Design Example Report Title No Electrolytic Capacitor, High Efficiency (≥82%), High Power Factor (>0.9) TRIAC Dimmable 7 WTYP LED Driver Using LinkSwitchTM-PH LNK403EG Specification 90 VAC – 265 VAC Input; 18 VTYP, 0.38 A Output Application LED Driver Author Applications Engineering Department Document Number DER-277 Date March 28, 2011 Revision 1.0 Summary and Features No electrolytic capacitor TRIAC dimmer compatible (including low cost leading edge type) o No output flicker o >100:1 dimming range Clean monotonic start-up – no output blinking Fast start-up (<100 ms) – no perceptible delay Consistent dimming performance unit to unit Highly energy efficient o ≥82% at 115 VAC, ≥85% at 230 VAC Low cost, low component count and small printed circuit board footprint solution o No current sensing required o Frequency jitter for smaller, lower cost EMI filter components Integrated protection and reliability features o Output open circuit / output short-circuit protected with auto-recovery o Line input overvoltage shutdown extends voltage withstand during line faults. o Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board o No damage during brown-out or brown-in conditions Meets IEC 61000-4-5 ring wave, IEC 61000-3-2 Class C harmonics and EN55015 B conducted EMI Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 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, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG Table of Contents 1 2 3 4 Introduction .............................................................................................................5 Power Supply Specification.....................................................................................7 Schematic ...............................................................................................................8 Circuit Description ...................................................................................................9 4.1 Input Filtering .......................................................................................................9 4.2 LinkSwitch-PH Primary ........................................................................................9 4.3 Bias Supply and Output Overvoltage Sensing.....................................................9 4.4 Output Feedback ...............................................................................................10 4.5 Output Rectification and Filtering.......................................................................10 4.6 TRIAC Phase Dimming Interface Circuitry.........................................................10 5 PCB Layout ...........................................................................................................11 6 Bill of Materials ......................................................................................................13 7 Transformer Specification .....................................................................................14 7.1 Electrical Diagram..............................................................................................14 7.2 Materials ............................................................................................................14 7.3 Transformer Build Diagram................................................................................15 7.4 Transformer Construction ..................................................................................15 8 Transformer Design Spreadsheet .........................................................................16 9 Performance Data .................................................................................................19 9.1 Efficiency vs. Line and Output (LED String) Voltage..........................................19 9.1.1 18 V ............................................................................................................19 9.1.2 15 V ............................................................................................................19 9.1.3 21 V ............................................................................................................20 9.2 Regulation .........................................................................................................21 9.2.1 Output Voltage and Line.............................................................................21 9.2.2 Line Regulation...........................................................................................22 10 Thermal Performance............................................................................................24 10.1 VIN = 115 VAC ...................................................................................................24 10.2 VIN = 230 VAC ...................................................................................................24 11 Harmonic Data ......................................................................................................25 12 Waveforms ............................................................................................................27 12.1 Input Line Voltage and Current ..........................................................................27 12.2 Drain Voltage and Current .................................................................................27 12.3 Output Voltage and Ripple Current....................................................................28 12.4 Drain Voltage and Current Start-up Profile ........................................................28 12.5 Output Current and Drain Voltage at Shorted Output ........................................29 12.6 Open Load Output Voltage ................................................................................29 13 Dimming ................................................................................................................30 13.1 Input Phase vs. Output Current .........................................................................30 13.2 Output Voltage and Input Current Waveforms During Dimming ........................31 13.2.1 VIN = 115 VAC / 60 Hz ................................................................................31 13.2.2 VIN = 230 VAC / 50 Hz ................................................................................32 14 Line Surge.............................................................................................................33 15 Conducted EMI .....................................................................................................34 Page 3 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 16 28-Mar-11 Revision History ....................................................................................................35 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 4 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 1 Introduction The document describes a power-factor corrected dimmable LED driver designed to drive an LED string of 18 V at a current of 0.38 A (both nominal) from an input voltage range of 90 VAC to 265 VAC. The LED driver utilizes the LNK403EG from Power Integrations. The design specifically eliminates electrolytic capacitors which limit operating life, especially when operated at high temperature. LinkSwitch-PH ICs allow the implementation of cost effective and low component count LED drivers which both meet power factor and harmonics limits but also offer enhanced end user experience. This includes ultra-wide dimming range, flicker-free operation (even with low cost with AC line TRIAC dimmers) and fast, clean turn on. The topology used is an isolated flyback operating in continuous conduction mode. Output current regulation is sensed entirely from the primary side eliminating the need for secondary side feedback components. No external current sensing is required on the primary side either as this is performed inside the IC further reducing components and losses. The internal controller adjusts the MOSFET duty cycle to maintain a sinusoidal input current and therefore high power factor and low harmonic currents. The LNK403EG also provides a sophisticated range of protection features including autorestart for open control loop and output short-circuit conditions. Line overvoltage provides extended line fault and surge withstand, output overvoltage protects the supply should the load be disconnect and accurate hysteretic thermal shutdown ensures safe average PCB temperatures under all conditions. In any LED luminaire the driver determines many of the performance attributes experienced by the end customer (user) including start-up time, dimming, flicker and unit to unit consistency. For this design a focus was given to compatibility with as wider range of dimmers and as large of a dimming range as possible, at both 115 VAC and 230 VAC. However simplification of the design is possible for single input voltage operations, nondimming or operation with a limited range of (higher quality) dimmers. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, transformer documentation and typical performance characteristics. Page 5 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 Figure 1 – Populated Circuit Board Photograph (Top View). PCB Outline Designed to Fit Inside PAR20 Enclosure. Figure 2 – Populated Circuit Board Photograph (Bottom View). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 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 a Frequency Output Output Voltage Output Current a Total Output Power Continuous Output Power Efficiency Full Load Symbol Min Typ Max Units Comment VIN fLINE 90 47 115 50/60 265 64 VAC Hz 2 Wire – no P.E. VOUT IOUT 15 18 0.38 21 V A 7 POUT VOUT = 21, VIN = 115 VAC, 25°C W 80 % o Measured at POUT 25 C Environmental Conducted EMI Meets CISPR 15B / EN55015B Designed to meet IEC950 / UL1950 Class II Safety Ring Wave (100 kHz) Differential Mode (L1-L2) Common mode (L1/L2-PE) Power Factor IEC 61000-4-5 , 200 A Measured at VOUT(TYP), IOUT(TYP) and 115/230 VAC 0.9 Harmonics Ambient Temperature kV 2.5 EN 61000-3-2 Class D b TAMB 40 o C Free convection, sea level Notes: a When configured for phase controlled (TRIAC) dimming, in order to give the widest dimming range, the output current for a LinkSwitch-PH design varies with line voltage. Therefore the output current specification is defined at a single line voltage only. For this design a line voltage of 115 VAC was selected. At higher line voltages the output current will increase and reduce with lower line voltages. The typical output current variation is +30% for a +200% increase in line voltage. A single resistor value change can be used to center the nominal output current for a given nominal line voltage. See Table 1 for the feedback resistor value vs. nominal line voltage. b Maximum ambient temperature specification may be increased by adding a small heat sink to the LinkSwitch-PH device. Page 7 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 3 Schematic Figure 3 – Schematic. Note: The power rating of R14 and R16 need to be double at 230 VAC input. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 4 Circuit Description The LinkSwitch-PH device is a controller and integrated 725 V MOSFET intended for use in LED driver applications. The LinkSwitch-PH is configured for use in a single-stage continuous conduction mode flyback topology and provides a primary side regulated constant current output while maintaining high power factor from the AC input. 4.1 Input Filtering Fuse F1 fuses the input and BR1 rectifies the AC line voltage. Inductor L1-L3, C2, R2, and R3 form the EMI filter and together with C7 (Y1 safety) capacitor allow the design to meet EN55015B conducted EMI limits. Capacitor C3 provides a low impedance path for the primary switching current, a low value of capacitance is necessary to maintain a power factor of greater than 0.9. 4.2 LinkSwitch-PH Primary Diode D6 and high-voltage SMD ceramic capacitors C16 and C17 detect the peak AC line voltage. This voltage is converted to a current into the VOLTAGE MONITOR (V) pin via R4 and R7. This current is also used by the device to set the input over/undervoltage protection thresholds. The V pin current and the FEEDBACK (FB) pin current are used internally to control the average output LED current. TRIAC phase-angle dimming applications require 49.9 k resistors on the REFERENCE (R) pin (R19) and 4 M on the V pin (R4+R7) to provide a linear relationship between input voltage and the output current, allowing dimming with standard TRIAC dimmers. Resistor R19 also sets the internal references to select the line undervoltage threshold. In TRIAC dimming configuration (as shown here) the line undervoltage threshold is lowered to allow start-up at smaller TRIAC conduction angles. Diode D1 and VR1 clamp the drain voltage to below the BVDSS rating (725 V) of the internal power MOSFET in U1. Diode D5 is necessary to prevent reverse current from flowing through the LinkSwitch-PH device (the result of the minimal input capacitance). 4.3 Bias Supply and Output Overvoltage Sensing Diode D3, C19, R5, R9 and R18 form the primary bias supply. This supplies the IC operating current into the BYPASS (BP) pin through D4 and R10 during normal operation. Resistor R5 provides filtering to improve output regulation while R9 and R10 act as a minimum load; this improves dimming range by causing the bias voltage to reduce as the output current falls. Capacitor C18 is the supply decoupling for the LinkSwitch-PH. During start-up C18 is charged to ~6 V from an internal high-voltage current source tied to the device DRAIN (D) pin. Once charged the energy stored in C18 is used to run the device until the output and bias winding voltage rise. A disconnected load / overvoltage shutdown function is provided by D8, C14, R24, VR3, C15, R23 and Q2. A second bias winding output voltage is used to eliminate the delay Page 9 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 introduced by the larger value of C19 compared to C14. Should the output LED load be disconnected, the output voltage and therefore the bias winding voltage across C14 will rise. Once this exceeds the voltage rating of VR3 plus the VBE of Q2 then Q2 is bias on which pulls the FB pin down. Once the current into the FB pin of U1 falls the device enters auto-restart, thereby limiting the output voltage. Resistor R24, C15 and R23 all provide filtering. 4.4 Output Feedback A current proportional to the output voltage from the primary bias winding is fed into the FB pin through R15. This information together with the line input voltage and the drain current are used to maintain a constant output current. 4.5 Output Rectification and Filtering Diode D2 rectifies the secondary winding while ceramic capacitors C20, C21, C22 and C23 filter the output. A Schottky diode was selected for high efficiency. 4.6 TRIAC Phase Dimming Interface Circuitry Components R12, R13, R20, R17, D7, Q1, C13, VR2, and Q3 in conjunction with R16 reduce the inrush current when the TRIAC dimmer turns on. This prevents the line inductance from peak charging input capacitance above the line voltage, causing flicker. During each AC cycle the input current flows through R16 for the first 0.6 ms at 115 VAC (0.3 ms at 230 VAC) of TRIAC conduction. After approximately 0.6 ms, Q3 turns on and shorts R16. This circuit allows the value of R16 to be large enough to limit the initial inrush current but keeps the power dissipation on R16 low for high-efficiency. Resistor R12, R13, R20 and C13 provide a 0.6 ms delay after the TRIAC conducts. Transistor Q1 discharges C13 when the TRIAC is not conducting. Zener diode VR2 clamps the gate voltage of Q3 to 15 V. Capacitor C9 and R14 form a passive bleeder circuit with keep the AC input current above the holding current threshold for the TRIAC to prevent multiple firings on each AC cycle causing flicker and shimmer. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 5 PCB Layout Figure 4 – Printed Circuit Layout Top. (Designed to Fit Inside PAR20 Lamp Form Factor). Page 11 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 Figure 5 – Printed Circuit Layout Bottom. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 6 Bill of Materials Item 1 2 3 4 5 6 7 8 9 10 11 Qty 1 1 1 1 1 1 1 1 2 1 1 12 4 13 14 15 16 17 1 1 1 1 1 Ref Des BR1 C2 C3 C7 C9 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 D1 D2 D3 D4 D5 18 1 D6 19 1 D7 20 21 1 1 22 3 23 24 25 26 27 2 3 1 1 1 28 3 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 2 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 D8 F1 FL1 FL2 FL3 LN L1 L2 L3 Q1 Q2 Q3 R2 R3 R24 R4 R7 R5 R6 R9 R18 R10 R12 R13 R14 R15 R16 R17 R19 R20 R23 RV1 T1 TP3 TP4 46 1 U1 47 48 49 1 1 1 VR1 VR2 VR3 Page 13 of 36 Description 600 V, 1 A, Bridge Rectifier, SMD, DFS 22 nF, 275 VAC, Film, X2 100 nF, 400 V, Film 2.2 nF, Ceramic, Y1 220 nF, 400 V, Film 15 nF, 50 V, Ceramic, X7R, 0805 1 F, 50 V, Ceramic, X7R, 0805 100 nF, 50 V, Ceramic, X7R, 0805 100 nF, 500 V, Ceramic, X7R, 1812 10 F, 16 V, Ceramic, X5R, 0805 10 F, 35 V, Ceramic,Y5V, 1210 22 F, 25 V, Ceramic, X5R, 1210 1000 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 200 V, 4 A, Schottky, SMC, DO-214AB 400V, 1 A, Rectifier, Fast Recovery, MELF (DL-41) 100 V, 1 A, Fast Recovery, 150 ns, SMA 200 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) 100 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 3.15 A, 250 V, Slow, RST PCB Terminal Hole, 22 AWG Test Point, WHT,THRU-HOLE MOUNT 1000 H, 0.14 A PNP, 400 V 150 MA, SOT-23 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 400 V, 1.7 A, 3.6 , N-Channel, DPAK 10 k, 5%, 1/8 W, Thick Film, 0805 2.00 M, 1%, 1/4 W, Thick Film, 1206 75 , 5%, 1/8 W, Thick Film, 0805 20 k, 5%, 1/4 W, Thick Film, 1206 10 k, 5%, 1/4 W, Thick Film, 1206 3 k, 5%, 1/4 W, Thick Film, 1206 750 k, 1%, 1/4 W, Thick Film, 1206 510 , 5%, 2 W, Metal Oxide 124 k, 1%, 1/8 W, Thick Film, 0805 130 , 5%, 1 W, Metal Oxide 15 , 1%, 1/8 W, Thick Film, 0805 49.9 k, 1%, 1/8 W, Thick Film, 0805 2.4 M, 5%, 1/8 W, Thick Film, 0805 1 k, 5%, 1/8 W, Thick Film, 0805 275 V, 80J, 10 mm, RADIAL Bobbin, RM6, Vertical, 6 pins Test Point, RED, Miniature THRU-HOLE MOUNT Test Point, BLK, Miniature THRU-HOLE MOUNT LinkSwitch, eSIP TM 200 V, 5 W, 5%, TVS, DO204AC (DO-15) 15 V, 5%, 500 mW, DO-213AA (MELF) 36 V, 5%, 500 mW, DO-213AA (MELF) Mfg Part Number DF06S-E3/45 ECQ-U2A223ML ECQ-E4104KF 440LD22-R ECQ-E4224KF ECJ-2VB1H153K 08055D105KAT2A CC0805KRX7R9BB104 VJ1812Y104KXEAT GRM21BR61C106KE15L GMK325F106ZH-T Mfg Vishay Panasonic Panasonic Vishay Panasonic Panasonic AVX Panasonic Vishay Murata Taiyo Yuden ECJ-4YB1E226M Panasonic UF4007-E3 MBRS4201T3G DL4936-13-F RS1B-13-F ES1D Vishay On Semi Diodes, Inc Diodes, Inc Vishay DL4007-13-F Diodes, Inc DL4002-13-F Diodes, Inc BAV21WS-7-F 507-1181 Diodes, Inc Belfuse N/A N/A 5012 SLF7045T-102MR14-PF FMMT558TA MMBT3904LT1G IRFR310TRPBF Keystone TDK Zetex On Semi Vishay ERJ-6GEYJ103V Panasonic ERJ-8ENF2004V ERJ-6GEYJ750V ERJ-8GEYJ203V ERJ-8GEYJ103V ERJ-8GEYJ302V ERJ-8ENF7503V RSF200JB-510R ERJ-6ENF1243V RSF100JB-130R ERJ-6ENF15R0V ERJ-6ENF4992V ERJ-6GEYJ245V ERJ-6GEYJ102V ERZ-V10D431 B65808-N1006-D1 5000 5001 Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic Yageo Panasonic Yageo Panasonic Panasonic Panasonic Panasonic Panasonic Epcos Keystone Keystone Power Integrations On Semi Diodes, Inc Diodes, Inc LNK403EG P6KE200ARLG ZMM5245B-7 ZMM5258B-7 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 7 Transformer Specification 7.1 Electrical Diagram RM6 FL1 W4 ½ Primary 64T #35 AWG NC W1 ½ Primary 64T #35 AWG W3 Output FL3 6 W2 Bias FL2 22T #28 TIW 1 26T #36 AWG 2 Figure 6 – Transformer Electrical Diagram. Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.2 1 second, 60 Hz, from pins 1, 2, 6, FL1 to FL2, FL3 Pins 1-FL1, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-FL1, all other windings open Pins 1-FL1 with FL2-FL3 shorted, measured at 100kHz, 0.4 VRMS 3000 VAC 2.45 mH ±10% 750 kHz (Min.) 35 H ±10% Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC95RM6 from TDK or equivalent, ALG = 149.5 nH/n2 Bobbin: 6 pin vertical, B-RM6-V-6P from Epcos, or equivalent Magnet Wire: #35 AWG. Magnet Wire: #36 AWG Magnet Wire: #28 AWG T.I.W. Tape: 3M 1298 Polyester Film, 7 mm wide. Mounting clip, CLI/P-RM6, and varnish. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 36 28-Mar-11 7.3 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG Transformer Build Diagram Pins Side 3L Tape W4 - Finish (FL1) 1L Tape W3 - Finish (FL3) 1L Tape W3 - Start (FL2) W2 - Finish (P2) W2 - Start (P6) 1L Tape W1 - Start (P1) Figure 7 – Transformer Build Diagram. 7.4 Transformer Construction Bobbin Preparation WD 1 Insulation WD 2 Insulation WD 3 Insulation WD 4 Insulation Final Assembly Page 15 of 36 Place the bobbin item [2] on the mandrel such that pin side on the left side. Winding direction is the clockwise direction. Start at pin 1, wind 64 turns of #35 AWG item [3] from left to right two layers. At the last turn exit the same slot, leave enough length wire floating to wind next 64 turns in WD4. Apply one layer of tape [6] for insulation. Start at pin 6, wind 26 turns of #36 AWG [4] wire from left to right. Finish at pin 2. Apple one layer of tape [6] for insulation. Leave about 1” of wire item [5], use small tape to mark as FL2, enter into slot of secondary side of bobbin, wind 22 turns in two layers. At the last turn exit the same slot, leave about 1”, and mark as FL3. Apple one layer of tape [6] for insulation. Continue to wind with floating wire, 64 turns of #35 AWG from left to right two layers. Leave 1” and mark as FL1 Apply three layers of tape [6] for insulation. Cut FL1, FL2, FL3 wire length to 0.75”. Grind core. Assemble core and varnish using item [7]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 8 Transformer Design Spreadsheet LinkSwitch-PH INPUT OUTPUT UNIT LinkSwitch-PH_042910: Flyback Transformer Design Spreadsheet ENTER APPLICATION VARIABLES Dimming YES YES required VACMIN 90 V !!! Info. When configured for dimming, best output current line regulation is achieved over a single input voltage range. Minimum AC Input Voltage VACMAX 132 V Maximum AC input voltage fL 50 Hz AC Mains Frequency VO 18 VO_MAX 19.80 V Typical output voltage of LED string at full load V Maximum expected LED string Voltage. VO_MIN 16.20 V Minimum expected LED string Voltage. V_OVP 21.78 V Overvoltage protection setpoint PO 6.8 W Output Power n 0.8 IO 0.38 VB 21 Typical full load LED current 21 Estimated efficiency of operation V Bias Voltage ENTER LinkSwitch-PH VARIABLES LinkSwitch-PH Chosen Device Current Limit Mode ILIMITMIN LNK403 Universal Power Out Full ILIMITMAX 12.5W 115 Doubled/230V 0.81 A 12.5W Select "RED" for reduced Current Limit mode or "FULL" for Full current limit mode Minimum current limit 0.92 A Maximum current limit Full fS 66000 Hz Switching Frequency fSmin 62000 Hz Minimum Switching Frequency fSmax 70000 Hz Maximum Switching Frequency 39.9 uA V pin current IV RV 4 M-ohms Upper V pin resistor RV2 1E+012 M-ohms Lower V pin resistor IFB 137.3 uA RFB1 131.1 k-ohms VDS 10 V VD 0.5 V VDB 0.7 V FB pin current (85 uA < IFB < 210 uA) FB pin resistor LinkSwitch-PH on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop (0.5 V for Schottky and 0.8 V for PN diode) Bias Winding Diode Forward Voltage Drop Key Design Parameters KP 0.99 LP 0.99 Ripple to Peak Current Ratio (For PF > 0.9, 0.4 < KP < 0.9) 2460 uH 108 V Reflected Output Voltage. Expected IO (average) 0.39 A Expected Average Output Current KP_VACMAX 1.04 TON_MIN 3.82 VOR 108 Primary Inductance Expected ripple current ratio at VACMAX us Minimum on time at maximum AC input voltage ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type RM6 RM6 Bobbin P/N: AE 0.36 0.36 cm^2 LE 2.86 2.86 cm AL 2280 2280 nH/T^2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com #N/A Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Page 16 of 36 28-Mar-11 BW DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 6.4 L 4 4 Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers NS 22 22 Number of Secondary Turns M 6.4 mm 0 mm DC INPUT VOLTAGE PARAMETERS VMIN 127 V Peak input voltage at VACMIN VMAX 187 V Peak input voltage at VACMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.48 Minimum duty cycle at peak of VACMIN IAVG 0.39 A Average Primary Current IP 0.44 A Peak Primary Current (calculated at minimum input voltage VACMIN) IRMS 0.14 A Primary RMS Current (calculated at minimum input voltage VACMIN) TRANSFORMER PRIMARY DESIGN PARAMETERS LP 2460 uH Primary Inductance NP 128 NB 26 ALG 149 nH/T^2 Gapped Core Effective Inductance BM 2330 Gauss Maximum Flux Density at PO, VMIN (BM<3100) BP 2820 Gauss Peak Flux Density (BP<3700) BAC 1153 Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) ur 1441 LG 0.28 mm Gap Length (Lg > 0.1 mm) BWE 25.6 mm Effective Bobbin Width Primary Winding Number of Turns Bias Winding Number of Turns Relative Permeability of Ungapped Core OD 0.20 mm Maximum Primary Wire Diameter including insulation INS 0.04 mm Estimated Total Insulation Thickness (= 2 * film thickness) DIA Bare conductor diameter 0.16 mm AWG 35 AWG CM 32 Primary Wire Gauge (Rounded to next smaller standard AWG value) Cmils Bare conductor effective area in circular mils Cmils/Am CMA 224 Primary Winding Current Capacity (200 < CMA < 600) p TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 2.56 A Peak Secondary Current ISRMS 0.82 A Secondary RMS Current IRIPPLE 0.72 A CMS 164 Cmils AWGS 27 AWG DIAS 0.36 mm Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter ODS 0.29 mm Secondary Maximum Outside Diameter for Triple Insulated Wire Output Capacitor RMS Ripple Current VOLTAGE STRESS PARAMETERS VDRAIN 408 V PIVS 54 V PIVB 63 V Estimated Maximum Drain Voltage assuming maximum LED string voltage (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage (calculated at VOVP, excludes leakage inductance spike) Bias Rectifier Maximum Peak Inverse Voltage (calculated at VOVP, excludes leakage inductance spike) FINE TUNING (Enter measured values from prototype) V pin Resistor Fine Tuning RV1 4.00 M-ohms Upper V Pin Resistor Value RV2 1.00E+12 M-ohms Lower V Pin Resistor Value Page 17 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 VAC1 115.0 V Test Input Voltage Condition1 VAC2 230.0 V Test Input Voltage Condition2 IO_VAC1 0.38 A Measured Output Current at VAC1 IO_VAC2 0.38 A Measured Output Current at VAC2 RV1 (new) 4.00 M-ohms New RV1 RV2 (new) 20911.63 M-ohms New RV2 V_OV 319.6 V Typical AC input voltage at which OV shutdown will be triggered V_UV 66.3 V Typical AC input voltage beyond which power supply can startup FB pin resistor Fine Tuning RFB1 131 k-ohms Upper FB Pin Resistor Value RFB2 1.00E+12 k-ohms Lower FB Pin Resistor Value VB1 18.9 V Test Bias Voltage Condition1 VB2 23.1 V Test Bias Voltage Condition2 IO1 0.38 A Measured Output Current at Vb1 IO2 0.38 A RFB1 (new) 131.1 k-ohms New RFB1 RFB2 (new) 1.00E+12 k-ohms New RFB2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Measured Output Current at Vb2 Page 18 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 9 Performance Data All measurements performed at room temperature. 9.1 Efficiency vs. Line and Output (LED String) Voltage 9.1.1 18 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 VIN (VAC) 90 100 115 130 VIN (VAC) 195 215 230 245 265 195 PIN (W) 8.2 8.55 9.06 9.56 PIN (W) 11.59 12.09 12.4 12.7 13.16 11.59 VOUT (V) 18.50 18.60 18.70 18.70 VOUT (V) 19.30 19.40 19.40 19.40 19.50 19.30 IOUT (mA) 335 352 376 401 IOUT (mA) 488 506 519 530 545 488 POUT (W) 6.60 6.93 7.45 7.98 POUT (W) 9.87 10.30 10.60 10.85 11.20 9.87 Efficiency (%) 80 81 82 83 Efficiency (%) 85 85 85 85 85 85 VIN (VAC) 90 100 115 130 VIN (VAC) 195 215 230 245 265 195 PIN (W) 6.9 7.2 7.65 8.1 PIN (W) 9.66 10.1 10.4 10.7 11.1 9.66 VOUT (V) 15.50 15.60 15.70 15.80 VOUT (V) 16.20 16.20 16.30 16.40 16.50 16.20 IOUT (mA) 339 358 382 405 IOUT (mA) 484 502 515 528 543 484 POUT (W) 5.57 5.87 6.32 6.75 POUT (W) 8.24 8.60 8.84 9.20 9.40 8.24 Efficiency (%) 81 82 83 83 Efficiency (%) 85 85 85 86 85 85 PF 0.98 PF 0.92 9.1.2 15 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 Page 19 of 36 PF 0.98 PF 0.89 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 9.1.3 21 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 VIN (VAC) 90 100 115 130 VIN (VAC) 195 215 230 245 265 195 PIN (W) 9.67 10 10.5 11.1 PIN (W) 13.5 14.1 14.5 14.8 15.3 13.5 VOUT (V) 21.40 21.50 21.70 21.80 VOUT (V) 22.30 22.40 22.40 22.50 22.60 22.30 IOUT (mA) 336 352 375 398 IOUT (mA) 487 507 519 531 545 487 POUT (W) 7.66 8.05 8.60 9.15 POUT (W) 11.40 11.90 12.30 12.50 12.90 11.40 Efficiency (%) 79 81 82 82 Efficiency (%) 84 84 85 84 84 84 PF 0.97 PF 0.93 87.0 15 V 18 V 21 V 86.0 Efficiency (%) 85.0 84.0 83.0 82.0 81.0 80.0 79.0 78.0 80 100 120 140 160 180 200 220 240 260 280 Input voltage (VAC) Figure 8 – Efficiency vs. Input Voltage, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 36 28-Mar-11 9.2 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG Regulation 9.2.1 Output Voltage and Line 610 115 VAC 230 VAC Output Current (mA) 560 510 460 410 360 310 260 14 15 16 17 18 19 20 21 22 Output Voltage (VDC) Figure 9 – Voltage and Line Regulation, Room Temperature. The line regulation result shown above is typical for a design where the phase angle dimming mode of U1 is selected (to provide a very wide dimming range). For a given line voltage the output current can be centered by changing the value of the FEEDBACK pin resistor (R15). The table below shows the resistor values to adjust the mean output current at specific input voltages, Line Voltage (VAC) 100 115 230 Value of R15 (kΩ) 118 127 174 Table 1 – Feedback Resistor Value to Center Output Current at Different Nominal Line Voltages. Page 21 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 9.2.2 Line Regulation 410 400 Input (VAC) 390 380 370 360 350 15 V 340 18 V 330 21 V 320 85 90 95 100 105 110 115 Output Current (mA) 120 125 130 135 Figure 10 – Low-Line Regulation, Room Temperature, Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 270 15 V 260 Input (VAC) 250 18 V 21 V 240 230 220 210 200 190 180 480 485 490 495 500 505 510 515 520 525 530 535 540 545 550 Output Current (mA) Figure 11 – High-Line Regulation, Room Temperature, Full Load. Page 23 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 10 Thermal Performance Images captured after running for 30 minutes at room temperature (25 °C), full load (18 V, 0.38 A). This indicates a LinkSwitch-PH (U1) operating temperature of ~80 °C at an external board ambient of 40 °C. As U1 is the highest temperature component on the board it provides effective thermal protection for the entire system via its internal thermal shutdown. The addition of a small heat sink (equal to the width of board) to U1 reduces the operating temperature by ~25 °C. 10.1 VIN = 115 VAC Figure 12 – Top Side. Figure 13 – Bottom Side. 10.2 VIN = 230 VAC Figure 14 – Top Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 15 – Bottom Side. Page 24 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 11 Harmonic Data The design passes Class C requirement. 70 Class C Limit DER-277 Harmonic Current 60 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 39 Harmonic Figure 16 – 115 VAC Harmonic, Room Temperature, Full Load. Page 25 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 45 28-Mar-11 Class C Limit DER-277 Harmonic Current 40 Current (mA) 35 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 Figure 17 – 230 VAC Harmonic, Room Temperature, Full Load. THD (%) VIN = 115 VAC Limit (%) Margin (%) 14 THD (%) 20 33 19 VIN = 230 VAC Limit (%) Margin (%) 33 13 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 12 Waveforms 12.1 Input Line Voltage and Current Figure 18 – 90 VAC, Full Load. Upper: IIN, 0.2 A / div. Lower: VIN, 200 V, 10 ms / div. Figure 19 – 265 VAC, Full Load. Upper: IIN, 0.1 A / div. Lower: VIN, 500 V / div., 10 ms / div. 12.2 Drain Voltage and Current Figure 20 – 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 200 V, 5 s / div. Page 27 of 36 Figure 21 – 265 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 200 V / div., 5 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 12.3 Output Voltage and Ripple Current Figure 22 – 90 VAC, Full Load. Upper: IRIPPLE, 0.5 A / div. Lower: VOUTPUT 10 V, 5 ms / div. Figure 23 – 265 VAC, Full Load. Upper: IRIPPLE, 0.5 A / div. Lower: VOUTPUT 10 V, 5 ms / div. 12.4 Drain Voltage and Current Start-up Profile Figure 24 – 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VOUTPUT, 5 V, 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 25 – 265 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUTPUT, 5 V, 10 ms / div. Page 28 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 12.5 Output Current and Drain Voltage at Shorted Output Figure 26 – 90 VAC, Full Load. Upper: IOUTPUT, 2 A / div. Lower: VDRAIN, 200 V, 200 ms / div. Figure 27 – 265 VAC, Full Load. Upper: IOUTPUT, 2 A / div. Lower: VDRAIN, 200 V, 200 ms / div. 12.6 Open Load Output Voltage Figure 28 – Output Voltage: 115 VAC. VOUT, 10 V / div., 500 ms / div. Figure 29 – Output Voltage: 230 VAC. VOUT, 10 V / div., 500 ms / div. Note: Under open load conditions the OV shutdown function is designed to prevent the output voltage exceeding SELV limits (45 V). This is achieved, however, the voltage rating of the output capacitors is exceeded which is acceptable for a fault condition. Page 29 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 13 Dimming 13.1 Input Phase vs. Output Current 115 VAC Phase angle IOUT(mA) 165 0.36 100 0.2 67 0.1 48 0.05 41 0.03 15 0.004 0.4 230 VAC Phase angle IOUT(mA) 139 0.37 72 0.2 54 0.1 9 0.04 9 0.025 9 0.019 115 VAC 230 VAC 0.35 Output Current (A) 0.3 0.25 0.2 0.15 0.1 0.05 0 0 20 40 60 80 100 120 140 160 180 Phase Angle (Degree) Figure 30 – Input Phase vs. Output Current. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 13.2 Output Voltage and Input Current Waveforms During Dimming 13.2.1 VIN = 115 VAC / 60 Hz Figure 31 – 115 VAC, Full Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 33 – 115 VAC, 48° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Page 31 of 36 Figure 32 – 115 VAC, 67° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 34 – 115 VAC, 15° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 13.2.2 VIN = 230 VAC / 50 Hz Figure 35 – 230 VAC, Full Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 37 – 230 VAC, 9° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 36 – 230 VAC, 54° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 38 – 230 VAC, 9° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Page 32 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 14 Line Surge Differential and common input line 200 A ring wave testing was completed on a single test unit to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) 2500 2500 2500 2500 2500 2500 Input Voltage (VAC) 230 230 230 230 230 230 Injection Location L to N L to N L to PE L to PE N to PE N to PE Injection Phase (°) 90 90 90 90 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Pass Pass Unit passes under all test conditions. Page 33 of 36 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-11 15 Conducted EMI Note: Refer to table for margin to standard – blue line is peak measurement but limit line is quasi peak. Figure 39 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55015 B Limits. Figure 40 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 B Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 36 28-Mar-11 DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 16 Revision History Date 28-Mar-11 Page 35 of 36 Author DK Revision 1.0 Description & changes Initial Release Reviewed Apps and Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-277 No Electrolytic Capacitor, 7 W LED Driver Using LNK403EG 28-Mar-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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, 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 2011 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 Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 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. 