How To Test The LED Driver Using The 3341G Series LED DC Electronic Load Simulator
How To Test The LED Driver Using The 3341G Series LED DC Electronic Load Simulator
To comply with the global trend of energy saving and reduce carbon emissions, LED lighting
applications are increasingly used in consumer products (such as LED TV, mobile phones,
flashlights, etc.), and for general lighting purposes, replacing inefficient incandescent bulbs.
Other examples include automotive applications (headlamps, directional lights, brake lights,
interior lights, fog lights, instrument lights and so on), public works (LED street lights, traffic
lights, etc.) and office lighting (to replace fluorescent). While the use of LED lighting was
initially limited to specific applications, it is now widely adopted by the market and attracts
massive investments. To be competitive in this growing market and stand out from
competitors, not only is the price and quality of the LED’s used important, of equal
importance are the supporting devices required , especially the LED driver power supply.
The LED current driver supply must support several combinations of up to dozens of LED,
either in series or parallel in actual application in order to achieve the required number of
lumens. The supply has to convert AC power into LED DC current. For these power supplies,
energy efficiency is an important parameter. To maintain overall energy efficiency, low
energy consumption and high efficiency LED lamps can reduce the amount of heat losses
and also can extend the LED light service life. Efficiency improvement is the goal of any LED
drive power design. The current trend in LED driver technology is towards higher voltage
applications at higher power levels to reduce overall current. Not only can this improve the
efficiency, is also saves cost of copper of materials used in wiring. In addition, in order to
further save energy, as well as to allow lighting adjustment to the surrounding environment,
dimming of LED lights can achieve further energy-saving. Thus, the LED driver must not only
provide a stable DC current source, it must also satisfy the dimming control requirements.
Almost lighting manufacturers are investing heavily in development and production of
constant current LED drive power supplies to meet the huge demands of lighting market. As
LED prices continue to decrease, they will soon completely replace the incandescent light
bulbs causing the market to expand rapidly in the future.
The output of an LED driver has a constant current profile. The output voltage is based on
the LED equivalent on voltage Vd and the equivalent series resistance Rd. Unlike a
traditional power supply, the output is a fixed voltage which necessitates the use of an LED
electronic load to quickly simulate and verify performance and reduce the product
development schedule for shorter time to market.
Prodigit introduced 3341G series LED dimmable DC electronic load, including 3341G (300V,
24A, 300W), 3342G (500V, 12A, 300W), 3343G (500V, 24A, 300W), 33401G (500V, 6A,
150Wx2) , LED drive power for testing and verification. These loads can simulate real LED
characteristics, based on LED parameters inputs (including Vd threshold voltage, Rd series
resistance, Vo output voltage, etc.). Thus, there is no longer any need to connect actual
LEDs to the LED drive power supply. It also allows for easy changes in the LED parameters
to simulate different number of LEDs in a string, LED specifications or LED brands. It also
has the necessary control signal for dimming control of the LED driver, including a 0 to 12V
Analog voltage and 0 to 1kHz, 0 to 100% duty cycle output signal which is the best tool to
test and verify LED power drivers.
AC Source
Personal Computer
6010 P o w e r s u p p l y p r o d u c t s a u t o m a t i c t e s t s y s t e m ( AT E )
First of all, we need to determine the load characteristics of an LED :
Figure 1 illustrates the use of a current source to drive LED lights. The LED equivalent
circuit consists of two parts, a series resistance Rd and a series voltage Vd shown in Figure
2. The LED characteristic curve is shown in Figure 3. When the two ends voltage of the LED
are greater than the LED equivalent series voltage Vd, the current flows through the LED
Io is (V - Vd) / Rd that is the equivalent resistance.
The current rating of an actual lighting LED is generally 350mA to 700mA. High-power LED
can demand as much as 1400mA to 2800mA. Forward voltage Vd is typically about 2.8V ~
3.4V. An LED luminous flux value is proportional to the current flowing through the LED. As
seen in Figure 3, the Vd voltage will increase the LED current and light output, producing
not only more light but also more heat generation as a function of I x Rd.
Since the LED driver is a constant current source, the voltage across the LED terminal is Vd
+ (IxRd) = Vo. The threshold voltage Vd has a negative temperature coefficient (about -2mV
/ ℃), which means Vd decreases with increasing temperature, resulting in a decrease in Vo
with increasing temperature. Because of the negative temperature coefficient of LED
characteristics, the LED power driver is a current source rather than a voltage source so the
life span of the LED is not decreased.
