DIODES AL1666 Dimmable LED Driver User Guide

DIODES AL1666 Dimmable LED Driver

General Description

This document describes a 0-10V dimmable high PFC single-stage Flyback LED driver utilizing the AL1666 primary-side controller, the AL8116 secondary-side dimming interface IC and the AL5822 LED current ripple suppressor. The LED driver provides a constant output current of 1200mA over a voltage range of 25V to 50V. It works from a universal voltage of 90VAC to 305VAC. The demonstration board can support 0-10V dimming mode. It works at 0-10V dimming mode when a 0-10V analog signal is connected to 0-10V input. A bill of materials is included that describes the parts used on this demonstration board. A schematic has also been included along with measured performance characteristics. These materials can be used as a reference design for your products.

Key Features

• Universal input: 90~305VAC
• 0-10V dimmable
• Deep dimming to 1% and light off
• Wide output voltage range: 25V to 50V
• Single-Stage topology: Flyback
• Accurate constant current(CC) regulation
• PF>0.96 at 90~300VAC input voltage with a full load
• THD<10% at 90~300VAC input voltage with full load
• Peak efficiency up to 89% at 230Vac input, 50V/1.2A output
• Low output LED current ripple(<5%)
• LED open protection
• LED short protection
• Secondary diode short protection
• Primary winding short protection
• Secondary winding short protection
• Built-in over-temperature protection

Applications

• 0-10V Dimmable LED Driver

Evaluation Board

Connection Instructions

• AC Input: AC-L
• AC Input: AC-N
• DC LED+ Output: LED+
• DC LED- Output: LED0-10V Signal Input: 0-10V DIM
• SGND: Secondary side GND

Quick Start Guide

1. Preset the isolated AC source to 120Vac/230Vac.
2. Ensure that the AC source is switched OFF or disconnected.
3. Connect the anode wire of the LED string to the LED+ of the evaluation board.
4. Connect the cathode wire of the LED string to the LED- terminal of the evaluation board.
5. Connect two AC line wires to the AC-L and AC-N terminals on the evaluation board.
6. Connect your 0-10V analog signal wire to the 0-10V input terminal if you want to make the evaluation board work at 0-10V dimming mode.
7. Ensure that the area around the board is clear and safe, and preferably that the board and LEDs are enclosed in a transparent safety cover.
8. Turn on the main switch. The LED string should light up. DO NOT TOUCH THE BOARD, LEDs OR BARE WIRING.

Evaluation Board Specifications

The table below represents the minimum acceptable performance of the Design.

Description| Symbol| Min| Typ| Max| Units| Comment
---|---|---|---|---|---|---
Input
Input voltage range| VIN| 90|  | 305| Vac|
Line frequency range| fLINE| 47|  | 63| Hz|
Power factor|  | 0.96|  |  |  | Full load@90~300VAC
THD|  |  |  | 10| %| Full load@90~300VAC
Output
Output current| Io|  | 1200|  | mA|
Maximum power|  |  |  | 60| W|
Output voltage| Vo| 25|  | 50| V|
Output voltage(LED open)|  |  | 63|  | V|
Line regulation|  |  |  | ±2| %|
Load regulation|  |  |  | ±2| %|
Current ripple|  |  |  | 5| %| Peak-to-peak
Startup time(AC to 90% Io)|  |  |  | 500| ms| Full load @120~277Vac
Efficiency
Active mode efficiency|  | 87|  |  | %| Full load @120~277Vac
Standby
Input power|  |  |  | 500| mW| LED open @120~277Vac
EMI Conduction Test
EMI Conduction Test| Pass EN55022 with 12dB margin @120Vac, 5dB margin @230Vac

Board Layouts

Schematic

Bill of Material

R21

| SMD Resistor, 1.6R, 1%, 1/4W| Yageo| 1206| 3
46| R22| SMD Resistor, 1.3R, 1%, 1/4W| Yageo| 1206| 1
47| R23| SMD Resistor, 47R, 5%, 1/4W| Yageo| 1206| 1
48| R24, R25,

R26

| SMD Resistor, 560K, 5%, 1/4W| Yageo| 1206| 3
49| R27, R28| SMD Resistor, 47R, 5%, 1/4W| Yageo| 1206| 2
50| R29, R30| SMD Resistor, 75K, 5%, 1/4W| Yageo| 1206| 2
51| R31| SMD Resistor, 20K, 5%, 1/4W| Yageo| 1206| 1
52| R32| SMD Resistor, 360K, 5%, 1/8W| Yageo| 0805| 1
53| R33| SMD Resistor, 750K, 5%, 1/8W| Yageo| 0805| 1
54| R34| SMD Resistor, 0R, 5%, 1/8W| Yageo| 0805| 1
55| R35, R36| SMD Resistor, 0.24R, 1%, 1/4W| Yageo| 1206| 2
56| R37| SMD Resistor, 27K, 5%, 1/8W| Yageo| 0805| 1
57| R38| NC| Yageo| 0805| 1
58| R39| SMD Resistor, 100K, 5%, 1/8W| Yageo| 0805| 1
59| R40| SMD Resistor, 4.7K, 5%, 1/4W| Yageo| 1206| 1
60| R41, R42,

