4-3W Dimmable LED Driver iW3610 · Intelligent wall dimmer detections Leading-edge dimmer ,...

4-3W Dimmable LED DriveriW3610

2iWatt Confidential – Do Not CopyDimmable LED Driver 19 Jul 2009 Page:

Design Purpose and FeatureIsolated ac-dc offline 100V / 230V

Intelligent wall dimmer detectionsLeading-edge dimmer , Trailing-edge dimmer , No-dimmer

Multiple dimming control schemeHybrid dimming schemePWM dimming scheme,360Hz or 900HzAmplitude dimming scheme

Wide dimming range from 2% up to 100%

No visible flicker

Resonant control to achieve high efficiency

High Power Factor, 0.8-0.9 without dimmer

Temperature degrade control to adjust the LED

Primary-only Sensing eliminates opto-isolator feedback and simplifies design


Schematics _Input 230Vac


BOM __Input 230Vac Item Qty. Ref. Description Cost (US Cent) / unit Sub-Total (Cent)

1 1 U1 iW3610, Digital PWM Controller,Dimmable, SO-82 1 C1 0.022uF,275V, X23 1 C2 0.01uF, 400V, MPP4 1 C3 6.8uF, 400V, E-CAP, 105'C5 1 C4 2.2nF, 250V, X7R, SMD12066 1 C5 Open7 1 C6 22pF, 16V, X7R, SMD 06038 1 C7 2.2nF,16V, X7R, SMD 06039 1 C8 47uF, 25V, E-CAP, 5X11mm 10 1 C9 22uF 25V,Tan-cap11 2 R1, R2 4.7KΩ ±5﹪, SMD-080512 2 R3,R4 330KΩ,±5﹪, SMD-120613 1 R5 390Ω,±5﹪, 2W14 2 R6, R7 100Ω±5﹪, SMD-120615 1 R8 22KΩ±5﹪, SMD-060316 1 R9 10Ω±5﹪, SMD-060317 2 R10,R11 330KΩ,±5﹪, SMD-120618 1 R12 220KΩ,±5﹪, SMD-120619 1 R13 220Ω±5﹪, SMD-080520 1 R15 5.1Ω ±1﹪, SMD-080521 1 R16 10Ω ±5﹪, SMD-060322 1 R18 4.7Ω ±5﹪, SMD-080523 1 R19 24KΩ ±1﹪, SMD-080524 1 R20 2.4KΩ ±5﹪, SMD-060325 1 R21 22KΩ ±5﹪, SMD-080526 1 NTC 47K SMD-0805, TSM2A47327 1 BR1 MB8S, SMD28 3 D1 D2 D3 UF4007,DO-4129 1 D4 FR07,DO-4130 2 D5 D6 1N4148 0.1A/100V, LL-3431 1 D7 SB2100, 2A 100V, Schottky32 1 Z1 Zener, 15V, LL-3433 1 FR1 10R,1W, FUSE Resistor34 1 Q1 2N60, TO-25135 1 Q2 1N60, TO-9236 1 Q3 F501, N-Depletion, 500V, SOT-2337 2 L1 L2 4.7mH, Drum choke, 6X8mm, 38 1 L3 4mH, EE10, 39 1 T1 EE13, Transformer


PCB and Layout

51mm

25mm

iW3610

AC Input

DC output

To LED


MATERIALS:1. Core : EE13 (Ferrite Material TDK PC40 or

equivalent)2. Bobbin : EE13 Vertical 3. Magnet Wires : Type 2-UEW 4. Layer Insulation Tape :3M1298 or equivalent.

SCHEMATICA

144T

28T

ELECTRICAL SPECIFICATIONS:1. Primary Inductance (Lp) = 2.4 mH @10KHz2. Primary Leakage Inductance (Lk)≤30uH@10KHz

1

2

4

5

Primary

Bias

Secondary 28 Turns

Transformer Design ___Input 230Vac

A(S)

Copper Shield 7(W)X28(L)

Bottom

B(F)

PRI SEC

FINISHED :1. Cut remained of Pin 3 6 7 8 9 10 after wires termination2. Varnish the complete assembly

0.3mm 14T –SecondaryTriple Insulation wire

5(F)

Winding Direction

2UEW 0.13mmx1 48T – Primary


3(F)

4(S)2UEW 0.11mmx2 28T –Bias

2(S)

1(F)



3(S)

1(F)

3


EMI Inductor L1,L2

Ferrite core size : AxB 6x8mm

Inductance @10kHz, 1V: 4.7mH +/-20%

DCR: 10 OHM +/-20%

L3 SCHEMATIC

0.17*1*300 Ts

ELECTRICAL SPECIFICATIONS:1. Inductance (Lp) = 4 mH @10KHz2. Core : EE10 (Ferrite Material TDK PC40 or equivalent)3. Bobbin : EE10 Vertical4. Ferrite core is connected to Pin 10 after assembling5. Cut remained of Pin2,3,6,7,8,9,10 after wires termination6. Varnish the complete assembly