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Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 Page 36 of 36 Design Example Report Title Retrofit A19 TRIAC Dimmable 8 W LED Driver Using LinkSwitchTM-PH LNK403EG Compatible with High Power Dimmers Specification 198 VAC – 265 VAC, (50/60 Hz) Input; 22 V, 380 mA Output Application LED Driver Author Applications Engineering Department Document Number DER-264 Date January 24, 2011 Revision 1.0 Summary and Features Superior performance and end user experience o TRIAC dimmer compatible (including low cost leading edge type and high power rating) No output flicker >1000:1 dimming range (dependant on dimmer model) o Clean monotonic start-up – no output blinking o Fast start-up (<100 ms) – no perceptible delay o Consistent dimming performance unit to unit Highly energy efficient o ≥78% at 230 VAC (≥83% non-dimming configuration) Low cost, low component count and single sided small printed circuit board footprint solution o No current sensing required o Frequency jitter for smaller, lower cost EMI filter components Integrated protection and reliability features o Output open circuit / output short-circuit protected with auto-recovery o Line input overvoltage shutdown extends voltage withstand during line faults. o Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board o No damage during brown-out or brown-in conditions IEC 61000-4-5 ring wave, IEC 61000-3-2 Class C and EN55015 B conducted EMI compliant Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 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, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 Table of Contents 1 2 3 4 Introduction .................................................................................................................5 Power Supply Specification ........................................................................................8 Schematic ...................................................................................................................9 Circuit Description.....................................................................................................10 4.1 Input Filtering .....................................................................................................10 4.2 LinkSwitch-PH Primary ......................................................................................10 4.3 Bias and Output Rectification ............................................................................10 4.4 TRIAC Phase Dimming Control .........................................................................10 5 PCB Layout...............................................................................................................11 6 Bill of Materials .........................................................................................................13 7 Heat Sink Drawings ..................................................................................................14 8 Transformer Specification .........................................................................................17 8.1 Electrical Diagram..............................................................................................17 8.2 Electrical Specifications .....................................................................................17 8.3 Materials ............................................................................................................17 8.4 Transformer Build Diagram................................................................................18 8.5 Transformer Construction ..................................................................................18 9 Transformer Illustrations ...........................................................................................19 10 Transformer Design Spreadsheet .........................................................................25 11 Performance Data .................................................................................................28 11.1 Dimming Configuration ......................................................................................29 11.2 Regulation .........................................................................................................31 11.2.1 Line Regulation...........................................................................................31 11.3 Non-Dimming Configuration ..............................................................................32 12 Thermal Performance............................................................................................33 13 Harmonic Data ......................................................................................................34 14 Waveforms ............................................................................................................35 14.1 Drain Voltage and Current .................................................................................35 14.2 Output Diode Peak Inverse Voltage...................................................................35 14.3 Input Line Voltage and Current (No TRIAC Dimmer Connected) ......................36 14.4 Input Voltage and Input Current Waveforms (During Dimming).........................36 14.4.1 VIN = 230 VAC / 60 Hz ................................................................................36 14.5 Output Voltage and Ripple Current....................................................................37 14.6 Drain Voltage and Current Start-up Profile ........................................................38 14.7 Output Current and Drain Voltage During Output Short-Circuit .........................39 14.8 Open Load Output Voltage ................................................................................39 15 Dimmer Compatibility ............................................................................................40 15.1 Dimming Test with 230 V TRIAC Dimmer Switches ..........................................40 16 Line Surge.............................................................................................................41 17 Conducted EMI .....................................................................................................42 17.1 Test Set-up ........................................................................................................43 18 Revision History ....................................................................................................44 Page 3 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 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 4 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 1 Introduction The document describes a high power-factor corrected dimmable LED driver designed to drive a 22 V nominal LED string at 380 mA from an input voltage range of 198 VAC to 265 VAC. The LED driver utilizes the LNK403EG from Power Integrations. LinkSwitch-PH ICs allow the implementation of cost effective and low component count LED drivers which both meet power factor and harmonics limits but also offer enhanced end user experience. This includes ultra-wide dimming range, flicker free operation (even with low cost with AC line TRIAC dimmers) and fast, clean turn on. The topology used is an isolated flyback operating in continuous conduction mode. Output current regulation is sensed entirely from the primary side eliminating the need for secondary side feedback components. No external current sensing is required on the primary side either as this is performed inside the IC further reducing components and losses. The internal controller adjusts the MOSFET duty cycle to maintain a sinusoidal input current and therefore high power factor and low harmonic currents. The LNK403EG also provides a sophisticated range of protection features including autorestart for open control loop and output short-circuit conditions. Line overvoltage provides extended line fault and surge withstand, output overvoltage protects the supply should the load be disconnect and accurate hysteretic thermal shutdown ensures safe average PCB temperatures under all conditions. In any LED luminaire the driver determines many of the performance attributes experienced by the end customer (user) including startup time, dimming, flicker and unit to unit consistency. For this design a focus was given to compatibility with as wider range of dimmers trading off dimmer compatibility against efficiency. Efficiency data for a nondimming configuration is shown in section 11 for reference. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, transformer documentation and typical performance characteristics. Page 5 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Figure 1 – Populated Circuit Board Photograph (Top View). PCB Outline Designed to Fit Inside A19 Enclosure. Figure 2 – Populated Circuit Board Photograph Single Sided PCB (Bottom View). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 Figure 3 – Populated Circuit Board Photograph Single Sided PCB (Side Views). Notes: See Figure 6 for Dimensions. Page 7 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 2 Power Supply Specification The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Symbol Min Typ Max Units Comment 2 Wire – no P.E. Input Voltage Frequency Output Output Voltage VIN fLINE 198 230 50/60 265 VAC Hz VOUT 18 22 25 V Output Current IOUT 380 mA POUT 8 W Total Output Power Continuous Output Power Efficiency Full Load 75 % VOUT = 22, VIN = 230 / 60Hz VAC, 25°C o Measured at POUT 25 C Environmental Conducted EMI Meets CISPR 15B / EN55015B Designed to meet IEC950 / UL1950 Class II Safety Ring Wave (100 kHz) Differential Mode (L1-L2) Common mode (L1/L2-PE) 2.5 Power Factor kV Measured at VOUT(TYP), IOUT(TYP) and 115 / 230 VAC 0.85 Harmonics IEC 61000-4-5 , 200 A EN 61000-3-2 Class D Ambient Temperature TAMB Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 40 o C Free convection, sea level Page 8 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 3 Schematic Figure 4 – Schematic. Page 9 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 4 Circuit Description The LinkSwitch-PH device is a controller and integrated 725 V MOSFET intended for use in LED driver applications. The LinkSwitch-PH is configured for use in a single-stage continuous conduction mode flyback topology and provides a primary side regulated constant current output while maintaining high power factor from the AC input. 4.1 Input Filtering Fuse F1 provide protection from catastrophic failure of any of the primary side components. Bridge BR1 rectifies the AC line voltage. Inductor L1-L2, C3, C10, R2, and R3 provide EMI filtering together with C17 Y capacitor. Small bulk capacitor C10 is required to provide a low impedance path for the primary switching current. A low value of capacitance is necessary to maintain a power factor of greater than 0.8. 4.2 LinkSwitch-PH Primary Diode D6 and C8 detect the peak AC line voltage. This voltage is converted to a current into the V pin via R4 and R7. This current is also used by the device to set the input over/undervoltage protection thresholds. The V pin current and the FB pin current are used internally to control the average output LED current. TRIAC phase-angle dimming applications require 49.9 k resistors on the R pin and 4 M on the V pin to provide a linear relationship between input voltage and the output current. Resistor R19 also sets the internal references to select the brown-in and brown-out and input overvoltage protection thresholds. Diode D1, R26, R28, R25 and C16 clamp due to leakage inductance generated voltage spikes on the drain to a safe level. Diode D5 is necessary to prevent reverse current from flowing through the LinkSwitch-PH device. 4.3 Bias and Output Rectification Diode D3, C6, R5, and R18 create the primary bias supply. This voltage is used to supply bias current into the BYPASS pin through D4 and R10. Capacitor C12 is the main supply for the LinkSwitch-PH, which is charged to ~6 V at start-up from an internal high-voltage current source tied to the device DRAIN pin. A current proportional to the output voltage from the primary bias winding is fed into the FEEDBACK pin through R15. Diode D2 rectifies the secondary winding while capacitor C4 filters the output. Zener Diode VR3, C15, R23, and Q2 provide an open load overvoltage protection function. This protects output capacitor C4 from excessive voltage should the load be disconnected. 4.4 TRIAC Phase Dimming Control Resistors R16 and R17 act as a damping network reducing input current ringing immediately after the TRIAC dimmer turns on. This prevents the input current falling to zero and therefore prevents multiple TRIAC firing events which results in output flicker. Capacitors C9, C11 and R14 keep the TRIAC current above the holding threshold during the remainder of the AC cycle also to prevent multiple firings and flicker. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 5 PCB Layout Figure 5 – Printed Circuit Layout, Top and Bottom Silkscreen. (Designed to Fit Inside A19 Lamp Form Factor). Page 11 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Figure 6 – Printed Circuit Layout, Top, Bottom, and Outline. (Designed to Fit Inside A19 Lamp Form Factor). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 6 Bill of Materials Item Qty Ref Des 1 1 BR1 2 2 C3 C10 3 1 C4 4 1 5 1 6 2 C9 C11 7 1 C12 Description Mfg Part Number Manufacturer 600 V, 0.5 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC MB6S-TP Micro Commercial ECQ-E4104KF Panasonic EKZE500ELL271MJ20S Nippon Chemi-Con C6 100 nF, 400 V, Film 270 F, 50 V, Electrolytic, Very Low ESR, 30 m, (10 x 20) 22 F, 50 V, Electrolytic, Low ESR, 900 m, (5 x 11.5) ELXZ500ELL220MEB5D Nippon Chemi-Con C8 1 F, 400 V, Electrolytic, (6.3 x 11) EKMG401ELL1R0MF11D United Chemi-Con 100 nF, 500 V, Ceramic, X7R, 1812 VJ1812Y104KXEAT Vishay 10 F, 16 V, Ceramic, X5R, 0805 GRM21BR61C106KE15L Murata 8 1 C15 100 nF 25 V, Ceramic, X7R, 0603 ECJ-1VB1E104K Panasonic 9 1 C16 1 nF, 1000 V, Ceramic, X7R, 0805 C0805C102KDRACTU Kemet 10 1 C17 1 nF, Ceramic, Y1 ECK-ANA102MB Panasonic 11 1 D1 600 V, 1 A, Fast Recovery, 250 ns, SMA RS1J-13-F Diodes, Inc 12 1 D2 150 V, 1 A, Ultrafast Recovery, 35 ns, SMB Case MURS115T3 On Semi 13 1 D3 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV21WS-7-F Diode Inc. 14 1 D4 75 V, 0.15 A, Fast Switching, 4 ns, MELF LL4148-13 Diode Inc. 15 1 D5 DIODE ULTRA FAST, SW, 200 V, 1 A, SMA US1D-13-F Diodes, Inc 16 1 D6 1000 V, 1 A, Rectifier, DO-41 1N4007-E3/54 Vishay 17 1 F1 3.15 A, 250 V, Slow, RST 507-1181 18 1 HS1 Bracket, Heat sink Small Right 19 2 L1 L2 1.5 mH, 0.18 A, 5.5 x 10.5 mm SBC1-152-181 Tokin 20 1 Q2 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3904LT1G On Semiconductor 21 2 R2 R3 10 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ103V Panasonic 22 2 R4 R7 2.0 M, 5%, 1/4 W, Carbon Film CFR-25JB-2M0 Yageo 23 1 R5 75 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ750V Panasonic 24 2 R6 R18 5.1 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ512V Panasonic 25 1 R10 3 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ302V Panasonic 26 1 R14 1 k, 5%, 1/2 W, Carbon Film CFR-50JB-1K0 Yageo 27 1 R15 178 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1783V Panasonic 28 2 R16 R17 510 , 5%, 1 W, Metal Oxide RSF100JB-510R Yageo 29 1 R19 49.9 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4992V Panasonic 30 1 R23 750 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ751V Panasonic 31 1 R25 100 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ101V Panasonic 32 2 R26 R28 100 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ104V Panasonic 33 1 R27 220 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ224V Panasonic 34 1 275 V, 23 J, 7 mm, RADIAL V275LA4P Littlefuse 35 5 RV1 TP1,TP2 TP3,TP5 TP6 Test Point, RED, Miniature THRU-HOLE MOUNT 5000 Keystone 36 1 TP4 Test Point, BLK, Miniature THRU-HOLE MOUNT 5001 Keystone 37 1 U1 LinkSwitch-PH, LNK403EG, eSIP LNK403EG Power Integrations 38 1 U2 Bobbin, RM6_S/I, Vertical, 4 pins w 2 pin clip CPV-RM6S/I-1S-8PD Ferroxcube 39 1 VR3 39 V, 5%, 150 mW, SSMINI-2 MAZS39000L Panasonic-SSG Page 13 of 45 Belfuse Custom Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 7 Heat Sink Drawings Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 45 DER-264 8 W A19 LED Driver Using LNK403EG Page 15 of 45 24-Jan-11 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 8 Transformer Specification 8.1 Electrical Diagram Figure 7 – Transformer Electrical Diagram. 8.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 8.3 1 second, 60 Hz, from pins 1-4 and leads FL1-FL2. Pins 1-2, all other windings open, measured at 100kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with leads FL1-FL2 shorted, measured at 100kHz, 0.4 VRMS. 3000 VAC 3.3 mH, ±5% 800 kHz (Min.) 30 H (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: RM6 and gapped ALG 203 nH/T2 Bobbin: RM6-Vertical, 8 pins (4/4). AllStar P/N: CPV-RM6 5/1-1S. Magnet wire: #37 AWG. Triple Insulated Wire: #27 AWG Tape: 3M 1298 Polyester Film, 6.5 mm wide, 2.0 mils thick or equivalent. Core clip: Ferroxcube #: FXC-0102718, CLI-RM6/I. Varnish: Dolph BC-359 or equivalent. Page 17 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 8.4 DER-264 8 W A19 LED Driver Using LNK403EG Transformer Build Diagram Figure 8 – Transformer Build Diagram. 8.5 Transformer Construction Bobbin Preparation Winding Preparation WD1 1st Primary Insulation WD2 Secondary Insulation WD3 Bias Insulation WD4 2nd Primary Insulation Final Assembly Remove all secondary pins and flange of bobbin item [2]. Cut all primary side pins. See picture below. Place the bobbin on the mandrel with the pin side is on the left side. Winding direction is clockwise direction. Take ~12 ft of wire item [3], start at pin 2, and wind 44 turns from left to right. Place 1 layer of tape item [5], then continue winding 44 turns from right to left and leave the remain of this wire on the mandrel for the WD4 2nd primary winding. Place 1 layer of tape item [5]. Use wire item [4], starting as FL1 (floating lead), wind 22 turns in 2 layers from left to right then from right to left and end at FL2. (The last turn might be on 3rd layer). Place 1 layer of tape item [5]. Start at pin 3, wind 27 turns of wire item [3] from left to right, spread the wire evenly. At the last turn bring the wire back to the left and terminate at pin 4. Place 1 layer of tape item [5]. Use the remain wire from WD1 1st Primary, continue winding 40 turns from left to right, at the last turn bring the wire back to the left and terminate at pin 1. Place 2 layers of tape item [5]. Grind, assemble, and secure core halves with clips item [6]. Dip varnish item [7]. Do not vacuum impregnate due to resultant higher capacitance and therefore higher EMI and lower efficiency. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 9 Transformer Illustrations Remove all secondary pins and flange of bobbin item [2]. Bobbin Preparation Cut all primary side pins. See picture beside. Page 19 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Winding Preparation Place the bobbin on the mandrel with the pin side is on the left side. Winding direction is clockwise direction. WD1 1st Primary Take ~ 12 ft of wire item [3], start at pin 2, and wind 44 turns from left to right. Place 1 layer of tape item [5], then continue winding 44 turns from right to left and leave the remain of this wire on the mandrel for the WD4 2nd primary winding. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 Insulation Place 1 layer of tape item [5]. WD2 Secondary Use wire item [4], starting as FL1 (floating lead), wind 22 turns in 2 layers from left to right then from right to left and end at FL2. (The last turn might be on 3rd layer). Page 21 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Insulation WD3 Bias Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Place 1 layer of tape item [5]. Start at pin 3, wind 27 turns of wire item [3] from left to right, spread the wire evenly. At the last turn bring the wire back to the left and terminate at pin 4. Page 22 of 45 DER-264 8 W A19 LED Driver Using LNK403EG Insulation WD4 2nd Primary Page 23 of 45 24-Jan-11 Place 1 layer of tape item [5]. Use the remain wire from WD1 1st Primary, continue winding 40 turns from left to right, at the last turn bring the wire back to the left and terminate at pin 1. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG Insulation Final Assembly Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Place 2 layers of tape item [5]. Grind, assemble, and secure core halves with clips item [6]. Vanish item [7]. Page 24 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 10 Transformer Design Spreadsheet ACDC_LinkSwitchPH_061010; Rev.1.1; Copyright Power Integrations 2010 INPUT ENTER APPLICATION VARIABLES Dimming required YES INFO OUTPUT Info YES VACMIN 198 VACMAX 264 fL VO 21.00 VO_MAX VO_MIN V_OVP IO 0.38 PO n 0.82 VB ENTER LinkSwitch-PH VARIABLES LinkSwitch-PH LNK403 Chosen Device LNK403 Current Limit Mode ILIMITMIN ILIMITMAX fS fSmin fSmax IV RV RV2 IFB RFB1 VDS 198 264 50 23.10 18.90 25.41 8.0 0.82 25 Power Out UNIT V V Hz V V V V W V Universal 12.5W RED RED 0.81 0.92 66000 62000 70000 80.6 4 1E+012 123.0 178.9 10 123.00 A A Hz Hz Hz uA M-ohms M-ohms uA k-ohms V VD 0.50 V VDB Key Design Parameters 0.70 V KP 1.11 1.11 125.00 3324 125 0.37 LP VOR Expected IO (average) KP_VACMAX Info 1.15 TON_MIN 2.40 PCLAMP 0.06 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type RM6S/I RM6S/I Bobbin RM6S/I AE 0.37 LE 2.92 AL 2150 BW 6.4 M 0 L 3.00 NS 22 DC INPUT VOLTAGE PARAMETERS VMIN 3 22 Page 25 of 45 uH V A 280 us W P/N: cm^2 cm nH/T^2 mm mm V LinkSwitch-PH_061010: Flyback Transformer Design Spreadsheet 8W A19 LED DRIVER !!! Info. When configured for dimming, best output current line regulation is achieved over a single input voltage range. Minimum AC Input Voltage Maximum AC input voltage AC Mains Frequency Typical output voltage of LED string at full load Maximum expected LED string Voltage. Minimum expected LED string Voltage. Over-voltage protection setpoint Typical full load LED current Output Power Estimated efficiency of operation Bias Voltage 115 Doubled/230V 12.5W Select "RED" for reduced Current Limit mode or "FULL" for Full current limit mode Minimum current limit Maximum current limit Switching Frequency Minimum Switching Frequency Maximum Switching Frequency V pin current Upper V pin resistor Lower V pin resistor FB pin current (85 uA < IFB < 210 uA) FB pin resistor LinkSwitch-PH on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop (0.5 V for Schottky and 0.8 V for PN diode) Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (For PF > 0.9, 0.4 < KP < 0.9) Primary Inductance Reflected Output Voltage. Expected Average Output Current !!! Info. PF at high line may be less than 0.9. Decrease KP for higher PF Minimum on time at maximum AC input voltage Estimated dissipation in primary clamp * Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Peak input voltage at VACMIN Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG 373 V 0.29 0.04 A IP 0.36 A IRMS 0.09 A TRANSFORMER PRIMARY DESIGN PARAMETERS LP 3324 NP 128 NB 26 ALG 203 BM 2549 BP 3085 Peak input voltage at VACMAX Minimum duty cycle at peak of VACMIN Average Primary Current Peak Primary Current (calculated at minimum input voltage VACMIN) Primary RMS Current (calculated at minimum input voltage VACMIN) Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Gauss Maximum Flux Density at PO, VMIN (BM<3100) Gauss Peak Flux Density (BP<3700) AC Flux Density for Core Loss Curves (0.5 X Peak BAC 1275 Gauss to Peak) ur 1350 Relative Permeability of Ungapped Core LG 0.21 mm Gap Length (Lg > 0.1 mm) BWE 19.2 mm Effective Bobbin Width Maximum Primary Wire Diameter including OD 0.15 mm insulation Estimated Total Insulation Thickness (= 2 * film INS 0.03 mm thickness) DIA 0.12 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 37 AWG standard AWG value) CM 20 Cmils Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < CMA 220 Cmils/Amp 600) LP_TOL 10 Tolerance of primary inductance TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 2.11 A Peak Secondary Current ISRMS 0.78 A Secondary RMS Current IRIPPLE 0.68 A Output Capacitor RMS Ripple Current CMS 156 Cmils Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next AWGS 28 AWG larger standard AWG value) DIAS 0.32 mm Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple ODS 0.29 mm Insulated Wire VOLTAGE STRESS PARAMETERS Estimated Maximum Drain Voltage assuming VDRAIN 627 V maximum LED string voltage (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse Voltage PIVS 90 V (calculated at VOVP, excludes leakage inductance spike) Bias Rectifier Maximum Peak Inverse Voltage PIVB 107 V (calculated at VOVP, excludes leakage inductance spike) FINE TUNING (Enter measured values from prototype) V pin Resistor Fine Tuning RV1 4.00 M-ohms Upper V Pin Resistor Value RV2 1.00E+12 M-ohms Lower V Pin Resistor Value VAC1 115.0 V Test Input Voltage Condition1 VAC2 230.0 V Test Input Voltage Condition2 IO_VAC1 0.38 A Measured Output Current at VAC1 IO_VAC2 0.38 A Measured Output Current at VAC2 RV1 (new) 4.00 M-ohms New RV1 RV2 (new) 20911.63 M-ohms New RV2 Typical AC input voltage at which OV shutdown V_OV 319.6 V will be triggered Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com uH Page 26 of 45 DER-264 8 W A19 LED Driver Using LNK403EG V_UV FB pin resistor Fine Tuning RFB1 RFB2 VB1 VB2 IO1 IO2 RFB1 (new) RFB2(new) Page 27 of 45 66.3 V 179 1E+012 22.5 27.5 0.38 0.38 178.9 1.00E+12 k-ohms k-ohms V V A A k-ohms k-ohms 24-Jan-11 Typical AC input voltage beyond which power supply can startup Upper FB Pin Resistor Value Lower FB Pin Resistor Value Test Bias Voltage Condition1 Test Bias Voltage Condition2 Measured Output Current at Vb1 Measured Output Current at Vb2 New RFB1 New RFB2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 11 Performance Data All measurements performed at room temperature. Yokogawa power meter model WT200 was used to measure accurately the output power and input power of the unit. Note: Measuring output power (voltage and current) using standard handheld digital multi-meters (DMMs) typically result in measurement inaccuracy, under reporting the output power delivered to the LED load and therefore efficiency. This is typically not a significant error for general power supply measurements as the output waveforms are DC. However for a power factor corrected, single stage LED driver the output voltage and current waveforms have a significant AC component. This AC component is made up of both ripple at the line voltage and high frequency ripple at the LinkSwitch-PH switching frequency. As lower cost DMMs have limited bandwidth (£1 kHz) an average response and expect perfect sinusoidal waveforms they cannot accurately measure such waveforms. As the level of the ripple component is a function of the value of the output capacitance as the output capacitance is reduced and the level of ripple increases the measurement error also increases. Alternatives to using a dedicated power meter (which must be capable of measuring from DC) are, a true RMS DMM, ideally with a bandwidth above the switching frequency, an oscilloscope with calibrated current probe or finally measuring the output voltage and current waveforms with an additional output capacitance temporarily added to reduce the output current ripple to <10%. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 11.1 Dimming Configuration Damper resistors (R16, R17) and Bleeder network (R14 and C11) were installed. Yokogawa power meter model WT200 was used to measure accurately the true output power and input power of the unit. VIN (60Hz) (VAC) 198 220 230 264 VO (NOM) (V) 21.93 22.03 22.07 22.2 IO (A) 0.361 0.379 0.388 0.413 PO (W) 7.53 7.97 8.17 8.78 PIN (W) 9.74 10.19 10.39 11.04 Efficiency (%) 77.31 78.21 78.63 79.53 VIN (60Hz) (VAC) 198 220 230 264 VO (NOM) (V) 24.63 24.75 24.8 24.96 IO (A) 0.362 0.382 0.391 0.417 PO (W) 7.66 8.13 8.35 9 PIN (W) 9.92 10.41 10.65 11.35 Efficiency (%) 77.22 78.10 78.40 79.30 VIN (60Hz) (VAC) 198 220 230 264 VO (NOM) (V) 18.05 18.14 18.18 18.33 IO (A) 0.376 0.397 0.406 0.435 PO (W) 5.81 6.17 6.33 6.87 PIN (W) 7.41 7.8 7.97 8.55 Efficiency (%) 78.41 79.10 79.42 80.35 Page 29 of 45 PF THD 0.92 0.9 0.89 0.83 26.1 27.4 PF THD 0.92 0.9 0.89 0.83 25.9 27.2 PF THD 0.88 0.86 0.86 0.84 29.2 30.9 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 81.0 Efficiency 22 V Efficiency 18 V Efficiency 25 V 80.5 Efficiency (%) 80.0 79.5 79.0 78.5 78.0 77.5 77.0 190 200 210 220 230 240 250 260 270 Line (VAC) Figure 9 – Efficiency at VOUT of 18 V, 22 V and 25 V vs. Input Voltage, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 11.2 Regulation 11.2.1 Line Regulation 0.44 0.43 22 V 18 V 25 V Output Current (A) 0.42 0.41 0.4 0.39 0.38 0.37 0.36 0.35 190 200 210 220 230 240 250 260 Line (VAC) Figure 10 – High Line Regulation, Room Temperature, Full Load. Page 31 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 270 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 11.3 Non-Dimming Configuration Damper resistors (R16, R17) and Bleeder network (R14 and C11) were NOT installed. Yokogawa power meter model WT200 was used to measure accurately the output power and input power of the unit. VIN (60Hz) (VAC) 198 220 230 264 VO (V) 21.90 21.95 21.98 22.06 IO (A) 0.358 0.373 0.379 0.400 PO (W) 7.48 7.81 7.95 8.42 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com PIN (W) 9.06 9.41 9.56 10.12 Effeciency (%) 82.56 82.98 83.16 83.20 PF 0.95 0.93 0.89 0.89 A-THD % 23 24 25 26 Page 32 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 12 Thermal Performance Unit was operated for 2 hours at room temperature, full load (22 V, 380 mA) prior to recording results. Description TAMB (OPEN FRAME) U1 (LNK403EG + HTSK) U1 (LNK403EG) BR1 (Bridge Rectifier) R17 / R16 (Damper) R14 (Bleeder) D1 (Snubber diode) D5 (Blocking diode) T1 (Transformer) D2 (Output Rectifier) C4 (Output E-cap) Page 33 of 45 198 V / 60 Hz (PO: 7.54 W; PIN: 9.71 W) (ºC) 28.6 61.9 66.9 55.0 89.2 70.4 61.4 62.1 56.0 62.1 45.9 230 V / 60 Hz (PO: 8.15 W; PIN: 10.34 W) (ºC) 28.7 65.2 70.8 62.4 88.9 73.2 62.9 63.7 58.8 64.9 48.9 264 V / 60 Hz (PO: 8.75 W; PIN: 10.93 W) (ºC) 30.2 65.7 71.6 59.4 87.3 74.2 64.3 64.1 58.5 67.8 49.0 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 13 Harmonic Data 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). 35 Class D Limit DER-264 Harmonic Data at 230 VAC 30 Current (mA) 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Harmonic Order Figure 11 – 230 VAC Harmonic, Room Temperature, Full Load. VIN = 230 VAC A-THD (%) 28 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Limit (%) 33 Margin (%) 5 Page 34 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 14 Waveforms 14.1 Drain Voltage and Current Figure 12 – 198 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 100 V, 10 s / div. Figure 13 – 265 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 100 V / div., 10 s / div. 14.2 Output Diode Peak Inverse Voltage Figure 14 – 265 VAC, Full Load. VPIV, 10 V, 5 ms / div. Page 35 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 14.3 Input Line Voltage and Current (No TRIAC Dimmer Connected) Figure 15 – 198 VAC, Full Load. Upper: IIN, 0.1 A / div. Lower: VIN, 200 V, 5 ms / div. Figure 16 – 265 VAC, Full Load. Upper: IIN, 0.1 A / div. Lower: VIN, 200 V / div., 5 ms / div. 14.4 Input Voltage and Input Current Waveforms (During Dimming) 14.4.1 VIN = 230 VAC / 60 Hz Figure 17 – 230 VAC, Full Phase. Upper: VIN, 500 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 18 – 230 VAC, 90° Phase. Upper: VIN, 500 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Page 36 of 45 DER-264 8 W A19 LED Driver Using LNK403EG Figure 19 – 230 VAC, 45° Phase. Upper: VIN, 500 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. 24-Jan-11 Figure 20 – 230 VAC, 12° Phase. Upper: VIN, 500 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. 14.5 Output Voltage and Ripple Current Figure 21 – 198 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUT 5 V, 5 ms / div. Page 37 of 45 Figure 22 – 230 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUT 5 V, 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 14.6 Drain Voltage and Current Start-up Profile Figure 23 – 198 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 100 V, 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 24 – 265 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VDRAIN, 100 V, 10 ms / div. Page 38 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 14.7 Output Current and Drain Voltage During Output Short-Circuit Figure 25 – 198 VAC, Full Load. Upper: IOUT, 0.2 A / div. Lower: VDRAIN, 100 V, 10 ms / div. Figure 26 – 265 VAC, Full Load. Upper: IOUT, 0.2 A / div. Lower: VDRAIN, 100 V, 10 ms / div. 14.8 Open Load Output Voltage Figure 27 – Output Voltage: 264 VAC. VOUT, 10 V / div., 200 ms / div. Page 39 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 15 Dimmer Compatibility Only the specified rating for voltage and line frequency of the particular dimmer evaluated was used. Failure to follow this results in misoperation of some dimmers. 15.1 Dimming Test with 230 V TRIAC Dimmer Switches Style Country/Standard Manufacturer Model Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Germany 230 V – 50 Hz Germany 230 V – 50 Hz Germany 230 V – 50 Hz Germany 230 V – 50 Hz Korea 220 V – 60 Hz Korea 220 V – 60 Hz Korea 220 V – 60 Hz Korea 220 V – 60 Hz Italy 230 V – 50 Hz Italy 230 V – 50 Hz China 220 V – 50 Hz China 220 V - 50 Hz China 220 V – 50 Hz China 220 V - 50 Hz China 220 V – 50 Hz China 220 V - 50 Hz China 220 V - 50 Hz Dimming Test Data Controlled Max. Min. Remark Current Current (mA) (mA) REV Dimmer 60 364 3 Busch 2250 364 43 Berker 2875 359 56 Merten 572499 373 34 Fantasia Special NK/TG100001 365 53 DED-120 BM2 363 7 SSD-500 381 35 ASW3520 372 63 Relco RM34DMA 377 10 Relco RT34DSL 381 74 CLIPMEI 383 25 KBE 384 10 MANK MK/TG100001 384 109 SB Electric BM2 374 12 EBAHuang 381 10 Myongbo 382 90 TCL Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com L2.0 44 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 40 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 16 Line Surge Differential input line 200 A ring wave testing was completed on a single test unit to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) Input Voltage (VAC) Injection Location Injection Phase (°) Test Result (Pass/Fail) +2500 230 L to N 90 Pass -2500 230 L to N 270 Pass Unit passes under all test conditions. Also unit passes with 3 kV ring wave surge voltage. Page 41 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 17 Conducted EMI Note: Refer to table for margin to standard – blue line is peak measurement but limit line is quasi peak. Power Integrations 23.Sep 10 18:35 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 Trace1: 30 MHz EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 9.55368135541 kHz 22.79 N gnd 2 Average 137.49880568 kHz 26.96 N gnd 2 Average 202.1773373 kHz 33.28 L1 gnd -20.23 2 Average 267.135089486 kHz 34.82 L1 gnd -16.38 1 Quasi Peak 269.806440381 kHz 47.28 L1 gnd -13.84 1 Quasi Peak 335.832355405 kHz 49.02 L1 gnd -10.28 2 Average 335.832355405 kHz 36.73 L1 gnd -12.57 1 Quasi Peak 401.705024172 kHz 50.07 L1 gnd -7.74 2 Average 401.705024172 kHz 36.72 L1 gnd -11.08 1 Quasi Peak 448.169580165 kHz 48.88 L1 gnd -8.02 2 Average 471.030732902 kHz 35.42 L1 gnd -11.07 1 Quasi Peak 667.263434405 kHz 49.67 L1 gnd -6.32 2 Average 667.263434405 kHz 34.08 L1 gnd -11.91 1 Quasi Peak 935.888336808 kHz 48.88 L1 gnd -7.11 2 Average 2.18042326152 MHz 31.99 L1 gnd -14.01 2 Average 12.3157210828 MHz 30.17 L1 gnd -19.82 Figure 28 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 B Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 42 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-Jan-11 17.1 Test Set-up Page 43 of 45 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 24-Jan-11 DER-264 8 W A19 LED Driver Using LNK403EG 18 Revision History Date 24-Jan-11 Author ME Revision 1.0 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Description & changes Initial Release Reviewed Apps and Mktg Page 44 of 45 DER-264 8 W A19 LED Driver Using LNK403EG 24-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. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, 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 2011 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 Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 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 e-mail: [email protected] INDIA #1, 14th 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] EUROPE HQ 1st Floor, St. James’s House East Street, Farnham Surrey GU9 7TJ United Kingdom Phone: +44 (0) 1252-730-141 Fax: +44 (0) 1252-727-689 e-mail: [email protected] CHINA (SHENZHEN) Rm A, B & C 4th Floor, Block C, Electronics Science and Technology Building 2070 Shennan Zhong Road Shenzhen, Guangdong, P.R.C. 518031 Phone: +86-755-8379-3243 Fax: +86-755-8379-5828 e-mail: [email protected] ITALY Via De Amicis 2 20091 Bresso MI Italy Phone: +39-028-928-6000 Fax: +39-028-928-6009 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] APPLICATIONS HOTLINE World Wide +1-408-414-9660 Page 45 of 45 APPLICATIONS FAX World Wide +1-408-414-9760 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Title Reference Design Report for a High Efficiency (≥81%), High Power Factor (>0.9) TRIAC Dimmable 7 WTYP LED Driver Using LinkSwitch®-PH LNK403EG Specification 90 VAC – 265 VAC Input; 21 VTYP, 0.33 A Output Application LED Driver Author Applications Engineering Department Document Number RDR-193 Date June 9, 2010 Revision 1.0 Summary and Features Superior performance and end user experience o TRIAC dimmer compatible (including low cost leading edge type) No output flicker >1000:1 dimming range o Clean monotonic start-up – no output blinking o Fast start-up (<100 ms) – no perceptible delay o Consistent dimming performance unit to unit Highly energy efficient o ≥81% at 115 VAC, ≥82% at 230 VAC Low cost, low component count and small printed circuit board footprint solution o No current sensing required o Frequency jitter for smaller, lower cost EMI filter components Integrated protection and reliability features o Output open circuit / output short-circuit protected with auto-recovery o Line input overvoltage shutdown extends voltage withstand during line faults. o Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board o No damage during brown-out or brown-in conditions Meets IEC 61000-4-5 ringwave, IEC 61000-3-2 Class C harmonics and EN55015 B conducted EMI Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 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, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG Table of Contents 1 2 3 4 Introduction .................................................................................................................5 Power Supply Specification ........................................................................................7 Schematic ...................................................................................................................8 Circuit Description.......................................................................................................9 4.1 Input Filtering .......................................................................................................9 4.2 LinkSwitch-PH Primary ........................................................................................9 4.3 Bias and Output Rectification ..............................................................................9 4.4 TRIAC Phase Dimming Control ...........................................................................9 5 PCB Layout...............................................................................................................11 6 Bill of Materials .........................................................................................................12 7 Transformer Specification .........................................................................................14 7.1 Electrical Diagram..............................................................................................14 7.2 Electrical Specifications .....................................................................................14 7.3 Materials ............................................................................................................14 7.4 Transformer Build Diagram................................................................................15 7.5 Transformer Construction ..................................................................................15 8 Transformer Design Spreadsheet .............................................................................16 9 Performance Data.....................................................................................................19 9.1 Efficiency vs. Line and Output (LED String) Voltage..........................................19 9.1.1 21 V ............................................................................................................19 9.1.2 18 V ............................................................................................................19 9.1.3 24 V ............................................................................................................20 9.2 Regulation .........................................................................................................21 9.2.1 Output Voltage and Line.............................................................................21 9.2.2 Line Regulation...........................................................................................22 10 Thermal Performance............................................................................................24 10.1 VIN = 115 VAC ...................................................................................................24 10.2 VIN = 230 VAC ...................................................................................................24 11 Harmonic Data ......................................................................................................25 12 Waveforms ............................................................................................................27 12.1 Input Line Voltage and Current ..........................................................................27 12.2 Drain Voltage and Current .................................................................................27 12.3 Output Voltage and Ripple Current....................................................................28 12.4 Drain Voltage and Current Start-up Profile ........................................................28 12.5 Output Current and Drain Voltage at Shorted Output ........................................29 12.6 Open Load Output Voltage ................................................................................29 13 Dimming ................................................................................................................30 13.1 Input Phase vs. Output Current .........................................................................30 13.2 Output Voltage and Input Current Waveforms During Dimming ........................31 13.2.1 VIN = 115 VAC / 60 Hz ................................................................................31 13.2.2 VIN = 230 VAC / 50 Hz ................................................................................32 14 Line Surge.............................................................................................................33 15 Conducted EMI .....................................................................................................34 16 Production Distribution Data..................................................................................36 Page 3 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 17 Revision History ....................................................................................................37 18 Appendix ...............................................................................................................38 18.1 Dimming Test with TRIAC Dimmer Switches ....................................................38 18.1.1 115 VAC Input, 60 Hz.................................................................................38 18.1.2 230 VAC Input, 50 Hz.................................................................................38 18.2 Audible Noise Test Data....................................................................................39 18.2.1 VIN = 115 VAC, Full Phase .........................................................................39 18.2.2 VIN = 115 VAC, Half Phase ........................................................................39 18.2.3 VIN = 230 VAC, Full Phase .........................................................................40 18.2.4 VIN = 230 VAC, Half Phase ........................................................................40 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 4 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 1 Introduction The document describes a high power-factor corrected dimmable LED driver designed to drive 21 V at 0.33 A from an input voltage range of 90 VAC to 265 VAC. The LED driver utilizes the LNK403EG from Power Integrations. LinkSwitch-PH ICs allow the implementation of cost effective and low component count LED drivers which both meet power factor and harmonics limits but also offer enhanced end user experience. This includes ultra-wide dimming range, flicker free operation (even with low cost with AC line TRIAC dimmers) and fast, clean turn on. The topology used is an isolated Flyback operating in continuous conduction mode. Output current regulation is sensed entirely from the primary side eliminating the need for secondary side feedback components. No external current sensing is required on the primary side either as this is performed inside the IC further reducing components and losses. The internal controller adjusts the MOSFET duty cycle to maintain a sinusoidal input current and therefore high power factor and low harmonic currents. The LNK403EG also provides a sophisticated range of protection features including autorestart for open control loop and output short-circuit conditions. Line overvoltage provides extended line fault and surge withstand, output overvoltage protects the supply should the load be disconnect and accurate hysteretic thermal shutdown ensures safe average PCB temperatures under all conditions. In any LED luminaire the driver determines many of the performance attributes experienced by the end customer (user) including startup time, dimming, flicker and unit to unit consistency. For this design a focus was given to compatibility with as wider range of dimmers and as large of a dimming range as possible, at both 115 VAC and 230 VAC. However simplification of the design is possible for both single input voltage operation, no dimming or operation with a limited range of (higher quality) dimmers. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, transformer documentation and typical performance characteristics. Page 5 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 Figure 1 – Populated Circuit Board Photograph (Top View). PCB Outline Designed to Fit Inside PAR20 Enclosure. Figure 2 – Populated Circuit Board Photograph (Bottom View). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 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 a Frequency Output Output Voltage Output Current a Total Output Power Continuous Output Power Efficiency Full Load Symbol Min Typ Max Units Comment VIN fLINE 90 47 115 50/60 265 64 VAC Hz 2 Wire – no P.E. VOUT IOUT 18 21 0.33 24 V A 7 POUT VOUT = 21, VIN = 115 VAC, 25°C W 80 % o Measured at POUT 25 C Environmental Conducted EMI Meets CISPR 15B / EN55015B Designed to meet IEC950 / UL1950 Class II Safety Ring Wave (100 kHz) Differential Mode (L1-L2) Common mode (L1/L2-PE) Power Factor IEC 61000-4-5 , 200 A Measured at VOUT(TYP), IOUT(TYP) and 115/230 VAC 0.9 Harmonics Ambient Temperature kV 2.5 EN 61000-3-2 Class D b TAMB 40 o C Free convection, sea level Notes: a When configured for phase controlled (TRIAC) dimming, in order to give the widest dimming range, the output current for a LinkSwitch-PH design varies with line voltage. Therefore the output current specification is defined at a single line voltage only. For this design a line voltage of 115 VAC was selected. At higher line voltages the output current will increase and reduce with lower line voltages. The typical output current variation is +30% for +200% increase in line voltage. A single resistor value change can be used to center the nominal output current for a given nominal line voltage. See Table 1 for the feedback resistor value vs. nominal line voltage. b Maximum ambient temperature specification may be increased by adding a small heatsink to the LinkSwitch-PH device. Page 7 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 3 Schematic Figure 3 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 4 Circuit Description The LinkSwitch-PH device is a controller and integrated 725 V MOSFET intended for use in LED driver applications. The LinkSwitch-PH is configured for use in a single-stage continuous conduction mode Flyback topology and provides a primary side regulated constant current output while maintaining high power factor from the AC input. 4.1 Input Filtering Fuse F1 fuses the input and BR1 rectifies the AC line voltage. Inductor L1-L3, C2, R2, and R3 form EMI filter with C7 Y capacitor. Small bulk capacitor C3 is required for a low impedance path for the primary switching current. A low value of capacitance is necessary to maintain a power factor of greater than 0.9. 4.2 LinkSwitch-PH Primary Diode D6 and C8 detect the peak AC line voltage. This voltage is converted to a current into the V pin via R4 and R7. This current is also used by the device to set the input over/undervoltage protection thresholds. The V pin current and the FB pin current are used internally to control the average output LED current. TRIAC phase-angle dimming applications require 49.9 k resistors on the R pin and 4 M on the V pin to provide a linear relationship between input voltage and the output current. Resistor R4 also sets the internal references to select the brown-in and brown-out and input overvoltage protection thresholds. Diode D1 and VR1 clamp the drain voltage to a safe level from the leakage inductance voltage spike. Diode D5 is necessary to prevent reverse current from flowing through the LinkSwitch-PH device. 4.3 Bias and Output Rectification Diode D3, C6, R5, R9 and R18 create the primary bias supply. This voltage created from the transformer bias winding supplies bias current into the BYPASS pin through D4 and R10. Capacitor C12 is the main supply for the LinkSwitch-PH, which is charged to ~6 V at start-up from an internal high-voltage current source tied to the device DRAIN pin. A current proportional to the output voltage from the primary bias winding is fed into the FEEDBACK pin through R15. Diode D2 rectifies the secondary winding while capacitors C4 and C5 filter the output. Diode D8, R24, C14, VR3, C15, R23, and Q2 provide an open load overvoltage protection function. This protects output capacitors, C4 and C5 from excessive voltage should the load be disconnected. 4.4 TRIAC Phase Dimming Control Components R12, R13, R20, R17, D7, Q1, C13, VR2, and Q3 in conjunction with R16 reduce the inrush current when the TRIAC dimmer turns on. This circuit allows the inrush current to flow through R16 for the first 2.4 ms at 115 VAC (1.2 ms at 230 VAC) of the TRIAC conduction. After approximately 2.4 ms, Q3 turns on and shorts R16. This keeps the power dissipation on R16 low. Resistor R12, R13, R20 and C13 provide a 2.4 ms Page 9 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 delay after the TRIAC conducts. Transistor Q1 discharges C13 when the TRIAC is not conducting. Zener VR2 clamps the gate voltage of Q3 to 15 V. Capacitor C9 and R14 keep the TRIAC current above the holding threshold to prevent multiple firings. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 5 PCB Layout Figure 4 – Printed Circuit Layout (Designed to Fit Inside PAR20 Lamp Form Factor). Page 11 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 6 Bill of Materials Item Qty Ref Des Description 1 1 BR1 600 V, 1 A, Bridge Rectifier, SMD, DFS 2 1 C2 22 nF, 275VAC, Film, X2 3 1 C3 4 2 C4 C5 5 1 C6 100 nF, 400 V, Film 270 F, 35 V, Electrolytic, Very Low ESR, 41 m, (8 x 20) 22 F, 50 V, Electrolytic, Low ESR, 900 m, (5 x 11.5) 6 1 C7 2.2 nF, Ceramic, Y1 7 1 C8 1 F, 400 V, Electrolytic, (6.3 x 11) 8 1 C9 9 1 C12 220 nF, 400 V, Film 100 F, 10 V, Electrolytic, Very Low ESR, 300 m, (5 x 11) Mfg Part Number Mfg DF06S-E3/45 Vishay ECQ-U2A223ML Panasonic ECQ-E4104KF Panasonic EKZE350ELL271MH20D Nippon Chemi-Con ELXZ500ELL220MEB5D Nippon Chemi-Con 440LD22-R Vishay EKMG401ELL1R0MF11D United Chemi-Con ECQ-E4224KF Panasonic EKZE100ELL101ME11D Nippon Chemi-Con 10 1 C13 68 nF, 50 V, Ceramic, X7R, 0805 ECJ-2YB1H683K Panasonic 11 1 C14 1 F, 50 V, Ceramic, X7R, 0805 08055D105KAT2A AVX Corporation 12 1 C15 100 nF, 50 V, Ceramic, X7R, 0805 ECJ-2YB1H104K Panasonic 13 1 D1 1000 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 14 1 D2 200 V, 4 A, Schottky, SMC, DO-214AB 15 1 D3 400V, 1 A, Rectifier, Fast Recovery, MELF (DL-41) 16 1 D4 100 V, 1 A, Fast Recovery, 150 ns, SMA 17 1 D5 18 1 D6 19 1 D7 200 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC 1000 V, 1 A, Rectifier, Glass Passivated, DO213AA (MELF) 100 V, 1 A, Rectifier, Glass Passivated, DO213AA (MELF) 20 1 D8 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 21 1 F1 FL1 FL2 FL3 3.15 A, 250 V, Slow, RST UF4007-E3 Vishay MBRS4201T3G ON Semiconductor DL4936-13-F Diodes Inc RS1B-13-F Diodes, Inc ES1D Vishay DL4007-13-F Diodes Inc DL4002-13-F Diodes Inc BAV21WS-7-F Diode Inc. 507-1181 Belfuse 22 3 23 2 24 3 LN L1 L2 L3 PCB Terminal Hole, 22 AWG N/A N/A Test Point, WHT,THRU-HOLE MOUNT 5012 Keystone SLF7045T-102MR14-PF TDK Corporation 25 1 Q1 PNP, 400V 150MA, SOT-23 FMMT558TA Zetex Inc 26 1 Q2 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3904LT1G On Semiconductor 27 1 400 V, 1.7 A, 3.6 , N-Channel, DPAK IRFR310TRPBF Vishay 1 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ102V Panasonic 2.00 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF2004V Panasonic 1000 H, 0.14 A 28 3 Q3 R2 R3 R23 29 2 R4 R7 30 1 R5 75 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ750V Panasonic 31 1 20 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ203V Panasonic 32 2 R6 R9 R18 10 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ103V Panasonic 33 1 3 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ302V Panasonic 750 k, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF7503V Panasonic 34 2 R10 R12 R13 35 1 R14 1 k, 5%, 1 W, Metal Oxide 36 1 R15 143 k, 1%, 1/8 W, Thick Film, 0805 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RSF100JB-1K0 Yageo ERJ-6ENF1433V Panasonic Page 12 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 37 1 R16 270 , 5%, 1/2 W, Carbon Film CFR-50JB-270R Yageo 38 1 R17 15 , 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF15R0V Panasonic 39 1 R19 49.9 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF4992V Panasonic 40 1 R20 2.4 M, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ245V Panasonic 41 1 R24 10 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ103V Panasonic 42 1 RV1 275 V, 80J, 10 mm, RADIAL 43 1 T1 44 1 TP3 45 1 TP4 46 1 U1 47 1 VR1 200 V, 1500W, TVS, GP-20 48 1 VR2 15 V, 5%, 500 mW, DO-213AA (MELF) ZMM5245B-7 Diodes Inc 49 1 VR3 39V, 5%, 500 mW, DO-213AA (MELF) ZMM5259B-7 Diodes Inc Page 13 of 41 ERZ-V10D431 Panasonic SNX-R1537 Santronics USA Test Point, RED,Miniature THRU-HOLE MOUNT 5000 Keystone Test Point, BLK,Miniature THRU-HOLE MOUNT 5001 Keystone LNK406EG Power Integrations 1.5KE200A-E3/54 Vishay Custom Transfomer, RM6,6pins LinkSwitch, LNK406EG, eSIP Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 7 Transformer Specification 7.1 Electrical Diagram Figure 5 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from pins 1, 2, 6, FL1 to FL2, FL3 Pins 1-FL1, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-FL1, all other windings open Pins 1-FL1 with FL2-FL3 shorted, measured at 100kHz, 0.4 VRMS 3000 VAC 2.45 mH ± 10% 750 kHz (Min.) 35 H ± 10% Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: PC95RM6 from TDK or equivalent, ALG = 149.5nH/n2 Bobbin: 6 pin vertical, B-RM6-V-6P from Epcos, or equivalent Magnet Wire: #35 AWG. Magnet Wire: #36 AWG Magnet Wire: #28 AWG T.I.W. Tape: 3M 1298 Polyester Film, 7 mm wide. Mounting clip, CLI/P-RM6, and varnish. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 41 09-Jun-10 7.4 RDR-193 7 W PAR20 LED Driver Using LNK403EG Transformer Build Diagram Pins Side 3L Tape W4 - Finish (FL1) 1L Tape W3 - Finish (FL3) 1L Tape W3 - Start (FL2) W2 - Finish (P2) W2 - Start (P6) 1L Tape W1 - Start (P1) Figure 6 – Transformer Build Diagram. 7.5 Transformer Construction Bobbin Preparation WD 1 Insulation WD 2 Insulation WD 3 Insulation WD 4 Insulation Final Assembly Page 15 of 41 Place the bobbin item [2] on the mandrel such that pin side on the left side. Winding direction is the clockwise direction. Start at pin 1, wind 64 turns of #35 AWG item [3] from left to right two layers. At the last turn exit the same slot, leave enough length wire floating to wind next 64 turns in WD4. Apply one layer of tape [6] for insulation. Start at pin 6, wind 26 turns of #36 AWG [4] wire from left to right. Finish at pin 2. Apple one layer of tape [6] for insulation. Leave about 1” of wire item [5], use small tape to mark as FL2, enter into slot of secondary side of bobbin, wind 22 turns in two layers. At the last turn exit the same slot, leave about 1”, and mark as FL3. Apple one layer of tape [6] for insulation. Continue to wind with floating wire, 64 turns of #35 AWG from left to right two layers. Leave 1” and mark as FL1 Apply three layers of tape [6] for insulation. Cut FL1, FL2, FL3 wire length to 0.75”. Grind core. Assemble core and varnish using item [7]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 8 Transformer Design Spreadsheet ACDC LinkSwitch-PH 042910; Rev.1.0; Copyright Power Integrations 2010 INPUT ENTER APPLICATION VARIABLES Dimming required YES INFO Info VACMIN VACMAX 265 fL VO OUTPUT UNIT LinkSwitch-PH_042910: Flyback Transformer Design Spreadsheet !!! Info. When configured for dimming, best output current line regulation is achieved over a single input voltage range. YES 90 V 265 V Maximum AC input voltage 50 Hz AC Mains Frequency 21.00 Minimum AC Input Voltage V Typical output voltage of LED string at full load VO_MAX 23.10 V Maximum expected LED string Voltage. VO_MIN 18.90 V Minimum expected LED string Voltage. V_OVP 25.41 V Over-voltage protection setpoint 6.9 W Output Power V Bias Voltage IO 0.33 Typical full load LED current PO n 0.8 VB 25 Estimated efficiency of operation 25 ENTER LinkSwitch-PH VARIABLES LinkSwitch-PH LNK403 Chosen Device Universal LNK403 Current Limit Mode FULL Power Out 12.5W 115 Doubled/230V 12.5W Select "RED" for reduced Current Limit mode or "FULL" for Full current limit mode FULL ILIMITMIN 0.81 A Minimum current limit ILIMITMAX 0.92 A Maximum current limit fS 66000 Hz Switching Frequency fSmin 62000 Hz Minimum Switching Frequency fSmax 70000 Hz Maximum Switching Frequency IV 39.9 uA RV 4 M-ohms Upper V pin resistor 1E+12 M-ohms Lower V pin resistor 139.0 uA RFB1 158.3 k-ohms VDS 10 V LinkSwitch-PH on-state Drain to Source Voltage RV2 IFB 139.00 V pin current FB pin current (85 uA < IFB < 210 uA) FB pin resistor VD 0.50 V Output Winding Diode Forward Voltage Drop (0.5 V for Schottky and 0.8 V for PN diode) VDB 0.70 V Bias Winding Diode Forward Voltage Drop Key Design Parameters KP 1.06 LP VOR 125.00 Expected IO (average) KP_VACMAX Ripple to Peak Current Ratio (For PF > 0.9, 0.4 < KP < 0.9) 1.06 Info TON_MIN 2450 uH 125 V Reflected Output Voltage. 