IRF840 [TI]
A 0.9-A Constant Current Supply with PFC for 100-W LED; 0.9 -A恒流电源带PFC的100W的LED型号: | IRF840 |
厂家: | TEXAS INSTRUMENTS |
描述: | A 0.9-A Constant Current Supply with PFC for 100-W LED |
文件: | 总17页 (文件大小:436K) |
中文: | 中文翻译 | 下载: | 下载PDF数据表文档文件 |
Using the UCC28810EVM-002
User's Guide
Literature Number: SLUU355A
March 2009–Revised June 2009
User's Guide
SLUU355A–March 2009–Revised June 2009
A 0.9-A Constant Current Supply with PFC for 100-W LED
Lighting Applications
1
2
Introduction
The UCC28810EVM-002 is a constant current non-isolated power supply for LED lighting applications. It
will convert universal mains (90 VRMS to 264 VRMS) to a 0.9-A constant current into a 100-W load. This
evaluation module will allow the customer evaluate the UCC28810/11 in a typical LED lighting application.
Description
The evaluation module uses a two stage approach to controlling the output current.
The first stage is a transition mode PFC circuit. This ensures the design meets the harmonic current or
power factor requirements set out by various standards, such as EN61000-3-2. The PFC circuit converts
the AC input to a regulated DC voltage. This DC voltage can be configured in one of two ways. The
default configuration of the module is that of a boost follower type PFC. The boost follower PFC is where
the PFC regulated output DC voltage tracks the AC input peak voltage. The second configuration requires
removing some components and changing a resistor value see below for more details. This second
configuration removes the tracking element of the PFC circuit. The PFC DC output voltage will then be
regulated to a fixed value in the region of 396 VDC.
The second stage also uses transition mode but is configured as a buck converter. It converts the PFC
output voltage to a fixed constant current. This circuit is capable of supplying 0.9 A into a 100-W load. It
also accepts PWM dimming inputs. Alternatively the user can use the PWM circuit on the module to see
the dimming function.
This module will work with most high brightness LED’s (HB-LED) that operate with 0.9 A and a total string
voltage drop of between 55 V and 110 V.
2.1 Typical Applications
•
•
•
AC Input General Lighting Applications Using HB-LED’s
Industrial, Commercial and Residential Lighting Fixtures
Outdoor Lighting: Street, Roadway, Parking, Construction and Ornamental LED Lighting Fixtures
2.2 Features
•
•
•
•
•
90 VRMS to 264 VRMS operation
Boost Follower or Fixed Output PFC Stage
PFC Disable
Output Current Disable
External or Internal PWM Dimming
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Electrical Performance Specifications
3
Electrical Performance Specifications
Table 1. UCC28810EVM-002 Electrical Performance Specifications
SYMBOL
PARAMETER
CONDITIONS
MIN
NOM
MAX
UNITS
INPUT CHARACTERSTICS
VIN
IIN
Input voltage
Input current
Power factor
90
264 VRMS
1.1 ARMS
0.175
0.95
PF
POUT = 80 W to 100 W
0.97
OUTPUT CHARACTERSTICS
PFC Stage
VOUT
LED Driver Stage
POUT Output power
IOUT
PFC output voltage
235
415 VDC
45
80
100
0.96
0.03
128
W
A
Output current
Line regulation
Frequency
0.84
0.9
60
kHz
SYSTEMS CHARACTERSTICS
η
Full load efficiency
90%
93%
PWM Dimming(1)
Threshold
0.72
200
0%
1.3
1000
90%
V
Frequency range
Duty cycle
Hz
(1)
The PWM dimming signal is inverted, 0% duty cycle is 100% LED current.
SLUU355A–March 2009–Revised June 2009
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Schematic
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4
Schematic
Figure 1. UCC28810EVM-002 PFC Stage Schematic
4
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Schematic
Figure 2. UCC28810EVM-002 Buck Stage Schematic
SLUU355A–March 2009–Revised June 2009
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Test Setup
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5
Test Setup
WARNING
High voltages, that may cause injury, exist on this evaluation
module (EVM). Please ensure all safety procedures are followed
when working on this EVM. Never leave a powered EVM
unattended. The use of isolated test equipment is highly
recommended.