1

4

PFC choke and EMI Inductor__ For input 230Vac

5

Coil contact ferrite core and soldered to Ground pin

Ground pin


Constant Current and Efficiency __No Dimmer

Vin Pin Vout Iout Ripple

(V) (W) (V) (A) (m A)

185 5.63 12.34 0.345 72 75.62% 56% 0.70

230 5.71 12.35 0.355 72 76.78% 52% 0.84

264 5.99 12.36 0.363 70 74.90% 65% 0.83

185 4.13 9.29 0.349 73 78.50% 55% 0.70

230 4.52 9.31 0.359 75 73.90% 58% 0.87

264 4.76 9.35 0.367 76 72.09% 68% 0.883LEDs

4LEDs

# of LEDs

efficiency PF3rd Harmonic

Vin 185-264Vac,without dimmer

Output: 3-4 LEDs


Constant Current and Efficiency_ with dimmer

Vin DIM Level Pin LED

VoltageLED

current Pout Eff ripple current DIM mode PF

(V) (W) (V) (mA) (W) (%) ( mA)

Max. 6.86 12.48 340 4.24 61.9% 65 Amp.

3.27 11.84 171 2.02 61.9% 22 Amp.

Min. 0.58 10.27 3 0.03 5.3% 18 Amp.&PWM

Max. 6.65 12.48 350 4.37 65.7% 64 Amp.

3.61 11.87 184 2.18 60.5% 25 Amp.

Min. 0.86 10.59 14 0.15 17.3% 48 Amp.&PWM

Max. 6.56 12.50 356 4.45 67.8% 66 Amp.

3.58 11.82 175 2.07 57.8% 22 Amp.

Min. 1.86 11.17 74 0.83 44.3% 126 Amp.&PWM

185

230

264

Leading edge dimmer

_Panasonic 300W

_4 LEDs

Leading edge dimmer

__ TCL

__ 4 LEDs


VoltageLED


(V) (W) (V) (mA) (W) (%) ( mA)

Max. 7.07 12.46 340 4.24 59.9% 65 Amp.

3.33 11.84 178 2.11 63.3% 22 Amp.

Min. 0.88 10.35 10 0.10 11.8% 16 Amp.&PWM

Max. 6.63 12.53 350 4.39 66.1% 68 Amp.

3.61 11.90 178 2.12 58.7% 25 Amp.

Min. 0.96 10.73 19 0.20 21.3% 58 Amp.&PWM

Max. 6.43 12.54 357 4.48 69.6% 66 Amp.

3.83 11.81 180 2.13 55.5% 25 Amp.

Min. 2.58 11.47 125 1.43 55.6% 148 Amp.&PWM

185

230

264


Constant Current and Efficiency_ with dimmer

Trailing edge dimmer

__ Niko 250W

__4 LEDs

Leading edge dimmer

__ Clipsal 32E450TM

__4 LEDs


VoltageLED


(V) (W) (V) (mA) (W) (%) ( mA)

Max. 4.59 12.08 230 2.78 60.5% 60 Amp.

3.57 11.73 152 1.78 49.9% 22 Amp.

Min. 1.32 10.80 32 0.35 26.2% 64 Amp.&PWM

Max. 5.59 12.31 286 3.52 63.0% 62 Amp.

4.15 11.87 176 2.09 50.3% 25 Amp.

Min. 2.32 11.25 79 0.89 38.3% 84 Amp.&PWM

Max. 6.46 12.46 331 4.12 63.8% 68 Amp.

4.08 11.80 162 1.91 46.9% 20 Amp.

Min. 3.24 11.55 122 1.41 43.5% 128 Amp.&PWM

185

230

264


VoltageLED


(V) (W) (V) (mA) (W) (%) ( mA)

Max. 5.47 12.37 290 3.59 65.6% 60 Amp.

3.75 11.80 155 1.83 48.8% 22 Amp.

Min. 0.95 10.51 11 0.12 12.1% 36 Amp.&PWM

Max. 6.66 12.60 355 4.47 67.2% 63 Amp.

4.30 11.93 182 2.17 50.5% 25 Amp.

Min. 1.66 10.98 45 0.49 29.8% 84 Amp.&PWM

Max. 6.95 12.60 363 4.57 65.8% 66 Amp.

3.99 11.82 166 1.96 49.2% 22 Amp.

