13 Tips for Choosing an LED Controller You Need to Know

In the process of designing the LED controller, I believe you will encounter various problems. LEDs use more and more in daily life. We need to realize different functions of LEDs and show different effects.

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In this article, we will provide readers with some tips. The design process of the LED controller and PCB board is a crucial step, and we will provide you with 13 notes in the article. Help you quickly build the LED controller you need. And choose the appropriate LED Controller manufacturer to turn your ideas into reality.

Constant Voltage or Current LED Controller

While you are manufacturing LED fixtures or just thinking of changing the controller, the main point to identify is that the output current and voltage remain valid for the LED itself. If the unit you are using already contains a current controller or has inbuilt resistors, you might have to think about using a constant voltage controller.

These voltage controllers will supply your LED unit with the necessary power to use current controllers or resistors. These units always need a stable source of operating voltage, which could differ from the one you are getting from the power outlet.

For example, when you use an LED in a car to when you use it in a house, the voltage varies. Constant voltage supply for PCB might not be required if you already have a current controller, which matches the voltage supplied from multiple power sources.

Wattage

Depending on the wattage of the LED product, you will have to consider your power source's voltage. If you need more than a single unit of LED, you have to calculate how much wattage it uses. The overall goal is to ensure that your complete LED unit has enough power supply based on the wattage.

Voltage/Current

As discussed before, the constant voltage supplies can keep a LED unit operating when you are using resistors and current controllers. While manufacturing a LED unit for your PCB board, you must account for both of these factors. The simplest way to do so is to ensure that you have checked the manufacturing requirements. Also, this should be compatible with the power source.

Dimming Importance

Dimmable LEDs can change their brightness, which means you have to consider a controller to handle this. The power source is usually good for determining whether or not your LED will be compatible with dimming. Read the specification to understand what kind of dimming control you need for the power source you are using, and follow that as the sample guideline.

Flickering

Consideration for flickering is a complicated issue. The LED lights with this capability usually use a 120-Hz alternation. This way, the complete line can withstand the fluctuation level up to twice the LED's recommended power frequency.

When the limits approach almost 100%, you will see much less flicker. A good rule of thumb is that the LED's controller output should be below 10% in a workplace setting. Decorative lighting might be able to accept near to 100% flickering.

Dimming Methods and Flickering

The dimming method used in LED manufacturing will also determine how the device will withstand flicker. Usually, the LED output goes above twice the frequency of the power line.

Many controllers handle this problem by switching the lights on and on frequently to achieve dimming, which is known as PWM or pulse width modulation. Our eyes cannot comprehend the change of such high frequency, and we see dimmed lights.

A Lifetime of LED Controller

It is a primary concern while selecting the LED controller for your PCB. The temperature control device, after opening 50,000 hours, the machine should still run at above 70% capacity.

Power Quality Measures (THD, PF, Universal Input Voltage)

The THD of the device should not go above 20%. Anything below 10% is considered extraordinary.

When you are considering a residential setup, PF is not as relevant. However, if you consider using it for commercial purposes, you should choose LEDs carefully.

A. S.'s conventional voltage setting is 277V. Commercial usage LED should be able to operate at this voltage. However, general consumer lighting runs at about 120V. Your LED controller should be capable of working on both ends to be considered universal input voltage abled.

Multiple Outputs

The benefit of using a LED controller with multiple outputs that are also independent needs to be considered. The controller will have the power to control each of these outputs separately. It means each of these channels will have their fault handling and current regulation.

That way, when one of the channels fails, the controller is still operable. So, instead of considering a single output of 2A, you might find four outputs of 500mA to keep a minimal load on the line.

Temperature and Weather Resistance

When keeping the LED controller in the working environment, they work best with LED controllers. The manufacturer specification will list the ideal temperature and environment for using the LED. You can determine this from the IP rating of the power sources.

LED Controller Size

The surface area where you will fit the LED device or the complete LED setup is a significant concern. If you want to meet this controller inside a cover, the controller needs to fit comfortably inside. The installation area should have enough space for the controllers.

Therefore, consider measuring the installation area to buy the right side of the LED controller. They are available in a variety of sizes that will fit the need of any customer.

IP Ratings

C The IP rating is what you look at when trying to understand what kind of environment the device can withstand. You can find the complete chart from a manufacturer. 

To read the rating, here is a breakdown of the naming convention. 

1. The 1st digit signifies whether your device has robust object protection.

2. The 2nd digit signifies whether your device has water protection.

Tradeoff Considerations

The LED device cost could require you to consider some vital tradeoffs, and here are the five most important factors you can find for the same.

