Design Example Report Title 7.5 W Power Factor Corrected TRIAC Dimmable Non-Isolated Tapped-Buck PAR16 Lamp Replacement LED Driver Using LinkSwitchTM-PL LNK458KG Specification 190 VAC – 265 VAC Input; 9 V (Typical), 800 mA Output Application LED Driver for PAR16 Lamp Replacement Author Applications Engineering Department Document Number DER-327 Date June 29, 2012 Revision 1.0 Summary and Features NEMA SSL 6-2010 compliant TRIAC dimming Single-stage, power factor corrected and accurate constant current (CC) output Low cost, low component count and small PCB footprint solution Highly energy efficient, >76% at 230 VAC input Fast start-up time (<50 ms) – no perceptible delay Integrated protection and reliability features No-load protection / hard short-circuit protected Auto-recovering thermal shutdown No damage during line brown-out or brown-in conditions PF >0.9 at 230 VAC ATHD <25% at 230 VAC Meets IEC 2.5 kV ring wave, 500 V differential line surge and EN55015 conducted EMI PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 4 Power Supply Specifications ...................................................................................... 5 Schematic ................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Input Stage .......................................................................................................... 7 4.2 Tapped-buck Topology Using LinkSwitch-PL Devices ........................................ 7 4.3 Output Feedback ................................................................................................. 7 4.4 Disconnected Load Protection............................................................................. 8 4.5 Overload and Short-Circuit Protection ................................................................. 8 4.6 Active Damper ..................................................................................................... 8 4.7 RCD Bleeder ....................................................................................................... 8 4.8 Line Surge Protection .......................................................................................... 8 5 PCB Layout and Outline ............................................................................................. 9 6 Populated PCB ......................................................................................................... 10 7 Bill of Materials ......................................................................................................... 11 8 Inductor Specification ............................................................................................... 12 8.1 Electrical Diagram ............................................................................................. 12 8.2 Electrical Specifications ..................................................................................... 12 8.3 Materials ............................................................................................................ 12 8.4 Inductor Build Diagram ...................................................................................... 13 8.5 Inductor Construction ........................................................................................ 13 9 Transformer Design Spreadsheet............................................................................. 14 10 Performance Data ................................................................................................. 17 10.1 Active Mode Efficiency ...................................................................................... 17 10.2 Line Regulation ................................................................................................. 18 10.3 Power Factor ..................................................................................................... 19 10.4 %ATHD ............................................................................................................. 20 10.5 Harmonic Content ............................................................................................. 21 10.6 Harmonic Measurements .................................................................................. 22 10.7 Dimming Characteristic ..................................................................................... 23 10.8 Unit to Dimmer Compatibility ............................................................................. 25 11 Thermal Performance ........................................................................................... 26 11.1 Equipment Used ................................................................................................ 26 11.2 Thermal Test Results ........................................................................................ 27 11.2.1 Normal Operation ....................................................................................... 27 11.3 Thermal Scans .................................................................................................. 28 12 Waveforms ............................................................................................................ 30 12.1 Drain Voltage and Current, Normal Operation................................................... 30 12.2 Drain Voltage and Current Start-up Profile ........................................................ 30 12.3 Output Voltage Start-up Profile.......................................................................... 