................................................ 11 Testing Results (case #2): ............................................................................ 12 CONCLUSION ............................................................................................................ 13 AL9910-EV8 (10/27/2011) Page 2 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 1. PURPOSE Introduction We are using our AL9910 Non-Dimmable board to evaluate two test condition requirements using highpower LEDs from Cree for functional performance. 1) Test condition requirement #1: VIN=120VAC; OUT=48V/90mA. 2) Test condition requirement #2: VIN=120VAC; OUT=96V/45mA. Customer: Cree Features Non-Dimmable Selectable 5W-8W output power Active PFC with power factor >0.9 No electrolytic capacitor High temperature operation Long operating life Typical Applications: Retrofit B10/E27 LED Light Bulbs Specifications Parameter AC Input Voltage DC Output Voltage Output Current Output Power Power Factor Efficiency Operating Ambient temperature Operating Junction Temperature ROHS Compliance Units V, AC V, DC mA W NA % C C NA Value 90 - 140 40 – 98 45 - 90 3–6 >0.9 87%-90% -40 to +85 -40 to +125 Yes Test conditions: Input Voltage: 120VAC, 60Hz Output Voltage: 40VDC - 98VDC Operating Ambient Temperature: -40°C to 85°C Connection Instructions: AC+ Input: Red – Hot AC- Input: Black - Neutral DC LED+ Output: LED+ (Red) DC LED- Output: LED- (Black) Board Dimension (components included): WxLxH (in mm) = 18mm x 25mm x 13mm AL9910-EV8 (10/27/2011) Page 3 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 2. EVALUATION BOARD INFORMATION 2.1 AL9910 Pin Assignment and Description AL9910 Pin Assignment (Top View) VIN 1 CS GND 2 Gate 8 Rosc 3 7 6 LD VDD 4 5 PWM_D AL9910 SO-8 AL9910 Pin Description Pin Name Pin Number VIN CS GND Gate 1 2 3 4 PWM_D 5 VDD 6 LD 7 ROSC 8 AL9910-EV8 (10/27/2011) Description Input voltage Senses LED string current Device ground Drives the gate of the external MOSFET Low Frequency PWM Dimming pin, also Enable input. Internal 100kΩ pull-down to GND Internally regulated supply voltage. 7.5V nominal for AL9910. Can supply up to 1 mA for external circuitry. A sufficient storage capacitor is used to provide storage when the rectified AC input is near the zero crossings Linear Dimming by changing the current limit threshold at current sense comparator Oscillator control. A resistor connected between this pin and ground sets the PWM frequency. Page 4 of 14 AL9910EV8 120VAC ND Ref Design Report 2.2 October 2011 Evaluation Board Schematic 2.1.1 Case #1 => Test conditions: VIN=120VAC; OUT=48V/90mA Figure 1: Evaluation Board Schematic (Case#1) 2.1.2 Case #2 => Test conditions: VIN=120VAC; OUT=96V/45mA Figure 2: Evaluation Board Schematic (Case#2) AL9910-EV8 (10/27/2011) Page 5 of 14 AL9910EV8 120VAC ND Ref Design Report 2.3 October 2011 Evaluation Board BOM List Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA # 2 3 4 5 6 7 8 9 10 11 12 13 Name U1 D1,2,3, 4 D6 Q1 C4 C3 R1 R3 R2 R4 R6 R9 R7 14 16 16 17 C1, C2 C5 L1 L2 1 Quantity Part number 1 AL9910S-13 Manufacturer Diodes Description Universal High Voltage LED Driver 1 1 1 1 1 1 1 1 1 1 1 1 HD02-T MUR160-T STD7NK40ZT4 C0402X7R1A221K C1608X7R1A105K CRCW0402330KFKTD CRCW04021K00FKED CRCW040222R0FKED CRCW08051R50FKEA CRCW120616R0FKEA CRCW1206510KJNEA CRCW0402787RFKED Diodes Diodes ST Vishay TDK Vishay Vishay Vishay Vishay Vishay Vishay Vishay RECT BRIDGE GP 200V 0.8A MINIDIP DIODE ULTRA FAST 1A 600V DO-41 MOSFET N-CH 400V 5.4A DPAK CAP CER 220PF 10V X7R 01005 CAP CER 1.0UF 10V X7R 0603 RES 330K OHM 1/16W 1% 0402 SMD RES 1.0K OHM 1/16W 1% 0402 SMD RES 22.0 OHM 1/16W 1% 0402 SMD RES 1.5 OHM 1/8W 1% 0805 SMD RES 16.0 OHM 1/4W 1% 1206 SMD RES 510K OHM 1/4W 5% 1206 SMD RES 787 OHM 1/16W 1% 0402 SMD 2 2 1 1 VJ1812Y104KXETW1BC UMK325C7106MM-T LPS5015-225ML 