Title Reference Design Report for a 12 W NonIsolated, Buck Topology, Power Factor Corrected, LED Driver Using LinkSwitchTM-PH LNK405EG Specification 90 VAC – 265 VAC Input; 36 V, 330 mA Output Application LED Driver Author Applications Engineering Department Document Number RDR-257 Date January 6, 2011 Revision 1.0 Summary and Features Dramatically simplifies off-line, power factor corrected, LED driver design Single-stage, power factor corrected, non-isolated LED driver Compact with extremely low component count High power factor >0.9 across line and load Very high efficiency >85%, 87% typical Low THD, <20% at 230 VAC No output current sensing required Advanced performance features Compensates for inductance tolerance Compensates for input voltage variations Compensates for output voltage variations Frequency jittering greatly reduces EMI filter costs Advanced protection and safety features Auto-restart protection for short-circuit Hysteretic thermal shutdown 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 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 Table of Contents 1 2 3 4 5 6 Introduction................................................................................................................. 4 Power Supply Specification ........................................................................................ 7 Schematic................................................................................................................... 8 Circuit Description ...................................................................................................... 9 PCB Layout ...............................................................................................................10 Bill of Materials ..........................................................................................................11 6.1 Electrical.............................................................................................................11 6.2 Optional OVP Circuit ..........................................................................................11 6.3 Mechanical .........................................................................................................12 7 Heat Sink Assembly ..................................................................................................13 8 Inductor Specification ................................................................................................14 8.1 Electrical Diagram ..............................................................................................14 8.2 Electrical Specifications......................................................................................14 8.3 Materials.............................................................................................................14 8.4 Inductor Build Diagram .......................................................................................14 9 Performance Data .....................................................................................................15 9.1 Efficiency ............................................................................................................15 9.2 Line and Load Regulation...................................................................................16 9.3 Power Factor ......................................................................................................17 9.4 THD ....................................................................................................................18 9.5 Harmonics ..........................................................................................................19 9.6 Test Data............................................................................................................21 9.6.1 Test Data, 13 LED Load.............................................................................21 9.6.2 Test Data, 12 LED