R44

| NC| –| –| 0
61| R43| SMD Resistor, 51K, 5%, 1/4W| Yageo| 1206| 1
62| R45, R46| SMD Resistor, 1M, 5%, 1/4W| Yageo| 1206| 2
63| RJ1, RJ2| SMD Resistor, 0R, 5%, 1/4W| Yageo| 1206| 2
64| L1| Common Choke, 1mH| Gaoya Coil| DIP| 1
65| L2| Common Inductor, UU10.5, 30mH| Gaoya Coil| DIP| 1
66| L3| Drum Inductor, 2.2mH, 1416mm| Gaoya Coil| DIP| 1
67| L4| Common Choke, 330uH| Gaoya Coil| DIP| 1
68| T1| Flyback Transformer, PQ2625, 6+6Pin, 0.32mH| Boody| DIP| 1
69| Q1, Q5| NC| –| –| 0
70| Q2| NPN-BJT, MMBT3904, 40V/0.2A| Diodes Inc| SOT-23| 1
71| Q3| N-Mos, IPA80R1KOC, 800V, Rdson=1ohm| Infineon| TO-220| 1
72| Q4| N-Mos, DMN10H100SK3-13, 100V| Diodes Inc| TO252| 1
73| U1| AL1666, High performance dimmable LED controller| Diodes Inc| SOIC-8| 1
74| U2| AL5822, 100/120Hz LED current ripple suppressor| Diodes Inc| SOT23-6| 1
75| U3| AL8116, Flexible dimming interface IC| Diodes Inc| SOT23-6| 1
76| U4| TCLT1006, Opto-coupler| Vishay| SOP-4L| 1
77| J1, J2| Jumper|  |  | 2
78| CN2| Connector, 2Pin|  |  | 1
---|---|---|---|---|---
79| PCB| FR4 Single layer, 11849mm|  |  | 1
Total| 91

Transformer Design

Materials

1. Core: PQ2625(Ferrite Material PC40 or equivalent)
2. Bobbin: PQ2625, Vertical, Primary=6 Pin, Secondary=6 Pin
3. Magnet Wires(Primary): Type 2-UEW
4. Magnet Wire(Secondary): Triple Insulated Wires
5. Layer Insulation Tape: 3M1298 or equivalent

Transformer Parameters

1. Primary Inductance (Pin3-Pin1)：LP=320uH, ±5%@1kHz
2. Primary Leakage Inductance (Short other Windings, test the inductance of Pin3-Pin1): LK<20uH, ±5%@1kHz
3. Primary Winding Turns (Pin3-Pin1): NP=38Ts
4. Secondary Winding 1 Turns (Pin12-Pin10): NS=16Ts
5. Secondary Winding 2 Turns (Pin9-Pin7): NS=14Ts
6.  Auxiliary Winding Turns (Pin6-Pin4): NAUX=13Ts

Transformer Winding Construction Diagram

the end
2| Insulation| 2 Layer of insulation tape
3| Wd2 Primary| Start at Pin 3, Wind 19 turns of Φ0.3mm2 wire and finish on Pin 2
4| Insulation| 2 Layer of insulation tape
---|---|---
5| Wd3 Secondary-1| Start at Pin 12, Wind 16 turns of Φ0.55mm2 triple insulation wire and finish on Pin 10
6| Insulation| 2 Layers of insulation tape

7

|

Wd4 Secondary-2

| Start at Pin 9, Wind 14 turns of Φ0.18mm1 triple insulation wire and finish on Pin7
8| Insulation| 2 Layers of insulation tape
9| Wd5 Primary| Start at Pin 2, Wind 19 turns of Φ0.3mm2 wire and finish on Pin 1
10| Insulation| 2 Layer of insulation tape
11| Wd6 Auxiliary| Start at Pin 6, Wind 13 turns of Φ0.2mm*2 wire and finish on Pin 4
12| Insulation| 2 Layers of insulation tape

Electrical Performance

Functional Waveform
This section shows the system’s basic operating waveforms, start-up characteristics, output LED voltage and current ripple, Flyback Mosfet & output diode voltage stress and circuit protection waveforms. The system has rich protections including LED open/short protection, primary winding/secondary winding short protection, output diode short protection etc.

EMI Conduction Test
Below are the EMC conduction test results, the data is taken at a maximum output current (1.2A) and full load voltage (50V) condition.

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