Engineering Sample Test Report LNK406EG for 15W T8 LED 50V, 300mA (18 LEDs ) 31 Mar, 2010 GML Major features 1) Low part count, Constant Current from Primary Side; 2) High PF, >0.9 and meet IEC10000-3-2 3) Universal input design 4) Design to fit T8 LED Lamp fixture 1. Power Supply Specification Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Description Input Voltage Power Factor Output Load Output Voltage Load Output Current Efficiency Total Output Power Continuous Output Power Peak Output Power Conducted EMI Margin Confidential and Proprietary Copyright http://www.powerint.com Symbol Min VIN PF 90 0.9 Vout Iout η Typ 50.0 0.3 Max Units 265 Vac V A 80% Pout 2 Wire no P.E Input 230 Vac 18pcs LEDs in series 115V/230V Input 15 6 comment/conditions W W dB Total power Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 2 2. Schematic Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) L4 3300 uH L2 1000 uH F1 L1 RV1 R1 4.7 k 20 mH N 3 L5 * R3 4.7 k BR1 R4 240 k D1 * : Not use R5 C2 100 nF 400 V D4 D5 150 1% C5 20 k 22 uF 50 V 5 1.4 M R9 C8 R10 133 k 1% 2.2 nF 250 VAC 6.2 k D6 LL4148 V FMMT491 LNK406E BP S FB R ZMM5261B VR2 Q1 U1 R14 R7 150 k 1% 100 nF R8 C11 24.9 k 50 V 4 C4 100 uF 25 V R12 1k C6 100 nF 50 V Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 C9 100 uF 63 V C10 100 uF 63 V R15 100 k EE19 LL4148 R6 C3 1 uF 400 V R13 R11 1.4 M D3 UF4005 1N4007 [email protected] 3 6 D Confidential and Proprietary Copyright http://www.powerint.com J2 UF4005 7 C1 47 nF 275 VAC L3 R2 4.7 k D2 UF4007 1N4007 1000 uH R17 * D7 2 8 4 R16* T1 1 9 VR1 P6KE200A 2 - 3.15 A 600 V + L6 * L 10 1 2KBP06M Page 3 C7 10 k 1 uF 50 V J3 3. PCB Layout and Assembly Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Page 4 LNK406EG Solder Side Minimum components for active PFC and Constant Current regulation AC Input Component Side Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 DC Output 4. BOM Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Item Number Quantity Part Reference 1 1 BR1 2 1 C1 3 1 C2 4 1 C3 5 1 C4 6 1 C5 7 2 C6 C11 8 1 C7 9 1 C8 10 2 C9 C10 11 2 D1 D5 12 1 D2 13 2 D3 D7 14 2 D4 D6 15 1 F1 16 1 L1 17 4 L2 L3 L5 L6 18 1 L4 19 1 Q1 20 3 R1 R2 R3 21 1 R4 22 1 R5 23 1 R6 24 1 R7 25 1 R8 26 1 R9 27 1 R10 28 1 R11 29 1 R12 30 1 R13 31 1 R14 32 1 R15 33 1 T1 34 1 U1 35 1 VR1 36 1 VR2 Confidential and Proprietary Copyright http://www.powerint.com Description 600 V, 2 A, Bridge Rectifier, Glass Passivated 47 nF, 275 VAC, Film, X2 100 nF, 6300 V, Film 1 uF, 400 V, Electrolytic, (6.3 x 11) 100 uF, 25 V, Electrolytic, Very Low ESR, 130 mOhm, (6.3 x 11) 22 uF, 50 V, Electrolytic, Low ESR, 900 mOhm, (5 x 11.5) 100 nF, 50 V, Ceramic, X7R, 0805 1 uF, 25 V, Ceramic, X7R, 0805 2.2 nF, Ceramic, Y1 100 uF, 63, Electrolytic, Low ESR, 255 mOhm, (10 x 12.5) 1000 V, 1 A, Rectifier, DO-41, 1N4007 1000 V, 1 A, Ultrafast Recovery, 75 ns, DO-41, UF4007 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41, UF4005 75 V, 0.15 A, Fast Switching, 4 ns, MELF, LL4148 3.15 A, 250V, Slow, TR5 20 mH, Common Mode Choke, EE8.3, 0.13mm 90T x2 1000 uH,0.3A, 8 x 10.5 mm 3300 uH,0.3A, 8 x 10.5 mm NPN,60V 1000MA, SOT-23 4.7 k, 5%, 1/4 W, Carbon Film 240 k, 5%, 1/4 W, Thick Film, 1206 1.2 M, 5%, 1/4 W, Thick Film, 1206 1.6 M, 5%, 1/4 W, Thick Film, 1206 150 k, 1%, 1/8 W, Thick Film, 0805 24.9 k, 1%, 1/4 W, Metal Film 6.2 k, 5%, 1/8 W, Thick Film, 0805 150 k, 1%, 1/8 W, Thick Film, 0805 20 k, 5%, 1/8 W, Thick Film, 0805 1 k, 5%, 1/8 W, Thick Film, 0805 150 