5.1 Test Equipment
See Figure 3 for recommended test set up.
5.1.1
5.1.2
5.1.3
Voltage Source:
Source 1: Isolated AC voltage source or VARIAC, capable of 90 VRMS to 264 VRMS at 150 W.
Source 2: A 3.3-V DC source capable of 100 mA.
•
•
Multimeters
Three digital multimeters are recommend, one for current measurement, A1, and two for voltage
measurements, V1 and V2.
Output Load
It is recommended that actual high brightness LED’s (HB-LED’s) are used for the load. They should be
rated at 0.9 A. The HB-LED’s should be connected in series. Their voltage drop should be between 55
VDC and 110 VDC. Alternatively a constant voltage electronic load could be used. If using a constant
voltage electronic load a 1000-µF/250 VDC capacitor is required at the input to the electronic load. The
1000 µF capacitor should not be used if using HB-LED’s as the load.
5.1.4
5.1.5
Oscilloscope
A digital or analog oscilloscope with current probe is required to view the AC current in the PFC inductor
or buck inductor.
Signal Generator
A signal generator that can produce a square wave pulse train at between 200 Hz and 1 kHz is required
to do external PWM dimming.
5.1.6
5.1.7
Fan
Forced air cooling is not required
Recommended Wire Gauge
A minimum of 18 AWG wire is recommended. Also the wire connections between the AC source and the
EVM, and the EVM and load should be less than two feet long. The AC input connector accepts a
standard IEC320-C13 connector with ground pin.
6
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Test Setup
5.2 Recommended Test Setup
90 - 265
VRMS
AC Source
Constant
Voltage
Load
CL1
Current Probe:
PFC inductor
ripple current
monitor
CL2
Current Probe:
Buck inductor
ripple current
monitor
+
-
L
N
TP4 & TP5
1000uF
250V
+
TP1 & TP2
PFC output voltage
Loop injection point
V2
A1
V1
IEC320
-C13
Plug
J2
TP3
J3
J4
Pin 1: PFC Shutdown
Pin 2: GND
Buck bias voltage monitor
Short pins to Enable
On Board Dimming
Pin 1: Buck Shutdown
Pin 2: GND
Pin 3 External PWM dimming input
Figure 3. UCC28810EVM-002 Recommended Test Set Up
Note: The 1000-µF/250-V capacitor on the output is not required if the load is a string of HB-LED’s.
5.3 List of Test Points
Table 2. Test Point Functions
TEST POINTS
TP1
NAME
DESCRIPTION
Loop injection point
TP2
Loop injection point, PFC output
Buck bias voltage output
TP3
VCC_BK
PFC+
TP4
PFC output voltage
TP5
PFC-
PFC output voltage ground
Buck bias voltage input
Buck bias voltage ground
Ground connection
TP6
VCC_BK
GND
TP7
TP8
GND
TP9
EN
Buck enable
TP10
TP11
J2-1
GND
Buck input voltage ground
Buck input voltage
BK_IN
PFC shutdown
GND
Apply 3.3 V to this pin to shutdown PFC stage
J2-2
J4-1
BK_Shutdown
GND
Apply 3.3 V to this pin to shutdown buck stage
Input for external PWM dimming
J4-2
J4-3
PWM Dim
Short the two pins on J3 to enable on board PWM diming. R26
varies dimming duty cycle
J3
On board dim
SLUU355A–March 2009–Revised June 2009
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Test Procedure
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6
Test Procedure
All tests will use the set up described in Section 5 of this user guide. Ensure potentiometer R26 is rotated
completely clockwise.
WARNING
HIGH VOLTAGE levels are present on this evaluation module
whenever it is energized. Proper precautions must be observed
whenever working with this module. There is an energy storage
capacitor (C17) on this module which must be discharged before
the board can be handled. Serious injury can occur if proper safety
procedures are not followed.
