Dimmable LED Driver with iw3614 (Input 180~264Vac Output 40V700mA)
Design Purpose and Feature (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Isolated ac-dc offline Input 230Vac, Output 12 LEDs 700mA Intelligent wall dimmer detections - Leading-edge dimmer, Trailing-edge dimmer, No-dimmer Multiple dimming control scheme - Hybrid dimming scheme - PWM dimming scheme,900hz - Amplitude dimming scheme Wide dimming range from 1% up to 100% No visible flicker Resonant control to achieve high efficiency High Power Factor, 0.95 without dimmer Temperature degrade control to adjust the LED Primary-only Sensing eliminates opto-isolator feedback and simplifies design Aug. 10, 2011 2
1.Schematics (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Aug. 10, 2011 3
2.PCB Layout (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) AC Input DC output To LED Primary Secondary iw3614-00 Aug. 10, 2011 4
3.BOM (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Item Reference Description Qty Item Reference Description Qty 1 IC1 iw3614, Digital PWM Controller,Dimmable, SO-8 1 29 R31,R32 3.6Ω ±1 %, SMD-1206 2 2 CX1 10nF,275V, X2 1 30 R8 300KΩ,±5%, 1/4W 1 3 CX2 47nF,275V, X2 1 31 R13 47Ω,±5%, 1W 1 4 C1 100nF,450V,P=7.5mm 1 32 R12 390Ω,±5 %, 2W 1 5 C3 22uF, 450V,E-CAP,105'C 1 33 FR1 T3.15A 250V 1 6 C12 47uF, 35V, E-CAP,105'C 1 34 BDR1 KBP307G KBP 1 7 C17 220uF,63V,E-CAP 1 35 D3 FR107, 1A/1000V,DO-41 1 8 C5 1nF,1kV,P=5.0mm 1 36 D5 FR102 1A/200V,DO-41 1 9 C10 47pF,50V, X7R, SMD-0805 1 37 D1,D2 ES1J 1A/600V, SMD 2 10 C11 2.2nF,50V, X7R, SMD-0805 1 38 D4 1N4148 0.1A/100V, SMD LL-34 1 11 C8 220pF,25V, X7R, SMD-0805 1 39 D6 FFAF10U40DN 10A 400V TO-22OF 1 12 C9 22nF,50V, X7R, SMD-0805 1 40 Z2 Zener, 15V, LL-34 1 13 C2 100nF,50V, X7R, SMD-0805 1 41 CY1 Y1,2.2nF,400V 1 14 C15,C13 C13 4.7uF/25V, SMD-1206 2 42 Q1 7N60,TO-220F 7A 600V 1 15 R26 2.2KΩ ±5 %, SMD-0805 1 43 Q2 4N60, TO-220F 4A 600V 1 16 R24 22KΩ ±5 %, SMD-0805 1 44 Q3 DMZ6005, N-Depletion, 600V, SOT-23 1 17 R14,R20 100KΩ±5 %, SMD-0805 2 45 Q4 MMBT4401, NPN, SOT-23 1 18 R19,R25 R25 10Ω±5 10Ω,±5 %, SMD-1206 2 46 Q5 BC807, PNP, SOT-23 1 19 R3 4.7KΩ,±5 %, SMD-1206 1 47 L2,L3 Drum choke 10X12mm 3.5mH, 2 20 R1,R2 10KΩ,±5 %, SMD-1206 2 48 L4 Drum choke 10X12mm 700uH, 1 21 R15,R16,R33,R34 22KΩ,±5 %, SMD-1206 4 49 L7 Common Mode Inductor T14*8*5.5 25mH 1 22 R35,R36 R36 100KΩ±5 100KΩ,±5 %, SMD-1206 2 50 L1 Common Mode Inductor T9*4 4.53 5*3 30uH 1 23 R9,R17.R18 300KΩ,±5 %, SMD-1206 3 51 L6 Common Mode Inductor T10*5*5 130uH 1 24 R29 510KΩ,±5 %, SMD-1206 1 52 L5 EE16 L=1.5mH 1 25 R21 1KΩ ±1 %, SMD-0805 1 53 T1 Transformer PQ2016 L=0.75mH 1 26 R28 24KΩ±1 2.4KΩ %, SMD-0805 1 54 HS1 copper 45+35*2*20mm 20mm 1 27 R27 27KΩ ±1 %, SMD-0805 1 55 HS2 copper 10*15*20mm 1 28 R22,R23 3.9Ω ±1 %, SMD-1206 2 56 FOR HS1,HS2 screw PM3*8 3 Aug. 10, 2011 5
