Low-Cost LED Driver Reference Board Demo

Low-Cost, High-Efficiency LED Driver Solution

Welcome to Infinia's lab for lighting applications. In the indoor lighting market, many applications require non-dimmable LED drivers with self-class features. To meet these requirements, a low-cost, high-efficiency solution is necessary.

Introduction to ICL-5102

The ICL-5102 is a combo IC designed for controlling PFC (Power Factor Correction) and LLC or LCC topology. This IC supports both DCM (Discontinuous Conduction Mode) and CRM (Continuous Conduction Mode) in different load ranges, ensuring the best efficiency and THD (Total Harmonic Distortion).

Benefits of ICL-5102

• The IC can handle high bus voltages, with a limit of only the pin-crippage distance. The normal version of ICL-5102 can handle around 650 V, while the high-voltage version (ICL-5102HV) can handle up to 980 V.
• The college transformer technology used in the IC provides robustness against negative voltage peaks on the switch node of the half-bridge during hard switching transients. It can handle negative voltage peaks as much as the positive one, making it more reliable than level shifter technology.
• The IC uses magnetic field to transfer driving signals from low side to high side, making it efficient compared to level shifter technology. This enables the IC to operate at higher frequencies, allowing for size reduction of the transformer and cost-down purposes.

Reference Board Design

A reference board has been designed using ICL-5102 to demonstrate its features. The board operates in an open-loop configuration, eliminating the need for operational amplifiers and optocouplers. This design choice significantly reduces costs.

Low-Cost Design Features

• The board operates in an open-loop configuration, which eliminates the need for expensive components like operational amplifiers and optocouplers.
• LCC topology is used to minimize LED current spread over the entire voltage range and temperature range. This ensures that the LED current remains stable despite changes in input voltage or temperature.

High-Frequency Operation

The board operates at a high frequency of around 200 kHz. This enables the use of smaller transformer cores and eliminates the need for external inductors, further reducing costs.

Performance Evaluation

The reference board has been connected to a 230V mains supply, and its input and output have been measured using a power analyzer. The results show that the system efficiency is around 92.5% at maximum power.

Waveforms and Efficiency

The waveforms of the board's voltage, current, and LED current have been measured. The LED current waveform is trapezoidal in shape, indicating low conduction losses and high efficiency.

Conclusion

The ICL-5102 IC provides a robust and efficient solution for non-dimmable LED drivers. Its features, such as high bus voltage handling, robustness against negative voltage peaks, and efficient operation, make it an ideal choice for low-cost and high-efficiency applications.

Introduction

Overview of the Reference Board

Key Features

• High-efficiency LED driver IC with high switching frequency (up to 1 MHz)
• Compact design with a small form factor ( approx. 2 inches x 1 inch)
• Low component count and minimal external components required
• Wide input voltage range (12V - 60V) and output current range (100mA - 3A)
• High level of integration, including internal oscillator, PWM generator, and fault detection

Advantages

• Reduced system cost due to lower component count and smaller form factor
• Improved efficiency and reliability, resulting in increased lifespan and reduced maintenance
• Easier design and implementation, with minimal external components required
• Faster time-to-market, thanks to the availability of a proven reference design

Applications

• LED strips and modules
• Downlights and spotlights
• Panels and ceiling lights
• Outdoor and industrial lighting

Demo Details

• A user-friendly interface with dip switches for easy configuration
• LED indicators for monitoring output current, voltage, and fault status
• A compact, space-saving design that allows for easy integration into existing systems

Conclusion