DK-114N-1 - Luminus Devices
Contents
1. PhlatLight LED Development Kit Manual DK 114N Series Introduction PhlatLight LEDs from Luminus Devices have been designed from the ground up to enable a new class of illumination and projection systems Benefiting from a suite of innovations in chip technology packaging and thermal management Phlat Light LEDs allow designers to achieve efficient light engine de signs and deliver high brightness solutions The DK 114N series of PhlatLight Development Kits was de signed for fast and simple evaluation of PhlatLight products The included electrical and thermal solutions enable custom ers to easily breadboard or prototype their system without time consuming and costly development of driver boards and heat sinks Capable of providing up to 14A and designed to work with all CBT and PT series parts and their associated applications the DK 114N development kits support various different drive con ditions and use scenarios Available in single or multiple channel versions the PhlatLight development kit will reduce development time of a PhlatLight based solution and provide a platform to build from LUMINUS Table of Contents Key Feat 8S x doa domu x e bad m ACC XR ACAD AR RE E d 2 Development Kit Contents 0000 cee 2 Heat Sink and Driver Module 000 2 Interface Board tase deca sis dom d REL 9s 98d d 2 Cable ASSCMDIY sars ara teu es o ges Ge meee aie A B Thermal Interface Materials and Mo2. tions of greater than 3 channels additional interface boards are included Additional channels will increase the quantities of each of these components The following sections describe the components in detail This development kit was designed with flexible features to al low for easy evaluation of PhlatLight LEDs It was not opti mized for size or for direct integration in end products However the underlying circuit and thermal design can be used as a reference by system designers To this effect the complete design files including schematics mechanical draw ings and bills of materials are available upon request Figure 1 Single Channel Evaluation Kit Contents LUMINUS PhlatLight DK 114N Series Development Kit Manual Phlatifejals Heat Sink Driver Board Assembly The heat sink and driver board are packaged together and mounted on a common metal substrate Figure 2 The module can be left as a free standing assembly on a bench top or it can be mounted on an optical table by using the standard optical post mounted on the heat sink Figure 2 Heat sink Driver board Assembly Heat Sink The heat sink is a high performance low cost and compact air cooled aluminum extrusion Measuring only 40 mm x 40 mm x 40mm the heat sink occupies a very small volume The typical thermal resistance from heat sink to ambient with the fan in operation is 0 6 9C W thereby enabling significant power dis sipation The
3. DK 114N Series Development Kit Manual age types a cable is soldered to the board The 12 cable assembly which includesthe interface board to driver board cables as well asthe interface board to fan cable connects as shown in Figures 13 and 14 The 12 ca ble assembly as shown in figure 13 connects the control board to a power supply This connection is shown in figure 15 Important Note In almost all cases the connectors will only insert in one direction Care must be taken not to force any of the connections as this may damage the connectors In the case that the connector can be connected improperly the con nector and mating cable are clearly marked with either color coding or lettering If powered with improper connections Figure 9 PhlatLight device placed on top of thermal inter damage can be caused to the LEDs and circuit boards face material 4 Insert screws in the holes of the coreboard and tighten To ensure equal pressure is exerted by all screws alternate tightening each screw until the board is securely fastened Figure 10 The device is now mounted and ready for elec trical connections Figure 11 CBT 54 LED to driver board cable interface Figure 10 Fully mounted PhlatLight device Electrical Connections The following sections assume that the user has all of the equipment listed in Table 1 1 Prepare the power supply and ensure the power supply be ing used is capable of providing enough
4. 264VAC 12V 8 5A 3 78 x 1 77 x 7 4 Enclosed Chassis 47 63Hz mount Elpac Power AC 100 264VAC 12V 8 3 47 63Hz 7 36 x 4 33 x 2 32 External Desktop Power One So AC 90 264VAC 12V 10 5A 5 x3 x1 25 Open Frame lutions 47 63Hz AULT Inc AC 100 264VAC 12V 10A 9 x 2 9 x2 Medical External 47 63Hz Lambda Power AC 90 264VAC 12V 12 5A 3 9 x 2 X 7 8 Enclosed Chassis 47 63Hz mount Table 3 List of AC DC power supplies with an isolated output LUMINUS Part FSK 530 12U S8SP 05005 SWS Series DPS50 SWS Series SWS Series FWP10012 D8F NC MBP125 1012 MW122RA12X XF01 SWS Series 2009 Luminus Devices Inc All Rights Reserved Page 9 PhlatLight DK 114N Series Development Kit Manual Appendix C Mechanical Dimensions LUMINUS 4X M2xD 4 HOLE PATTERN FOR C21 PACKAGES _ 4X M2 50x0 45 HOLE PATTERN F FOR Cll PACKAGES HEAT SINK FAN OPTICAL POST DRIVER BOARD BASE PLATE i 1 Lt 1 4b 4 i i l 5 i IEEE i il m I E P M DIMENSIONS rmm IN ALL TOLERANCES t 25mm 010 IN 100 3 7 110 33 4 34 2009 Luminus Devices Inc All Rights Reserved Page 10 Appendix D Specifications of Driver PhlatLight DK 114N Series Development Kit Manual Input Specifications Value Unit Note Input Voltage 12 V Max Supply