R, 1%, 1/8 W, Thick Film, 0805 10 k, 5%, 1/8 W, Thick Film, 0805 51 k, 5%, 1/4 W, Thick Film, 1206 EER Special, 5+5 LinkSwitch, LNK406E, eSIP 200 V, 5%, TVS, DO204AC (DO-15) P6KE200A 45 V, 5%, 0.5 W Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 5 5. Transformer Information Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Instruction for start of first winding… 4 R+ 26T 3 30T Secondary 27T GND 5 6 Bias Winding Start from pin-5 & ended at pin3 in “Clockwise” direction when looking from the arrow direction Rotating SCHEMATIC Primary Page 6 15T 7 4(F) 2UEW 0.25mm 13T – Primary (Clockwise) 3(S) 2UEW 0.25mm 13T – Primary (Clockwise) GND (F) ELECTRICAL SPECIFICATIONS: 1. Primary Inductance (Lp) = 800 uH± 7% @66KHz 0.4V 2. Primary Leakage Inductance 20uH @66KHz 0.4V 3. Electrical Strength = 3KV, 50/60Hz,1Min Secondary Primary R+(S) 3T Tape Triple Insulated Wire Clockwise) 0.3mm 10T – Secondary Triple Insulated Wire Clockwise) 0.3mm 10T – Secondary Triple Insulated Wire Clockwise) 0.3mm 10T – Secondary MATERIALS: 1. Core : EER25 Special (Ferrite Material TDK PC40 or equivalent) 2. Bobbin : Vertical (5+5 pins). 3. Magnet Wires (Pri&Bias&Shield) : Type 2-UEW 4. Magnet Wire (Sec) : Triple Insulated Wires 5. Layer Insulation Tape :3M1298 or equivalent. FINISHED : 2UEW 0.25mm 15T – Bias (Clockwise) 7(F) 6(S) 1T Tape 3(F) 2UEW 0.25mmx1_ 13T – Primary (Clockwise) 5(S) 2UEW 0.25mmx1_ 14T – Primary (Clockwise) 1. Varnish the complete assembly Confidential and Proprietary Copyright http://www.powerint.com 1T Tape Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 6. Efficiency Performance Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Page 7 Efficiency VS Input Voltage 90.00% 85.00% Efficiency 80.00% 75.00% 70.00% 65.00% 60.00% 55.00% 50.00% 80 100 120 140 160 180 200 220 Input Voltage ( Unit: V ) 240 260 280 Note: 18pcs LED in series as output load Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 7. Harmonic Current (EN61000-3-2, Class-C) for <25W Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Harmonic Order EN6100-3-2 n 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 mA/W 3.40 1.90 1.00 0.50 0.35 0.30 0.26 0.23 0.20 0.18 0.17 0.15 0.14 0.13 0.12 0.12 0.11 0.10 0.10 115V/60Hz Current Limit Measured Pin=20W mA mA 68.00 29.21 38.00 15.51 20.00 8.37 10.00 4.99 7.00 3.51 5.92 2.67 5.13 2.21 4.53 1.52 4.05 1.38 3.67 0.9 3.35 0.97 3.08 0.74 2.85 0.77 2.66 0.59 2.48 0.55 2.33 0.49 2.20 0.4 2.08 0.39 1.97 0.32 Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS 230V/50Hz Current Limit Measured Pin=19 mA mA 64.60 17.64 36.10 10.56 19.00 5.8 9.50 5.07 6.65 3.23 5.63 2.94 4.88 2.3 4.30 1.9 3.85 1.82 3.48 1.16 3.18 1.47 2.93 0.76 2.71 1.17 2.52 0.64 2.36 0.9 2.22 0.61 2.09 0.64 1.98 0.6 1.88 0.44 Page 8 Result PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS PASS Note: 18pcs LED in series as output load Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 8. Power Factor Performance Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Page 9 PF VS Input 1 0.95 0.9 0.85 0.8 0.75 0.7 0.65 0.6 0.55 0.5 80 100 120 140 160 180 200 220 240 260 280 Note: 18pcs LED in series as output load Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 9. Constant Current Performance Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Page 10 Output Current( Unit:A ) Output Current VS Input Voltage 0.340 0.320 0.300 0.280 0.260 0.240 0.220 0.200 0.180 0.160 0.140 0.120 0.100 0.080 0.060 0.040 0.020 0.000 80 100 120 140 160 