0.33 A Expected Average Output Current !!! Info. PF at high line may be less than 0.9. Decrease KP for higher PF 1.35 1.91 Primary Inductance us Minimum on time at maximum AC input voltage ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type RM6 Bobbin AE RM6 #N/A 0.3600 0.36 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com P/N: cm^2 #N/A Core Effective Cross Sectional Area Page 16 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG LE 2.8600 2.86 cm AL 2280.0 2280 nH/T^2 BW 6.4 6.4 mm Bobbin Physical Winding Width 0 mm Safety Margin Width (Half the Primary to Secondary Creepage Distance) M L NS Core Effective Path Length Ungapped Core Effective Inductance 4.00 4 Number of Primary Layers 22 22 Number of Secondary Turns DC INPUT VOLTAGE PARAMETERS VMIN 127 V Peak input voltage at VACMIN VMAX 375 V Peak input voltage at VACMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX 0.50 IAVG 0.33 A Average Primary Current Minimum duty cycle at peak of VACMIN IP 0.42 A Peak Primary Current (calculated at minimum input voltage VACMIN) IRMS 0.14 A Primary RMS Current (calculated at minimum input voltage VACMIN) LP 2450 uH NP 128 TRANSFORMER PRIMARY DESIGN PARAMETERS Primary Inductance Primary Winding Number of Turns NB 26 ALG 150 nH/T^2 Gapped Core Effective Inductance BM 2244 Gauss Maximum Flux Density at PO, VMIN (BM<3100) BP 2715 Gauss BAC 1122 Gauss Peak Flux Density (BP<3700) AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) ur 1441 LG 0.28 BWE 25.6 mm Effective Bobbin Width OD 0.20 mm INS 0.04 mm Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) DIA 0.16 mm Bare conductor diameter 35 AWG AWG Bias Winding Number of Turns Relative Permeability of Ungapped Core mm Gap Length (Lg > 0.1 mm) Primary Wire Gauge (Rounded to next smaller standard AWG value) CM 32 Cmils CMA 234 Cmils/Amp Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 600) TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 2.45 A Peak Secondary Current ISRMS 0.72 A Secondary RMS Current IRIPPLE 0.65 A CMS 145 Cmils AWGS 28 AWG DIAS 0.32 mm ODS 0.29 mm Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular mils Secondary Wire Gauge (Rounded up to next larger standard AWG value) Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for Triple Insulated Wire VOLTAGE STRESS PARAMETERS VDRAIN Page 17 of 41 628 V Estimated Maximum Drain Voltage assuming maximum LED string voltage (Includes Effect of Leakage Inductance) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG PIVS 90 V PIVB 107 V 09-Jun-10 Output Rectifier Maximum Peak Inverse Voltage (calculated at VOVP, excludes leakage inductance spike) Bias Rectifier Maximum Peak Inverse Voltage (calculated at VOVP, excludes leakage inductance spike) FINE TUNING (Enter measured values from prototype) V pin Resistor Fine Tuning RV1 4.00 M-ohms Upper V Pin Resistor Value RV2 1E+12 M-ohms Lower V Pin Resistor Value VAC1 115.0 V VAC2 230.0 V Test Input Voltage Condition2 IO_VAC1 0.33 A Measured Output Current at VAC1 IO_VAC2 0.33 A Measured Output Current at VAC2 RV1 (new) 4.00 M-ohms RV2 (new) 20911.63 M-ohms Test Input Voltage Condition1 New RV1 New RV2 V_OV 319.6 V Typical AC input voltage at which OV shutdown will be triggered V_UV 66.3 V Typical AC input voltage beyond which power supply can startup FB pin resistor Fine Tuning RFB1 158 k-ohms Upper FB Pin Resistor Value RFB2 1E+12 k-ohms Lower FB Pin Resistor Value VB1 22.5 V Test Bias Voltage Condition1 VB2 27.5 V Test Bias Voltage Condition2 IO1 0.33 A Measured Output Current at Vb1 IO2 0.33 A RFB1 (new) 158.3 k-ohms New RFB1 Measured Output Current at Vb2 RFB2(new) 1.00E+12 k-ohms New RFB2 Note: Actual RFB = 142 k due to lower bias voltage. Measured PF at 230 VAC was 0.9. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 9 Performance Data All measurements performed at room temperature. 9.1 Efficiency vs. Line and Output (LED String) Voltage 9.1.1 21 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 VIN (VAC) 90 100 115 130 VIN (VAC) 185 200 215 230 245 265 PIN (W) 7.63 8.1 8.78 9.37 PIN (W) 10.82 11.15 11.48 11.8 12.11 12.53 VOUT (V) 21 21.09 21.24 21.36 VOUT (V) 21.63 21.68 21.74 21.79 21.83 21.88 IOUT (mA) 295 314 340 362 IOUT (mA) 415 426 437 448 458 471 POUT (W) 6.20 6.62 7.22 7.73 POUT (W) 8.98 9.24 9.50 9.76 10.00 10.31 Efficiency (%) 81 82 82 83 Efficiency (%) 83 83 83 83 83 82 VIN (VAC) 90 100 115 130 VIN (VAC) 185 200 215 230 245 265 PIN (W) 6.57 6.95 7.48 7.98 PIN (W) 9.27 9.56 9.84 10.12 10.4 10.76 VOUT (V) 17.82 17.91 18.04 18.14 VOUT (V) 18.42 18.43 18.5 18.54 18.59 18.64 IOUT (mA) 301 318 343 365 IOUT (mA) 418 429 440 451 461 474 POUT (W) 5.36 5.70 6.19 6.62 POUT (W) 7.70 7.91 8.14 8.36 8.57 8.84 Efficiency (%) 82 82 83 83 Efficiency (%) 83 83 83 83 82 82 PF 0.97 PF 0.9 9.1.2 18 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 Page 19 of 41 PF 0.96 PF 0.88 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 9.1.3 24 V Hz 60 60 60 60 Hz 50 50 50 50 50 50 84 VIN (VAC) 90 100 115 130 VIN (VAC) 185 200 215 230 245 265 PIN (W) 8.76 9.26 10.07 10.76 PIN (W) 12.39 12.77 13.14 13.51 13.86 14.32 VOUT (V) 24.07 24.17 24.35 24.49 VOUT (V) 24.8 24.86 24.92 24.98 25.04 25.1 IOUT (mA) 290 309 337 359 IOUT (mA) 412 424 435 446 456 468 POUT (W) 6.98 7.47 8.21 8.79 POUT (W) 10.22 10.54 10.84 11.14 11.42 11.75 Efficiency (%) 80 81 81 82 Efficiency (%) 82 83 82 82 82 82 200 225 PF 0.97 PF 0.91 18 V 21 V 24 V Efficiency (%) 83 82 81 80 79 75 100 125 150 175 250 275 Input Voltage (VAC) Figure 7 – Efficiency vs. Input Voltage, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 41 09-Jun-10 9.2 RDR-193 7 W PAR20 LED Driver Using LNK403EG Regulation 9.2.1 Output Voltage and Line 500 115 V 230 V Output Current (mA) 450 400 350 300 250 17 18 19 20 21 22 23 24 25 Output Voltage (VDC) Figure 8 – Voltage and Line Regulation, Room Temperature. The line regulation result shown above is typical for a design where the phase angle dimming mode of U1 is selected (to provide a very wide dimming range). For a given line voltage the output current can be centered by changing the value of the FEEDBACK resistor (R15). The table below shows the resistor values to adjust the mean output current at specific input voltages, Line Voltage (VAC) 100 115 230 Value of R15 (kΩ) 133 143 182 Table 1 – Feedback Resistor Value to Center Output Current at Different Nominal Line Voltages. Page 21 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 9.2.2 Line Regulation 370 21 V 18 V 24 V 360 Output Current (mA) 350 340 330 320 310 300 290 280 85 90 95 100 105 110 115 120 125 130 135 Input Voltage (VAC) Figure 9 – Low Line Regulation, Room Temperature, Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 41 09-Jun-10 480 Output Current (mA) 470 RDR-193 7 W PAR20 LED Driver Using LNK403EG 21 V 18 V 24 V 460 450 440 430 420 410 180 190 200 210 220 230 240 Input Voltage (VAC) 250 260 Figure 10 – High Line Regulation, Room Temperature, Full Load. Page 23 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 270 RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 10 Thermal Performance Images captured after running for 30 minutes at room temperature (25 °C), full load. This indicates an operating temperature of 100°C at 50°C for the LinkSwitch-PH. The addition of a small heatsink (width of board) to the device reduces the operating temperature by ~25°C. 10.1 VIN = 115 VAC Figure 11 – Top Side. Figure 12 – Bottom Side. 10.2 VIN = 230 VAC Figure 13 – Top Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 14 – Bottom Side. Page 24 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 11 Harmonic Data The design passes Class C requirement. 70 Class C Limit RD-193 Harmonic Data at 115 VAC 60 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 39 Harmonic Figure 15 – 115 VAC Harmonic, Room Temperature, Full Load. Page 25 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 45 09-Jun-10 Class C limit RD-193 Harmonic Data at 230 VAC 40 Current (mA) 35 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 Figure 16 – 230 VAC Harmonic, Room Temperature, Full Load. THD (%) VIN =115 VAC Limit (%) Margin (%) 21.00 THD (%) 27.80 33 12.0 VIN = 230 VAC Limit (%) Margin (%) 33 5.2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 12 Waveforms 12.1 Input Line Voltage and Current Figure 17 – 90 VAC, Full Load. Upper: IIN, 0.2 A / div. Lower: VIN, 200 V, 10 ms / div. Figure 18 – 265 VAC, Full Load. Upper: IIN, 0.1 A / div. Lower: VIN, 500 V / div., 10 ms / div. 12.2 Drain Voltage and Current Figure 19 – 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 200 V, 5 s / div. Page 27 of 41 Figure 20 – 265 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VDRAIN, 200 V / div., 5 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 12.3 Output Voltage and Ripple Current Figure 21 – 90 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUTPUT 5 V, 5 ms / div. Figure 22 – 265 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUTPUT 5 V, 5 ms / div. 12.4 Drain Voltage and Current Start-up Profile ` Figure 23 – 90 VAC, Full Load. Upper: IDRAIN, 0.2 A / div. Lower: VOUTPUT, 5 V, 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 24 – 265 VAC, Full Load. Upper: IRIPPLE, 0.2 A / div. Lower: VOUTPUT, 5 V, 10 ms / div. Page 28 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 12.5 Output Current and Drain Voltage at Shorted Output Figure 25 – 90 VAC, Full Load. Upper: IOUTPUT, 1 A / div. Lower: VDRAIN, 200 V, 200 ms / div. Figure 26 – 265 VAC, Full Load. Upper: IOUTPUT, 1 A / div. Lower: VDRAIN, 200 V, 200 ms / div. 12.6 Open Load Output Voltage Figure 27 – Output Voltage: 115 VAC. VOUT, 10 V / div., 500 ms / div. Page 29 of 41 Figure 28 – Output Voltage: 230 VAC. VOUT, 10 V / div., 500 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 13 Dimming 13.1 Input Phase vs. Output Current 115 VAC Phase Angle IOUT (mA) 163 310 91 150 61 70 35 24 9 2 0 0 230 VAC Phase Angle IOUT (mA) 160 430 88 210 61 110 49 74 34 28 11 8 0 0 0.5 115 VAC 230 VAC 0.45 LED Current (A) 0.4 0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 0 20 40 60 80 100 120 140 160 180 Phase Angle (°) Figure 29 – Input Phase vs. Output Current. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 13.2 Output Voltage and Input Current Waveforms During Dimming 13.2.1 VIN = 115 VAC / 60 Hz Figure 30 – 115 VAC, Full Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 31 – 115 VAC, 60° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 32 – 115 VAC, 35° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 33 – 115 VAC, 8° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Page 31 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 13.2.2 VIN = 230 VAC / 50 Hz Figure 34 – 230 VAC, Full Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 35 – 230 VAC, 49° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 36 – 230 VAC, 34° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Figure 37 – 230 VAC, 12° Phase. Upper: VOUT, 10 V / div. Lower: IIN, 0.1 A / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 14 Line Surge Differential and common input line 200A ring wave testing was completed on a single test unit to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load and operation was verified following each surge event. Surge Level (V) 2500 2500 2500 2500 2500 2500 Input Voltage (VAC) 230 230 230 230 230 230 Injection Location L to N L to N L to PE L to PE N to PE N to PE Injection Phase (°) 90 90 90 90 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Pass Pass Unit passes under all test conditions. Page 33 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 15 Conducted EMI Note: Refer to table for margin to standard – blue line is peak measurement but limit line is quasi peak. Power Integrations 27.Apr 10 15:55 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 PK CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz Trace1: 30 MHz EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 128.247618558 kHz 26.98 N gnd 2 Average 132.133649648 kHz 31.57 N gnd 2 Average 136.137431366 kHz 29.83 N gnd 1 Quasi Peak 190.46019728 kHz 48.16 L1 gnd -15.85 2 Average 200.175581485 kHz 40.71 N gnd -12.89 1 Quasi Peak 261.871472881 kHz 40.66 N gnd -20.70 1 Quasi Peak 332.507282579 kHz 45.95 L1 gnd -13.43 2 Average 397.727746704 kHz 38.88 L1 gnd -9.01 1 Quasi Peak 401.705024172 kHz 49.29 L1 gnd -8.52 1 Quasi Peak 466.367062279 kHz 48.81 N gnd -7.76 2 Average 466.367062279 kHz 38.69 N gnd -7.88 1 Quasi Peak 530.769219795 kHz 46.57 L1 gnd -9.42 2 Average 530.769219795 kHz 35.42 L1 gnd -10.57 2 Average 598.084042089 kHz 36.37 L1 gnd -9.62 1 Quasi Peak 667.263434405 kHz 48.01 N gnd -7.98 2 Average 667.263434405 kHz 35.42 N gnd -10.57 1 Quasi Peak 935.888336808 kHz 45.80 L1 gnd -10.19 2 Average 4.16322710559 MHz 38.65 N gnd -7.34 1 Quasi Peak 4.33227082061 MHz 45.55 N gnd -10.44 Figure 38 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55015 B Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG Power Integrations 27.Apr 10 15:58 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 PK CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz Trace1: 30 MHz EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 130.825395691 kHz 32.43 N gnd 2 Average 136.137431366 kHz 34.96 L1 gnd 1 Quasi Peak 192.364799253 kHz 47.32 L1 gnd -16.60 2 Average 202.1773373 kHz 38.56 N gnd -14.95 1 Quasi Peak 267.135089486 kHz 41.78 N gnd -19.42 2 Average 269.806440381 kHz 34.00 N gnd -17.11 2 Average 335.832355405 kHz 33.36 L1 gnd -15.94 1 Quasi Peak 352.963180679 kHz 39.19 L1 gnd -19.69 2 Average 405.722074413 kHz 33.60 N gnd -14.13 1 Quasi Peak 409.779295157 kHz 42.10 N gnd -15.54 2 Average 471.030732902 kHz 31.24 L1 gnd -15.25 1 Quasi Peak 515.159375557 kHz 41.49 N gnd -14.50 2 Average 541.437681113 kHz 33.55 N gnd -12.44 2 Average 673.936068749 kHz 32.91 L1 gnd -13.08 2 Average 4.37559352882 MHz 40.83 N gnd -5.16 1 Quasi Peak 4.55326017222 MHz 46.83 N gnd -9.16 Figure 39 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 B Limits. Page 35 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 16 Production Distribution Data Each RD-193 board is ATE tested and the data recorded prior to shipping. The distribution data for output current is presented below for a fixed line condition of 115 VAC and a device junction temperature of 50°C. This shows very low unit to unit variation (sigma of 3.3 mA) which includes both the device and external component influences. Histogram of Average Output Current Normal Vin = 115 VAC 35 Mean StDev N 30 0.3358 0.003328 92 Frequency 25 20 15 10 5 0 0.30 0.31 0.32 0.33 Iout (A) 0.34 0.35 0.36 Figure 40 – Production Variation of IOUT at 115 VAC. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 17 Revision History Date 09-Jun-10 Page 37 of 41 Author DK Revision 1.0 Description & changes Initial Release Reviewed Apps and Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 18 Appendix 18.1 Dimming Test with TRIAC Dimmer Switches 18.1.1 115 VAC Input, 60 Hz Style Country Manufacturer Model number Max Current (mA) Dimming Test Data Controlled Min. Min. Current Current without Off Switch (mA) (mA) Rotary 1 Taiwan WS-5005 325 3 0 2 USA Leviton OB4911 324 16 0 1 USA Lutron GLR11-F38875 288 14 0 2 Taiwan SG Electric XH004186 310 2 0 Slider 18.1.2 230 VAC Input, 50 Hz Dimming Test Data Min. Current Style Country Manufacturer Model Number Max. Current Controlled Min. Current without Off Switch (mA) (mA) (mA) Rotary 1 Taiwan Y-25088A 440 2 2 Taiwan 3 Taiwan Y-25082A 439 2 D-2160B 442 4 China CLIPMEI 440 5 China MBR 440 6 China KBE 438 0 0 30 5 0 92 7 0 7 China MANK NK/TG100001 441 8 China SB Electric BM2 426 2 0 9 China EBAHuang 440 1 0 10 China Myongbo 444 100 11 China TCL 438 48 12 Italy RTS34DLI 444 53 L2.0 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 120 Page 38 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 18.2 Audible Noise Test Data Unit measured open frame with calibrated laboratory microphone placed 25 mm above the transformer. Results show very acceptable audible noise levels created by supply when using leading edge phase angle dimming. Levels measured were only slightly above noise floor. 18.2.1 VIN = 115 VAC, Full Phase +80 +70 +60 +50 +40 d B r A +30 +20 +10 +0 -10 -20 -30 2k 4k 6k 8k 10k 12k 14k 16k 18k 20k 22k Hz Figure 41 – 2 kHz – 22 kHz. 18.2.2 VIN = 115 VAC, Half Phase +80 +70 +60 +50 +40 d B r A +30 +20 +10 +0 -10 -20 -30 2k 4k 6k 8k 10k 12k 14k 16k 18k 20k 22k Hz Figure 42 – 2 kHz – 22 kHz. Page 39 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-193 7 W PAR20 LED Driver Using LNK403EG 09-Jun-10 18.2.3 VIN = 230 VAC, Full Phase +80 +70 +60 +50 +40 d B r +30 +20 A +10 +0 -10 -20 -30 2k 4k 6k 8k 10k 12k 14k 16k 18k 20k 22k Hz Figure 43 – 2 kHz – 22 kHz. 18.2.4 VIN = 230 VAC, Half Phase +80 +70 +60 +50 +40 d B r A +30 +20 +10 +0 -10 -20 -30 2k 4k 6k 8k 10k 12k 14k 16k 18k 20k 22k Hz Figure 44 – 2 kHz – 22 kHz. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 41 09-Jun-10 RDR-193 7 W PAR20 LED Driver Using LNK403EG 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, 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 2010 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 Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 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 e-mail: [email protected] INDIA #1, 14th 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] UNITED KINGDOM 1st Floor, St. James’s House East Street, Farnham Surrey, GU9 7TJ United Kingdom Phone: +44 (0) 1252-730-141 Fax: +44 (0) 1252-727-689 e-mail: [email protected] CHINA (SHENZHEN) Rm A, B & C 4th Floor, Block C, Electronics Science and Technology Building 2070 Shennan Zhong Road Shenzhen, Guangdong, P.R.C. 518031 Phone: +86-755-8379-3243 Fax: +86-755-8379-5828 e-mail: [email protected] ITALY Via De Amicis 2 20091 Bresso MI Italy Phone: +39-028-928-6000 Fax: +39-028-928-6009 e-mail: [email protected] SINGAPORE 51 Newton Road, #15-08/10 Goldhill Plaza Singapore, 308900 Phone: +65-6358-2160 Fax: +65-6358-2015 e-mail: [email protected] APPLICATIONS HOTLINE World Wide +1-408-414-9660 Page 41 of 41 APPLICATIONS FAX World Wide +1-408-414-9760 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Design Example Report Title Highly Accurate (<±5%) Constant Current TRIAC Dimmable, High Power Factor (0.9) 7.4 W Output LED Driver Using LinkSwitchTM-PH LNK403EG Specification 176 VAC – 265 VAC Input; 66 V, 112 mA Output Application A19 LED Driver Author Applications Engineering Department Document Number DER-296 Date November 3, 2011 Revision 1.0 Summary and Features TRIAC dimmer compatible >1000:1 dimming range (TRIAC dependent) Clean monotonic start-up – no output blinking Fast start-up (<300 ms) – no perceptible delay Highly energy efficient ≥82% at 230 VAC Low cost, low component count and small printed circuit board footprint solution Excellent line and load regulation, <2% typical Frequency jitter for smaller, lower cost EMI filter Integrated protection and reliability features Output open circuit / output short-circuit protected with auto-recovery Line input overvoltage shutdown extends voltage withstand during line faults Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board IEC 61000-4-5 ring wave, IEC 61000-3-2 Class C and EN55015 B conducted EMI compliant Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 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, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Table of Contents 1 2 3 4 Introduction .................................................................................................................5 Power Supply Specification ........................................................................................7 Schematic ...................................................................................................................8 Circuit Description .......................................................................................................9 4.1 Input Filtering .......................................................................................................9 4.2 LinkSwitch-PH Primary ........................................................................................9 4.3 Feedback ...........................................................................................................10 4.4 Output Rectification ...........................................................................................11 4.5 TRIAC Phase Dimming Control Compatibility ....................................................11 5 PCB Layout...............................................................................................................13 6 Bill of Materials .........................................................................................................14 7 Transformer Specification .........................................................................................15 7.1 Electrical Diagram..............................................................................................15 7.2 Electrical Specifications .....................................................................................15 7.3 Materials ............................................................................................................15 7.4 Transformer Build Diagram ................................................................................16 7.5 Transformer Construction ..................................................................................16 8 Transformer Design Spreadsheet .............................................................................17 9 Performance Data .....................................................................................................20 9.1 Efficiency ...........................................................................................................20 9.2 Line and Load Regulation ..................................................................................21 9.3 Power Factor .....................................................................................................22 9.4 A-THD................................................................................................................23 9.5 Harmonic Currents.............................................................................................24 9.5.1 63 V LED Load ...........................................................................................24 9.5.3 66 V LED Load ...........................................................................................25 9.5.4 69 V LED Load ...........................................................................................26 9.6 Test Data ...........................................................................................................27 9.6.1 Test Data, 63 V LED Load ..........................................................................27 9.6.2 Test Data, 66 V LED Load ..........................................................................27 9.6.3 Test Data, 69 V LED Load ..........................................................................27 9.6.4 230 VAC 50 Hz, 63 V LED Load Harmonics Data ......................................28 9.6.5 230 VAC 50 Hz, 66 V LED Load Harmonics Data ......................................29 9.6.6 230 VAC 50 Hz, 69 V LED Load Harmonics Data ......................................30 10 Dimming Performance Data......................................................................................31 10.1 Performance with Dimmers from China .............................................................31 10.2 Performance with Dimmers from Germany ........................................................33 10.3 Minimum Dimming Waveforms ..........................................................................34 11 Thermal Performance ...............................................................................................37 11.1 Non-Dimming VIN = 230 VAC, 50 Hz, 66 V LED Load .......................................37 11.2 Dimming VIN = 230 VAC 50 Hz, 90˚ Conduction Angle, 66 V LED Load ...........37 11.3 Dimming VIN = 265 VAC 50 Hz, 90˚ Conduction Angle, 66 V LED Load ...........38 12 Waveforms................................................................................................................39 12.1 Input Line Voltage and Current without Dimmer ................................................39 Page 3 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 12.2 Input Line Voltage and Current During Dimming ............................................... 40 12.2.1 Dimmer: CLIPMEI-CHINA .......................................................................... 40 12.3 Output Current at Normal Operation ................................................................. 41 12.4 Output Current During Dimming Operation ....................................................... 42 12.4.1 Dimmer: CLIPMEI-CHINA .......................................................................... 42 12.5 Drain Voltage and Current at Normal Operation................................................ 43 12.6 Start-Up Drain Voltage and Current .................................................................. 45 12.7 Output Diode PIV .............................................................................................. 45 12.8 Output Current/Voltage Rise and Fall ................................................................ 46 12.9 Output Current and Drain Voltage During Output Short Condition .................... 47 12.10 Open Load Output Voltage ............................................................................ 47 13 Conducted EMI ......................................................................................................... 48 13.1 Test Set-up ........................................................................................................ 48 14 Line Surge ................................................................................................................ 50 15 Revision History........................................................................................................ 51 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 4 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 1 Introduction The document describes a non-isolated high power factor (PF) TRIAC dimmable LED driver designed to drive a nominal LED string voltage of 66 V at 110 mA from an input voltage range of 176 VAC to 265 VAC. The LED driver utilizes the LNK403EG from the LinkSwitch-PH family of ICs. The topology used is a single-stage non-isolated flyback that meets the stringent space requirements for this design. Enhanced line and load output current regulation requirement is achieved by using a sensing resistance and shunt regulator. High power factor and low THD is achieved by employing the LinkSwitch-PH IC which also provides a sophisticated range of protection features including auto-restart for open control loop and output short-circuit conditions. Line overvoltage provides extended line fault and surge withstand, output overvoltage protects the supply should the load be disconnected and accurate hysteretic thermal shutdown ensures safe average PCB temperatures under all conditions. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, transformer documentation and typical performance characteristics. Figure 1 – Populated Circuit Board Photograph (Top View). Page 5 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 Figure 2 – Populated Circuit Board Photograph (Bottom View). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 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 176 230 50 265 VAC Hz 2 Wire – no P.E. VOUT IOUT 108 POUT 81 66 112 116 V mA 7.4 W 82 % VOUT = 66, VIN = 230 VAC, 25°C o Measured at POUT 25 C Environmental Conducted EMI CISPR 15B / EN55015B Safety Ring Wave (100 kHz) Differential Mode (L1-L2) Common mode (L1/L2-PE) Non-Isolated 2.5 kV Differential Surge 500 V Power Factor 0.9 Harmonic Currents Ambient Temperature Page 7 of 52 Measured at VOUT(TYP), IOUT(TYP) and 230 VAC, 50 Hz Class C specifies Class D Limits when PIN <25 W EN 61000-3-2 Class D (C) TAMB 50 o C Free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 3 Schematic Figure 3 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 4 Circuit Description The LinkSwitch-PH device is a controller with an integrated 725 V power MOSFET for use in LED driver applications. The LinkSwitch-PH is configured for use in a single-stage continuous conduction mode flyback topology and provides a primary side regulated constant current output while maintaining high power factor from the AC input. 4.1 Input Filtering Fuse F1 provides protection from component failure and RV1 provides a clamp to limit the maximum voltage during differential line surge events. A 275 VAC rated part was selected, being slightly above the maximum specified operating voltage of 265 VAC. Diode bridge BR1 rectifies the AC line voltage with capacitor C5 providing a low impedance path (decoupling) for the primary switching current. A low value of capacitance (sum of C4 and C5) is necessary to maintain a power factor of greater than 0.9. EMI filtering is provided by inductors L1 and L2, and capacitors C4 and C5. Resistor R4 and R5 across L1 and L2 damp any LC resonances due to the filter components and the AC line impedance which would ordinarily show up on the conducted EMI measurements. 4.2 LinkSwitch-PH Primary One side of the transformer (T1) is connected to the DC bus and the other to the DRAIN pin of the LinkSwitch-PH. During the on-time of the MOSFET current ramps through the primary, storing energy which is then delivered to the output during the MOSFET off-time. An RM6 core size was selected to meet both the power handling and size requirements of the design. To provide peak line voltage information to U1, the incoming rectified AC peak charges C6 via D2. This is then fed into the VOLTAGE MONITOR (V) pin of U1 as a current via R11, R12, and R19. Resistor R10 provides a discharge path for C6 with a time constant much longer than that of the rectified AC to prevent the V pin current being modulated at the line frequency (which would degrade power factor). To extend the dimming range R13 disables the line brown-out function of the V pin by supplying a current >IUV- into the V pin. The current is determined by the BYPASS (BP) pin, V pin voltages and the value of R13 and is ~30 A for this design. The line overvoltage shutdown function, sensed via the V pin current, extends the rectified line voltage withstand (during surges and line swells) to the 725 BVDSS rating of the internal power MOSFET. The V pin current and the FEEDBACK (FB) pin current are used internally to control the average output LED current. For phase angle dimming applications a 49.9 k resistor is used on the REFERENCE (R) pin (R14) and 4 M (R11+R12+R19+R13) on the V pin to Page 9 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 provide a linear relationship between input voltage and the output current. This maximizes the dimming range when used with TRIAC dimmers. The value of R14 is used to select between two values of internal line input brown-in and brown-out thresholds. During the power MOSFET off-time, D3, R15, R16, and C7 clamp the drain voltage to a safe level which would otherwise rise due to the effects of leakage inductance. Diode D4 is necessary to prevent reverse current from flowing through U1 while the voltage across C5 (rectified input AC) falls to below the reflected output voltage (VOR). Capacitor C8 provides local decoupling for the BP pin of U1 which is the supply pin for the internal controller. During start-up, C8 is charged to ~6 V from an internal highvoltage current source connected to the D pin. Once charged U1 starts switching at which point the operating supply current is provided from the output via R17. Diode D6 isolates the BP pin from the output capacitance C16 to prevent the start-up time increasing due to charging of both C8 and C16. 4.3 Feedback A current sense resistor (R32 parallel with R33) and a shunt regulator U2 is employed to enable very tight output current regulation for this design. Output current sensed by R32 and R33 is filtered by R31 and C12, with values chosen to have a time constant greater than the line frequency in order to remove the line frequency harmonics and thus enable the slow loop response necessary to maintain high power factor and low THD. This voltage is then compared with the internal reference of U2 to provide a regulated output current of 112 mA. Capacitor C11 and R30 provide feedback compensation for the shunt regulator U2. During normal operation without a dimmer, the cathode voltage of U2 adjusts the feedback current fed to IFB of U1 thru R28 to maintain a constant output current. Resistor R18 provides bias supply to U2, D7 blocks the current from R18 being fed to IFB and disengages U2 during dimming. The maximum output power (output current) is dictated by the sum of resistances R28 and R29. Total combined resistance of R28 and R29 is selected to match the IFB current requirement of the design I FB VOUT VFB R28 R29 140A The maximum operating IFB also dictates the maximum overshoot of the output current during line transients. This overshoot happens because of the slow loop response of the current sense feedback network to maintain high power factor. On this design maximum output peak current is below 175 mA as shown below. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Figure 4 – 265 VAC - 0 - 265 VAC Line Transient. Upper: VIN 200 V / div., Lower: IOUT 50 mA / div. This condition is not present during normal start-up condition when C11 is still discharged as shown on the waveforms of section 12.8. Zener diode VR1 limits the maximum voltage on the cathode to anode of U2 which has a maximum rating of 30 V. The ratio of R28 and R29 is then selected to have a voltage at the anode of D7 to be less than VR1. This is to ensure that during dimming condition, D7 is reverse biased and natural dimming through IFB and IV current feedbacks takeover the control of the output current. Zener diode VR2 is an optional component that is used to protect the current sense resistors R32 and R33 during output short condition. The network formed by D8, R34, R35, and VR3 forms the OVP circuit. During open load condition, VR3 will be forward biased and inject a current on the V pin through D8 and R35. This will increase IV current and will eventually trigger the OV protection of the IC and stop the switching, thus limiting the output voltage to ~ VR3 + VV. 4.4 Output Rectification The transformer secondary winding is rectified by D12 and filtered by C16. Capacitor C16 was selected to give an LED ripple current equal to ±30% of the mean value. For designs where higher ripple is acceptable, the output capacitance value can be reduced (and for lower ripple increased). 4.5 TRIAC Phase Dimming Control Compatibility The requirement to provide output dimming with low cost, TRIAC based, leading edge phase dimmers introduced a number of tradeoffs in the design. Due to the much lower power consumed by LED based lighting the current drawn by the lamp can fall below the holding current of the TRIAC within the dimmer. This causes Page 11 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 undesirable behavior such as the lamp turning off before the end of the dimmer control range and/or flickering as the TRIAC fires inconsistently. The relatively large impedance the LED lamp presents to the line allows significant ringing to occur due to the inrush current charging the input capacitance when the TRIAC turns on. This too can cause similar undesirable behavior as the ringing may cause the TRIAC current to fall to zero. To overcome these issues, passive damper and passive bleeder circuits were added. The drawback of these circuits is increased dissipation and therefore reduced efficiency of the supply. For non-dimming applications these components can simply be omitted. The passive damper consists of components R20 and R21 which dampen ringing of the input network during TRIAC dimming. The passive bleeder circuit is comprised of C9 and parallel combination of R1, R2, and R3. This keeps the input current above the TRIAC holding current while the driver input current increases during each AC half-cycle preventing the TRIAC switch from oscillating at the start of each conduction angle period. This arrangement provided flicker-free dimming operation with phase angle dimmers from Europe, China, Korea, both leading-edge and lagging-edge types. 