Output Ripple

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By introducing a power conversion that can alternate between two stages, the LED controller can deal with the output ripple requirement. Alternatively, you can use a two-step conversion. The first step would be to provide a steady power source, and the second stage will create the output current. This kind of design comes with two separate chips and costs more. 

If you are willing to use the single power conversion, you will get the device at a much-reduced cost.

Startup Time

The startup time of the device can determine the price of it. It is all about the efficiency of the equipment at the cost you are willing to pay. In general, the quick starting LEDs have high power utilization, which can fast charge the capacitors. But this high power remains steady throughout the usage, which means the device does not operate efficiently.  

The excess power usage is a waste and will cost you much more in the long run. If a fast startup time is not mandated, then you can switch it out for a lower cost version and save electricity in the process for as long as the device is in use.

Dimming Level and Efficiency

The lower efficiency devices will provide lower levels of dimming. Fortunately, some improvement is being made in this area to counteract balancing the dimming and efficiency.

Cost and Efficiency

When you are using high-frequency transformers, the device is likely to cost much more. The same is true for bigger fluctuating transistors.

Universal Input Voltage and Cost

The universal input voltage has the power to handle both high and low current levels. It all depends on the current level you are using. If the LED can work in single voltage mode, then you will save money on buying a product that does not have universal input voltage.

However, if you have confusion regarding what voltage is needed, it is best to pay the higher price to get a product that won't fault out after a few uses.

Summary

Selecting the LED controller for your PCB should be a careful consideration due to the product's lifetime. But this does not have to be a difficult task. Utilize this guide to identify the optimum performance of your lighting system.

If you need a specific production, you can contact us. We have more than ten years of PCB board manufacturing experience and can give you reasonable suggestions.

Introduction

LED lighting is fast replacing traditional incandescent and fluorescent lighting due to benefits like high energy efficiency, long life and design flexibility. At the heart of an LED lighting product are the LED chips which provide the illumination. Choosing the right LED chips is crucial for achieving the target light output, efficiency, color characteristics and reliability.

This article discusses how to select appropriate LED chips for lighting design including parameters like power, luminous efficacy, color temperature, CRI index and thermal management. Read on for practical guidance to pick optimal LEDs for your lighting application.

Key LED Chip Specifications

The main parameters that characterize an LED chip are:

Power Rating

• Measured in Watts
• Determines light output
• Options range from 0.2W to over 10W

Forward Voltage

• Typical values between 2V to 4V
• Impacts the driver design

Luminous Efficacy

• Measure of light output vs input power
• Given in lumens/Watt (lm/W)
• Higher is more energy efficient

Peak Wavelength

• Determines color ' 620-630nm is red, 520-535nm is green etc.
• For white LEDs, blue chip + yellow phosphor is common

Color Temperature

• Warm white, neutral or cool white
• Measured in Kelvin (K)
• -K is warm white, -K is cool white

CRI Index

• Color Rendering Index
• Rating of color quality ' maximum of 100
• Higher CRI gives better light quality

Viewing Angle

• Beam width at 50% intensity points
• Narrow (15°), medium (25-50°) or wide (120°+) available

Lifetime

• Hours of operation before light output declines by 30%
• 30,000 to 100,000 hour lifetimes are common

Package Type

• Surface mount or through-hole LEDs
• Defines how it's soldered to PCBs

Key Considerations for LED Chip Selection

Primary aspects to consider when choosing LED chips for lighting include:

Target Luminosity

• How much visible light is needed for the application?
• Select chips with lumen output in required range

Efficiency

• Higher lumens/watt improves energy efficiency
• Balances luminosity vs power consumption

Color Temperature

• Depends on lighting ambiance needed
• Warm, neutral or cool white?

Color Quality

• Higher CRI gives better light quality
• CRI 80+ is desirable for most lighting

Operating Life

• Lifetime of LED chips should match product life
• Select chips with 50,000 hours or greater lifetime

Thermal Management

• LEDs produce heat which impacts performance
• Ensure ambient temperatures are within chip rating

Driver Interface

• Forward voltage and constant current needs
• Match to chosen LED driver design

Physical Size

• Overall dimensions and pad spacing
• Ensure PCB layout accommodates chip package

Budget

• Balance performance vs unit cost of LED chips

Let's look at some of these aspects in more detail.

LED Chip Power Ratings

Available LED chip power ratings include:

• Low power: 0.2W to 0.5W
• Medium power: 1W to 3W
• High power: 5W to 10W

Higher power LEDs produce greater luminous output. But the increased heat needs thermal management.

For most general lighting like bulbs, downlights and strips, mid-power 1W to 3W LED chips offer a good compromise between light output and easier thermal control vs high power chips.