For the actual LED Vd and Rd values and characteristics, refer to the LED manufacturer's
specifications or use the actual test data of the LED components. For the latter approach,
change the current values through the LED one by one and record the corresponding LED
terminal voltage at each step so you can draw the entire characteristic curve of LED I / V
current-voltage.
Although a schematic typically uses an LED symbol, in reality, due to LED lighting color
difference between manufacturer's models, or different working temperature and other
factors, the resulting in LED Vd and Rd differs. Thus, there are three different
characteristics of LED respectively LED1, LED2, LED3, corresponding to Vd1, Vd2, Vd3 and
Rd1, Rd2, Rd3.
Rd1 Rd2 Rd Rd3 Rd2
I Rd3 I I Rd1
Io Io Io
V Vd1 V V
Vd Vd2 Vd3 Vd1 Vd2 Vd3
The Vd of LED is same, The Vd of LED is difference, The Vd and Rd of LED are all
but Rd is difference but Rd is same difference (Vd3 > Vd2 > Vd1)
(Rd3 > Rd2 > Rd1) (Vd3 > Vd2 > Vd1) and Rd1 > Rd2 > Rd3
When the lumen output of a single LED is insufficient, you can choose a higher power LED or use multiple LEDs
in series. Since multiple LEDs in series can increase the output brightness, multi-unit LED array packaged
products are already available. In this case, Vd and Rd will be multiplied by the number of LEDs in series.
Figure 4 through 6 show the equivalent circuit and the corresponding characteristic curve for a variety of LED
series configurations and their various LED lighting applications :
LED x1
Single LED I
Prodigit 3341G / 3342G / 3343G LED electronic load modules are designed for LED simulation and
can simulate configurations from a single LED to multiple LED series. The series voltage can be as
high as 500V. You can also simulate multiple LED in parallel. The parallel maximum current can up
to 24A with power up to 300W. In addition, the 33401G module has two independent 150W x 2 LED
electronic load channels, suitable for power up to 150W. This supports testing of two LED power
supplies simultaneously.
For LED Driver output voltages higher than 500V, there is a 600V option available when placing the
order. For more details please refer to Prodigit's website or contact Prodigit’s sales department.
The following sections describe the differences between the LED mode load and the general
electronic load :
The purpose of an LED driver is to convert electricity into LED lighting suitable for driving the a light
fixture according to the end-user needs. There can be special types and general types of lighting.
Specific type LED drivers are configured with LED lights such as E27 bulb, MR16 cup lamps, or T5 /
T8 lamps and other smaller lighting devices. These devices have the circuitry that drives the LEDs
integrated with a specific number of LEDs while still packaged into a standard lamp shape product.
For general configuration, the LED driver and LED lights are separated in two parts: the LED driver
has a rated constant current output, where power and voltage can be an interval range. This means
that the number of LED lighting on the environment can be adjusted. Usually these are higher power
lighting units for commercial or industrial use.
I
Test voltage source or
current source One LOAD
CR Mode CURRENT
RESISTANCE
power-up
V
INPUT VOLTAGE
One
Test the battery Load power value, the load current will
CP Mode discharge capacity vary with the battery terminal voltage,
For Battery Constantly automatically adjusted to a
fixed power value。
Vd and Rd setting
Test the LED drive
Two
LED Mode power
LED Vd and Rd values, Simulate LED。
For LED Driver
The CR mode of electronic load; only need to set one parameter, setting CR mode and R = Vo / Io, is
used as a voltage source or current load, although the CR mode may be used to test LED Driver, but the
equivalent circuit is different from the same characteristics as the LED and cannot achieve the
effectiveness of LED simulation.
The CV mode of electronic load; only need to set one parameter, setting CV mode and V = Vo are used
as the current source of the load, although the CV mode may be used to test the LED Driver, the
equivalent circuit is different from the same characteristics as the LED and cannot achieve the
effectiveness of LED simulation.
LED mode : LED mode is for the simulation the equivalent circuit diagram Figure 2 of the LED, Integration
of the above CR mode + CV mode, 3341G series LED mode must also set two parameters
simultaneously, they are Vd and Rd respectively. Figure 14 shows the current waveform and the actual
LED load, same as those in Figure 13.
As the general type LED drive power supply can be used with a variety of combinations of LED lights, so
one by one the parameters of LED mode load must be set, including Vd, Rd, Vo, Io, etc.. As the actual
LED driver connected LED will be in accordance with the brand, specifications, series, parallel and other
conditions to have different load, doing so one by one will results in expensive test costs. The use of an
electronic LED load to simulate the combination of different LED to test results in time and cost savings.