6.1 Applying Power to the EVM
1. Set up the EVM as described in Section 5 of this user guide.
2. Ensure the AC source is off.
3. Ensure potentiometer R26 is rotated completely clockwise.
4. Set constant voltage load to between 55 V and 110 V. If using a HB-LED string ensure the voltage
drop, when operating, is between 55 V to 110 V nominal. Note the 1000-µF/250 V capacitor is not
required on the output if using a HB-LED string.
5. Set AC source to 90 VRMS.
6. Turn on AC source.
7. Monitor PFC output voltage at TP4 and TP5, V2.
8. Monitor output current at A1.
9. Monitor output voltage at V1.
10. The EVM is now ready for testing.
6.2 Line/Load Regulation and Efficiency Measurement Procedure
1. Apply power to the EVM per Section 6.1.
2. Vary the constant voltage load from 110 V to 55 V.
3. Observe output current on A1 stays constant.
4. Vary AC source from 90 VRMS to 264 VRMS.
5. Observe output current on A1 stays constant.
6. PFC inductor ripple current can be measured at CL1 using an oscilloscope and current probe.
7. The buck output inductor current can be measured at CL2 using an oscilloscope and current probe.
8. See Section 7 for some typical test results.
6.3 PFC Disable
1. Ensure the AC source is off.
2. Connect a DC source to J2.
3. Set DC source to 0 V.
4. Apply power to the EVM per Section 6.1.
5. Increase DC source to 3.3 V. This input can accept up to 12 V.
6. Observe PFC output voltage reduces, V2.
7. PFC inductor ripple current looses high frequency component.
8
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Test Procedure
6.4 Buck Disable
1. Ensure the AC source is off.
2. Connect a DC source to J4, pins 1 and 2.
3. Set DC source to 0 V.
4. Apply power to the EVM per Section 6.1.
5. Increase DC source to 3.3 V. This input can accept up to 12 V.
6. Observe output current, A1, drops to zero.
7. PFC voltage, V2, does not change.
6.5 Internal Dimming Function
1. Ensure the AC source is off.
2. Ensure jumper is present on J3.
3. Apply power to the EVM per Section 6.1.
4. Rotate R26 potentiometer slowly anti clockwise.
5. Observe output current on A1 reduce from nominal 0.9 A to 0.1 A. If LED string is attached observe
LED’s dim.
6.6 External Dimming Function
1. Ensure the AC source is off.
2. Ensure jumper is removed from J3.
3. Connect signal generator to J4, pins 3 and 2.
4. Set signal generator to generator a pulse from 0 V to 3.3 V at 200 Hz with variable duty cycle. Note
when the PWM signal is high the LED light is reduced. 100% duty cycle will turn LED off.
5. Apply power to the EVM per Section 6.1.
6. Vary the duty cycle of the signal generator output.
7. Observe output current, A1, changes. If an LED string is attached observe LED’s dim.
6.7 Configuring the PFC Stage for Fixed Output
The EVM ships configured as a boost follower PFC. Using a soldering iron some simple component
modifications can change the PFC configuration from boost follower to fixed output voltage.
1. Remove R1, R3, R4, R6, C1 and Q1.
2. Change R11 to 6.49 kΩ.
3. The EVM now uses a fixed output voltage PFC stage. Repeat tests to see functionality.
6.8 Equipment Shutdown
1. If DC sources are connected to shutdown pins, J2 and J4, ensure they are set to 0 V.
2. Ensure load is at maximum, this will help discharge C17.
3. Turn off AC source.
4. Monitor PFC output voltage V2. Do not handle EVM until V2 reads less than 50 VDC.
SLUU355A–March 2009–Revised June 2009
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Performance Data and Typical Characteristic Curves
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7
Performance Data and Typical Characteristic Curves
Figure 4 through Figure 8 present some typical performance curves for the UCC28810EVM-002 with 30
Cree XRE LED’s at 900 mA.