5. 7 and LED being used Tek Run isis 55757 riii ER TETY EEPE arssrii la WIDE XT rv HE Tom a y 8EOUDpS PhlatLight DK 114N Series Development Kit Manual gha Freq 20 RHE Chi Rise gai Tms Ch3 Fall EELEE 4 Sep 20405 8g 20 0 Figure 19 Input and output optical pulse Tek Run Trig chi Te9v T Wioous A Chl 7 30 v WE soomv uo 18 608015 Figure 20 Rise time example Chi 10V T BE soomv ii 33 2680ps Figure 21 Fall time example MIT 00ys Al Chl J 5 40 V Ch3 Rise 549 7ns 55ep 2008 14 39 17 Ch3 Fall 531 5ns 55ep 2008 14 39 54 Appendix A Electrical Design Considerations LUMINUS It is important to note that all PT and CBT series PhlatLight LEDs are built in a common anode configuration That is the copper core board is at a positive electrical potential in oper ation If this is not factored into the design it becomes diffi cult to connect multiple devices to a common heat sink The DK 114N development kit addresses this by configuring the de vices in a grounded common anode topology As a result the LED anode is kept at ground and the cathode is at a negative potential The LED anode can be in direct electrical contact with the heat sink without concern of electrical contact with other LEDs It is important to note that while the heat sink is at ground there is still power passing through it For further information please contact Luminu
6. current channel 7 A Efficiency gt 90 Output Specifications Value Unit Note Max output current 17 A Output current ripple pulsed lt 10 Of set current Output Pulse Rise time lt 1 us Output Pulse Fall Time lt 1 us Output Setting Time 5 us min current to max Control Specifications Value Unit Note Max Pulse Frequency 240 kHz Duty Cycle Range 0 100 Appendix E Driver Board Schematic and Pinout LUMINUS Table 4 Driver board Specifications Differential Pair R14 C D BHER j zu ukuuH gt i i seuz wus 2009 Luminus Devices Inc All Rights Reserved Page 11 Appendix F Cable and Connector Pinout Info Interface Board Pin Driver Board pin Comment Pin1 Pin 1 GND Pin 2 Pin 2 Analog ADJ Pin 3 Pin 3 POT Pin 4 Pin 4 Enable Pin 5 Pin 5 PWM Pin 6 Pin 6 Vinx Pin 7 Pin 7 Thermistor Pin 8 Pin 8 Thermistor Table 5 Interface Board to Driver Board Signal Interface Board Pin Driver Board pin Comment Pin1 Pin1 12V Pin 2 Pin 2 12V Pin 3 Pin 3 12V Pin4 Pin 4 GND Pin 5 Pin 5 GND Pin 6 Pin 6 GND Table 6 Interface Board to Driver Board Power Interface Board Pin Fan pin Comment Pin 1 Pin 1 12 Pin 2 Pin 2 GND Table 7 Interface Board to Fan Interface Board Pin Color Comment Pin 1 Red 12 Pin 2 Black GND Table 8 Interface Board to Power Supply LUMINUS PhlatLig
7. A Figure 5 Left picture TIM cut for C21 package types Right picture TIM cut for C11 package types Mounting screws for the various package types are included M2x5 screws are provided for attachment of C21 package types PT54 PT39 CBT 54 and CBT 40 M2 5x6 screws are provided for attachment of C11 package types PT85 PT120 CBT 85 CBT 90 and CBT 120 2009 Luminus Devices Inc All Rights Reserved Page 3 User Instructions The following procedure explains how to setup the PhlatLight Evaluation Kit It is recommended that the table be equipped with ESD protection Important Note The driver board is capable of providing 14A of current to any device Not all PhlatLight products can be powered at 14A Care must be taken to ensure the proper cur rent is applied to the device Consult the product data sheets for current limitations of specific devices Equipment Required by User In order to power and use the development kit some addition al equipment is required Table 1 lists the type of equipment as well as a suggested part An additional list of other compat ible power supplies is provided in Appendix B Important Note It is very important that the power supply feature an isolated output If the AC input ground is tied to the DC output ground of the power supply it will cause dam age to the driver board All of the recommended supplies fea ture an isolated output Please refer to Appendix A for more informatio