31 12.4 Input and Output Voltage and Current Profiles .................................................. 31 12.5 Drain Voltage and Current Profile: Normal Operation to Output Short .............. 32 12.6 Drain Voltage and Current Profile: Start-up with Output Shorted ...................... 33 12.7 No-Load Operation ............................................................................................ 34 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 12.8 AC Cycling .........................................................................................................35 12.9 Dimming Sample Waveforms ............................................................................36 12.10 Line Surge Waveform ....................................................................................37 12.10.1 Ring Wave Surge ....................................................................................37 12.10.2 Differential Line Surge ............................................................................38 13 Line Surge .............................................................................................................39 14 Conducted EMI .....................................................................................................40 14.1 Equipment .........................................................................................................40 14.2 EMI Test Set-up .................................................................................................40 14.3 EMI Test Result .................................................................................................41 15 Revision History ....................................................................................................43 Important Note: Although this board is designed to satisfy safety requirements for non-isolated LED drivers, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Page 3 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 1 Introduction This document is an engineering report describing a non-isolated LED driver (power supply) utilizing a LNK458KG from the LinkSwitch-PL family of devices. The DER-327 provides a single 7.5 W dimmable constant current output. The key design goals were high efficiency and small size. This allowed the driver to fit into PAR16 sized lamps and be as close to a production design as possible. Figure 1 – PCB Assembly. The board was optimized to operate over the high-line AC input voltage range (190 VAC to 265 VAC, 47 Hz to 63 Hz). LinkSwitch-PL IC based designs provide a high power factor (>0.9) meeting current international requirements. The form factor of the board was chosen to meet the requirements for standard PAR16 LED replacement lamps. The output is non-isolated and requires the mechanical design of the enclosure to isolate the output of the supply and the LED load from the user. The document contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, PIXI spreadsheet and performance data. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 2 Power Supply Specifications The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Input Voltage Frequency Output Output Voltage Output Current Total Output Power Continuous Output Power Efficiency Nominal Symbol Min Typ Max Units Comment VIN fLINE 190 47 230 50/60 265 63 VAC Hz 2 Wire – no P.E. VOUT IOUT 8.4 760 9 800 9.6 840 V mA POUT 7.5 W 76 % At 230 VAC o Measured at POUT 25 C at 230 VAC Environmental Conducted EMI Meets CISPR22B / EN55015 Line Surge Differential Mode (L1-L2) 500 V 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Ring Wave (100 kHz) Differential Mode (L1-L2) 2.5 kV 2 Short-Circuit Series Impedance Power Factor ATHD Page 5 of 44 0.9 At 230 VAC 25 % At 230 VAC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 3 Schematic Figure 2 – Schematic for 9 V / 800 mA PAR16 Replacement Lamp Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 4 Circuit Description The LinkSwitch-PL (U1) family is highly integrated power ICs intended for use in LED driver applications. The LinkSwitch-PL provides high power factor in a single-stage conversion topology while regulating the output current across the range of input (190 VAC to 265 VAC) and output voltage conditions typically encountered in LED driver applications. All of the control circuitry responsible for these functions plus a high-voltage power MOSFET is incorporated into the IC. 4.1 Input Stage Fuse F1 provides protection against component failure. A relatively high, fast 3.15 A rating was needed to prevent false opening during line surges. Fuse F1 may be replaced with a fusible resistor (2 W, 3.3 ) for lower cost but lowers efficiency. The maximum input voltage is clamped by RV1 during differential line surges. The AC input is full wave rectified by BR1. Capacitor C4, C5 and differential choke L1 and L2 form the EMI filter. Total input filter capacitance is limited to low value to maintain high power factor. This input multiple Lfilter networks plus the frequency jittering feature of LinkSwitch-PL ensures compliance with Class B emission limits. Resistors R6 and R12 damp the resonance of the EMI filter, preventing peaks in the EMI spectrum when measured in a system (driver plus enclosure). Remove R6 and R12 if radiated EMI spectrum has significant margin in system level application. Inductor L1 and L2 are positioned after the bridge to avoid an imbalance in the EMI scan between line and neutral. This also allows the use of small high-voltage ceramic capacitors in the input filter. 