Load.............................................................................21 9.6.3 Test Data, 11 LED Load.............................................................................21 9.6.4 230 VAC, 50 Hz Harmonics Data, PIN = 14.529 W.....................................22 9.6.5 115 VAC, 60 Hz Harmonics Data, PIN = 13.96 W.......................................23 10 Waveforms ................................................................................................................24 10.1 Input Line Current...............................................................................................24 10.2 Drain Voltage and Current Normal Operation.....................................................25 10.3 Drain Voltage and Current Start-up Operation ...................................................26 10.4 Output Current, Normal Condition, VOUT ~ 36 V .................................................27 10.5 Output Current Ripple, VOUT ~ 36 V....................................................................28 10.6 Output Current and Voltage at Power-up, Power-down .....................................29 10.7 Output Short .......................................................................................................30 10.8 Open Load/LED Condition..................................................................................30 11 Thermal Measurements.............................................................................................31 11.1 Thermal Test Set-up...........................................................................................31 11.2 Thermal Test Results .........................................................................................31 12 Conducted EMI Measurements .................................................................................32 12.1 Conducted EMI Test Set-up ...............................................................................32 12.1.1 Configuration A: Solder Side of Driver Facing Grounded T8 Fixture..........32 12.1.2 Configuration B: Component Side of Driver Facing Grounded T8 Fixture..33 12.2 Conducted EMI Test Results..............................................................................34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 12.3 Configuration A Conducted Emission ................................................................ 34 12.4 Configuration B Conducted Emission ................................................................ 36 13 Power Line Transient Tests ...................................................................................... 38 14 Revision History........................................................................................................ 39 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. Page 3 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 1 Introduction The document describes a non-isolated, power-factor corrected, low THD, high efficiency LED driver designed to drive an LED string with a nominal voltage of 36 V at a current of 330 mA from an input voltage range of 90 VAC to 265 VAC. It is designed to fit inside a T8 tube fixture. The LinkSwitch-PH has been developed to cost effectively design a single-stage power factor corrected LED driver with primary-side constant current control. The LinkSwitch-PH controller was optimized for LED driver applications with minimal external parts count and control of the output current through the LED load without the use of an optocoupler. The LinkSwitch-PH monolithically integrates the 725 V power MOSFET and controller. The controller consists of an oscillator, PWM, 6 V regulator, BYPASS pin programming functions, over-temperature protection, frequency jittering, cycle-by-cycle current limit, leading edge blanking, and charge controller for output CC (constant-current) control. The LinkSwitch-PH also provides a sophisticated range of protection features including auto-restart for control loop open/short faults and output short-circuit conditions. Accurate hysteretic thermal shutdown ensures safe average PCB temperatures under all conditions. The non-isolated power factor corrected buck presented in this report shows how LinkSwitch-PH dramatically simplifies off-line, high-efficiency, power factor corrected LED driver design with very low parts count. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, conducted EMI measurements, thermal measurements, power line transient tests, inductor documentation and typical performance characteristics. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG Figure 1 – Populated Circuit Board Photograph. Figure 2 – Populated Circuit Board Photograph, Top. Page 5 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 Figure 3 – Populated Circuit Board Photograph, Bottom. Figure 4 – Side View Showing SCR Rework. Note: The SCR on this board has been replaced with a higher current surge rating SCR for improved reliability during open load conditions. The original footprint on the board caters for a TO-92 package and the board will be revised to fit the TO-251 package on a future revision. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 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 LED Voltage LED Current Total Output Power Continuous Output Power Symbol Min Typ Max Units Comment VIN fLINE 90 47 265 63 VAC Hz 2 Wire – no P.E. 50/60 VOUT 30 38 V mA 36 330 12 POUT W Environmental Conducted EMI Meets CISPR22B / EN55022B Safety Non isolated Line Transient 2.5 Efficiency Class C Power Factor Page 7 of 40 Ringwave (500 A) 85 Harmonic Ambient Temperature kV 61000-3-2 0.9 TAMB 25 o C Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 3 Schematic Figure 5 – Schematic. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 4 Circuit Description The LinkSwitch-PH (U1) is a highly integrated primary side controller intended for use in LED driver applications. The LinkSwitch-PH provides high power factor in a single-stage conversion topology while regulating the output current in a wide range of input and output voltage variations typical in LED driver application environment. All of the control circuitry responsible for these functions plus a high-voltage power MOSFET is incorporated into the device. Capacitor C1, C2, and differential choke L1, and L2 perform EMI filtering while maintaining high-power factor. This input filter network plus the frequency jittering feature of LinkSwitch-PH allows compliance to Class B emission limits. Resistor R1 and R2 were used to damp the resonance of the EMI filter, preventing peaks in EMI. The buck power circuit with floating output connection composed of U1 (power switch + control), D2 (free-wheeling diode), C5 (output capacitor), and L3 (output inductor). Diode D3 was used to prevent negative voltage appearing across drain-source of U1 especially near the zero-crossing of the input voltage. Diode D1 and C3 detect the peak AC line voltage. The voltage across C3 along with R3, R4, and R5 sets current fed into the V pin. This current is used by U1 to control line undervoltage (UV), overvoltage (OV), and provide feed-forward current which in conjunction with the FEEDBACK pin current provides constant current to the LED load. The FEEDBACK pin current used by U1 for output voltage feedback is provided by the voltage to current converter network formed by R7-R10, Q1, C6, and D4. Output voltage is converted to feedback current by the following relation: I F B k VOUT where 1 R8 k * R7 R8 R9 The voltage across R8 was chosen to be high enough to eliminate or minimize the effect of the temperature and VCE dependence on the VBE voltage of Q1 The board also has an optional OVP circuit formed by VR1, SCR1, R11 and C7. During open load condition SCR1 will conduct and force U1 to enter into auto-restart condition. Page 9 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 5 PCB Layout Figure 6 – Printed Circuit Layout,, Top, 2” (50.8 mm) x 0.95” (24.1 mm). Figure 7 – Printed Circuit Layout,, Bottom. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 6 Bill of Materials 6.1 Electrical Item Qty Ref Des Description 1 1 BR1 1000 V, 0.8 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC 2 1 C1 3 1 C2 4 1 C3 2.2 F, 400 V, Electrolytic, (6.3 x 11) TAB2GM2R2E110 LTEC 5 1 C4 10 F, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E106M Panasonic 6 1 C5 220 F, 50 V, Electrolytic, Very Low ESR, 42 m, (10 x 16) EKZE500ELL221MJ16S Nippon Chemi-Con 7 1 C6 1 F, 100 V, Ceramic, X7R, 1206 ECJ-3YB1E105K Panasonic 8 1 D1 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) DL4007-13-F Diodes Inc 9 1 D2 400 V, 1 A, Ultrafast Recovery, 35 ns, SMB Case US1G Diodes Inc 10 1 D3 100 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC ES1B-13-F Diodes Inc 11 1 D4 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diode Inc. 12 1 F1 3.15 A, 250 V, Slow, RST 507-1181 Belfuse 13 2 L1 L2 14 1 L3 EE13 680 H Inductor PNP, Small Signal BJT, 500 V, 0.15 A, SOT23 15 1 Q1 16 2 R1 R2 17 2 R3 R4 18 1 19 1 20 21 22 23 24 25 26 6.2 Mfg Part Number Mfg B10S-G Comchip 100 nF, 630 V, Film ECQ-E6104KF Panasonic 100 nF, 400 V, Film ECQ-E4104KF Panasonic 2.2 mH, 0.19 A, Ferrite Core CTCH895F-222K CTParts SNX R1551 Santronics USA FMMT560TA Zetex 10 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ103V Panasonic 2.00 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF2004V Panasonic R5 1.00 M, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1004V Panasonic R6 24.9 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF2492V Panasonic 1 R7 76.8 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF7682V Panasonic 1 R8 34.8 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF3482V Panasonic 1 R9 90.9 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF9092V Panasonic 1 R10 47 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ473V Panasonic 1 R12 0 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEY0R00V Panasonic 1 RV1 275 V, 23 J, 7 mm, RADIAL V275LA4P Littlefuse 1 U1 LinkSwitch-PH, LNK405EG, eSIP LNK405EG Power Integrations Optional OVP Circuit Item Qty Ref Des Description Mfg Part Number Mfg 1 1 VR1 47 V, 5%, 500 mW, DO-35 1N5261B-T Diodes Inc 2 1 SCR1 SCR, 400 V, 10 A, TO-251 S4010VS3 LittelFuse 3 1 R11 10 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ103V Panasonic 4 1 C7 10 nF 50 V, Ceramic, X7R, 0603 ECJ-1VB1H103K Panasonic Page 11 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 6.3 06-Jan-11 Mechanical Item Qty Ref Des Description Mfg Part Number Mfg 1 1 HSK RD257_HSK 2 1 SCREW1 3 1 ESIP CLIP1 Heat sink Hardware, Edge Clip 16.5 mm L x 7.5 mm W x 0.5 mm H 4 1 NUT1 Nut, Hex 4-40, SS 5 1 TE1 Terminal, Eyelet, Tin Plated Brass, Zierick PN 190 190 Zierick 6 1 TP1 Test Point, WHT, Miniature THRU-HOLE MOUNT 5002 Keystone 7 2 TP2 TP4 Test Point, BLK, Miniature THRU-HOLE MOUNT 5001 Keystone 8 1 TP3 Test Point, RED, Miniature THRU-HOLE MOUNT 5000 Keystone SCREW MACHINE PHIL Flat head 4-40 X 1/4 SS Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com PH-3 Page 12 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 7 Heat Sink Assembly Figure 8 – Heat Sink Dimensions. Figure 9 – Heat Sink Assembly Drawing. Page 13 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 8 Inductor Specification 8.1 Electrical Diagram Figure 10 – Inductor Electrical Diagram. 8.2 Electrical Specifications Inductance Resonant Frequency 8.3 680 H ±5% 1 MHz (Min.) Materials Item [1] [2] [3] [4] 8.4 Pins 1-3, all other windings open, measured at 66 kHz, 0.4 VRMS Pins 1-3, all other windings open Description Core: PC44 EE13 (NC2H) Bobbin: EE13, Vertical, 10 pins, 5/5. Magnet Wire: #29 AWG. Tape: 3M 1298 Polyester Film, 7.5 mm wide. Inductor Build Diagram Figure 11 – Inductor Build Diagram. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9 Performance Data The following data were measured using 3 sets of load (i.e. 11, 12, and 13 LED strings to represent the load range of 30 V ~ 36 V output voltage). Refer to the table on Section 9.6 for the complete set of test data values. All measurements performed at room temperature. 