4.Transformer Design (AC input 180~264Vac,Output 52V700mA 14 LEDs_ iw3614) SCHEMATIC 2 11 Primary 1 26T 7 PRI Sec 1 5 Secondary 16T 2(F) 3(S) 0.24mmx1 13T Primary clockwise Bias 6T 9 6(F) 6 5(S) 2UEW 0.2mmx3 5T Bias clockwise ELECTRICAL SPECIFICATIONS: 1. Primary Inductance (Lp) = 0.62mH @10KHz 2. Primary Leakage Inductance (Lk) 40uH@10KHz MATERIALS: 1. Core : PQ3216 (Ferrite Material TDK PC40 or equivalent) 2. Bobbin : PQ3216 Vertical Primary=6, Secondary=5 3. Magnet Wires (Pri) : Type 2-UEW 4. Magnet Wire (Sec) : Triple Insulated Wires 5. Layer Insulation Tape :3M1298 or equivalent. 2UEW 0.45mmx1 5T Second clockwise Triple Insulation wire 2UEW 0.45mmx1 5T Second clockwise Triple Insulation wire 2UEW 0.45mmx1 6T Second clockwise Triple Insulation wire FINISHED : 1. Cut remained of Pin4,7,8,10 after wires termination 0.24mmx1 13T Primary clockwise 1(F) 2. Varnish the complete assembly 3. Core is connected to primary pin4 Bottom 6(S) 3(S) Copper shielding (4*15mm) 9(F) 11(S) Aug. 10, 2011 6
5.PFC Inductor L3 Design (AC input 180~264Vac,Output 53V700mA 14 LEDs_ iw3614) SCHEMATIC 3 ELECTRICAL SPECIFICATIONS: 1.Inductance (Lp) = 1.25mH @10KHz 2.Core Core:EE16 (Ferrite Material TDK PC40 or equivalent) 0.27*1*200Ts 3.Bobbin : EE10 horizontal 4.Ferrite core is connected to Pin 5 after assembling 5.Cut remained of Pin1,4,6,7,9,10 after wires termination 8 6.Varnish the complete assembly 5 10 1 5 Aug. 10, 2011 7
6. Common Mode Inductor (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) 6. 1 Common Mode Inductor L1 core size:t9*4.5*3 Wire gauge: 0.35mm*2(Insulation& 2-UEW wire) 9 Turns Inductance @10kHz, 1V: 30uH +/-20% ICR: 0.3 OHM +/-20% 6. 2 Common Mode Inductor L7 core size : T 14*8*5.5 Wire gauge: 0.35mm, 60 Turns Inductance @10kHz, 1V: 25mH +/-20% lcr: 3.5 OHM +/-20% 6. 3 Common Mode Inductor L6 core size : T 10*5*5 Wire gauge: 0.35mm, 9 Turns Inductance @10kHz, 1V: 130uH +/-20% lcr: 01OHM 0.1 +/-20% Aug. 10, 2011 8
7.Differential Mode Inductor (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) 7.1 Differential Mode Inductor L2,L3 Ferrite core size : AxB 10x12mm 7.2 Differential Mode Inductor L4 Wire gauge: 0.24mm, 290 Turns Inductance @10kHz, 1V: 3.5mH +/-20% ICR: 2.6 OHM +/-20% Ferrite core size : AxB 10x12mm Wire gauge: 0.35mm, 130 Turns Inductance @10kHz, 1V: 700uH +/-20% ICR: 0.5 OHM +/-20% Aug. 10, 2011 9