4.2 Tapped-buck Topology Using LinkSwitch-PL Devices The tapped-buck power train is composed of U1 (power switch + control), D4 (freewheeling diode), C9 (output capacitor), and T1 (inductor). Diode D3 was used to prevent negative voltage appearing across the drain-source of U1 especially near the zero-crossing of the input voltage. The bypass capacitor C8 provides the internal supply for U1, it is charged via the drain during MOSFET off-time during start-up. For better efficiency and during dimming it is supplied via the extra winding of the inductor through the rectification of D5 and filtering of C11. 4.3 Output Feedback The output current is sensed by the voltage drop across R13 and then filtered by a low pass filter (R14 and C7). This biases the LinkSwitch-PL operating point such that the average FEEDBACK (FB) pin voltage is maintained at 290 mV in steady-state operation (800 mA output current). Bypass capacitor C10 is used to reduce dissipation across R13 thus increasing efficiency. Page 7 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 4.4 Disconnected Load Protection The reference is design is protected against accidental LED load disconnection (such as during production). The controller will operate in burst mode in order to prevent drastic failure in the board by limiting the output voltage via the reflected voltage from the auxiliary winding of the inductor through VR3 and the FB pin. The controller will in pulseskip mode every time the FB pin voltage reaches 520 mV threshold. 4.5 Overload and Short-Circuit Protection The load is protected against overload and short-circuits via a primary current limit. During short, primary current will build-up until it reaches current limit. Refer to shortcircuit waveforms for more information. 4.6 Active Damper The active damper network is used to limit the inrush current, associated voltage spikes and ringing when the TRIAC within a dimmer turns on. This connects a resistance (R11) in series with the input rectifier for a short period during each AC half-cycle, to minimize the dissipation across damper resistor R11. It is then bypassed for the remainder of the AC cycle via a parallel MOSFET (Q3). Resistor R7, R8, R9 and C3 determine the delay before the turn-on of Q3. Transistor Q1 ensures the reset of Q3 every AC half-cycle. 4.7 RCD Bleeder Resistors R1, R2 and C2 form a bleeder network which ensures that the initial input current is high enough to meet the TRIAC latching and holding current requirement, especially during small TRIAC conduction angle. Diode D6 reduces the power loss (through R1 and R2) during the decay of energy in C2. 4.8 Line Surge Protection The active damper is used to reduce the voltage stress across the power MOSFET in U1. If the instantaneous input voltage exceeds 400 V, Q3 will turn-off making a potential voltage divider between the impedance of the tapped-buck converter and R11. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 5 PCB Layout and Outline Figure 3 – Top Printed Circuit Layout. Figure 4 – Bottom Printed Circuit Layout. Page 9 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 6 Populated PCB Figure 5 – Populated Circuit Board (top side). Figure 6 – Populated Circuit Board (bottom side). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 7 Bill of Materials Item Qty Ref Des 1 1 BR1 2 1 C2 Description 1000 V, 0.8 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC 220 nF, 500 V, Ceramic, X7R, 1825 3 1 C3 1 nF, 50 V, Ceramic, COG 4 1 C4 33 nF, 400 V, Film Mfg Part Number Manufacturer B10S-G Comchip VJ1825Y224KBEAT4X Vishay B37979G5102J000 Epcos ECQ-E4333KF Panasonic 5 1 C5 47 nF, 400 V, Film ECQ-E4473KF Panasonic 6 1 C7 1 F 16 V, Ceramic, X5R, 0402 C1005X5R1C105M TDK 7 1 C8 C1608X5R1A106M TDK 8 1 C9 EKZE160ELL681MH20D Nippon Chemi-Con 9 1 C10 10 F, 10 V, Ceramic, X5R, 0603 680 F, 16 V, Electrolytic, Very Low ESR, 38 m, (8 x 20) 10 F, 10 V, Ceramic, X7R, 0805 C2012X7R1A106M TDK 10 1 C11 10 F, 16 V, Ceramic, X7R, 1206 11 1 C12 12 1 D1 13 2 D2 D6 14 1 D3 470 pF, 1000 V, Ceramic, COG, 1206 100 V, 1 A, Rectifier, Glass Passivated, DO213AA (MELF) 600 V, 1 A, Ultrafast Recovery, 75 ns, SOD123 60 V, 1 A, Diode Schottky PWRDI 123 15 1 D4 50 V, 5 A, Schottky, DO-201AD 16 1 D5 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 17 1 F1 18 2 L1 L2 3.15 A, 250 V, Slow, RST 19 1 Q1 20 1 Q2 21 1 Q3 22 2 R1 R2 1 k , 5%, 1/2 W, Thick Film, 2010 23 2 R3 R4 24 1 R5 25 2 26 2 27 28 2.2 mH, 0.27 A PNP, Small Signal BJT, 40 V, 0.6 A, TO-92 NPN, Small Signal BJT, GP SS, 40 V, 0.6 A, SOT-23 600 V, 400 mA, 8.5 , N-Channel, SOT 223 C3216X7R1C106M TDK VJ1206A471JXGAT5Z Vishay DL4002-13-F Diodes, Inc. UFM15PL-TP Micro Commercial DFLS160-7 Diodes, Inc. SB550 Vishay BAV21WS-7-F Diodes, Inc. 507-1181 Belfuse CTSCH875DF-222K Coilcraft 2N4403RLRAG On Semi MMBT4401T-7-F Diodes, Inc. STN1HNK60 ST ERJ-14YJ102U Panasonic 750 k, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF7503V Panasonic 499 k, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF4993V Panasonic R6 R12 10 k 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ103V Panasonic R7 R8 1.50 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1504V Panasonic 1 R9 1.2 M, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ125V Panasonic 1 R10 15 , 5%, 1/8 W, Carbon Film 29 1 R11 300 , 5%, 1 W, Pulse Proof, Thick Film, 2010 30 1 R13 31 1 R14 32 1 33 CFR-12JB-15R Yageo CRCW2010330RJNEFHP Vishay/Dale 0.374 , 1%, 1/3 W, Thick Film, 1206 SR732BLTER374F KOA Speer 4.7 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ472V Panasonic R15 2 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ202V Panasonic 1 R16 100 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ104V Panasonic 34 1 R17 20 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ203V Panasonic 35 1 RV1 275 V, 23 J, 7 mm, RADIAL 36 1 T1 Custom Made, EFD15, Horizontal, 8 pins Littlefuse Custom Made Custom Made 37 1 U1 LNK458KG Power Integrations 38 1 VR1 100 V, 5%, 500 mW, DO-35 1N5271B-TP Micro Commercial 39 1 VR2 15 V, 5%, 500 mW, DO-213AA (MELF) ZMM5245B-7 Diodes, Inc. 40 1 VR3 15 V, 5%, 150 mW, SSMINI-2 DZ2S15000L Panasonic Page 11 of 44 LinkSwitch-PL, eSOP-12B V275LA4P Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 8 Inductor Specification 8.1 Electrical Diagram Figure 7 – Transformer Electrical Diagram. 