9.1 Efficiency 88.5 13 LED String 12 LED String 11 LED String 88.0 Efficiency (%) 87.5 87.0 86.5 86.0 85.5 85.0 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (VAC) Figure 12 – Efficiency vs. Load and Input Voltage. Page 15 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9.2 Line and Load Regulation 360 13 LED String 12 LED String 11 LED String 350 Output Current (mA) 06-Jan-11 340 330 320 310 300 85 100 115 130 145 160 175 190 205 220 235 250 265 280 Input Voltage (VAC) Figure 13 – Regulation vs. Load and Input Voltage. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 40 06-Jan-11 9.3 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG Power Factor 1.00 13 LED String 12 LED String 11 LED String 0.99 Power Factor 0.98 0.97 0.96 0.95 0.94 0.93 85 100 115 130 145 160 175 190 205 220 235 250 265 Input Voltage (VAC) Figure 14 – Power Factor vs. Load and Input Voltage. Page 17 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9.4 06-Jan-11 THD 23.5 13 LED String 12 LED String 11 LED String 21.5 THD (A/%) 19.5 17.5 15.5 13.5 11.5 9.5 7.5 85 100 115 130 145 160 175 190 205 220 235 250 265 280 Input Voltage (VAC) Figure 15 – THD vs. Load and Input Voltage. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9.5 Harmonics Per IEC 61000-3-2 (2005) for Class C compliance for an active input power <25 W requires meeting Class D limits. Where Figures 15 and 16 show Class D limits these are intended to show the limits for Class C compliance (Class D limits). 60 Class D Limit RD-257 Harmonic Data at 230 VAC Harmonic Current (mA) 50 40 30 20 10 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 Harmonic Order Figure 16 – 230 VAC Input, 50 HZ Current Harmonics. Page 19 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 39 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 100 06-Jan-11 Class D Limit RD-257 Harmonic Data at 115 VAC 90 Harmonic Current (mA) 80 70 60 50 40 30 20 10 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order Figure 17 – 115 VAC Input, 60 Hz Current Harmonics. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9.6 Test Data All measurements were taken with the board at open frame, 25˚C ambient 9.6.1 Test Data, 13 LED Load VIN (VAC) FLINE (Hz) PIN, (W) PF A-THD (%) IOUT (mA) VOUT (V) POUT (W) Efficiency (%) 90 100 115 132 185 200 230 240 265 60 60 60 60 50 50 50 50 50 13.68 13.87 14.12 14.31 14.55 14.52 14.46 14.43 14.32 0.991 0.993 0.993 0.990 0.980 0.975 0.963 0.959 0.945 12.99 11.13 10.64 12.03 16.20 17.30 19.33 19.97 21.12 318.1 324.2 331.3 336.6 341.5 340.7 337.8 336.6 332.6 36.99 37.00 37.03 37.04 37.03 37.01 37.02 37.01 37.00 11.91 12.14 12.40 12.59 12.79 12.76 12.65 12.59 12.43 87.1 87.5 87.8 88.0 87.9 87.8 87.5 87.3 86.8 9.6.2 Test Data, 12 LED Load VIN (VAC) FLINE (Hz) PIN, (W) PF A-THD (%) IOUT (mA) VOUT (V) POUT (W) Efficiency (%) 90 100 115 132 185 200 230 240 265 60 60 60 60 50 50 50 50 50 12.45 12.75 13.07 13.33 13.72 13.74 13.74 13.73 13.69 0.992 0.993 0.992 0.989 0.978 0.973 0.961 0.957 0.942 11.38 10.39 10.75 12.35 16.47 17.66 19.33 19.88 20.97 311.2 319.6 328.2 335.0 343.3 343.0 341.5 340.5 337.6 34.53 34.56 34.59 34.62 34.60 34.62 34.62 34.59 34.61 10.89 11.18 11.48 11.73 12.03 12.02 11.95 11.92 11.82 87.4 87.7 87.9 88.0 87.6 87.5 87.0 86.8 86.3 9.6.3 Test Data, 11 LED Load VIN (VAC) FLINE (Hz) PIN, (W) PF A-THD (%) IOUT (mA) VOUT (V) POUT (W) Efficiency (%) 90 100 115 132 185 200 230 240 265 60 60 60 60 50 50 50 50 50 11.67 11.88 12.16 12.39 12.80 12.84 12.91 12.92 12.93 0.993 0.993 0.991 0.988 0.976 0.971 0.958 0.953 0.937 10.48 10.04 11.05 12.82 16.79 17.87 19.34 19.72 20.63 316.4 322.9 331.0 337.9 346.5 346.8 346.7 346.2 344.1 31.67 31.69 31.72 31.71 31.72 31.72 31.71 31.71 31.73 10.15 10.37 10.64 10.84 11.14 11.15 11.15 11.13 11.06 86.9 87.3 87.5 87.5 87.1 86.9 86.3 86.1 85.5 Page 21 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 9.6.4 230 VAC, 