8.Constant Current and Efficiency (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Vin Pin Vout Iout Ripple(PK) Vcc #of LEDs efficiency PF (V) (W) (V) (ma) (ma) (V) 180 35.20 42.75 701 40 85.14% 0.974 14.64 190 34.91 42.43 702 40 85.32% 0.981 14.65 200 34.60 42.27 27 702 40 85.76% 0.988 14.66 207 34.42 42.15 702 40 85.97% 0.990 14.67 12LEDS 220 34.24 42.03 703 40 86.29% 0.991 14.68 230 34.10 41.93 703 40 86.44% 0.990 14.69 240 33.96 41.85 704 40 86.76% 0.987 14.70 250 33.86 41.72 705 40 86.87% 0.982 14.71 264 33.84 41.69 706 40 86.98% 0.965 14.72 Aug. 10, 2011 10
9. Regulation, Efficiency Measurement (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) 100% 90% Efficiency-Vin EFF(%) 80% 70% 60% 50% 40% 30% 20% 10% 0% 180 190 200 210 220 230 240 250 260 270 Vin(V) Aug. 10, 2011 11
10. Regulation, Iout Measurement (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Io out(ma) 750 Iout-Vin 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0 180 190 200 210 220 230 240 250 260 270 Vin(V) Aug. 10, 2011 12
11. Regulation, PF Measurement (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) 1.00 PF-Vin PF 0.90 080 0.80 0.70 0.60 0.50 0.40 030 0.30 0.20 0.10 0.00 180 190 200 210 220 230 240 250 260 270 Vin(V) Aug. 10, 2011 13
12. Regulation, Vout-Iout Measurement (AC input 180~264Vac,Output 40V700mA Electrical Load _ iw3614) Vout(V) 49 Iout-Vout 48 47 OVP 46 45 44 43 42 41 40 39 38 37 36 35 34 207Vac 33 32 230Vac 31 30 264Vac 29 28 27 26 25 24 23 22 21 20 19 0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750 Iout (ma) Aug. 10, 2011 14
13.Constant Current and Efficiency_ with dimmer (AC input 180~264Vac,Output 40V700mA 12 LEDs_ iw3614) Vin DIM Level Pin LED Voltage LED current Pout Eff ripple current VCC DIM mode (V) (W) (V) (ma) (W) (%) ( ma) (V) Leading edge dimmer _ WUYOU 400W _12 LEDs 207 230 264 Max. 34.95 43.28 701 30.34 86.8% 40 14.60 Amp. 18.38 40.85 359 14.67 79.8% 28 14.57 Amp. Min. 0.67 31.75 5 0.16 23.7% / 10.04 Amp.&PWM Max. 34.50 43.08 702 30.24 87.7% 40 14.61 Amp. 18.16 40.49 349 14.13 77.8% 28 14.59 Amp. Min. 0.85 32.03 7 0.22 26.4% / 11.1010 Amp.&PWM Max. 34.59 43.20 704 30.41 87.9% 40 14.61 Amp. 19.10 40.87 356 14.55 76.2% 30 14.58 Amp. Min. 0.90 32.04 7 0.22 24.9% / 11.10 Amp.&PWM Trailing edge dimmer Etman ETM321S 315W 12 LEDs Vin DIM Level Pin LED Voltage LED current Pout Eff ripple current (V) (W) (V) (ma) (W) (%) ( ma) (V) 207 230 VCC DIM mode Max. 35.24 43.30 701 30.35 86.1% 40 14.59 Amp. 17.92 40.74 345 14.06 78.4% 28 14.55 Amp. Min. 3.37 34.58 35 1.21 35.9% / 12.99 Amp.&PWM Max. 35.10 43.13 702 30.28 86.3% 40 14.61 Amp. 18.85 40.70 362 14.73 78.2% 28 14.60 Amp. Min. 3.88 34.67 40 1.39 35.7% / 13.12 Amp.&PWM 264 Max. 35.36 43.30 704 30.48 86.2% 40 14.62 Amp. 19.12 40.85 354 14.46 75.6% 28 14.59 Amp. Min. 4.26 34.75 38 1.32 31.0% / 13.11 Amp.&PWM Aug. 10, 2011 15