8. at sink and the LED will power on Operating Instructions There are multiple different ways the PhlatLight DK 114N De velopment Kit can be operated The LEDs can be driven in con tinuous current controlled mode via on board POTs or through an external analog voltage Additionally each channel has in puts for an external function generator signal to pulse the LEDs and is capable of pulsing at frequencies of greater than 40kHz 1 2 3 To change the current when either the interface board or driver board is enabled rotate the on board POT Each POT will only function when enabled on the interface board Clockwise rotation increases the current while counter clockwise rotation will decrease the current To change the current when the external adjust is enabled attach a 0 5V signal to the ADJ test points These are la beled T3 T4 T7 T8 T11 and T12 Each test point is also labeled with either GND or ADJ When hooking up the 0 5V signal ensure that the ground cable is attached to the GND test point and the positive cable is attached to the ADJ test point The current to the LED will adjust with the voltage signal A higher voltage corresponds with a higher current It is recommended not to exceed a 5V signal as compo nents may overheat To measure the current going to the LED use a volt meter and measure the voltage across the sense resistor on the driver board For ease of probing two tes
9. ble 2 de tails the various different configurations J umper Location Function n Figure 14 Interface board to driver board cable connec tions Figure 15 Interface board to power supply cable interface 3 On each channel of the interface board there are two jumpers mounted One of these jumpers enables or dis LUMINUS No jumper J200r 190r 14 J180r J 130r 15 External 0 5 V current control Driver POT current control Control board POT current control Table 2 Control Board J umper Locations Position the jumpers as necessary to enable the type of control required The locations of these jumpers are shown in Figure 16 The central channel is detailed in the figure The locations are identical in the other two channels ENAJ l Luminus Device Inc Evaluation Kit Control Boord Figure 16 Jumper Locations 2009 Luminus Devices Inc All Rights Reserved Page 6 5 6 Rotate all of the current controlling POTs located at P1 P2 and P3 on the control board and at P1 on the driv er board counter clockwise until they stop The imbedded arrow should point towards the 10 on the POT The POT is now set at the minimum current setting The evaluation kit is now ready to be powered on Turn on the power supply The supply will draw a small amount of power To turn on any channel open the enable pin by removing the jumper Both the fan on the he
10. bolt pattern on the front face of the sink allows for easy mounting of all CBT and PT series modules All modules can be mounted either horizontally or vertically allowing for easy prototypes of systems Driver Board The driver board designed around National Semiconductor s LM3433 IC is designed to provide up to 14A of current to any PT or CBT series PhlatLight LED The board is mounted close to the heat sink and LED to ensure cable lengths are kept at a minimum 3 Longer cable lengths will cause increased cur rent ringing when pulsing the LEDs Using a negative rail grounded common anode topology the LM3433 driver board enables the anodes of multiple PhlatLight LEDs to be in electrical contact with each other There is no need to electrically isolate the anodes of the LEDs from each other or the heat sink 2009 Luminus Devices Inc All Rights Reserved Page 2 The driver board is fully capable of driving the LEDs in either CW or pulsed mode PWM frequencies in excess of 40kHz are feasible An external function generator is required for gener ating the pulse trains Interface Board The included interface board is meant to serve as a clean in terface from the user supplied lab equipment to the driver boards Each interface board is capable of routing power and signal control to up to three driver boards A potentiometer POT is included for all three channels to allow for manual ad justment of intensity Alternati
11. ht DK 114N Series Development Kit Manual LED Pin Driver Board Pin Comment Pin 1 Pin 1 Thermistor Pin 2 Pin 2 Thermistor Pin 3 Pin 4 LED Cathode Pin 6 Pin 4 Pin 8 LED Cathode Pin 10 Pin 5 Pin 12 LED Cathode Pin 14 Pin 6 Pin 3 LED Anode Pin 5 Pin 7 Pin 7 LED Anode Pin 9 Pin 8 Pin 11 LED Anode Pin 13 Table 9 LED to Driver Board C21 Package Style LED Pin Driver Board Pin Color Comment Pin 1 N A Green LED Anode Pin 2 N A Yellow LED Cathode Table 10 LED to Driver Board C11 Package Style Appendix G Future Iterations and Features Additional features and other enhancements to the develop ment kits are always in process and in development Among the planned additional features are e Thermistor test points for active monitoring of thermistor Built in pulse train generator for simple PWM testing Built in fan controller to regulate junction temperature e Computer based interface for power and color control For more information about these features please contact Lu minus Devices 2009 Luminus Devices Inc All Rights Reserved Page 12 PhlatLight DK 114N Series Development Kit Manual The products their specifications and other information appearing in this document are subject to change by Luminus Devices without notice Lumi nus Devices assumes no liability for errors that may appear in this document and no liability otherwise ar