50 Hz Harmonics Data, PIN = 14.529 W 9.6.4.1 EN61000-3-2 n Measured (mA) 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 64.070 0.050 8.630 5.750 3.120 2.080 1.960 1.870 1.890 1.830 1.960 1.440 1.340 1.030 0.870 0.730 0.610 0.590 0.470 0.580 0.640 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Base I Harmonics (mA/W) 230 V Limit (mA) Remarks 3.40000 1.90000 1.00000 0.50000 0.35000 0.29615 0.25667 0.22647 0.20263 0.18333 0.16739 0.15400 0.14259 0.13276 0.12419 0.11667 0.11000 0.10405 0.09872 49.399 27.605 14.529 7.265 5.085 4.303 3.729 3.290 2.944 2.664 2.432 2.237 2.072 1.929 1.804 1.695 1.598 1.512 1.434 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 22 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 9.6.5 115 VAC, 60 Hz Harmonics Data, PIN = 13.96 W 9.6.5.1 EN61000-3-2 Page 23 of 40 n Measured (mA) 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 121.260 0.210 4.450 4.060 6.110 6.150 5.210 3.470 1.900 2.110 2.060 1.960 1.790 1.270 0.770 0.480 0.540 0.870 0.960 0.890 0.540 Base I Harmonics (mA/W) 115 V Limit (mA) Remarks 3.40000 1.90000 1.00000 0.50000 0.35000 0.29615 0.25667 0.22647 0.20263 0.18333 0.16739 0.15400 0.14259 0.13276 0.12419 0.11667 0.11000 0.10405 0.09872 94.928 53.048 27.920 13.960 9.772 8.269 7.166 6.323 5.657 5.119 4.674 4.300 3.981 3.707 3.467 3.257 3.071 2.905 2.756 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 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 10 Waveforms 10.1 Input Line Current Figure 18 – 90 VAC 60 Hz, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 19 – 115 VAC 60 Hz, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 20 – 230 VAC 50 Hz, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 21 – 265 VAC 50 Hz, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 10.2 Drain Voltage and Current Normal Operation Figure 22 – 90 VAC 60 Hz, Full Load. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 50 V, 5 ms / div. Figure 23 – 90 VAC 60 Hz, Full Load. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 50 V, 5 μs / div. Figure 24 – 265 VAC 50 Hz, Full Load. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 25 – 265 VAC 50 Hz, Full Load. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 μs / div. Page 25 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 10.3 Drain Voltage and Current Start-up Operation Figure 26 – 265 VAC 50 Hz, 0˚Full Load Start-up. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 27 – 265 VAC 50 Hz, 90˚Full Load Start-up. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 2 ms / div. Page 26 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 10.4 Output Current, Normal Condition, VOUT ~ 36 V Figure 28 – 90 VAC 60 Hz, Full Load. IOUT, 100 mA / div., 10 ms / div. Figure 29 – 115 VAC 60 Hz, Full Load. IOUT, 100 mA / div., 10 ms / div. Figure 30 – 230 VAC 50 Hz, Full Load. IOUT, 100 mA / div., 10 ms / div. Figure 31 – 265 VAC 50 Hz, Full Load. IOUT, 100 mA / div., 10 ms / div. Page 27 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 10.5 Output Current Ripple, VOUT ~ 36 V Figure 32 – 90 VAC 60 Hz, Full Load. IOUT, AC Coupled, 100 mA / div., 10 ms / div. Figure 33 – 115 VAC 60 Hz, Full Load. IOUT, AC Coupled, 100 mA / div., 10 ms / div. Figure 34 – 230 VAC 50 Hz, Full Load. IOUT, AC Coupled, 100 mA / div., 10 ms / div. Figure 35 – 265 VAC 50 Hz, Full Load. IOUT, AC Coupled, 100 mA / div., 10 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 10.6 Output Current and Voltage at Power-up, Power-down Figure 36 – 90 VAC 60Hz, Output Rise. Upper: IOUT, 100 mA / div. Lower: VOUT, 10 V, 50 ms / div. Figure 37 – 90 VAC 60Hz, Output Fall. Upper: IOUT, 100 mA / div. Lower: VOUT, 10 V, 50 ms / div. Figure 38 – 265 VAC 50 Hz, Output Rise. Upper: IOUT, 100 mA / div. Lower: VOUT, 10 V, 50 ms / div. Figure 39 – 265 VAC 50 Hz, Output Fall. Upper: IOUT, 100 mA / div. Lower: VOUT, 10 V, 50 ms / div. Page 29 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 10.7 Output Short Figure 40 – 265 VAC 60 