Design Example Report Title High Efficiency (>90%), High Power Factor (>0.97), Low A-THD (<15%), 20 W Output NonIsolated Buck LED Driver Using LinkSwitchTMPL LNK460KG Specification 195 VAC – 265 VAC Input; 85 VTYP, 240 mA Output Application T8 LED Tube Author Applications Engineering Department Document Number DER-337 Date May 10, 2013 Revision 1.2 Summary and Features Low cost, low component count (29 parts), small size (height <8 mm), and single-sided PCB Single-stage power factor correction and constant current (CC) output Highly energy efficient, >90% Integrated protection and reliability features Output short-circuit protection with auto-recovery Auto-recovering thermal shutdown with hysteresis No damage during brown-out conditions PF >0.97, % ATHD <15% at nominal 230 VAC input Easily meets Class C harmonic requirement (>25 W) even with multiple tubes in parallel operation Meets 1 kV 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-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 3 Power Supply Specification ........................................................................................ 4 Schematic ................................................................................................................... 5 Circuit Description ...................................................................................................... 6 4.1 Input EMI Filtering ............................................................................................... 6 4.2 Power Circuit ....................................................................................................... 6 4.3 Output Feedback ................................................................................................. 6 4.4 Open Load Protection (Optional) ......................................................................... 7 5 PCB Layout ................................................................................................................ 8 6 Bill of Materials ........................................................................................................... 9 7 PIXls Design Spreadsheet ........................................................................................ 10 8 Performance Data .................................................................................................... 12 8.1 Efficiency ........................................................................................................... 12 8.2 Line and Load Regulation.................................................................................. 13 8.3 Power Factor ..................................................................................................... 14 8.4 A-THD ............................................................................................................... 15 8.5 Harmonic Content ............................................................................................. 16 8.5.1 80 V Output ................................................................................................ 16 8.5.2 85 V Output ................................................................................................ 17 8.5.3 90 V Output ................................................................................................ 18 8.6 Test Data ........................................................................................................... 19 8.6.1 Test Data, 80 V Output............................................................................... 19 8.6.2 Test Data, 85 V Output............................................................................... 19 8.6.3 Test Data, 90 V Output............................................................................... 19 8.6.4 230 VAC 50 Hz, 80 V Output, Harmonics Data .......................................... 20 8.6.5 230 VAC 50 Hz, 85 V Output, Harmonics Data .......................................... 21 8.6.7 230 VAC 50 Hz, 90 V Output, Harmonics Data .......................................... 22 9 Thermal Performance ............................................................................................... 23 10 Waveforms ............................................................................................................ 24 10.1 Input Voltage and Input Current at Normal Operation ....................................... 24 10.2 Output Current and Output Voltage at Normal Operation .................................. 25 10.3 Output Current / Voltage Rise and Fall .............................................................. 26 10.4 Input Voltage and Output Current Waveform at Start-up ................................... 