Prodigit 3341G series LED mode load simulator provides two kinds of settings to simulate the actual LED
light. These settings are very convenient and can save a lot of computing procedures and time.
The first : Vo, Vd, Rd (details show the Left hand side below)
The second : Vo, Vd, Io (details show the Right hand side below)
Press the Config key to enter Config mode, LED indicator ON , it operates to set the order to display
Rd and Io。
As shown below:
Rd setting Io setting
At this time, press Mode key to LED Mode, then Preset ON.
Set Vo Set Vo
Set Vd Set Vd
Set Rd Set Io
How to set 3341G series Vo, Vd, Rd, No
3341G series LED mode load requires setting of Vo, Io and Rd so as to simulate the LED
characteristics curve shown in Figure 3, so it is not the actual LED load value.
An LED load equivalent circuit is composed of two parameters Vd and Rd. Because Io is
provided by the LED Driver which is presented on the LED the voltage value Vo = Vd + Io x
Rd, the actual output current and setting value will have a deviation. The relative value of Vo
will not be the same. This can be verified by reading the ammeter of the 3341G series LED
electronic load or using the actual LED Lamp + ammeter.
Upper trace
Analog VDIM
Lower trace
LED Driver Io
• DIM : PWM Io by analog voltage control
Upper trace
Analog VDIM
Lower trace
LED Driver Io
Upper trace
PWM VDIM
Lower trace
LED Driver Io
With the implementation of PWM dimming, the LED Driver output voltage and current are
variable. This may lead to the meter reading of 3341G series LED electronic load to be not
stable enough. However, the 3341G series LED electronic load has built-in voltmeter and
ammeter averaging. The user can freely set 1, 2, 4, 8, 16, 32, 64 times averaging reading
value of the meter. Of course, the more readings are selected, the value of the average
reading value will be more stable, but the relative reaction time will be longer. Set the
averaging value so that the value can be stable and the reaction speed can be acceptable.
The above detailed description is 3341G series LED load for LED Driver test, in addition, you can refer
to another special article of our company to discuss dimming LED lighting dimming test, can get more
test information. For high throughput manufacturing testing Prodigit provides the 6010 ATE test
system, The 6010 ATE test system is a flexible, high-speed, high-quality test system, the following is
detailed description of 6010 LED ATE test system hardware architecture:
(Note: This structure is with a 4 * 4 test fixture, to provide the required large and fast production line of
four U.U.T simultaneously test)
6010 ATE for LED Driver System Diagram
SW41
UUT A1
Noise & Timing Analyzer
AC IN OUT SW31 1
SW11 DIM IN
Meter 1 LOAD 1
SW21 UUT B1 DIM OUT
DIM IN OUT
AC IN
SW42
UUT A2
Noise & Timing Analyzer
AC IN OUT SW32 2
SW12 DIM IN
Meter 2 LOAD 2
SW22 UUT B2 DIM OUT
DIM IN OUT
AC SOURCE SW01 AC IN
SW43
UUT A3
Noise & Timing Analyzer
AC IN OUT SW33 3
SW13 DIM IN
Meter 3 LOAD 3
5303 SW23 UUT B3 DIM OUT
In-rush test
source DIM IN OUT
AC IN
SW44
UUT A4
Noise & Timing Analyzer
AC IN OUT SW34 4
SW14 DIM IN
Meter 4 LOAD 4
SW24 UUT B4 DIM OUT
DIM IN OUT
AC IN
3341G 4031
3342G
5310 99092 FIXTURE Single Channel Noise &
1KVA, AC Source 4013 Timing measurement
4 Channel Power Meter
5303 4032
AVR for 200A In-rush test
3343G
99095 LIGHT & FAN Sensor
60104+3342G+4031
SW01 : General test or SW11 ~SW14 : AC Voltage select Switch for UUT A/B AC Input
In-rush Current test SW21~ SW24 : DC Load Dim select Switch for UUT A/B Dim
SW31 ~SW34 : DC Load select Switch for UUT A/B Output.
SW41~ SW44 : Noise & Timing Meter select Switch for UUT A/B
Output.