Hz, Output Short. Upper: IDRAIN, 1 A / div. Lower: VDRAIN, 100 V, 200 ms / div. Figure 41 – 265 VAC 60 Hz, Output Short. Upper: IDRAIN, 1 A / div. Lower: VDRAIN, 100 V, 10 ms / div. 10.8 Open Load/LED Condition Figure 42 – 90 VAC 60 Hz, Open Load. CH2: IOUT, 200 mA / div. CH4: VOUT, 10 V, 1s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 43 – 265 VAC 60 Hz, Open Load. CH2: IOUT, 200 mA / div. CH4: VOUT, 10 V, 1s / div. Page 30 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 11 Thermal Measurements 11.1 Thermal Test Set-up Thermal Measurements were done with the buck board inside the T8 fixture operated at room temperature. The ambient measurement location inside the assembly is shown below. Figure 44 – Ambient Inside Location. Figure 45 – Thermal Measurement Set-up. 11.2 Thermal Test Results Component / Location Ambient Inside LinkSwitch-PH Output Inductor, Wire Output Inductor, Core EMI Diff-Choke Output Capacitor Free Wheel Diode Ambient (room) Input Condition VOUT, V IOUT, mA POUT, W VIN, VAC Page 31 of 40 Absolute Temperature, (˚C) 66 83 76 75 74 70 72 27 55 80 76 74 62 68 69 26 35.54 334.00 11.87 90.00 35.48 321.00 11.39 265.00 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 12 Conducted EMI Measurements 12.1 Conducted EMI Test Set-up Conducted EMI were measured with the LED Board inside the T8 tube together with the LED load .The tube is mounted on a typical T8 holder and the metal body of the fixture was connected to earth ground. Two different set-ups were measured corresponding to the position of the driver with respect to the grounded fixture. 12.1.1 Configuration A: Solder Side of Driver Facing Grounded T8 Fixture Figure 46 – Configuration A EMI Measurement Set-up. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 12.1.2 Configuration B: Component Side of Driver Facing Grounded T8 Fixture Figure 47 – Configuration B EMI Measurement Set-up. Page 33 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 12.2 Conducted EMI Test Results 12.3 Configuration A Conducted Emission Power Integrations 04.Jan 11 17:22 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 100 kHz 120 EN55015Q LIMIT CHECK 110 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Trace1: EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 67.8393045788 kHz 36.50 L1 gnd 2 Average 126.977840157 kHz 40.85 N gnd 2 Average 130.825395691 kHz 43.64 N gnd 2 Average 133.454986145 kHz 48.07 N gnd 2 Average 138.873793737 kHz 42.63 N gnd 2 Average 165.693318812 kHz 36.82 L1 gnd -18.34 1 Quasi Peak 198.193645035 kHz 53.04 L1 gnd -10.64 2 Average 198.193645035 kHz 43.54 L1 gnd -10.13 1 Quasi Peak 264.49018761 kHz 44.90 L1 gnd -16.38 2 Average 264.49018761 kHz 36.27 L1 gnd -15.01 1 Quasi Peak 332.507282579 kHz 46.51 L1 gnd -12.87 2 Average 332.507282579 kHz 35.69 L1 gnd -13.69 1 Quasi Peak 397.727746704 kHz 45.29 L1 gnd -12.61 2 Average 397.727746704 kHz 33.62 L1 gnd -14.27 1 Quasi Peak 598.084042089 kHz 44.56 L1 gnd -11.43 Figure 48 – Conducted EMI, ~36 V Load, 115 VAC, 60 Hz, and EN55022 B Limits. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG Power Integrations 04.Jan 11 16:50 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 100 kHz 120 EN55015Q LIMIT CHECK 110 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Trace1: EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 126.977840157 kHz 39.02 L1 gnd 2 Average 130.825395691 kHz 44.17 L1 gnd 2 Average 133.454986145 kHz 39.70 N gnd 2 Average 137.49880568 kHz 30.25 L1 gnd 2 Average 165.693318812 kHz 34.81 L1 gnd -20.35 1 Quasi Peak 198.193645035 kHz 53.67 L1 gnd -10.01 2 Average 198.193645035 kHz 45.06 L1 gnd -8.62 1 Quasi Peak 264.49018761 kHz 48.20 L1 gnd -13.08 2 Average 264.49018761 kHz 38.63 L1 gnd -12.65 1 Quasi Peak 332.507282579 kHz 43.95 L1 gnd -15.43 2 Average 332.507282579 kHz 34.59 L1 gnd -14.79 1 Quasi Peak 397.727746704 kHz 41.02 L1 gnd -16.87 1 Quasi Peak 660.656865747 kHz 44.23 L1 gnd -11.76 2 Average 660.656865747 kHz 33.59 L1 gnd -12.40 2 Average 