Min. 2.38 11.20 84 0.94 39.5% 124 Amp.&PWM

185

230

264


Waveform @ 230Vac and rated LED load

Blue: Input waveform after bridge rectifier_Min.levelGreen: Output Current

Blue: Input waveform after bridge rectifier_Max.levelGreen: Output Current

Blue: Input waveform after bridge _Min.levelGreen: Output Current

Output current waveform

Blue: Input waveform after bridge _Max.levelGreen: Output Current

Input waveform after bridge rectifier

Trailing edge dimmerLeading edge dimmerNo- dimmer


Harmonic and AC current waveform_ No dimmer

Harmonics current @230Vac

Meet IEC61000-3-2 requirement

Ac current waveform @230Vac

PF=0.86


Dimming curve__ Iout Vs Dimmer’s Scale

0 2 4 6 8 10 12

Dimmer graduation

LED Current (mA)

Clipsal

Niko

Iout

Input 230Vac, dimming with Niko and Clipsal dimmer

Measure the output current, Maximum is 348mA

350mA

50

100

150

200

250

300


OTP_ Temperature degrade curve_TSM2A473(47K)

Iout0

100

200

300

400

500

0.20.30.40.50.60.70.8V_vt (V)

Iout(mA)

0

2

4

6

8

10

12

NTC(Kohm)

100 Voltage on Vt pin

Constant current at low temperature

Temperature degrade range

Thermal shut down


Key components specification


Schematics _Input 120Vac


BOM __Input 120VacItem Qty. Ref. Description Cost (US Cent) / unit Sub-Total (Cent)

1 1 U1 iW3610, Digital PWM Controller,Dimmable, SO-82 1 C1 0.022uF,275V, X23 1 C2 0.01uF, 400V, MPP4 1 C3 10uF, 200V, E-CAP, 105'C5 1 C4 2.2nF, 250V, X7R, SMD12066 1 C5 Open7 1 C6 22pF, 16V, X7R, SMD 06038 1 C7 2.2nF,16V, X7R, SMD 06039 1 C8 47uF, 25V, E-CAP, 5X11mm 10 1 C9 22uF 25V,Tan-cap11 2 R1, R2 4.7KΩ ±5﹪, SMD-080512 2 R3,R4 120KΩ,±5﹪, SMD-120613 1 R5 390Ω,±5﹪, 2W14 2 R6, R7 100Ω±5﹪, SMD-120615 1 R8 22KΩ±5﹪, SMD-060316 1 R9 10Ω±5﹪, SMD-060317 2 R10,R11 100KΩ,±5﹪, SMD-120618 1 R12 220KΩ,±5﹪, SMD-120619 1 R13 220Ω±5﹪, SMD-080520 1 R15 5.1Ω ±1﹪, SMD-080521 1 R16 10Ω ±5﹪, SMD-060322 1 R18 4.7Ω ±5﹪, SMD-080523 1 R19 24KΩ ±1﹪, SMD-080524 1 R20 2.4KΩ ±5﹪, SMD-060325 1 R21 22KΩ ±5﹪, SMD-080526 1 NTC 47K SMD-0805, TSM2A47327 1 BR1 MB8S, SMD28 3 D1 D2 D3 UF4007,DO-4129 1 D4 FR07,DO-4130 2 D5 D6 1N4148 0.1A/100V, LL-3431 1 D7 SB2100, 2A 100V, Schottky32 1 Z1 Zener, 15V, LL-3433 1 FR1 10R,1W, FUSE Resistor34 1 Q1 2N60, TO-25135 1 Q2 1N60, TO-9236 1 Q3 F501, N-Depletion, 500V, SOT-2337 2 L1 L2 4.7mH, Drum choke, 6X8mm, 38 1 L3 4mH, EE10, 39 1 T1 EE13, Transformer


MATERIALS:1. Core : EE13 (Ferrite Material TDK PC40 or

equivalent)2. Bobbin : EE13 Vertical 3. Magnet Wires : Type 2-UEW 4. Layer Insulation Tape :3M1298 or equivalent.

SCHEMATICA

144T

28T

ELECTRICAL SPECIFICATIONS:1. Primary Inductance (Lp) =1.5 mH @10KHz2. Primary Leakage Inductance (Lk)≤30uH@10KHz

1

2

4

5

Primary

Bias

Secondary 28 Turns

Transformer Design ___Input 120Vac

A(S)

Copper Shield 7(W)X28(L)

Bottom

B(F)

PRI SEC

FINISHED :1. Cut remained of Pin 3 6 7 8 9 10 after wires termination2. Varnish the complete assembly


5(F)

Winding Direction



3(F)

4(S)2UEW 0.11mmx2 28T –Bias

2(S)

1(F)



3(S)

1(F)

3


EMI Inductor L1,L2

Ferrite core size : AxB 6x8mm

Inductance @10kHz, 1V: 4.7mH +/-20%

DCR: 10 OHM +/-20%

L3 SCHEMATIC

0.17*1*200 Ts

ELECTRICAL SPECIFICATIONS:1. Inductance (Lp) = 1 mH @10KHz2. Core : EE10 (Ferrite Material TDK PC40 or equivalent)3. Bobbin : EE10 Vertical4. Ferrite core is connected to Pin 10 after assembling5. Cut remained of Pin2,3,6,7,8,9,10 after wires termination6. Varnish the complete assembly

1

4

PFC choke and EMI Inductor__ For input 230Vac

5

Coil contact ferrite core and soldered to Ground pin

Ground pin

4-3W Dimmable LED Driver iW3610 · Intelligent wall dimmer detections Leading-edge dimmer ,...

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