8.2 Electrical Specifications Primary Inductance 8.3 Pins 6-7, all other windings open, measured at 100 kHz, 0.4 VRMS 1.25 mH ±7% Materials Item [1] [2] [3] [4] [5] [6] Description Core: EFD-15; TDK-PC44 or equivalent. Bobbin: EFD-15; 4/4 pin Horizontal Magnet Wire: #28 AWG. Magnet Wire: #37 AWG. Tape, Polyester film, 3M 1350F-1 or equivalent, 9 mm wide. Loctite Super Glue Control Gel. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 44 29-Jun-12 8.4 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG Inductor Build Diagram Finish (P2) Start (P5) Finish (P7) Start (P8) Finish (P1) Start (P5) Finish (P1) Start (P5) Finish (P1) Start (P5) Finish (P8) Start (P6) Figure 8 – Transformer Build Diagram. 8.5 Inductor Construction Bobbin Preparation For the purpose of these instructions, bobbin is oriented on winder such that pin 1 side is on the left. Winding direction is counter-clockwise. WDG 1 WDG 2 WDG 3 WDG 4 Insulation WDG 5 Insulation WDG 6 Taping Start at pin 6. Wind 130 turns of item [4] and terminate at pin 8. Start at pin 5. Wind 23 turns of item [3] and terminate at pin 1. Start at pin 5. Wind 23 turns of item [3] and terminate at pin 1. Start at pin 5. Wind 23 turns of item [3] and terminate at pin 1. Add 1 layer of tape of item [5]. Start at pin 8. Wind 177 turns of item [4] and terminate at pin 7. Add 2 layer of tape of item [5]. Start at pin 5. Wind 19 turns of item [4] and terminate at pin 2. Add 1 layer of tape to secure the winding. Grind the core to get the specified inductance. Apply tape to secure both cores. Cut pins 3, 4 and 8. Apply adhesive item [6] to core and bobbin to prevent core movement. Final Assembly Page 13 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 9 Transformer Design Spreadsheet ACDC_LinkSwitch-PL-TapBuck_121611; Rev.1.0; Copyright Power Integrations INPUT INFO 2011 ENTER APPLICATION VARIABLES VACMIN 190 VACTYP 230 VACMAX 265 FL VOMIN 8.40 VO 9.00 VOMAX 9.60 IO 0.80 Power n 0.76 Dimming Application Yes ENTER LinkSwitch-PL VARIABLES Chosen Device ILIMITMIN ILIMITTYP ILIMITMAX VOR Turns Ratio LNK458 OUTPUT UNIT 190.00 230.00 265.00 50.00 8.40 9.00 9.60 0.80 7.20 V V V Hz V A W 0.76 Yes LNK458 1.01 1.15 1.29 102.02 10.74 A A A V TON 2.55 us FSW 122.81 kHz Duty Cycle 31.35 % IRMS IPK 0.10 0.48 A A KDP Warning 1.03 ENTER INDUCTOR CORE/CONSTRUCTION VARIABLES Core Type Core Type Custom Core Part Number EFD15 EFD15 Bobbin part number AE LE 15.00 34.00 15.00 34.00 AL 780.00 780.00 8.85 8.85 BW INDUCTOR DESIGN PARAMETERS - LPMIN 1348.50 LPTYP 1450.00 1450.00 LP_TOLERANCE 7.00 7.00 TURNS_TOTAL 270 270.00 ALG 19.89 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ACDC_LinkSwitch-PL_TB LinkSwitch-PL Tapped Buck Design Spreadsheet Design Title Minimum AC Input Voltage Typical AC Input Voltage Maximum AC Input Voltage AC Mains Frequency Minimum Output Voltage of LED string Output Voltage of LED string Maximum Output Voltage of LED string Output Current riving LED strings Continuous Output Power Efficiency Estimate at output terminals. Under 0.7 if no better data available Enter Yes if design uses TRIAC dimming, otherwise select No Chosen LinkSwitch-II device Minimum Current Limit Typical Current Limit Maximum Current Limit Reflected output voltage Primary to secondary turns ratio Expected on-time of MOSFET at low line and PO Expected switching frequency at low line and PO Expected operating duty cycle at low line and PO Worst case primary RMS current at VO Worst case peak primary current at VO LinkSwitch-PL must operate in discontinuous mode (KP > 1) for good power factor. Consider reducing the primary inductance, changing the number of turns or increasing the device size Enter Transformer Core If custom core is used - Enter part number here Bobbin Part number (if available) mm^2 Core Effective Cross Sectional Area mm^2 Core Effective Path Length nH/turn^ Ungapped Core Effective Inductance 2 mm Bobbin Physical Winding Width Minimum Inductance (Includes inductance of input and output winding) Typical inductance (Includes inductance of uH input and output winding) % Tolerance of the inductance Total number of turns (Includes input and Turns output winding turns). nH/turn^ Gapped Core Effective Inductance uH Page 14 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 2 BM BP Warning BAC ur LG 1839.89 Gauss 4934.15 Gauss 919.95 Gauss 140.69 0.92 mm Input Section NL_INPUT 247.00 AWG 36.00 L CMA 4.25 245.24 Cmils Output Section TURNS_OUTPUT 23.00 AWG_OUTPUT 24.00 L_OUTPUT CMA_OUTPUT Bias Section Use Bias? TURNS_BIAS 1.47 251.24 VBIAS Auto 8 PIVBS Warning Yes 21.00 8.00 37.68 Cmils Calculated Worst Case Maximum Flux Density (BM < 3000 G ) Peak Flux Density above maximum recommended value (BP < 3600 