180 200 220 Input Voltage ( Unit: V ) 240 260 280 Note: 18pcs LED in series as output load Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 10. Output Ripple Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Full Load, VIN =90V Confidential and Proprietary Copyright http://www.powerint.com Full Load, VIN =265V Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 11 11. Output Startup Characteristic Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Full Load, VIN =90V Confidential and Proprietary Copyright http://www.powerint.com Full Load, VIN =265V Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 12 12. AC Input Voltage and Current Waveform Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Voltage Voltage Current Current Full Load, 115Vac Confidential and Proprietary Copyright http://www.powerint.com Full Load, 230Vac Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 13 13. Drain switched voltage Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Page 14 Test Condition: VIN=265VAC,IOUT=0.3A 18pcs LED in series Result: VDS_MAX=592V (Data sheet from LinkSwitch – PH family) Confidential and Proprietary Copyright http://www.powerint.com Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 14. EMI Performance @EN55012, Class-B (QP and AV) Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) Loaded at 300mA LED load: 18pcs in series QP QP AV AV 115VAC, LIVE and NEUTRAL Confidential and Proprietary Copyright http://www.powerint.com 230VAC, LIVE and NEUTRAL Power Integrations China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828 Page 15 China Sale Contacts and Important Note Engineering Report (LNK406EG for 15W T8 LED 50V,300mA) China Sales Contacts Important note CHINA (Shanghai) Room 1601/1610, Tower 1 Kerry Everbright City No.218 Tianmu Road West Shanghai, PRC 200070 TEL: +86-21-6354 6323 FAX: +86-21-6354 6325 E-mail: [email protected] 中国上海 上海市天目西路218号 嘉里不夜城第一座1601/1610室 邮编: 200070 电话:+86-21-6354 6323 传真:+86-21-6354 6325 电子邮件: [email protected] CHINA (Shenzhen) Rooms A, B and C, 4th Floor, Block C. Electronic Science & Technology Bldg. 2070 Shennan Zhong Road Shenzhen, Guangdong China, 518031 TEL:+86-755-8379-3243 FAX:+86-755-8379-5828 E-mail: [email protected] 中国深圳 深圳市深南中路2070号 电子科技大厦C座4楼A,B,C,室 邮编: 518031 电话:+86-755-8379-3243 传真:+86-755-8379-5828 电子邮件：[email protected] CHINA (PI Guangzhou Lab) Room 311,3nd floor, No.9, Jianggong Road, Tianhe Software Park, Zhongshan thoroughfard, Tianhe District, Guangzhou, China, 510660 TEL:+86 20-8566-4509 FAX:+86 20-8555-1081 E-mail: [email protected] 中国深圳-广州实验室 广州市天河区中山大道 天河软件园建工路9号3楼311室 邮编:510660 电话:+86-20-8566-4509 传真 +86 20-8555-1081 E-mail: [email protected] CHINA (PI Chengdu Lab) Room 1426,Colorful Holiday Internation Mansion No.2 Baisi Street,Chengdu, China, 610016 TEL: +86-28-8676-3012 FAX: +86-28-8676-3011 E-mail: [email protected] 中国深圳-成都实验室 四川省成都市白丝街2号 缤纷假日国际公寓1426号 邮编:610016 电话:+ 传真:+ 86-28-8676-3012 86-28-86763011 E-mail: [email protected] Confidential and Proprietary Copyright http://www.powerint.com Page 16 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. The products and applications illustrated herein (including circuits external to the products and transformer construction) 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 China-ShenZhen Branch Room A, B & C, 4th floor, Block C, Electronic Science & Technology Bldg., , 2070 Shennan Zhong Road, Shenzhen, Guangdong, China. Zip Code:518031 TEL:+86(755)83793243, Fax:+86(755)83795828