EFFICIENCY/POWER FACTOR
vs
LINE VOLTAGE
TOTAL HARMONIC DISTORTION
vs
LINE VOLTAGE
12
1.00
10
8
0.98
0.96
0.94
Power Factor
6
4
2
0.92
0.90
Efficiency
0.88
0
80 100 120 140 160 180 200 220 240 260
VRMS - Line Voltage - V
80 100 120 140 160 180 200 220 240 260
VRMS - Line Voltage - V
Figure 4.
Figure 5.
7.1 Transient
TRANSITION MODE BUCK PWM RESPONSE
(Ch1 and Ch 4 share GND reference)
TRANSITION MODE BUCK PWM RESPONSE EXPANDED
(Ch1 and Ch4 share GND reference)
Ch1:
Buck VIN
Ch3:
LED Current
Ch1:
Buck VIN
Ch4:
LED Voltage
0.5 A/div.
Ch4:
LED Voltage
0.5 A/div.
Ch2:
Buck VDS
Ch2:
Buck VDS
Ch3: LED
Current
Figure 6.
Figure 7.
10
A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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Performance Data and Typical Characteristic Curves
7.2 Input Current
TRANSITION MODE BUCK PWM AND LINE INPUT CURRENT
(Ch1 and Ch4 share GND reference)
Ch1:
Buck VIN
Ch3:
AC Input
Current
Ch4:
LED VOUT
Ch2:
Buck VDS
Figure 8.
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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EVM Assembly Drawing and PCB layout
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8
EVM Assembly Drawing and PCB layout
Figure 9 through Figure 11 show the design of the UCC28810EVM-002 printed circuit board.
Figure 9. UCC28810EVM-002 Top Layer Assembly Drawing (top view)
Figure 10. UCC28810EVM-002 Top Copper (top view)
Figure 11. UCC28810EVM-002 Bottom Layer (viewed through top layer)
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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List of Materials
9
List of Materials
The EVM components list according to the schematic shown in Figure 1 and Figure 2.
Table 3. List of Materials
QTY
REF DES
C1
DESCRIPTION
MFR
PART NUMBER
1
Capacitor, ceramic, 10 µF, 25 V, X5R, 20%, 1206
Std
Std
Std
C2, C5
Capacitor, metallized polyester film, 0.1 µF, 275 VAC,
10%, X2, 17.5 mm x 5.5 mm
2
Std
2
1
C3, C4
C6
Capacitor, ceramic disc, 1 nF, 250 V, Y1/X1
Capacitor, ceramic, 2.2 µF, 25 V, X7R, 10%, 0805
Capacitor, ceramic, 1 nF, 50 V, NPO, 5%, 0805
Panasonic
Std
ECK-ANA102MB
Std
C7, C9,
6
C10, C21,
C23, C25
Std
Std
1
1
C8
Capacitor, ceramic, 330 nF, 16 V, X7R, 10%, 0805
Capacitor, ceramic, 18 pF, 50 V, NPO, 5%, 1206
Std
Std
Std
Std
C11
C12, C28, Capacitor, ceramic, 1 µF, 25 V, X5R, 10%, 0805
C34
3
Std
Std
C13, C20, Capacitor, ceramic, 0.1 µF, 25 V, X7R, 10%, 0805
C29
3
1
2
Std
Std
C14
Capacitor, polypropylene film, 0.56 µF, 400 V, 5%
Panasonic
Std
ECW-F4564JL
Std
C15, C16 Capacitor, aluminum electrolytic, 100 µF, 35 V, 20%, 6.3
mm x 11.5 mm
1
1
2
1
1
1
1
2
1
2
2
1
2
2
2
2
2
C17
C18
Capacitor, aluminum electrolytic, 82 µF, 450 V, TS-HB
Capacitor, ceramic, 10 µF, 25 V, X7R, 10%, 1210
Panasonic
Std
ECO-S2WB820BA
Std
C19, C22 Capacitor, ceramic, 10 nF, 50 V, X7R, 10%, 0805
Std
Std
C24
C26
C27
C30
Capacitor, ceramic, 100 pF, 200 V, NPO, 5%, 0805
Capacitor, ceramic, 47 pF, 50 V, NPO, 5%, 0805
Capacitor, ceramic, 33 pF, 50 V, NPO, 5%, 1206
Capacitor, polypropylene film, 0.56 µF, 630 V, 5%
Std
Std
Std
Std
Std
Std
Panasonic
Panasonic
Std
ECW-F6564JL
ECQ-E2105KF
Std
C31, C32 Capacitor, metallized polyester film, 1.0 µF, 250 V, 10%
C33 Capacitor, ceramic, 470 pF, 50 V, NPO, 5%, 0805
CL1, CL2 Current loop, wire, 20 AWG., stranded, 3.0 in.