G ). Reduce BP by increasing the number of turns, increasing the core size, or reducing the IC size; Verify at short-circuit condition AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) Relative Permeability of Ungapped Core Gap Length (Lg > 0.1 mm) Section of winding that conducts only during ON time of the LINKSwitch-II Number of turns in Input section. Primary Wire Gauge (Rounded to next smaller standard AWG value) Number of Layers (Input section) Current Density capacity 200 < CMA < 500 Section of winding that conducts both when the Linkswitch-II is ON and OFF. Number of Turns in Output winding. To adjust number of turns change INDUCTOR_RATIO Output Winidng Wire Gauge (Rounded to next smaller standard AWG value) Number of Layers (Output winding) Current Density capacity 200 < CMA < 500 Is a Bias winding used? Turns Number of turns of Bias Winding Bias Voltage may be too low to supply the IC V with Energy. Verify performance on the bench Output Rectifier Maximum Peak Inverse V Voltage (calculated at maximum VAC and max VO) CURRENT WAVEFORM SHAPE PARAMETERS DMAX 31.35 % IAVG 0.04 A IP 0.48 A ID_PK 5.16 A ISW_RMS 0.10 A ID_RMS 1.61 A IL_RMS 0.10 A IL_TAP_RMS 1.62 A RFEEDBACK 0.38 ohm CBP 10.00 uF 527.86 V Duty cycle measured at minimum input voltage Input average current measured at the minimum input voltage Peak Primary current at maximum input voltage Peak output winding current at the maximum input voltage Switch RMS current measured at the minimum input voltage RMS current of freewheeling diode at maximum input voltage RMS current of the primary section of the inductor measured at the minimum input voltage RMS current of the output winding section of the inductor at the maximum input voltage FEEDBACK WINDING PARAMETERS This is a first approximation for the sense resistor and will likely require fine tuning in the bench Minimum required Bypass pin capacitor for correct operation VOLTAGE STRESS PARAMETERS VDRAIN Page 15 of 44 Estimated worst case drain voltage at maximum input voltage Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG VOR 102.02 V PIVS 41.52 V 29-Jun-12 Reflected output voltage Output Rectifier Maximum Peak Inverse Voltage (calculated at maximum VAC and maximum VO) Note: Peak Flux Density (BP) is above the recommended 3600 G, in this particular design actual measurement at worst case condition with line, load and temperature no core saturation occurred. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 10 Performance Data All measurements performed at 25 ºC room temperature, with an input frequency of 60 Hz unless otherwise specified. 10.1 Active Mode Efficiency 78.0 9.7 VDC Output 8.8 VDC Output 8.3 VDC Output 77.5 Efficiency (%) 77.0 76.5 76.0 75.5 75.0 74.5 175 185 195 205 215 225 235 245 255 265 AC Input Voltage (VRMS / 50 Hz) Figure 9 – Efficiency with Respect to AC Input Voltage at 30 mA. Page 17 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 275 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 10.2 Line Regulation The LinkSwitch-PL device regulates the output by controlling the power MOSFET on-time and switching frequency to maintain the average FEEDBACK pin at its 0.29 V threshold. Slight changes in output current may be observed when input or output conditions are changed or after AC cycling due to the device selecting a slightly different operating state (selection of on-time and frequency). 8 8.3 VDC Output 8.8 VDC Output 9.7 VDC Output 6 Regulation (%) 4 2 0 -2 -4 -6 -8 175 185 195 205 215 225 235 245 255 265 275 AC Input Voltage (VRMS / 50 Hz) Figure 10 – Line Regulation, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 10.3 Power Factor 0.98 9.7 VDC Output 8.8 VDC Output 8.3 VDC Output 0.96 Power Factor (PF) 0.94 0.92 0.90 0.88 0.86 0.84 185 195 205 215 225 235 245 255 265 AC Input Voltage (VRMS / 50 Hz) Figure 11 – High Power Factor within the Operating Range for 230 V LED. Page 19 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 275 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 10.4 %ATHD 40 8.3 VDC Output 8.8 VDC Output 9.7 VDC Output 35 30 THD (%) 25 20 15 10 5 0 175 185 195 205 215 225 235 245 255 265 275 AC Input Voltage (VRMS / 50 Hz) Figure 12 – Very Low %ATHD at 115 VAC. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 10.5 Harmonic Content 35 Limit 8.8 VDC Output Harmonic Content (mA) 30 25 20 15 10 5 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order Figure 13 – Meets EN61000-3-2 Harmonics Contents Standards for <25 W Rating for 230 V LED Output. Page 21 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 10.6 Harmonic Measurements VAC (VRMS) 230 Freq (Hz) 50.00 nth Order mA Content % Content 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 44.83 0.03 5.04 4.66 4.73 3.05 1.36 1.98 1.32 0.66 0.79 1.30 1.50 0.92 0.53 0.47 0.44 0.51 0.62 0.51 0.26 0.33 0.44 0.38 0.31 0.24 0.06% 11.25% 10.39% 10.56% 6.79% 3.02% 4.42% 2.94% 1.47% 1.77% 2.90% 3.34% 2.05% 1.17% 1.05% 0.99% 1.14% 1.37% 1.14% 0.59% 0.74% 0.98% 0.85% 0.69% 0.54% I (mA) P PF 45.91 9.6660 Limit (mA) <25 W 0.9139 32.8644 18.3654 9.6660 4.8330 3.3831 2.8626 2.4809 2.1891 1.9586 1.7721 1.6180 1.4886 1.3783 1.2832 1.2005 1.1277 1.0633 1.0058 0.9542 Remarks Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Table 1 – 230 VAC Input Current Harmonic Measurement for 9 V LED. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 10.7 Dimming Characteristic Dimming characteristic from a controlled AC supply to emulate the TRIAC conduction pattern. The reference design meets the dimming requirement as set by National Electrical Manufacturers Association (NEMA) Standards Publication SSL 1-2010 (Electronic Drivers for LED Devices, Arrays or Systems) and SSL 6-2010 (Solid State Lighting for Incandescent Replacement-Dimming). 800 Dim to Full Brightness 700 NEMA Light Output Upper Limit NEMA Light Output Lower Limit Output Current (mA) 600 500 400 300 200 100 0 0 20 40 60 80 100 120 140 160 180 Phase Angle (Conduction; º) Figure 14 – Dimming Curve Characteristic from Full Dim to Full Brightness. Meets NEMA SSL 6-2010. Page 23 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 800 Full Brightness to Dim 700 NEMA Light Output Upper Limit NEMA Light Output Lower Limit 500 400 300 Output Current (mA) 600 200 100 0 180 160 140 120 100 80 60 40 20 0 Phase Angle (Conduction; º) Figure 15 – Dimming Characteristic from Full Brightness to Full Dimming. Meets NEMA SSL 6-2010. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 10.8 Unit to Dimmer Compatibility These are the list of dimmers verified for this reference design. Users are not limited on the following list. Make sure to test the dimmers according to its recommended operating line input frequency to avoid flicker. Dimmer Maximum Conduction IOUT Angle (mA) (º) 174 793.2 Minimum Conduction IOUT Angle (mA) (º) 37.11 67.5 Input Origin 230 V / 50 Hz China TCL 630 W 230 V / 50 Hz China SEN BO LANG 300 W 167 790.5 56.88 Brand Dimming Ratio 11.8 :1 134.3 5.9 :1 230 V / 50 Hz China EBA HUANG 165 774.2 41.76 63.6 12.2 :1 230 V / 50 Hz China SB ELECTRC 600 W 166 778.5 49 94.8 8.2 :1 230 V / 50 Hz China MYONGBO 169 814 62.71 130.7 6.2 :1 230 V / 50 Hz China KBE 650 W 171 804.2 34.74 55 14.6 :1 230 V / 50 Hz China CLIPMEI 172 808 54 112 7.2 :1 230 V / 50 Hz China MANK 200 W 166 803 68.5 66.186 12.1 :1 230 V / 50 Hz German BUSCH2250 600 W 152 776.5 43.74 74.9 10.4 :1 230 V / 50 Hz German REV 300 W 151 745.2 38.06 44.9 16.6 :1 230 V / 50 Hz German MERTEN 572499 159 805 40.35 65.8 12.2 :1 230 V / 50 Hz German BERKER 150 747 54.18 105 7.1 :1 230 V / 50 Hz Italy RM34DMA 160 W 160.27 780 48.42 96.5 8.1 :1 230 V / 50 Hz Italy Relco RT34DSL 163 797 50.22 119 6.7 :1 Page 25 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 11 Thermal Performance 11.1 Equipment Used Chamber: AC Source: Wattmeter: Data Logger: Tenney Environmental Chamber Model No: TJR-17 942 Chroma Programmable AC Source Model No: 6415 Yokogawa Power Meter Model No: WT2000 Yokogawa MV2000 Figure 16 – Thermal Chamber Set-up Showing Box Used to Prevent Airflow Over UUT. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 11.2 Thermal Test Results 11.2.1 Normal Operation Load: 8 V / 800 mA LED load. The unit was verified inside an enclosure box to avoid the effect of the circulating air in the chamber (LED load was outside the chamber). Component PCB Board Ambient Bridge (BR1) LNK458KG (U1) FET Damper (Q3) Output Diode (D4) Transformer (T1) EMI Choke (L1) Device Temperature (ºC) 190 VAC / 50 Hz 265 VAC / 50 Hz 25 50 25 50 40.7 63.7 38.2 63.0 77.4 99.2 78.4 99.6 64.7 93.1 59.6 84.7 69.8 92.8 68.7 91.1 69.8 92.6 60.4 81.6 43.9 67.7 38.0 62.4 Table 2 – Thermal Data, No Potting. Page 27 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 11.3 Thermal Scans The scan is conducted at ambient temperature of 25 ºC open frame, 190 VAC / 50 Hz input. Figure 17 – LNK458KG U1 Case Temperature. Figure 18 – BR1 Bridge Rectifier. Figure 19 – Damper FET Q3 Case Temperature. Figure 20 – Transformer T1. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG Figure 21 – D4 Output Diode. Figure 22 – L1 EMI Choke. Figure 23 – C9 Output Capacitor. Figure 24 – L2 EMI Choke. Page 29 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 12 Waveforms 12.1 Drain Voltage and Current, Normal Operation No saturation in the inductor and design guaranteed to work in discontinuous mode within the operating input voltage. Figure 25 – 190 VAC / 50 Hz, 9 V LED String. Ch2: VDRAIN, 200 V / div. Ch3: IDRAIN, 0.2 A / div. Time Scale: 5 ms / div. Zoom Time Scale: 10 s / div. Figure 26 – 265 VAC / 50 Hz, 9 V LED String. Ch2: VDRAIN, 200 V / div. Ch3: IDRAIN, 0.2 A / div. Time Scale: 5 ms / div. Zoom Time Scale: 10 s / div. 12.2 Drain Voltage and Current Start-up Profile Device has a built in soft-start thereby reducing the stress in the device, transformer and output diode. Figure 27 – 190 VAC / 50 Hz, 9 V LED String. Ch1: VOUT, 2 V / div. Ch2: VDS, 200 V / div. Ch3: IDRAIN, 200 mA / div., Time Scale: 5 ms / div. Zoom Time Scale: 5 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 28 – 265 VAC / 50 Hz, 9 V LED String. Ch1: VOUT, 2 V / div. Ch2: VDS, 200 V / div. Ch3: IDRAIN, 200 mA / div., Time Scale: 5 ms / div. Zoom Time Scale: 5 s / div. Page 30 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 12.3 Output Voltage Start-up Profile Start-up time <50 ms; the reference design will emit light within 50 ms at non-dimming operation. Figure 29 – 190 VAC / 60 Hz, 9 V LED. Ch1: VOUT, 2 V / div. Ch2: VIN, 200 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div., 100 ms / div. Figure 30 – 265 VAC / 60 Hz, 9 V LED. Ch1: VOUT, 2 V / div. Ch2: VIN, 200 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div., 100 ms / div. 12.4 Input and Output Voltage and Current Profiles Output current ripple is inversely proportional to the impedance of the LED. Verify the current ripple on the actual LED to be used in the system. Increase output capacitance for less output current ripple. IPK-PK/IAVG=1.46 IPK-PK = 1.15A Figure 31 – 190 VAC / 