12. ising from the application or use of the product or information contained herein None of the information provided herein should be considered to be a representation of the fitness or suit ability of the product for any particular application or as any other form of warranty Luminus Devices product warranties are limited to only such warranties as accompany a purchase contract or purchase order for such products Nothing herein is to be construed as constituting an additional warranty No information contained in this publication may be considered as a waiver by Luminus Devices of any intellectual property rights that Luminus Devices may have in such information PhlatLight is a registered trademark of Luminus Devices Inc all rights reserved This product is protected by U S Patents 6 831 302 7 074 631 7 083 993 7 084 434 7 098 589 7 105 861 7 138 666 7 166 870 7 166 871 7 170 100 7 196 354 7 211 831 7 262 550 7 274 043 7 301 271 7 341 880 7 344 903 7 345 416 7 348 603 7 388 233 7 391 059 Patents Pending in the U S and other countries Luminus Devices 1100 Technology Park Dr 978 528 8000 T Billerica MA 01821 978 528 8001 F E mail sales luminus com www luminus com Pauri 2009 Luminus Devices Inc All Rights Reserved LUMINUS Page 13
13. n on these requirements Lab Equipment Recommended Part 12V Lab Power Supply Lambda ZUP20 20 Oscilloscope Tektronix TDS 3024B Waveform Generator Agilent 33220A Multimeter Fluke 187 Photodetector Thorlabs PDA10A Table 1 Additional Lab Equipment PhlatLight Device Mounting Instructions The following procedure explains the process to properly mount a PhlatLight device to the included heat sink using the included thermal interface material and mounting hardware The primary goal isto ensure there is good thermal contact be tween the backside of the copper core board and the front face of the heat sink 1 Use a thermal pad of an area slightly larger than the area of the core board Figure 6 LUMINUS PhlatLight DK 114N Series Development Kit Manual Figure 6 PhlatLight device and an appropriate thermal in terface material 2 Prepare the heat sink surface by dusting or removing any particulates that have accumulated on the surface Place the thermal pad on the heat sink with pre drilled holes matching the hole pattern on the core board of the device Figures 7 and 8 Figure 7 Prepared heat sink with pre drilled bolt pattern Figure 8 C21 package type thermal interface material placed on heat sink 3 Place the device on the thermal pad taking care that the hole patterns match Figure 9 2009 Luminus Devices Inc All Rights Reserved Page 4 Phlatfejals PhlatLight
14. power to the devic es A single channel at full power will draw up to 80W at 12V and 6 5A If using a variable power supply like the Lambda ZUP2020 preset the voltage to 12V and set the current to the maximum Power off the supply until all con nections are established and the board settings are ready 2 Attach all of the wiring included in the kit The short 3 cable connects the LED C21 package types only to the driver board as shown in Figures 11 and 12 For C11 pack 1 2009 Luminus Devices Inc All Rights Reserved L U IV N J S Page 5 Figure 12 CBT 54 LED to driver board cable interface Figure 13 Driver board to interface board cable connec tions PhlatLight DK 114N Series Development Kit Manual 4 ables the channel and the other controls functionality of the board The enable disable jumper is located at the positions la beled ENA1 ENA2 and ENA3 When these positions are open not shorted the channel is enabled When they are closed shorted the channel is disabled Position the enable disable jumpers so that the two pins are closed shorted For the other jumper there are three different possible po sitions for the jumper each of which enables different functionality with respect to the control of the driver board It is possible to enable the current controlling POT on the driver board or the POT on the interface board or to control the current via a 0 5V external input Ta
