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Smallest GU10 LED driver


LED Driver Design with iW1810

Summary and Features : 1. LED driver, 12V, CC@0.35A ; Wide range AC input range @90-264Vac 2 For Isolated or Non-isolated Applications 3. High Efficiency and Minimum Parts count 4. 4 Meet EMI EN55015B-QP & AV limits 5. Fully protected against AC input UV, OV, O/P Short/Open, meet single point failure test.

1. Specification

Description Input Voltage Frequency Open-load Input Power (264VAC) Output
Const Voltage

Symbol

Min

Typ

Max

Units

Comment

VIN fLINE

90 47

100/240 100/2 0 50/60 3.5

264 26 63

VAC Hz W

2 Wire

@ 0-350 m A @ 7--12V

VOUT_CV IOUT_CV 0.31

12 0.35

15 0.38

V A mA

Measured at the PCB connector

Const Current

Output Ripple Current Continuous Output Power Output short circuit test Efficiency Others Turn on Delay Time Inrush current Hi-pot test Conducted EMI Surge Test Operation Temperature Topr
iWatt Confidential iWatt Confidential

Measured at the LED load Auto restart Auto-restart Measured at end of PCB @ 115Vac At rated input voltage 115 Vac At rated input voltage 115 Vac Isolated / Non-isolated Floating / Grounding Differential mode

POUT IOUT MAX OUT_MAX

W A 70 1 10 4 Meets EN55015B 50 °C % Sec A kV

η

Free convection, sea level
Aug16, 2010 2

2. Schematic Circuit

iWatt Confidential iWatt Confidential Aug16, 2010 3

3. Bill of Material

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Qty. 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 U1 C1 C2 C4 C5 C6 C3 BR1 D1 D2 D3 R1

Ref.

Description iW1810, Off-line digital PWM Controller, SOT-8 6.8uF, 400V, E-CAP, 6 8 F 400V E CAP 105'C 1nF, 250V, Ceramic Capacitor,SMD-0805 4.7uF/25V, SMD-1206 10uF/25V, SMD-1206 470pF100V, SMD-0603 SMD 0603 22pF/25V, SMD-0603 MB8S 1N4148 0.1A/100V, LL-34 SS110 ,1A100V, SMD FR107,1A/1000V 9.1K?±5﹪, SMD-0603 1M?,±5﹪, SMD-1206 120K? ±5﹪, SMD-1206 3.6?±1 3 6? 1﹪, SMD 0805 SMD-0805 24K?±1﹪, SMD-0603 5.6K?±1﹪, SMD-0603 10K? ±5﹪, SMD-0805 560K?,±5﹪, SMD 0805 SMD-0805 10?,±5﹪, SMD-0603 10R,1W, FUSE Resistor 4.7mH, 0410 EE10, Transformer

Cost (US Cent) / unit

Sub-Total (Cent)

R2,R3 R4 R5 R8 R6 R10 R9 R7 FR1 L1 T1

iWatt Confidential iWatt Confidential Aug16, 2010 4

4.Circuit Board Photograph
Primary Secondary

EE10

Top side

iW1810(under the cap ) 15mm

Bottom side

iWatt Confidential

26mm
iWatt Confidential Aug16, 2010 5

5. Transformer Design
Bobbin to be “rotated” in Anti-clockwise direct looking from pin 1/4 side. (Wire to be “started” from pin-4 & “ended” at pin-3 in a Clockwise direction when looking from pin 1/4 side) Pin 4 Pin 5

SCHEMATIC 5 Primary 4 196T A 31T B 22T
电气同名端

Pin 1

Winding Wi di machine

Primary

3 Bias 6

2UEW 0.13mmx1 16T –Bias ( Anti-clockwise) closed

6(S) A(F) B(S) 6(S) 5(F)

0.20mmx1 15T –Secondary (Anti-clockwise) y( ) Triple Insulation wire

ELECTRICAL SPECIFICATIONS: 1. Primary Inductance ( p) = 2.2mH @10KHz y (Lp) @ 2. Primary Leakage Inductance (Lk)≤150uH@10KHz 3(F) MATERIALS: 1. Core : EE10 (Ferrite Material TDK PC40 or equivalent) 2. Bobbin : EE10 Vertical 3. Magnet Wires : Type 2-UEW 4. Layer Insulation Tape :3M1298 or equivalent. FINISHED :
1. 2. Varnish the complete assembly Core is connected to pin6 ( primary ground )
iWatt Confidential iWatt Confidential

0.20mmx1 16T –Secondary (Anti-clockwise ) Triple Insulation wire

2UEW 0.13mmx1 22T – Bias (Anti-clockwise)

spread

2UEW 0.12mmx1 49T – Primary (clockwise)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