50 Hz, 9 V LED String. COUT = 680 F Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 50 mA / div. Ch4: IOUT, 200 mA / div., 5 ms / div. Page 31 of 44 Figure 32 – 265 VAC / 50 Hz, 9 V LED String. COUT = 680 F Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 50 mA / div. Ch4: IOUT, 200 mA / div., 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG IPK-PK/IAVG=1.12 29-Jun-12 IPK-PK= 0.935A Figure 33 – 190 VAC / 50 Hz, 9 V LED String. COUT = 2 X 680 F Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 50 mA / div. Ch4: IOUT, 200 mA / div., 5 ms / div. Figure 34 – 265 VAC / 50 Hz, 9 V LED String. COUT = 2 X 680 F Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 50 mA / div. Ch4: IOUT, 200 mA / div., 5 ms / div. 12.5 Drain Voltage and Current Profile: Normal Operation to Output Short No saturation in the inductor during short-circuit, inductor current is limited by the ILIM. Figure 35 – 265 VAC / 50 Hz, Normal Operation then Output Short. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div., 10 ms / div. Z3: IDRAIN, 0.2A / div., 100 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 36 – 265 VAC / 50 Hz, Normal Operation then Output Short. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div., 10 ms / div. Z3: IDRAIN, 0.2A / div., 100 s / div. Page 32 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG Figure 37 – 265 VAC / 50 Hz, Normal Operation then Output Short. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div., 10 ms / div. Z3: IDRAIN, 0.2 A / div., 200 s / div. Figure 38 – 265 VAC / 50 Hz, Normal Operation then Output Short. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div., 10 ms / div. Z3: IDRAIN, 0.2 A / div., 1 ms / div. 12.6 Drain Voltage and Current Profile: Start-up with Output Shorted No saturation in the inductor during start-up short-circuit due to the built-in soft-start. Figure 39 – 190 VAC / 50 Hz, Output Shorted. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div, 10 ms / div. Z3: IDRAIN, 0.2 A / div., 10 s / div. Page 33 of 44 Figure 40 – 265 VAC / 50 Hz, Output Shorted. Ch1: VDRAIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IDRAIN, 0.2 A / div, 10 ms / div. Z3: IDRAIN, 0.2 A / div., 10 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 12.7 No-Load Operation The driver is protected during no-load operation, U1 operating is cycle skipping mode. Figure 41 – 265 VAC / 50 Hz, Start-up No-load. Ch1: VOUT, 200 V / div. Ch2: VOUT, 4 V / div. Ch2: IDRAIN, 0.2 A / div. Ch4: IOUT, 0.2 A / div. Time Scale: 100 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 42 – 265 VAC / 50 Hz, Start-up No-load. Ch1: VOUT, 200 V / div. Ch2: VOUT, 4 V / div. Ch2: IDRAIN, 0.2 A / div. Ch4: IOUT, 0.2 A / div.,100 ms / div. Z3: IDRAIN, 0.1A / div., 5 s / div. Page 34 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 12.8 AC Cycling The reference design has no perceptible delay. Figure 43 – 230 VAC / 50 Hz, 1 s On – 1 s Off. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch4: IOUT, 500 mA / div. Time Scale: 2 s / div. Figure 44 – 230 VAC / 50 Hz, 500 ms On – 500 ms Off. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch4: IOUT, 500 mA / div. Time Scale: 2 s / div. Figure 45 – 230 VAC / 50 Hz, 300 ms On – 300 ms Off. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch4: IOUT, 500 mA / div. Time Scale: 2 s / div. Figure 46 – 230 VAC / 50 Hz, 1 s On – 1 s Off. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch4: IOUT, 500 mA / div. Time Scale: 2 s / div. Page 35 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 12.9 Dimming Sample Waveforms Figure 47 – 230 VAC / 50 Hz, Sen Bo Lang Chinese Dimmer at Full TRIAC Conduction. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div. Time Scale: 5 ms / div. Figure 48 – 230 VAC / 50 Hz, Sen Bo Lang Chinese Dimmer at Minimum TRIAC Conduction. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div. Time Scale: 5 ms / div. Figure 49 – 230 VAC / 50 Hz, BUSCH2250 600 W German Dimmer at Full TRIAC Conduction. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div. Time Scale: 5 ms / div. Figure 50 – 230 VAC / 50 Hz, BUSCH2250 600 W German Dimmer at Minimum TRIAC Conduction. Load: 9 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 2 V / div. Ch3: IIN, 100 mA / div. Ch4: IOUT, 200 mA / div. Time Scale: 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 12.10 Line Surge Waveform 12.10.1 Ring Wave Surge Figure 51 – 230 VAC / 60 Hz, 9 V Load, VDS = 590 VPK (+) 2.5 kV Differential Ring Surge at 0º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 500 s / div. Figure 52 – 230 VAC / 60 Hz, 9 V Load, VDS = 613 VPK (+) 2.5 kV Differential Ring Surge at 90º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 50 s / div. Figure 53 – 230 VAC / 60 Hz, 9 V Load, VDS = 635 VPK (-) 2.5 kV Differential Ring Surge at 270º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 50 s / div. Figure 54 – 230 VAC / 60 Hz, 9 V Load, VDS = 661 VPK (-) 2.5 kV Differential Ring Surge at 0º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 1 ms / div. Page 37 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 12.10.2 29-Jun-12 Differential Line Surge Figure 55 – 230 VAC / 60 Hz, 9 V Load, VDS = 629 VPK (+) 500 V Differential Line Surge at 0º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 20 s / div. Figure 56 – 230 VAC / 60 Hz, 9 V Load, VDS = 711 VPK (+) 500 V Differential Line Surge at 90º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 20 s / div. Figure 57 – 230 VAC / 60 Hz, 9 V Load, VDS = 590 VPK (-) 500 V