Std
NA
D1, D2
D3
Diode, 1.5 A, 600 V
Std
BYG10J
GBJ606
Diode, bridge rectifier, 6 A, 600 V
Diode, Schottky, 1.5 A, 30 V
Diode, Schottky, 1 A, 90 V
Std
D4, D16
D5, D7
D6, D17
D8, D18
D9, D10
Std
SL13-E3/61T
BYS11-90-E3/TR
1SS355
Std
Diode, switching, 90 V, 225 mA Ifm, high speed
Diode, ultra fast, 8 A, 600 V
Diode, Zener, 18 V, 1 W
Rohm
IR
HFA08TB60S
SMAZ18-13
Std
D11, D13, Diode, signal, 300 mA, 75 V, 35 mW
D15
3
Std
1N4148W
2
1
D12, D21 Diode, dual Schottky, 200 mA, 30 V
Std
Std
BAT54C
D14
Diode, Zener, 5.1 V, 1 W
SMAZ5V1-13-F
D19, D20, Diode, Zener, 500 mW, 75 V
D22, D23
4
Std
MMSZ5267BT1
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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List of Materials
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Table 3. List of Materials (continued)
QTY
1
REF DES
F1
DESCRIPTION
MFR
PART NUMBER
SMP 1.25
Std
Fuse, SMP, 1.25 A
Bel
Std
1
F1
Fuse 250 V UL fast 5 X 20 MM
Fuse clip, 5 x 20 mm, PC mount
2
FH1
Wickmann
Aavid
01000056H
593002
2
HS1, HS2 Heatsink, TO-220, vertical mount, 15°C/W
1
J1
Connector, AC receptacle, board mount, R/A, 9 mm
Header, male 2 pin, 100-mil spacing, (36-pin strip)
Header, male 3 pin, 100-mil spacing, (36-pin strip)
Terminal block, 2 pin 9.52-mm spacing
Inductor, thru hole, 1.3 A, 126 mΩ
Qualtek Electronics
Sullins
703W-00/54
PTC36SAAN
PTC36SAAN
OSTT7022150
33331C
2
J2, J3
J4
1
Sullins
1
J5
OST
1
L1
muRata
1
L2
Transformer, 1 prim, 1 sec, 1 mH, 3.1 A
Transformer, 1 prim, 1 sec, 400 µH, 2 A
Transistor, NPN, 75 V, 500 mA
Coiltronics
Coiltronics
CTX16-18484
CTX33-18428
1
L3
Q1, Q2,
Q4, Q7
4
Std
MMBT2222A
1
1
1
2
2
1
1
2
Q3
MOSFET, N-channel , 400 V, 10 A
MOSFET, N-channel, 500 V, 6 A
IR
IRF840
STP6NK50Z
FMMT560
Std
Q5
ST
Q6
Bipolar, PNP, -500 V, -500 mA
Zetex
Std
Std
Std
Std
Std
R1, R3
R2, R5
R4
Resistor, chip, 301 kΩ, 1/4 W, 1%, 1206
Resistor, chip, 1.00 MΩ, 1/4 W, 1%, 1206
Resistor, chip, 4.02 kΩ, 1/8 W, 1%, 0805
Resistor, chip, 6.19 kΩ, 1/8 W, 1%, 0805
Resistor, chip, 4.75 kΩ, 1/8 W, 1%, 0805
Std
Std
R6
Std
R7, R28
Std
R8, R11, Resistor, chip, 10.7 kΩ, 1/8 W, 1%, 0805
6
R29, R30,
R33, R44
Std
Std
1
1
1
R9
Resistor, chip, 24.3 kΩ, 1/8 W, 1%, 0805
Resistor, chip, 6.81 kΩ, 1/8 W, 1%, 0805
Resistor, chip, 332 Ω, 1/8 W, 1%, 0805
Std
Std
Std
Std
Std
Std
R10
R12
R13, R15, Resistor, chip, 511 kΩ, 1/4 W, 1%, 1206
R39, R40
4
Std
Std
2
1
2
2
2
2
2
2
1
1
R14, R16 Resistor, chip, 100 kΩ, 1/4 W, 1%, 1206
Std
Std
R17
Resistor, chip, 47.5 Ω, 1/8 W, 1%, 0805
Std
Std
R18, R37 Resistor, chip, 21.5 kΩ, 1/8 W, 1%, 0805
R19, R36 Resistor, chip, 10.0 Ω, 1/8 W, 1%, 0805
R20, R35 Resistor, chip, 0.40 Ω, 1 W, 1%, 2512
R22, R23 Resistor, chip, 200Ω, 1/2 W, 1%, 1812