But specialty lighting like high bay lighting may use higher 5W-10W LEDs. While battery powered flashlights can use tiny 0.2W-0.5W chips.

Lumen Output

The lumen rating of LED chips depends on the power and efficacy. Various luminosity bins are available for each LED chip ranging from low to high lumens.

Typical lumen output for various power LEDs:

• 1W LED chip ' 100 to 130 lumens
• 3W LED chip ' 250 to 300 lumens
• 5W LED chip ' 400 to 500 lumens
• 10W LED chip ' 900 to lumens

Select chips with lumen output that meet the application's illumination needs. Combine multiple lower lumen LEDs for higher brightness.

LED Chip Efficacy

Higher efficacy or lumens/watt improves lighting energy efficiency. LED chip efficacy has increased enormously over the years due to technology improvements.

• Older LED chips had efficacy of 30-60 lm/W
• Mid-power modern LEDs now achieve up to 90-120 lm/W
• High power LEDs range from 100-150 lm/W

For a given power rating, choose LED chips with the highest efficacy within budget. This maximizes light output vs power consumption.

Color Temperature

LED Aluminum Substrate

Color temperature determines the visual color tone of white light ' from warm white to cool white.

Common white LED color temperatures:

• Warm white: K to K
• Neutral white: K to K
• Cool white: K to K

Warm white is commonly used in homes for cozy lighting. Cool white is preferred where brighter illumination is needed. Select color temperature depending on lighting ambiance needed.

CRI Index

The Color Rendering Index (CRI) indicates how accurately colors are displayed in the light.

• Low CRI like 70-75 gives poor color
• Medium CRI of 80-90 is generally acceptable
• High CRI > 90 approximates natural light

Aim for LED chips delivering 80+ CRI for quality lighting applications. chips with CRI 90+ can provide near natural color rendition.

LED Chip Lifetime

LED chips last much longer than traditional light sources. But over time, light output gradually declines due to phosphor degradation.

• 30,000 hours is minimum lifetime needed
• 50,000 hours is typical for quality mid-power LED chips
• 100,000 hours lifetime LEDs are used for extra reliability

Match the LED chip operating life to the target product lifespan. Also factor in ambient temperature which affects LED lifetime.

Thermal Management

LED chips generate significant heat. Operating at high temperatures lowers light output and shortens lifetime. Effective thermal management is vital.

• Use quality aluminum PCBs or ceramic substrates to conduct heat away from the LED chips.
• Thermal interface materials like epoxy or grease improve heat transfer to the board.
• Ensure ambient air temperature around LEDs stays within recommended range.
• Allow spacing between LEDs for airflow to limit temperature rise.

Proper thermal design greatly improves LED chip performance and longevity.

LED Chip Packages

Common LED chip package types include:

• SMD ' Low profile surface mount devices, easy to solder
• COB ' Chip on board arrays, combine multiple LEDs
• Through-hole ' Used for screw based bulbs
• Ceramic substrates ' Provide electrical isolation

SMD packages allow easier PCB assembly while COB arrays simplify optics design. Consider package height restrictions and soldering processes when selecting.

Conclusion

Choosing optimal LED chips by carefully evaluating key parameters like power rating, luminosity, efficiency, color characteristics, lifetime and thermal management enables creating energy-efficient, long lasting and good quality lighting products. Leverage the latest mid-power and high-power LED chips to realize substantial energy savings and simplified lighting design. With technology advancements delivering ever more performant LED chips, lighting product developers can take advantage by selecting the most appropriate chips to meet their precise application needs.

FAQs

What are the main differences between mid-power and high-power LED chips?

Mid-power LEDs (1-3W) strike a balance between light output and easier thermal management. High-power LEDs (5-10W) produce higher brightness but require substantial heat sinking.

How important is the PCB design for an LED lighting product?

Proper PCB thermal management through large copper planes, thermal vias, airflow and heat sinks is crucial to ensure LED chips operate at optimal temperature for maximum light output and reliability.

What causes LED chips to degrade over their lifetime?

Operating LED chips at high junction temperatures accelerates luminous decay, color shift and failures over time. Quality encapsulation also protects against moisture ingress and corrosion.

Can the color temperature of white LEDs shift over their lifetime?

Yes, white LEDs can gradually shift to a bluer tone over tens of thousands of hours of use. Higher quality LED chips exhibit better color consistency throughout their lifetime.

How does photon efficiency relate to LED efficacy?

Photon or wall-plug efficiency defines the LED chip's inherent ability to convert electrons to photons. Maximizing this improves luminous efficacy (lumens per watt). Chip design, materials and packaging maximize photon efficiency.

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