27 10.5 Drain Waveforms at Normal Operation.............................................................. 28 10.6 Freewheeling Diode Waveforms at Normal Operation ...................................... 29 10.7 Start-up Drain Voltage and Current ................................................................... 30 10.8 Drain Current and Drain Voltage During Output Short-Circuit ........................... 31 10.9 No-Load Output Voltage .................................................................................... 32 11 Conducted EMI ..................................................................................................... 33 12 Line Surge............................................................................................................. 35 13 Revision History .................................................................................................... 36 Important Note: Although this board is designed to satisfy safety isolation requirements, 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. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 1 Introduction The document describes a non-isolated, high efficiency, high power factor (PF) LED driver designed to drive a nominal LED string voltage of 85 V at 240 mA from an input voltage range of 195 VAC to 265 VAC (47 Hz – 63 Hz). The LED driver utilizes the LNK460KG from the LinkSwitch-PL family of ICs. The topology used is a single-stage non-isolated buck that meets the stringent space and efficiency requirements for this design. LinkSwitch-PL based designs provide high power factor (>0.9) meeting international requirements. This document contains the LED driver specification, schematic, PCB details, bill of materials, transformer documentation and typical performance characteristics. Figure 1 – Populated Circuit Board (158 mm x 16 mm). Page 3 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 2 Power Supply Specification 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 Full Load Symbol Min Typ Max Units Comment VIN fLINE 195 230 265 VAC Hz 2 Wire – no P.E. VOUT IOUT 80 90 V mA 50 20 POUT 85 240 90 W % Measured at 230 VAC input Environmental Conducted EMI CISPR 15B / EN55015B Safety Ring Wave (100 kHz) Differential Mode (L1-L2) Non-Isolated Differential Surge (L1-L2) Power Factor 0.90 ATHD 2.5 kV 1 kV 15 Harmonic Currents Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Measured at VOUT(TYP), IOUT(TYP) and 230 VAC, 50 Hz 0.97 EN 61000-3-2 Class C % Measured at VOUT(TYP), IOUT(TYP) and 230 VAC, 50 Hz Class C Limits (For PIN >25 W Limit) Page 4 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 3 Schematic Figure 2 – Schematic. Page 5 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 4 Circuit Description The LinkSwitch-PL (U1) is a highly integrated primary-side controller intended for use in LED driver applications. The LinkSwitch-PL provides high power factor while regulating the output current across a range of input (195 VAC to 265 VAC) in a single conversion stage. The design also supports the output voltage variations typically encountered in LED driver applications. All of the control circuitry responsible for these functions plus the high-voltage power MOSFET is incorporated into the IC. 4.1 Input EMI Filtering Inductors L1, L2, L3 and C1, C2 filter the switching current presented by the buck converter to the line. Resistor R1, R2 and R3 across L1, L2 and L3 damp any resonances between the input inductors, capacitors and the AC line impedance which create peaks in the conducted EMI spectrum. MOV RV1 provides a clamp to limit the maximum voltage during differential line surge events. Zener diode VR1 is added to increase immunity to differential line surge, clamping at a lower voltage than the MOV. Bridge rectifier BR1 rectifies the AC line voltage with capacitor C1 and C2 providing a low impedance path (decoupling) for the primary switching current. A low value of capacitance (sum of C1 and C2) is necessary to maintain a power factor greater than 0.9. 4.2 Power Circuit The circuit is configured as a Buck converter with the SOURCE (S) pin of U1 connected to the cathode side of the freewheeling diode D2 and DRAIN (D) pin connected to the positive side of the DC rectified input through D1. Diode D1 is used to prevent reverse current flowing (source to drain) when the output voltage is greater than the voltage across C2. The output inductor, L4, and the output capacitor, C6, form a low pass filter which reduces the rectangular waveform at the filter input. Capacitor C3 provides local decoupling for the BYPASS (BP) pin of U1 which is the supply pin for the internal controller. During start-up, C3 is charged to ~6 V from an internal high-voltage current source connected to the DRAIN pin. Once charged U1 starts switching at which point the operating supply current is provided from the L4 inductor via R4, D3 and D4 Rectifier diodes D3 and D4 were selected to be low capacitance diodes to minimize the effect of the OVP circuit (D3, D4, VR2 and VR3) on the output regulation. 