13R475C Vishay Taiyo Coilcraft Murata CAP Multilayer Cer (MLCC) – SMD / SMT 1812 0.1uF 500volts X7R 10% CAP CER 4.7uF//4.7uF 100V X7R 1210 Inductor 2.2mH 64mA Inductor Radial 4.7mH 0.16A AL9910-EV8 (10/27/2011) Page 6 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 Case #2 => Test conditions: VIN=120VAC; OUT=96V/45mA # 2 3 4 5 6 7 8 9 10 11 12 13 Name U1 D1,2,3, 4 D6 Q1 C4 C3 R1 R3 R2 R4 R6 R9 R7 14 16 16 17 C1, C2 C5 L1 L2 1 Quantity Part number 1 AL9910S-13 Manufacturer Diodes Description Universal High Voltage LED Driver 1 1 1 1 1 1 1 1 1 1 1 1 HD02-T MUR160-T STD7NK40ZT4 C0402X7R1A221K C1608X7R1A105K CRCW0402330KFKTD CRCW04021K00FKED CRCW040222R0FKED CRCW08052R94FKEA CRCW120616R0FKEA CRCW1206510KJNEA CRCW0402787RFKED Diodes Diodes ST Vishay TDK Vishay Vishay Vishay Vishay Vishay Vishay Vishay RECT BRIDGE GP 200V 0.8A MINIDIP DIODE ULTRA FAST 1A 600V DO-41 MOSFET N-CH 400V 5.4A DPAK CAP CER 220PF 10V X7R 01005 CAP CER 1.0UF 10V X7R 0603 RES 330K OHM 1/16W 1% 0402 SMD RES 1.0K OHM 1/16W 1% 0402 SMD RES 22.0 OHM 1/16W 1% 0402 SMD RES 2.94 OHM 1/8W 1% 0805 SMD RES 16.0 OHM 1/4W 1% 1206 SMD RES 510K OHM 1/4W 5% 1206 SMD RES 787 OHM 1/16W 1% 0402 SMD 2 2 1 1 VJ1812Y104KXETW1BC C3225X7S2A475K LPS5015-225ML 13R476C Vishay TDK Coilcraft Murata CAP Multilayer Cer (MLCC) – SMD / SMT 1812 0.1uF 500volts X7R 10% CAP CER 4.7uF//4.7uF 100V 1210 Inductor 2.2mH 64mA Inductor Radial 47mH 0.045A AL9910-EV8 (10/27/2011) Page 7 of 14 AL9910EV8 120VAC ND Ref Design Report 2.4 October 2011 Evaluation Board Layouts Figure 3: Top-View PCB Layout Figure 4: Bottom-View PCB Layout AL9910-EV8 (10/27/2011) Page 8 of 14 AL9910EV8 120VAC ND Ref Design Report 2.5 October 2011 Evaluation Board Snapshots Figure 5: Top-View PCB Board Figure 6: Top-View PCB Board in Bulb Module AL9910-EV8 (10/27/2011) Page 9 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 3. LED OUTPUT 3.1 LED P/N: Cree XM-L T6 LED Output: ~+48V (ideal) 3.2 LED P/N: Cree XPSTAR103 LED Output: ~+96V (ideal) AL9910-EV8 (10/27/2011) Page 10 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 4. EVALUATION BOARD TESTING SUMMARY 4.1 Testing Results (case #1): (Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA): (Case #1 = > Test conditions: VIN=120VAC; OUT=48V/90mA): Board # 1 2 Cree LED 48V 48V VRMS (V) 120.52 120.62 AL9910-EV8 (10/27/2011) IRMS (mA) 34.45 35.32 PIN (W) PFC 4.032 4.125 0.969 0.966 VLED (V) 41.35 41.4 ILED (mA) 91.14 91.95 Efficiency (%) POUT (W) 3.566 3.625 88.44 87.88 Page 11 of 14 AL9910EV8 120VAC ND Ref Design Report 4.2 October 2011 Testing Results (case #2): (Case #2 = > Test conditions: VIN=120VAC; OUT=96V/45mA): (Case #2 = > Test conditions: VIN=120VAC; OUT=96V/45mA): Board # 1 Cree LED 96 VRMS (V) 120.02 AL9910-EV8 (10/27/2011) IRMS (mA) 37.03 PIN (W) PFC 4.227 0.962 VLED (V) 94.43 ILED (mA) POUT (W) 46.17 3.704 Efficiency (%) 87.63 Page 12 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 5. CONCLUSION It is concluded that the new circuit implementation of replacing the inductor (L2) and changing the RSENSE (R4) fully function as expected. As configured in a high-power 48V LED module, the efficiency is about ~88% and PFC is ~0.969. As configured in a high-power 96V LED module, the efficiency is about ~87.6% and PFC is ~0.962. Main benefits are achieved in the high-power LED evaluation: 1) High Efficiency 2) High PFC (>0.9) 3) No electrolytic capacitor 4) Correct average LED output current 5) Suitable for E27 LED Light Bulbs AL9910-EV8 (10/27/2011) Page 13 of 14 AL9910EV8 120VAC ND Ref Design Report October 2011 IMPORTANT NOTICE DIODES INCORPORATED MAKES NO WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, WITH REGARDS TO THIS DOCUMENT, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A 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. 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