14.VDS waveform (AC input 264Vac,Output 40V700mA Electrical Load _ iw3614) Test Condition: VIN=264VAC, VOUT_CV=43V Result: VDS_MAX=528V Test Condition: VIN=264VAC, NO LOAD Result: VDS_MAX=512V Remark: Mosfet Spec 7A 600V Aug. 10, 2011 16
15.Secondary rectifying tube waveform (AC input 264Vac,Output 40V700mA Electrical Load _ iw3614) Test Condition: VIN=264VAC, VOUT_CV=43V Result: VRRM_MAX=280V Test Condition: VIN=264VAC, NO LOAD Result: VRRM_MAX=284V Remark: Diode Spec 10A 400V Aug. 10, 2011 17
16.Vcc rectifying tube waveform (AC input 264Vac,Output 40V700mA Electrical Load _ iw3614) Test Condition: VIN=264VAC, VOUT_CV=43V Result: VRRM_MAX=118V Test Condition: VIN=264VAC, NO LOAD Result: VRRM_MAX=112V Remark: Diode Spec 1A 200V Aug. 10, 2011 18
17. Transformer Flux Density (AC input 180Vac,Output 40V700mA Electrical Load _ iw3614) Transformer information: N P = 52Ts, L P =0.75mH,Ae=62mm^2 (PQ2016) Ip is monitored at 180Vac and 701mA load (Max Output Power). Ip=1070mA B MAX =(IP*LP) /(NP*AE) =(1070*0.75)/( ( 52*62) =0.249Tesla Aug. 10, 2011 19
18.Start up time (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) Vout 0.291S Iout Vin Adjust R15,R16,R33 15,R16,R33, R33, R34 will adjust power on delay time, Please pay attention to input power of short circuit when there is a litter resistance on R15&R16&R33 15&R16&R33&R34. &R34. Aug. 10, 2011 20
19.Harmonic and current waveform (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) Harmonics current @230Vac THD=12 12.21% 21% AC current waveform @230Vac PF=0.988 Aug. 10, 2011 21
20. Conducted EMI (Full Load, output floating ) (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) Peak Scan QP Limit line Input=230VAC L line QP scan Peak Scan QP Limit line Input=230VAC N line QP scan Aug. 10, 2011 22
21. Conducted EMI (Full Load, Output is earthing) (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) Peak Scan QP Limit line Input=230VAC L line QP scan Peak Scan QP Limit line Input=230VAC N line QP scan Aug. 10, 2011 23
22. Radiated IEM (for reference) (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) EN55022 LIMIT 28MHz 200MHz Note: 1, Vin=230Vac 2, Output is floating Aug. 10, 2011 24
23. Radiated IEM (for reference) (AC input 230Vac,Output 40V700mA 12 LEDs_ iw3614) EN55022 LIMIT 28MHz 200MHz Note: 1, Vin=230Vac 2, Output is earthing Aug. 10, 2011 25
24.iW3614 驱动板工作后, 首先检查的项目 检查项目检查内容判断标准结论 MOSFET 在输入电压最高的时候的 Vds 值 0.8~0.9*Vds Max. 输出整流管 反向电压及 Trr 的参数范围 低输出电压 肖特基 FFAF10 较高输出电压 HER U40DN 高电压小电流 超快恢复 Vcc 整流管反向电压及 Trr 的参数范围推荐用 1N4148 或 FR102/FR103 FR102 Vcc 电压 调光最大位置和最小位置时的 Vcc 最大亮度 / 最多灯数 <16V 14.72V 10.10V 最小亮度 / 最小灯数 >8V 变压器 Bmax. 0.249 Vsense 正常工作时的 Vsense 电压 最高输出电压时的 Vsense (Knee) 应该低于 14V 1.4V, 以确保工作于 CC mode(<1.538v) OVP 输出开路时 Vsense 电压 OVP 是 1.7V, 确认输出开路时 MOSFET Vds 是安全的, 输出整流 管电压及 Vcc 的值 Tesla Aug. 10, 2011 26