4.3 Output Feedback Resistor R6 and R7 are used to sense the diode current of the buck converter. The value was adjusted to center the output current at 240 mA at nominal input voltage. Capacitor C4 is used to filter the high frequency component of the diode current which helps improve overall efficiency by reducing the RMS current through R6 and R7. Resistor R5 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG and C5 provide additional filtering to lower the ripple of the voltage feed to the FEEDBACK (FB) pin of U1 for improved regulation. 4.4 Open Load Protection (Optional) The LED driver is protected in the event of accidental open load operation (only possible during line production testing) by monitoring the voltage across the output inductor during energy decay (MOSFET off-time). Zener diodes VR2 and VR3 set the OVP threshold which forces U1 to enter cycle-skipping mode. Resistor R8 is used to limit the maximum output voltage by partially discharging the output when the load is disconnected. This reduces efficiency during normal operation but also ensures the LEDs extinguishing completely when the AC is removed. Want More? Use your smartphone and free software from www.neoreader.com (or any other free QR Code Reader from your smartphone’s App Store) and you will be connected to related content Page 7 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 5 PCB Layout Single sided for low cost. Figure 3 – Top Side (PCB Dimension: 158 mm x 16 mm). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 6 Bill of Materials Total electrical components: 29 parts Item Qty Ref Des 1 1 BR1 2 2 C1 C2 3 1 C3 4 1 C4 10 F, 16 V, Ceramic, X5R, 0805 5 1 C5 6 1 C6 7 1 D1 1 F 16 V, Ceramic, X7R, 0603 100 F, 100 V, Electrolytic, Gen. Purpose, (10 x 20) 200 V, 3 A, Diode Super-Fast, SMD, SMB 8 1 D2 600 V, 3 A, Fast Recovery, 35 ns, SMB Case STTH3R06U ST Micro 9 2 D3 D4 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV21WS-7-F Diodes, Inc. 10 1 F1 11 3 L1 L2 L3 12 1 L4 13 4 R1 R2 R3 R5 14 1 R4 15 1 16 1 17 18 19 Description Mfg Part Number Mfg DF08S Diodes, Inc. 100 nF, 500 V, Ceramic, X7R, 1812 VJ1812Y104KXEAT Vishay 10 F, 10 V, Ceramic, X5R, 0603 C1608X5R1A106M GRM21BR61C106K E15L C1608X7R1C105M TDK Murata UVZ2A101MPD Nichicon ES3DB-13-F Diodes, Inc. 800 V, 1 A, Bridge Rectifier, SMD, DFS 3.15 A, 250 V, Slow, RST TDK 507-1181 Belfuse L03316-102-RM ICE Components 270 H, 1.2 A, SMD SRR1280-271V4K Bourns 3.3 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ332V Panasonic 36 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ363V Panasonic R6 20 , 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF20R0V Panasonic R7 2.00 , 1%, 1/4 W, Thick Film, 1206 MCR18EZHFL2R00 Rohm Semi 1 R8 100 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ104V Panasonic 1 RV1 1 U1 1000 H, 0.3 A 275 V, 80J, 10 mm, RADIAL LinkSwitch-PL, eSOP-12P ERZ-V10D431 Panasonic LNK460KG Power Integrations 20 1 VR1 350 V, 400 W, 5%, DO214AC (SMA) SMAJ350A LittleFuse 21 1 VR2 18 V, 5%, 150 mW, SSMINI-2 MAZS1800ML Panasonic 22 1 VR3 91 V, 5%, 500 mW, SOD-123 MMSZ5270BT1G ON Semi Page 9 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 7 PIXls Design Spreadsheet ACDC_LinkSwitch-PLBuck_031512; Rev.1.1; INPUT Copyright Power Integrations 2011 ENTER APPLICATION VARIABLES VACMIN 195 VACTYP VACMAX INFO FL OUTPUT UNIT 195.00 230.00 265.00 V V V 50.00 Hz VOMIN 80.00 80.00 V VO 85.00 85.00 V VOMAX 90.00 90.00 V IO PO 0.24 0.24 20.40 A W n 0.90 0.90 No No Dimming Application ENTER LinkSwitch-PL VARIABLES Chosen Device LNK460 ILIMITMIN ILIMITTYP ILIMITMAX LNK460 1.64 1.86 2.08 A A A TON 2.09 us FSW 122.81 kHz Duty Cycle 25.63 % IRMS 0.28 A IPK 1.78 A KDP 1.30 ENTER INDUCTOR CORE/CONSTRUCTION VARIABLES Core Type Core Type Custom Core Part Number SRR1280-271K SRR1280-271K 243.00 uH 270.00 uH LP_TOLERANCE 10.00 CURRENT WAVEFORM SHAPE PARAMETERS 10.00 % DMAX 25.63 % IAVG 0.10 A LPTYP 270.00 Info IP 1.78 A ISW_RMS 0.28 A Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Minimum AC Input Voltage Typical AC Input Voltage Maximum AC Input Voltage AC Mains Frequency. (between 47Hz and 63Hz) 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 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 drain RMS current at VO Worst case peak primary current at VO Worst case ratio between off-time of switch and reset time of core Enter Transformer Core If custom core is used - Enter part number here Bobbin Part number (if available) - Bobbin part number INDUCTOR DESIGN PARAMETERS LPMIN ACDC_LinkSwitch-PL Buck Design Spreadsheet Minimum Inductance The IC may be entering in dimming mode assuming worst case inductance, VOMAX, and VACMIN Tolerance of the inductance Duty cycle measured at minimum input voltage Input average current measured on the Mosfet at the minimum input voltage Peak Drain current at maximum input voltage MOSFET RMS current measured at Page 10 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG ID_RMS 0.52 A IL_RMS 0.58 A the minimum input voltage RMS current of freewheeling diode at maximum input voltage RMS current of the inductor at the maximum input voltage FEEDBACK AND BYPASS PIN PARAMETERS RFEEDBACK 2.04 ohm CBP 1.00 uF VOLTAGE STRESS PARAMETERS VDRAIN 374.77 V PIVS 374.77 V This is a first approximation for the sense resistor and will likely require fine tuning in the bench. Value calculated with typical inductance, and minimum input voltage. Minimum Bypass pin capacitor required Estimated worst case drain voltage Output Rectifier Maximum Peak Inverse Voltage Note: 1) The peak current should be lower than typical current limit. 2) The measured minimum input voltage was 180 VAC at 90 V output with maximum LP without entering in dimming mode Page 11 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 8 Performance Data All measurements were taken at room temperature using an LED load. The following data were measured using 3 sets of loads to represent the load range of 80 V to 90 V output voltage. Refer to the table on Section 8.6 for the complete set of test data values. 8.1 Efficiency All greater than 90% across line input. 92.0 80 V 85 V 90 V 91.8 91.6 Efficiency (%) 91.4 91.2 91.0 90.8 90.6 90.4 90.2 90.0 185 195 205 215 225 235 245 255 265 275 Input Voltage (VAC) Figure 4 – Efficiency vs. Line and Load Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 37 10-May-13 8.2 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG Line and Load Regulation 290 80 V 85 V 90 V Output Current (mA) 280 270 260 250 240 230 220 185 195 205 215 225 235 245 255 265 Input Voltage (VAC) Figure 5 – Regulation vs. Line and Load. Page 13 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 275 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 8.3 10-May-13 Power Factor All greater than 0.95 PF across line input 0.987 80 V 85 V 90 V 0.986 Power Factor 0.985 0.984 0.983 0.982 0.981 0.980 0.979 0.978 175 185 195 205 215 225 235 245 255 265 275 Input Voltage (VAC) Figure 6 – Power Factor vs. Line and Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 37 10-May-13 8.4 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG A-THD All less than 20 % A-THD across line input. 21 80 V 85 V 90 V 20 19 A-THD (%) 18 17 16 15 14 13 12 185 195 205 215 225 235 245 255 265 Input Voltage (VAC) Figure 7 – A-THD vs. Line and Load. Page 15 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 275 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 8.5 Harmonic Content The design met the limits for Class C equipment for an active input power of >25 W to be able to use several units in parallel. 8.5.1 80 V Output 35 Class C Limit 80 V Harmonic Content (%) 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 Number (n) Figure 8 – 80 V Output. Input Current Harmonics at 230 VAC, 50 Hz. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 8.5.2 85 V Output 35 Class C Limit 85 V Harmonic Content (%) 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 number (n) Figure 9 – 85 V Output. Input Current Harmonics at 230 VAC, 50 Hz. Page 17 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 8.5.3 90 V Output 35 Class C Limit 90 V Harmonic Content (%) 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 number (n) Figure 10 – 90 V Output. Input Current Harmonics at 230 VAC, 50 Hz. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 8.6 Test Data All measurements were taken with the board at open frame, 25 ºC ambient, and 50 Hz line frequency. 