15. s Interface Board Analog Dimming PWM Dimming Analog Dimming lt 4 l GND PWM Dimming Analog Dimming PWM Dimming Figure 22 Grounded Common Anode Configuration This configuration requires that the AC ground line from the supply providing power to the driver board is isolated from the DC ground line A short list of isolated power supplies is pro vided in Appendix B Appendix B Isolated AC DC Power Supplies Table 3 shows a list of isolated AC DC power supplies A power supply with isolated outputs is required to properly drive the DK 114N drivers Failure to use a similar power supply will re sult in a malfunctioning board Various different power supplies are listed in the table For best efficiency it is recommended to select a power supply that closely matches the required power 2009 Luminus Devices Inc All Rights Reserved Page 8 PhlatLight DK 114N Series Development Kit Manual CUI Inc AC 85 264 VAC 12V 2 5A 3 7 x2 x 0 85 Thru hole SMT 47 400Hz Omron AC 85 264VAC 12V 4 2A 5 x 3 34 x 1 57 47 63Hz Lambda Power AC 90 264VAC 12V 3A 3 62 x 1 46 x 6 26 Enclosed Chassis 47 63Hz mount 30W 50W 50W 60W 75W 100W 100W 125W 120W 150W Globtek Inc AC 90 264VAC 12V 5A 47 440Hz 5 24 x 2 39 x 1 62 External Desktop Lambda Power C 90 264VAC 12V 6 3A 3 7 x 1 69 x 6 69 Enclosed Chassis 47 63Hz mount Lambda Power AC 90
16. t studs have been placed to the left and right of R15 Figure 17 shows the location of the test studs on the driver board Figure 18 shows a conversion plot between the sense resistor voltage and the current going to the LED The current can also be calculated by the following formula V Sense bomn Equation 1 Sense where Vsense is the voltage measured across the sense re sistor in Volts V and Rsense is the value of the sense resis LUMINUS PhlatLight DK 114N Series Development Kit Manual tor in Ohms The sense resistor value is 0 0052 The output value will the be current going to the LED in amps A ary Ew Sense Resistor Test Studs Figure 17 Sense resistor location on driver board LED Current A Vense mV Figure 18 LED Current vs Vsense voltage 4 To modulate the LEDs through PWM connect a function generator to the test points labeled PWM and GND These test points are also labeled T1 T2 T5 T6 T9 and T10 The pulse output should be set to 0 5V where 5V represents off and OV represents on Proper operation is best monitored by using a photo detec tor to observe the light output from the LED Figures 16 18 show plots of typical waveforms The device under test was a blue CBT 54 run at 14A and 5096duty cycle at 30kHz Actual waveforms will depend on the specific driver 2009 Luminus Devices Inc All Rights Reserved Page
17. unting Hardware 3 Use Instructions PLC Ae oe oe oS 4 Additional Required Lab Equipment 4 PhlatLight Device Mounting Instructions 4 Electrical Setup Instructions 05 5 Operating Instructions lens 7 Appendix A Electrical Design Considerations 8 Appendix B Isolated AC DC Power Supplies 8 Appendix C Mechanical Dimensions 10 Appendix D Specifications of Driver Board 11 Appendix E Driver Board Schematic 11 Appendix F Cable and Connector Pinout Info 12 Appendix G Future Iterations and Features 12 2009 Luminus Devices Inc All Rights Reserved 960017 Rev A Key Features Drive any CBT or PT series PhlatLight LED up to 14A e Pulse frequencies of greater than 40kHz possible Analog current control via on board potentiometers or ex ternal voltage e Simple current and voltage measurements Fastrise and fall times less than 1 microsecond e Fast current level switching less than 5 microseconds Development Kit Contents The contents of each PhlatLight DK 114A Development Kit will depend on the number of channels ordered As shown in Figure 1 each kit includes the following components e Interface board Heat sink driver board assembly e Cable assemblies e Thermal interface materials and mounting hardware User Manual Each interface board supports up to 3 channels For configura
18. vely the current level can be controlled via a user supplied voltage signal which allows for analog dimming Likewise there are inputs for a user supplied pulse train which allows for pulsed width modulation PWM of the LEDs Figure 3 Interface Board Cable Assembly Each development kit includes all of the cables necessary for proper setup The primary cables included are as follows Power supply to interface board Interface board to driver board power Interface board to driver board signal e Interface board to fan Driver board to LED The interface board to driver board cables power and signal and the interface board to fan cable come bundled together For pinout information please refer to Appendix F In the cases of using any of the C11 package types PT85 PT120 CBT 85 CBT 90 and CBT 120 the driver board to LED cable is integrated into the driver board LUMINUS PhlatLight DK 114N Series Development Kit Manual Figure 4 Included Cable Assemblies For optimum performance it is not recommended to increase the length of the driver to LED cable A longer cable will result in decreased performance when pulsing the LEDs Thermal Interface Materials TIMs and Mounting Hardware Also included in the kit are precut sheets of a high performance thermal interface material eGraf HiTherm 1205 and the re quired mounting hardware for the devices rc at ases A A iD oe eee ote I ea ey
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