4(S)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

Aug16, 2010

6

6. Efficiency Vs Input Voltage

90 80 70 60 Eff(%) 50 40 30 20 10 0 85 105 125 145 165 185 Vin(Vac) 205 225 245 265

* Note: Output voltage measured at end of PCB.
iWatt Confidential iWatt Confidential Aug16, 2010 7

7. Output VI Characteristics
* Note: Output voltage measured at PCB end, TAMB=25
VIN=115Vac, TAMB=25 VIN=230Vac, TAMB=25

Vout

13 12 11

V-I Curve

Vout 13 12 11 10 9 8 7 6 5 0 50 100

V-I Curve

10 9 8 7 6 5 0 50 100 150 200
Iout

250

300

350

400

150

200 Iout

250

300

350

400

CC limit :320~380mA

CC limit :320-380mA

iWatt Confidential iWatt Confidential Aug16, 2010 8

8. VCE Waveform

Test Condition: VIN=264VAC,IOUT=0.35A Result: VCE_MAX=524V

Iw1810, 800V BJT inside

iWatt Confidential iWatt Confidential Aug16, 2010 9

9. Thermal test _1

Component s
IC

90Vac

264Vac

87.6 87 6 °C

85.9 85 9 °C

C1 , 6.8uF/400V

71.7 °C

76.6 °C

T1

86.5 °C

90.1 °C

Ambient

23.1 °C

24.2 °C

The driver is inside the case

1810 is under the E-cap Ewith thermal silica on the case

C1

T1

iWatt Confidential iWatt Confidential Aug16, 2010 10

10.Conducted EMI

VIN=230VAC/50Hz, Live

PK SCAN

Better EMI performance for high frequency and radiated
VIN=230VAC/50Hz, Neutral

PK SCAN

Test Conditions : LED & Full load. Output LED lamp. iWatt Confidential
iWatt Confidential Aug16, 2010 11

Change Vcc winding to drive 1-3 LEDs 改变VCC 绕组圈数 可以兼容1 3PCS LEDS 绕组圈数, 可以兼容1-3PCS

1. Schematic Circuit change

Change C6 to 1nF/100V

Change R7 to 4.7R Change R7 g to 39K

iWatt Confidential iWatt Confidential Aug16, 2010 13

2. Transformer Design__ For 1-3 PCS LEDs
Bobbin to be “rotated” in Anti-clockwise direct looking from pin 1/4 side. (Wire to be “started” from pin-4 & “ended” at pin-3 in a Clockwise direction when looking from pin 1/4 side) Pin 4 Pin 5

SCHEMATIC 5 Primary 4 196T A 31T B

Pin 1

Winding Wi di machine

Primary

3 Bias 6 31T

Just change the Vcc winding to 31T
电气同名端

2UEW 0.13mmx1 16T –Bias ( Anti-clockwise) closed

6(S) A(F) B(S) 6(S) 5(F)

0.20mmx1 15T –Secondary (Anti-clockwise) y( ) Triple Insulation wire

ELECTRICAL SPECIFICATIONS: 1. Primary Inductance ( p) = 2.2mH @10KHz y (Lp) @ 2. Primary Leakage Inductance (Lk)≤150uH@10KHz 3(F) MATERIALS: 1. Core : EE10 (Ferrite Material TDK PC40 or equivalent) 2. Bobbin : EE10 3. Magnet Wires : Type 2-UEW 4. Layer Insulation Tape :3M1298 or equivalent. FINISHED :
1. 2. Varnish the complete assembly Core is connected to pin5 ( primary ground )
iWatt Confidential iWatt Confidential

0.20mmx1 16T –Secondary (Anti-clockwise ) Triple Insulation wire

2UEW 0.13mmx1 31T – Bias (Anti-clockwise)

spread

2UEW 0.12mmx1 49T – Primary (clockwise)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

4(S)

2UEW 0.12mmx1 49T – Primary ( Clockwise)

Aug16, 2010

14

3. Output VI Characteristics after change
* Note: Output voltage measured at PCB end, TAMB=25
VIN=115Vac, TAMB=25 VIN=230Vac, TAMB=25

Vout

V-I Curve

13 12 11 10 9 8 7 6 5 4 3 2 1

Vout 13 12 11 10 9 8 7 6 5 4 3 2 1

V-I Curve

0

50

100

150

200
Iout

250

300

350

400

0

50

100

150

200 Iout

250

300

350

400

Keep at CC mode in wide output range from 11V to 2V, possible to drive 1-3 pcs LEDs 1CC limit :310~330mA CC limit :310-330mA

iWatt Confidential iWatt Confidential Aug16, 2010 15


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