8.6.1 Test Data, 80 V Output Input VAC Freq (VRMS) (Hz) 195 50 16.78 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 80.1000 252.600 20.540 210 50 209.89 114.22 23.626 0.986 15.31 80.2000 264.200 21.520 21.19 91.09 2.11 220 50 219.94 104.11 22.580 0.986 14.22 80.0000 253.000 20.530 20.24 90.92 2.05 230 50 229.98 96.72 21.928 0.986 13.75 79.9000 245.800 19.910 19.64 90.80 2.02 265 50 265.00 80.31 20.906 0.982 13.16 79.7000 234.000 18.890 18.65 90.36 2.02 PCAL (W) 21.97 Calculation Efficiency (%) 91.51 Loss (W) 2.07 VIN (VRMS) 194.98 Input Measurement IIN PIN PF (mARMS) (W) 117.34 22.506 0.984 %ATHD PCAL (W) 20.23 Calculation Efficiency (%) 91.26 Loss (W) 1.97 8.6.2 Test Data, 85 V Output Input VAC Freq (VRMS) (Hz) 195 50 18.16 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 84.8000 259.100 22.290 210 50 209.94 123.23 25.460 0.984 16.52 84.9000 270.000 23.270 22.92 91.40 2.19 220 50 219.99 112.89 24.475 0.986 15.25 84.7000 260.000 22.330 22.02 91.24 2.15 230 50 230.03 107.30 24.328 0.986 14.67 84.6000 258.200 22.140 21.84 91.01 2.19 265 50 265.05 84.73 22.088 0.984 13.4 84.3000 235.100 20.050 19.82 90.77 2.04 PCAL (W) 23.31 Calculation Efficiency (%) 91.72 Loss (W) 2.13 VIN (VRMS) 195.00 Input Measurement IIN PIN PF (mARMS) (W) 127.23 24.358 0.982 %ATHD 8.6.3 Test Data, 90 V Output Input VAC Freq (VRMS) (Hz) 195 50 19.91 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 90.2000 258.400 23.630 210 50 209.91 132.60 27.331 0.982 18.06 90.4000 272.600 25.000 24.64 91.47 2.33 220 50 219.96 126.07 27.272 0.983 16.96 90.2000 272.200 24.910 24.55 91.34 2.36 230 50 230.00 116.17 26.323 0.985 15.45 90.1000 263.300 24.040 23.72 91.33 2.28 265 50 265.02 93.76 24.460 0.984 13.94 89.7000 244.800 22.230 21.96 90.88 2.23 VIN (VRMS) 194.97 Page 19 of 37 Input Measurement IIN PIN PF (mARMS) (W) 134.99 25.764 0.979 %ATHD Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 8.6.4 230 VAC 50 Hz, 80 V Output, Harmonics Data V 230 Freq 50.00 I (mA) 96.72 P 21.9280 PF 0.9858 nth Order 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 mA Content 95.76 0.03 9.41 5.43 3.15 2.12 2.17 2.39 2.63 1.41 0.50 1.36 2.62 1.72 0.89 0.20 1.48 1.35 1.07 0.67 0.24 % Content Limit >25 W Remarks 0.03% 9.83% 5.67% 3.29% 2.21% 2.27% 2.50% 2.75% 1.47% 0.52% 1.42% 2.74% 1.80% 0.93% 0.21% 1.55% 1.41% 1.12% 0.70% 0.25% 2.00% 29.57% 10.00% 7.00% 5.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com %THD 13.75 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 20 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 8.6.5 230 VAC 50 Hz, 85 V Output, Harmonics Data Page 21 of 37 V 230 Freq 50.00 I (mA) 107.30 P 24.3280 PF 0.9856 nth Order 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 mA Content 106.10 0.13 12.20 5.85 3.49 2.13 2.12 2.88 1.90 0.90 1.51 1.63 2.48 1.61 0.36 1.20 1.38 1.54 0.99 0.16 0.90 % Content Limit >25 W Remarks 0.12% 11.50% 5.51% 3.29% 2.01% 2.00% 2.71% 1.79% 0.85% 1.42% 1.54% 2.34% 1.52% 0.34% 1.13% 1.30% 1.45% 0.93% 0.15% 0.85% 2.00% 29.57% 10.00% 7.00% 5.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% %THD 14.67 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 8.6.7 230 VAC 50 Hz, 90 V Output, Harmonics Data V 230 Freq 50.00 I (mA) 116.17 P 26.3230 PF 0.9852 nth Order 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 mA Content 114.77 0.08 13.95 7.62 3.11 2.65 2.39 2.45 1.71 1.37 1.94 1.90 2.31 0.74 0.64 1.51 2.08 0.96 0.26 0.73 1.06 % Content Limit >25 W Remarks 0.07% 12.15% 6.64% 2.71% 2.31% 2.08% 2.13% 1.49% 1.19% 1.69% 1.66% 2.01% 0.64% 0.56% 1.32% 1.81% 0.84% 0.23% 0.64% 0.92% 2.00% 29.56% 10.00% 7.00% 5.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% 3.00% Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com %THD 15.45 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 22 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 9 Thermal Performance Images captured after running for >30 minutes at room temperature (25 °C), no airflow, open frame at VIN = 230 VAC The unit was placed inside a box with no airflow and the internal ambient was raised slowly until OTP occurred and the measured internal ambient at which the OTP occurred was 87 °C. A small heat spreader (copper plate: 16 mm x 12 mm x 10 mil) attached to the top of the IC raised the internal ambient to 97 °C at the OTP trip point. Figure 11– Output Inductor: 73 ºC. Page 23 of 37 Figure 12– LNK460KG: 76 ºC. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 10 Waveforms 10.1 Input Voltage and Input Current at Normal Operation Figure 13 – 195 VAC, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 200 V, 10 ms / div. Figure 14 – 210 VAC, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 200 V, 10 ms / div. Figure 15 – 230 VAC, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 200 V, 10 ms / div. Figure 16 – 265 VAC, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 200 V, 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10.2 Output Current and Output Voltage at Normal Operation Figure 17 – 195 VAC, 50 Hz Full Load. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 10 ms / div. Figure 18 – 210 VAC, 50 Hz Full Load. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 10 ms / div. Figure 19 – 230 VAC, 50 Hz Full Load. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 10 ms / div. Figure 20 – 265 VAC, 50 Hz Full Load. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 10 ms / div. Page 25 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 10.3 Output Current / Voltage Rise and Fall Figure 21 – 195 VAC Output Rise. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 100 ms / div. Figure 22 – 195 VAC Output Fall. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 2 s / div. Figure 23 – 265 VAC Output Rise. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 100 ms / div. Figure 24 – 265 VAC Output Fall. Upper: IOUT, 200 mA / div. Lower: VOUT, 20 V, 2 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10.4 Input Voltage and Output Current Waveform at Start-up Figure 25 – 195 VAC, 50 Hz. Upper: IOUT, 200 mA / div. Lower: VIN, 200 V, 100 ms / div. Figure 26 – 210 VAC, 50 Hz. Upper: IOUT, 200 mA / div. Lower: VIN, 200 V, 100 ms / div. Figure 27 – 230 VAC, 50 Hz. Upper: IOUT, 200 mA / div. Lower: VIN, 200 V, 100 ms / div. Figure 28 – 265 VAC, 50 Hz. Upper: IOUT, 200 mA / div. Lower: VIN, 200 V, 100 ms / div. Page 27 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 10.5 Drain Waveforms at Normal Operation Figure 29 – 195 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 30 – 195 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 s / div. Figure 31 – 265 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 32 – 265 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10.6 Freewheeling Diode Waveforms at Normal Operation Figure 33 – 195 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 34 – 195 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 s / div. Figure 35 – 265 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 36 – 265 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 s / div. Page 29 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 10.7 Start-up Drain Voltage and Current Figure 37 – 195 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 38 – 265 VAC, 50 Hz. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Page 30 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10.8 Drain Current and Drain Voltage During Output Short-Circuit Figure 39 – 195 VAC, 50 Hz Output Short Condition. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN,100 V, 5 ms / div. Figure 40 – 195 VAC, 50 Hz Output Short Condition. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 10 s / div. Figure 41 – 265 VAC, 50 Hz Output Short Condition. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 42 – 265 VAC, 50 Hz Output Short Condition. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 50 s / div. Page 31 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 10.9 No-Load Output Voltage Figure 43 – 195 VAC, 50 Hz No-Load Characteristic. Upper: VOUT, 20 V / div. Lower: VDRAIN, 200 V / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 44 – 265 VAC, 50 Hz No-Load Characteristic. Upper: VOUT, 50 V / div. Lower: VDRAIN, 200 V / div., 5 ms / div. Page 32 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 11 Conducted EMI The unit was tested using LED load (85 V) with input voltage of 230 VAC, 60 Hz at room temperature. Power Integrations 22.Jun 12 10:44 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 45 – Conducted EMI 85 V / 240 mA Load, 230 VAC, 60 Hz, and EN55015 Limits. Page 33 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 Figure 46 – Conducted EMI, 85 V / 240 mA Load, 230 VAC, 60 Hz, and EN55015 Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 12 Line Surge Input voltage was set at 230 VAC / 60 Hz. Output was loaded with 85 V LED string and operation was verified following each surge event. Differential input line 1.2 / 50 s surge testing was completed on one test unit to IEC61000-4-5. Surge Level (V) 10strikes/condition +1000 -1000 +1000 -1000 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L to N L to N Injection Phase (°) 0 0 90 90 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) 10strikes/condition +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 0 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Freewheeling diode voltage waveforms during surge test Figure 47 – 230 VAC, 50 Hz 1 kV Surge Test. VDIODE, 200 V / div, 20 s /div. Figure 48 – 230 VAC, 50 Hz 2.5 kV Ring Test. VDIODE, 200 V / div, 20 s / div. Unit passes under all test conditions. Page 35 of 37 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 10-May-13 13 Revision History Date 30-Jul-12 11-Sep-12 10-May-13 Author DK KM KM Revision 1.0 1.1 1.2 Description and Changes Initial Release Updated Figure 1 Updated L4 on BOM and Schematic Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Reviewed Apps & Mktg Apps & Mktg Apps & Mktg Page 36 of 37 10-May-13 DER-337 T8 20 W / 85 V LED Driver Using LNK460KG 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. 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