R24, R42 Resistor, chip, 10.0 kΩ, 1/8 W, 1%, 0805
R25, R46 Resistor, chip, 100 kΩ, 1/8 W, 1%, 0805
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
R26
R27
Potentiometer, 3/8 cermet, single turn, flat
Bourns
Std
3362P-504
Std
Resistor, chip, 665 Ω, 1/4 W, 1%, 1206
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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List of Materials
Table 3. List of Materials (continued)
QTY
REF DES
DESCRIPTION
MFR
PART NUMBER
R31, R32, Resistor, chip, 15.0 kΩ, 1/8 W, 1%, 0805
R45
3
Std
Std
1
1
1
1
2
1
1
1
1
2
2
2
2
2
1
R34
R38
R41
R43
Resistor, chip, 560 Ω, 1/8 W, 1%, 0805
Resistor, chip, 0.47 Ω, 1 W, 1%, 2512
Resistor, chip, 4.75 kΩ, 1/4 W, 1%, 1206
Resistor, chip, 221 kΩ, 1/8 W, 1%, 0805
Std
Std
Std
Std
Std
TI
Std
Std
Std
Std
R47, R48 Resistor, chip, 221 kΩ, 1/4 W, 1%, 1206
Std
U1
U2
U3
--
LED Lighting Power Controller
Timer, Low-Power CMOS
LED Lighting Power Controller
PCB, 10.4 in x 2 in x 0.062 in
Washer, #4, shoulder, nylon
Heatpad TO-220 0.009" SP900
Washer, #4 split, ss
UCC28810D
TLC555D
UCC28811D
HPA439 REVA
TI
TI
Any
Keystone
Bergquist
Std
SP900S-90
Std
Std
Std
Nut, #4-40, ss
Std
Screw, #4 - 40, SS, 0.5 in.
Connector, jumper, shorting, gold, 0.100"
Std
JP1
Sullens
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A 0.9-A Constant Current Supply with PFC for 100-W LED Lighting Applications
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EVALUATION BOARD/KIT IMPORTANT NOTICE
Texas Instruments (TI) provides the enclosed product(s) under the following conditions:
This evaluation board/kit is intended for use for ENGINEERING DEVELOPMENT, DEMONSTRATION, OR EVALUATION PURPOSES
ONLY and is not considered by TI to be a finished end-product fit for general consumer use. Persons handling the product(s) must have
electronics training and observe good engineering practice standards. As such, the goods being provided are not intended to be complete
in terms of required design-, marketing-, and/or manufacturing-related protective considerations, including product safety and environmental
measures typically found in end products that incorporate such semiconductor components or circuit boards. This evaluation board/kit does
not fall within the scope of the European Union directives regarding electromagnetic compatibility, restricted substances (RoHS), recycling
(WEEE), FCC, CE or UL, and therefore may not meet the technical requirements of these directives or other related directives.
Should this evaluation board/kit not meet the specifications indicated in the User’s Guide, the board/kit may be returned within 30 days from
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