Differential Line Surge at 0º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 50 s / div. Figure 58 – 230 VAC / 60 Hz, 9 V Load, VDS = 705 VPK (-) 500 V Differential Line Surge at 270º. Ch2: VBULK, 100 V / div. Ch3: VDS, 100 V / div. Ch4: IDRAIN, 0.5 A / div. Time Scale: 20 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 13 Line Surge Input voltage was set at 230 VAC / 60 Hz. Output was loaded with 9 V LED string and operation was verified following each surge event. Two units were tested to confirm the results. Differential input line 1.2 / 50 s surge testing was completed on one test unit to IEC61000-4-5. Surge Level (V) +500 -500 +500 -500 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L to N L to N Injection Phase (°) 0 270 90 180 Test Result (Pass/Fail) Pass Pass Pass Pass Differential input line ring surge testing was completed on one test unit to IEC61000-4-5. Surge Level (V) +2500 -2500 +2500 -2500 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L to N L to N Injection Phase (°) 0 270 90 180 Test Result (Pass/Fail) Pass Pass Pass Pass Unit operated normally under all test conditions. Page 39 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 14 Conducted EMI 14.1 Equipment Receiver: Rohde & Schwartz ESPI - Test Receiver (9 kHz – 3 GHz) Model No: ESPI3 LISN: Rohde & Schwartz Two-Line-V-Network Model No: ENV216 14.2 EMI Test Set-up Usually the LED driver is placed in a conical metal housing (for self-ballasted lamps; CISPR15 Edition 7.2) but since the lamp housing was not available the UUT was tested as shown in the Figure 59. Figure 59 – Conducted Emissions Measurement Set-up. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 14.3 EMI Test Result Power Integrations 13.Mar 12 12:06 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 EN55015Q 110 1 QP CLRWR 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 100 90 2 AV CLRWR TDF 80 70 60 50 EN55015A 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 60 – Conducted EMI, 9 V Output / 800 mA Steady-State Load, 230 VAC, 60 Hz, and EN55015 Limits. Page 41 of 44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG Trace1: 29-Jun-12 EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 9.64921816896 kHz 23.65 L1 gnd 2 Average 11.6573068347 kHz 21.09 N gnd 2 Average 129.530094744 kHz 28.73 N gnd 1 Quasi Peak 165.693318812 kHz 47.31 L1 gnd -17.85 2 Average 259.278686021 kHz 37.44 L1 gnd -14.00 1 Quasi Peak 790.243042258 kHz 38.46 L1 gnd -17.53 1 Quasi Peak 1.29965885429 MHz 38.62 L1 gnd -17.37 1 Quasi Peak 1.71722750422 MHz 38.58 L1 gnd -17.41 1 Quasi Peak 1.84110031489 MHz 38.03 L1 gnd -17.96 2 Average 2.0745979178 MHz 22.90 L1 gnd -23.09 1 Quasi Peak 2.24649226677 MHz 38.92 L1 gnd -17.07 1 Quasi Peak 2.55671775336 MHz 38.50 L1 gnd -17.49 2 Average 3.41194975314 MHz 23.43 L1 gnd -22.56 1 Quasi Peak 3.80660433999 MHz 39.69 L1 gnd -16.30 2 Average 3.80660433999 MHz 25.04 L1 gnd -20.96 1 Quasi Peak 4.04078721227 MHz 38.63 L1 gnd -17.36 2 Average 4.04078721227 MHz 23.89 L1 gnd -22.10 1 Quasi Peak 4.20485937664 MHz 39.40 L1 gnd -16.59 2 Average 20.4573750697 MHz 17.29 N gnd -32.70 2 Average 29.8580960942 MHz 25.43 L1 gnd -24.56 Figure 61 – Conducted EMI, 9 V / 800 mA Steady-State Load Steady-State Load, 230 VAC, 60 Hz, and EN55015 Limits. Line and Neutral Scan Design Margin Measurement. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 42 of 44 29-Jun-12 DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 15 Revision History Date 29-Jun-12 Page 43 of 44 Author JDC Revision 1.0 Description and Changes Initial Release Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-327 7.5 W Tapped-Buck Power Supply Using LNK458KG 29-Jun-12 For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits’ external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2012 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Lindwurmstrasse 114 80337, Munich Germany Phone: +49-895-52739110 Fax: +49-895-527-39200 e-mail: [email protected] JAPAN Kosei Dai-3 Building 2-12-11, Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033 Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu District Taipei 114, Taiwan R.O.C. Phone: +886-2-2659-4570 Fax: +886-2-2659-4550 e-mail: [email protected] CHINA (SHANGHAI) Rm 1601/1610, Tower 1 Kerry Everbright City No. 218 Tianmu Road West Shanghai, P.R.C. 200070 Phone: +86-021-6354-6323 Fax: +86-021-6354-6325 INDIA th #1, 14 Main Road Vasanthanagar Bangalore-560052 India Phone: +91-80-4113-8020 Fax: +91-80-4113-8023 e-mail: [email protected] KOREA RM 602, 6FL Korea City Air Terminal B/D, 159-6 Samsung-Dong, Kangnam-Gu, Seoul, 135-728 Korea Phone: +82-2-2016-6610 Fax: +82-2-2016-6630 e-mail: [email protected] SINGAPORE 51 Newton Road, #19-01/05 Goldhill Plaza Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: [email protected] EUROPE HQ 1st Floor, St. James’s House East Street, Farnham Surrey GU9 7TJ United Kingdom Phone: +44 (0) 1252-730141 Fax: +44 (0) 1252-727-689 e-mail: [email protected] APPLICATIONS HOTLINE World Wide +1-408-4149660 e-mail: [email protected] CHINA (SHENZHEN) 3rd Floor, Block A, Zhongtou International Business Center, No. 1061, Xiang Mei Road, FuTian District, ShenZhen, China, 518040 Phone: +86-755-8379-3243 Fax: +86-755-8379-5828 e-mail: [email protected] ITALY Via Milanese 20, 3rd. Fl. 20099 Sesto San Giovanni (MI) Italy Phone: +39-024-550-8701 Fax: +39-028-928-6009 e-mail: [email protected] Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com APPLICATIONS FAX World Wide +1-408-4149760 Page 44 of 44