SW31
UUT A1
Noise & Timing Analyzer
AC IN OUT SW21 1
SW11
Meter 1 LOAD 1
UUT B1
OUT
AC IN
SW32
UUT A2
Noise & Timing Analyzer
AC IN OUT SW22 2
SW12
Meter 2 LOAD 2
UUT B2
OUT
AC SOURCE SW01 AC IN
SW33
UUT A3
Noise & Timing Analyzer
AC IN OUT SW23 3
SW13
Meter 3 LOAD 3
5303 UUT B3
In-rush test
source OUT
AC IN
SW34
UUT A4
Noise & Timing Analyzer
AC IN OUT SW24 4
SW14
Meter 4 LOAD 4
UUT B4
OUT
AC IN
3310F & 3311F & 3315F
4031
5302A, 99093 TEST FIXTURE ADAPTER
270VA, AC Source 4015A
4 Channel Power Meter+THD
3312F & 3314F
99092 FIXTURE
5310
1KVA, AC Source 4013 Single Channel Noise &
4 Channel Power Meter Timing measurement
5303
AVR for 200A In-rush test 4032
3332F & 3336F
99094 Quick Charger Emulator
60104+3311F+4031
SW01 : General test or SW11 ~SW14 : AC Voltage select Switch for UUT A/B AC Input
In-rush Current test SW21 ~SW24 : DC Load select Switch for UUT A/B Output.
SW31~ SW34 : Noise & Timing Meter select Switch for UUT A/B
Output.
SW31
UUT A1
Noise & Timing
Analyze 1
SW11 AC IN OUT SW21
Meter 1 LOAD 1
UUT B1
OUT
AC IN
SW32
UUT A2
Noise & Timing
Analyze 2
SW12 AC IN OUT SW22
Meter 2 LOAD 2
UUT B2
OUT
AC SOURCE SW01 AC IN
UUT A3 SW33
Noise & Timing
Analyze 3
SW13 AC IN OUT SW23
Meter 3 LOAD 3
5303 UUT B3
In-rush test
source OUT
AC IN
SW34
UUT A4
Noise & Timing
Analyze4
SW14 AC IN OUT SW24
Meter 4 LOAD 4
UUT B4
OUT
AC IN
4031
5302A, 99093 TEST FIXTURE ADAPTER
270VA, AC Source 4015A
4 Channel Power Meter+THD
3312F & 3314F
60104+3311F+4031
SW01 : General test or SW11 ~SW14 : AC Voltage select Switch for UUT A/B AC Input
In-rush Current test SW21 ~SW24 : DC Load select Switch for UUT A/B Output.
SW31~ SW34 : Noise & Timing Meter select Switch for UUT A/B
Output.
SW21
OUT 1
SW11 AC IN Load 1
OUT 2
Power Meter
1
UUT B1
SW22
SW01 OUT 1
AC SOURCE AC IN Load 2
OUT 2
Power Meter
2
UUT B2
SW24
OUT 1
AC IN Load 4
OUT 2
4031
5302A, 99093 TEST FIXTURE ADAPTER
270VA, AC Source 4015A
4 Channel Power Meter+THD
3312F & 3314F
99092 FIXTURE
5310
1KVA, AC Source 4013 單Channel 雜訊&時序測量
4 Channel Power Meter
5303 4032
AVR for 200A In-rush test
3332F & 3336F
99094 Quick Charger Emulator
雙Channel 雜訊&時序測量
99096 BMS BD Control Box
60104+3311F+4031
SW01 : General test or SW11 ~SW14 : AC Voltage select Switch for UUT A/B AC Input
In-rush Current test SW21 ~SW24 : DC Load select Switch for UUT A/B Output.
SW31~ SW34 : Noise & Timing Meter select Switch for UUT A/B
Output.
OUT 1
Power Meter
1
SW23
UUT B
Load 3
OUT 1
5303
In-rush test
source OUT 2
AC IN SW33 Noise & Timing
OUT 3 Meter 3
OUT 4 SW24
Load 4
4031
5302A, 99093 TEST FIXTURE ADAPTER
270VA, AC Source 4015A
4 Channel Power Meter+THD
3312F & 3314F
99092 FIXTURE
5310
1KVA, AC Source 4013 單Channel 雜訊&時序測量
4 Channel Power Meter
5303 4032
AVR for 200A In-rush test
3332F & 3336F
99094 Quick Charger Emulator
雙Channel 雜訊&時序測量
99096 BMS BD Control Box
60104+3311F+4031
SW01 : General test or SW11 ~SW14 : AC Voltage select Switch for UUT A/B AC Input
In-rush Current test SW21 ~SW24 : DC Load select Switch for UUT A/B Output.
SW31~ SW34 : Noise & Timing Meter select Switch for UUT A/B
Output.