19.2717727102 MHz 30.90 L1 gnd -19.09 Figure 49 – Conducted EMI, ~36 V Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 35 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 12.4 Configuration B Conducted Emission Power Integrations 04.Jan 11 17:53 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 100 kHz 120 EN55015Q LIMIT CHECK 110 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Trace1: EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 67.8393045788 kHz 36.63 L1 gnd 2 Average 126.977840157 kHz 40.99 L1 gnd 2 Average 130.825395691 kHz 43.32 N gnd 2 Average 133.454986145 kHz 47.40 L1 gnd 2 Average 138.873793737 kHz 42.48 L1 gnd 2 Average 165.693318812 kHz 36.70 N gnd -18.46 1 Quasi Peak 198.193645035 kHz 53.11 N gnd -10.56 2 Average 198.193645035 kHz 43.49 N gnd -10.18 1 Quasi Peak 264.49018761 kHz 45.24 N gnd -16.05 2 Average 264.49018761 kHz 36.40 N gnd -14.88 1 Quasi Peak 332.507282579 kHz 47.00 N gnd -12.38 2 Average 332.507282579 kHz 36.07 N gnd -13.31 1 Quasi Peak 397.727746704 kHz 45.76 N gnd -12.13 2 Average 397.727746704 kHz 33.81 N gnd -14.08 1 Quasi Peak 598.084042089 kHz 45.24 N gnd -10.75 Figure 50 – Phase L1: Conducted EMI, ~36 V Load, 115 VAC, 60 Hz, and EN55022 B Limits. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG Power Integrations 04.Jan 11 18:47 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 100 kHz 120 EN55015Q LIMIT CHECK 110 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Trace1: EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 128.247618558 kHz 20.13 L1 gnd 2 Average 130.825395691 kHz 36.31 L1 gnd 2 Average 133.454986145 kHz 49.08 L1 gnd 2 Average 137.49880568 kHz 43.09 N gnd 1 Quasi Peak 200.175581485 kHz 55.08 N gnd 2 Average 202.1773373 kHz 45.17 N gnd -8.34 1 Quasi Peak 267.135089486 kHz 51.19 N gnd -10.01 2 Average 267.135089486 kHz 39.86 N gnd -11.34 1 Quasi Peak 335.832355405 kHz 48.18 N gnd -11.11 2 Average 335.832355405 kHz 37.06 N gnd -12.24 1 Quasi Peak 401.705024172 kHz 43.65 N gnd -14.16 2 Average 401.705024172 kHz 34.00 N gnd -13.81 1 Quasi Peak 471.030732902 kHz 44.63 N gnd -11.85 1 Quasi Peak 536.076911993 kHz 46.34 N gnd -9.65 2 Average 536.076911993 kHz 34.66 N gnd -11.34 2 Average 673.936068749 kHz 36.58 N gnd -9.41 1 Quasi Peak 737.073953121 kHz 48.69 N gnd -7.30 -8.51 Figure 51 – Phase N: Conducted EMI, ~36 V Load, 230 VAC, 60 Hz, and EN55022 B Limits. Page 37 of 40 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 13 Power Line Transient Tests The unit was subjected to ±2500 V 100 kHz ring wave, both at 115 VAC and 230 VAC. A test failure was defined as a non-recoverable interruption of output requiring supply repair or recycling of input voltage. Level (V) Input Voltage (VAC) Injection Location Injection Phase (°) ±2500 115 L1, L2 0 ±2500 115 L1, L2 90 ±2500 230 L1, L2 0 ±2500 230 L1, L2 90 Type 100 kHz Ring Wave (500 A) 100 kHz Ring Wave (500 A) 100 kHz Ring Wave (500 A) 100 kHz Ring Wave (500 A) Test Result (Pass/Fail) Pass Pass Pass Pass Note: 500 V Differential Surge test was also carried out and the unit still pass (no damage). However the surge rating of C3 (450 V for 400 V rated) was exceeded. To limit the peak voltage at C3, a higher value capacitance must be used at the peak detector. A 4.7 F capacitor was tested and C3 peak voltage was limited to 464 V. A 450 V rated capacitor is recommended to avoid stressing C3 during these tests. Voltage Across C3, 100V/div, 100us/div Voltage Across C1, 200V/div, 100us/div Figure 52 – 500 V Differential Surge, 230 VAC, 90º. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 40 06-Jan-11 RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 14 Revision History Date 06-Jan-11 Page 39 of 40 Author CA Revision 1.0 Description & changes Initial Release Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-257 12 W Non-isolated BUCK LED Driver Using LNK405EG 06-Jan-11 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. 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