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 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 5 PCB Layout Figure 5 – PCB Layout and Outline (60 mm x 20 mm). Figure 6 – Top Side. Figure 7 – Bottom Side. Figure 8 – Bottom Side Component Placement. Page 13 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 6 Bill of Materials Item Qty Ref Des 1 1 BR1 2 1 C4 Description 1000 V, 0.8 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC 68 nF, 630 V, Film 3 1 C5 33 nF, 400 V, Film 4 1 C6 5 1 6 7 Mfg Part Number Manufacturer B10S-G Comchip Technology ECQ-E6683KF Panasonic ECQ-E4333KF Panasonic 2.2 F, 400 V, Electrolytic, (8 x 11.5) SMG400VB2R2M8X11LL Nippon Chemi-Con C7 1000 pF, 630 V, Ceramic, X7R, 1206 ECJ-3FB2J102K Panasonic 1 C8 10 F, 16 V, Ceramic, X7R, 1206 1 C9 100 nF, 630 V, Film 8 1 C10 100 nF, 25 V, Ceramic, X7R, 0805 9 1 C11 1 F, 50 V, Ceramic, X7R, 0805 10 1 C12 11 1 C16 12 2 D2 D4 13 2 D3 D12 14 4 D5 D6 D7 D8 1 F, 16 V, Ceramic, X5R, 0603 100 F, 100 V, Electrolytic, Gen. Purpose, (10 x 20) DIODE ULTRA FAST, SW 600 V, 1 A, SMA 600 V, 1 A, Ultrafast Recovery, 35 ns, SMB Case 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 Fuse, Pico, 2 A, 250 V, Fast, Axial C3216X7R1C106M TDK ECQ-E6104KF Panasonic ECJ-2VB1E104K Panasonic 08055D105KAT2A AVX GRM188R61C105KA93D Murata UVZ2A101MPD Nichicon US1J-13-F Diodes, Inc. MURS160T3G On Semi BAV21WS-7-F Diodes, Inc. 0263002.MXL Littlefuse 15 1 F1 16 2 L1 L2 17 3 R1 R2 R3 18 2 R4 R5 4.7 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ472V Panasonic 19 1 R10 510 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ514V Panasonic 20 3 R11 R12 R19 1.3 M, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1304V Panasonic 21 1 R13 100 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1003V Panasonic 22 1 R14 49.9 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4992V Panasonic 23 2 R15 R16 390 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ394V Panasonic 24 1 R17 20 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ203V Panasonic 25 1 R18 39 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ393V Panasonic 26 2 R20 R21 27 1 R28 100 k, 1%, 1/16 W, Thick Film, 0603 28 1 R29 29 2 R30 R35 30 1 31 2 32 33 2.2 mH, 0.16 A, Ferrite Core 1.5 k, 5%, 1 W, Thick Film, 2512 47 , 5%, 2 W, Metal Film CTSCH875DF-222K CT Parts ERJ-1TYJ152U Panasonic NFR0200004709JR500 Vishay ERJ-3EKF1003V Panasonic 357 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF3573V Panasonic 1 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ102V Panasonic R31 47 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ473V Panasonic R32 R33 22.1 , 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF22R1V Panasonic 1 R34 10 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ103V Panasonic 1 RV1 275 V, 23 J, 7 mm, RADIAL V275LA4P Littlefuse 34 1 T1 Bobbin, RM6, Vertical, 6 pins 35 1 U1 36 1 U2 37 1 VR1 LinkSwitch-PH, eSIP 1.24 V Shunt Regulator IC, 1%, -40 to 85 C, SOT23-3 27.0 V, 5%, 150 mW, SOD-323 MAZS2700ML Panasonic 38 1 VR2 TVS 5.0 V 4002 UNI 5% SMD SMAJ5.0A Diodes, Inc. 39 1 VR3 75 V, 500 mW, 5%, DO-35 BZX55C75 Vishay Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com B65808-N1006-D1 Epcos LNK403EG Power Integrations LMV431AIMF National Semi Page 14 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 7 Transformer Specification 7.1 Electrical Diagram Figure 9 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 7.3 1 second, 60 Hz, from pins 2, 6 to FL1, 3. Pins 2-6, all other windings open, measured at 66 kHz, 0.4 VRMS. Pins 2-6, all other windings open. Pins 2-6, with FL1-pin 3 shorted, measured at 100 kHz, 0.4 VRMS. 3000 VAC 3320 H ±7% 500 kHz (Min.) 70 H ±10% Materials Item [1] [2] [3] [4] [5] [6] Description Core: PC40RM6Z-12. Bobbin: B-RM6-V-6 pins-(3/3) With mounting clip, CLIP-RM6. Tape, Polyester film, 3M 1350F-1 or equivalent, 6.4 mm wide. Wire: Magnet, #34 AWG, solderable double coated. Wire: Magnet, #30 AWG, solderable double coated. Transformer Varnish, Dolph BC-359 or equivalent. Page 15 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 7.4 03-Nov-11 Transformer Build Diagram Figure 10 – Transformer Build Diagram. 7.5 Transformer Construction Bobbin Preparation Primary Winding (W1) Output Winding (W2) Final Assembly Place the bobbin item [2] on the mandrel such that pin side on the left side. Winding direction is the clockwise direction. Starting at pin 6, wind 128 turns of wire item [4] in four layers. Apply one layer of tape item [3] per layer. Finish at pin 2. Leave about 1” of wire item [5], use small tape to mark as FL1, enter into slot of secondary side of bobbin, wind 84 turns in four layers. Apply one layer of tape item [3] per layer. Finish at pin 3. Grind core to get 3.32 mH inductance. Assemble and secure core halves. Dip impregnate using varnish item [5]. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 8 Transformer Design Spreadsheet ACDC_LinkSwitchPH_032511; Rev.1.3; INPUT Copyright Power Integrations 2011 ENTER APPLICATION VARIABLES Dimming required YES VACMIN 176 VACMAX 265 fL VO 66.00 VO_MAX VO_MIN V_OVP IO 0.11 PO n VB 66 ENTER LinkSwitch-PH VARIABLES LinkSwitch-PH LNK403 Chosen Device Current Limit Mode ILIMITMIN ILIMITMAX fS fSmin fSmax IV RV RV2 IFB RFB1 RED 141.00 VDS INFO OUTPUT Info YES 176 265 50 72.60 59.40 79.86 7.3 0.8 66 LNK403 Power Out UNIT V V Hz V V V V A W V Universal 6.5W RED 0.74 0.85 66000 62000 70000 80.6 4 1E+012 141.0 446.8 A A Hz Hz Hz uA M-ohms M-ohms uA k-ohms 10 V VD 0.50 V VDB Key Design Parameters 0.70 V KP 1.00 LP VOR Expected IO (average) KP_VACMAX 101.33 TON_MIN 1 3324 101.33 0.11 1.04 uH V A 2.28 us PCLAMP 0.07 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type RM6S/I RM6S/I RM6S/I_BO Bobbin BBIN AE 0.37 LE 2.92 AL 2150 BW 6.4 M L NS Page 17 of 52 0 4.00 84 4 84 W P/N: cm^2 cm nH/T^2 mm mm LinkSwitch-PH_032511: Flyback Transformer Design Spreadsheet !!! Info. When configured for dimming, best output current line regulation is achieved over a single input voltage range. Minimum AC Input Voltage Maximum AC input voltage AC Mains Frequency Typical output voltage of LED string at full load Maximum expected LED string Voltage. Minimum expected LED string Voltage. Over-voltage protection setpoint Typical full load LED current Output Power Estimated efficiency of operation Bias Voltage 115 Doubled/230V 2.5W Select "RED" for reduced Current Limit mode or "FULL" for Full current limit mode Minimum current limit Maximum current limit Switching Frequency Minimum Switching Frequency Maximum Switching Frequency V pin current Upper V pin resistor Lower V pin resistor FB pin current (85 uA < IFB < 210 uA) FB pin resistor LinkSwitch-PH on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop (0.5 V for Schottky and 0.8 V for PN diode) Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (For PF > 0.9, 0.4 < KP < 0.9) Primary Inductance Reflected Output Voltage. Expected Average Output Current Expected ripple current ratio at VACMAX Minimum on time at maximum AC input voltage Estimated dissipation in primary clamp * Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Number of Primary Layers Number of Secondary Turns Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG 249 375 V V 0.30 0.06 A IP 0.43 A IRMS 0.12 A TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP NB ALG 3324 128 84 203 uH 03-Nov-11 Peak input voltage at VACMIN Peak input voltage at VACMAX Minimum duty cycle at peak of VACMIN Average Primary Current Peak Primary Current (calculated at minimum input voltage VACMIN) Primary RMS Current (calculated at minimum input voltage VACMIN) Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN BM 3012 Gauss (BM<3100) BP 3645 Gauss Peak Flux Density (BP<3700) AC Flux Density for Core Loss Curves (0.5 X BAC 1506 Gauss Peak to Peak) ur 1350 Relative Permeability of Ungapped Core LG 0.21 mm Gap Length (Lg > 0.1 mm) BWE 25.6 mm Effective Bobbin Width Maximum Primary Wire Diameter including OD 0.20 mm insulation Estimated Total Insulation Thickness (= 2 * INS 0.04 mm film thickness) DIA 0.16 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 35 AWG standard AWG value) CM 32 Cmils Bare conductor effective area in circular mils Cmils/A Primary Winding Current Capacity (200 < CMA 270 mp CMA < 600) LP_TOL 7 7 Tolerance of primary inductance TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 0.65 A Peak Secondary Current ISRMS 0.25 A Secondary RMS Current IRIPPLE 0.23 A Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular CMS 51 Cmils mils Secondary Wire Gauge (Rounded up to next AWGS 33 AWG larger standard AWG value) Secondary Minimum Bare Conductor DIAS 0.18 mm Diameter Secondary Maximum Outside Diameter for ODS 0.08 mm Triple Insulated Wire VOLTAGE STRESS PARAMETERS Estimated Maximum Drain Voltage assuming VDRAIN 584 V maximum LED string voltage (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse PIVS 326 V Voltage (calculated at VOVP, excludes leakage inductance spike) Bias Rectifier Maximum Peak Inverse Voltage PIVB 327 V (calculated at VOVP, excludes leakage inductance spike) FINE TUNING (Enter measured values from prototype) V pin Resistor Fine Tuning RV1 4.00 M-ohms Upper V Pin Resistor Value 1000000000 RV2 M-ohms Lower V Pin Resistor Value 000.00 VAC1 115.0 V Test Input Voltage Condition1 VAC2 230.0 V Test Input Voltage Condition2 IO_VAC1 0.11 A Measured Output Current at VAC1 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG IO_VAC2 RV1 (new) RV2 (new) 0.11 4.00 20911.63 A M-ohms M-ohms V_OV 319.6 V V_UV 66.3 V 447 1E+012 59.4 72.6 0.11 0.11 446.8 1.00E+12 k-ohms k-ohms V V A A k-ohms k-ohms FB pin resistor Fine Tuning RFB1 RFB2 VB1 VB2 IO1 IO2 RFB1 (new) RFB2(new) Page 19 of 52 Measured Output Current at VAC2 New RV1 New RV2 Typical AC input voltage at which OV shutdown will be triggered Typical AC input voltage beyond which power supply can startup Upper FB Pin Resistor Value Lower FB Pin Resistor Value Test Bias Voltage Condition1 Test Bias Voltage Condition2 Measured Output Current at Vb1 Measured Output Current at Vb2 New RFB1 New RFB2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 9 Performance Data All measurements performed at room temperature using an LED load. The following data were measured using 3 sets of loads to represent a voltage of 97 V ~ 103 V. The table in Section 9.6 shows complete test data values. 9.1 Efficiency 83.2 63 V 83.0 66 V 69 V 82.8 Efficiency (%) 82.6 82.4 82.2 82.0 81.8 81.6 81.4 81.2 81.0 170 180 190 200 210 220 230 240 250 260 270 Input Voltage (VAC) Figure 11 – Efficiency vs. Line and Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 52 03-Nov-11 9.2 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Line and Load Regulation 112.0 63 V 66 V 111.5 69 V Output Current (mA) 111.0 110.5 110.0 109.5 109.0 170 180 190 200 210 220 230 240 250 260 Input Voltage (VAC) Figure 12 – Regulation vs. Line and Load. Page 21 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 270 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 9.3 03-Nov-11 Power Factor 0.98 63 V 66 V 0.96 69 V Power Factor (pf) 0.94 0.92 0.90 0.88 0.86 0.84 170 180 190 200 210 220 230 240 250 260 270 Input Voltage (VAC) Figure 13 – Power Factor vs. Line and Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 52 03-Nov-11 9.4 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG A-THD 27.5 63 V 27.0 66 V 69 V 26.5 A-THD (%) 26.0 25.5 25.0 24.5 24.0 23.5 23.0 22.5 170 180 190 200 210 220 230 240 250 260 Input Voltage (VAC) Figure 14 – A-THD vs. Line and Load. Page 23 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 270 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 9.5 Harmonic Currents The design met the limits for Class C equipment for an active input power of <25 W. In this case IEC61000-3-2 specifies that harmonic currents shall not exceed the limits of Class D equipment1. Therefore the limits shown in the charts below are Class D limits which must not be exceeded to meet Class C compliance. 9.5.1 63 V LED Load 35 Class D (C) Limit mA Content Harmonic Current (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 Number (n) Figure 15 – 63 V LED Load Input Current Harmonics at 230 VAC, 50 Hz. 1 IEC6000-3-2 Section 7.3, table 2, column 2. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 9.5.3 66 V LED Load 35 Class D (C) Limit mA Content Harmonic Current (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 Number (n) Figure 16 – 66 V LED Load Input Current Harmonics at 230 VAC, 50 Hz. Page 25 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 9.5.4 69 V LED Load 35 Class D (C) Limit mA Content Harmonic Current (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 Number (n) Figure 17 – 69 V LED Load 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 26 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 9.6 Test Data All measurements were taken with the board at open frame, 25 °C ambient, and 50 Hz line frequency. 9.6.1 Test Data, 63 V LED Load 23.0 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 62.90 110.60 6.97 180.05 50.04 8.55 0.949 23.3 62.90 110.60 6.97 6.96 81.49 1.58 220.08 41.97 8.45 0.914 26.0 62.80 110.60 6.96 6.95 82.41 1.49 230.14 40.51 8.43 0.904 26.4 62.80 110.60 6.96 6.95 82.60 1.47 265.12 36.69 8.40 0.864 27.0 62.80 110.60 6.96 6.95 82.84 1.44 PCAL (W) 7.32 VIN (VRMS) 176.01 Input Measurement IIN PIN PF (mARMS) (W) 51.18 8.58 0.952 %ATHD PCAL (W) 6.96 Calculation Efficiency (%) 81.25 Loss (W) 1.61 9.6.2 Test Data, 66 V LED Load 23.03 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 66.20 110.60 7.33 180.04 52.53 9.00 0.952 23.28 66.20 110.50 7.33 7.32 81.43 1.67 220.08 43.89 8.88 0.919 25.96 66.10 110.60 7.32 7.31 82.44 1.56 230.13 42.34 8.86 0.909 26.45 66.10 110.60 7.32 7.31 82.64 1.54 265.11 38.23 8.83 0.871 27.13 66.10 110.60 7.32 7.31 82.90 1.51 PCAL (W) 7.62 VIN (VRMS) 176.00 Input Measurement IIN PIN PF (mARMS) (W) 53.74 9.03 0.954 %ATHD Calculation Efficiency (%) 81.21 Loss (W) 1.70 9.6.3 Test Data, 69 V LED Load 23.11 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 69.00 110.50 7.64 180.04 54.70 9.391 0.954 23.29 69.00 110.50 7.63 7.62 81.25 1.76 220.08 45.55 9.253 0.923 25.86 68.90 110.50 7.63 7.61 82.46 1.62 230.13 43.92 9.230 0.913 26.47 68.90 110.50 7.63 7.61 82.67 1.60 265.11 39.55 9.198 0.877 26.99 68.90 110.50 7.63 7.61 82.95 1.57 VIN (VRMS) 176.00 Input Measurement IIN PIN PF (mARMS) (W) 55.95 9.416 0.956 Page 27 of 52 %ATHD Calculation Efficiency (%) 81.14 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Loss (W) 1.78 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 9.6.4 230 VAC 50 Hz, 63 V LED Load Harmonics Data nth Order mA Content 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 39.16 7.70 4.70 2.27 2.37 1.25 1.58 0.80 1.03 0.65 0.78 0.55 0.62 0.52 0.50 0.45 0.40 0.39 0.34 0.33 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Base Limit mA/W Actual Limit 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 28.6450 16.0075 8.4250 4.2125 2.9488 2.4951 2.1624 1.9080 1.7072 1.5446 1.4103 1.2975 1.2013 1.1185 1.0463 0.9829 0.9268 0.8767 0.8317 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 28 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 9.6.5 230 VAC 50 Hz, 66 V LED Load Harmonics Data Page 29 of 52 nth Order mA Content 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 40.93 8.11 4.89 2.36 2.47 1.32 1.48 0.95 1.04 0.61 0.79 0.50 0.64 0.52 0.50 0.42 0.38 0.36 0.31 0.31 Base Limit mA/W Actual Limit 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 30.1104 16.8264 8.8560 4.4280 3.0996 2.6227 2.2730 2.0056 1.7945 1.6236 1.4824 1.3638 1.2628 1.1757 1.0999 1.0332 0.9742 0.9215 0.8742 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-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 9.6.6 230 VAC 50 Hz, 69 V LED Load Harmonics Data nth Order mA Content 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 42.44 8.51 5.03 2.48 2.54 1.36 1.54 0.86 1.03 0.61 0.78 0.54 0.61 0.47 0.47 0.41 0.37 0.36 0.32 0.31 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Base Limit mA/W Actual Limit 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 31.4058 17.5503 9.2370 4.6185 3.2330 2.7356 2.3708 2.0919 1.8717 1.6935 1.5462 1.4225 1.3171 1.2263 1.1472 1.0777 1.0161 0.9611 0.9119 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Page 30 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 10 Dimming Performance Data TRIAC dimming results were taken at an input voltage of 230 VAC, 50 Hz line frequency, room temperature, and a nominal 66 V LED load. 10.1 Performance with Dimmers from China 120 Clipmei TCL 630 W 100 SEN BO LANG 300 W Output Current (mA) EBA HUANG SB ELECT 600 W 80 MYONGBO KBE 650 W MANK 200 W 60 40 20 0 0 20 40 60 80 100 120 Conduction Angle (˚) 140 160 Figure 18 – China Dimmers Dimming Curve. Page 31 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 180 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG CLIPMEI Minimum Conduction Angle (˚) 28.8 TCL 630 W 03-Nov-11 11.28 Maximum Conduction Angle (˚) 169.2 43.2 21 165.6 110.6 SEN BO LANG 300 W 61.2 35.2 166.5 110.6 EBA HUANG 18 1.2 166.5 110.6 SB ELECT 600 W 18 2.4 156.6 110.6 MYONGBO 57.6 34.5 169.2 110.6 KBE 650 W 14.4 0.87 165.6 110.6 MANK 200 W 68.4 41.7 167.4 110.6 Dimmer Minimum IOUT (mA) Maximum IOUT (mA) 110.6 Figure 19 – China Dimmers Minimum and Maximum Dimming Characteristic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 10.2 Performance with Dimmers from Germany 120 Output Current (mA) 100 Trailing Edge Type 80 60 BUSCH 2250 MERTEN 572499 40 BUSCH 6513 BERKER 2875 20 0 0 20 40 60 80 100 120 Conduction Angle (˚) 140 160 Figure 20 – German Dimmers Dimming Curve. BUSCH 2250 Minimum Conduction Angle (˚) 39.6 18.5 Maximum Conduction Angle (˚) 153 MERTEN 572499 39.6 14.57 160.2 110.6 BUSCH 6513 39.6 32 142.2 110.6 BERKER 2875 46.8 22.75 151.2 110.6 Dimmer Minimum IOUT (mA) Maximum IOUT (mA) 110.6 Figure 21 – German Dimmers Minimum and Maximum Dimming Characteristics. Page 33 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 180 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 10.3 Minimum Dimming Waveforms The following waveforms were taken with the dimmer at low dim position and with the LED Load still conducting. Input: 230 VAC, 50 Hz (Agilent 6812B AC Source) Load: 66 V LED Load Figure 22 – Dimmer: EBA HUANG. Conduction Angle: 18˚. IOUT: 1.2 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 400 A / div., 10 ms / div. Figure 23 – Dimmer: KBE 650 W. Conduction Angle: 18˚. IOUT: 2 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 2 mA / div., 5 ms / div. Figure 24 – Dimmer: MANK 200 W. Conduction Angle: 68.4˚. IOUT: 45 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 10 ms / div. Figure 25 – Dimmer: MYONGBO. Conduction Angle: 57.6˚. IOUT: 33 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Figure 26 – Dimmer: SB ELECT 600 W. Conduction Angle: 18˚. IOUT: 2 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 2 mA / div., 5 ms / div. Figure 27 – Dimmer: SEN BO LANG 300 W. Conduction Angle: 61.2˚. IOUT: 35 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 10 ms / div. Figure 28 – Dimmer: TCL 630 W. Conduction Angle: 28.8˚. IOUT: 21 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 10 mA / div., 10 ms / div. Figure 29 – Dimmer: BERKER 2875. Conduction Angle: 47˚. IOUT: 22 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 10 ms / div. Page 35 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Figure 30 – Dimmer: BUSCH 2250. Conduction Angle: 40˚. IOUT: 18 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 5 ms / div. 03-Nov-11 Figure 31 – Dimmer: BUSCH 6513. Conduction Angle: 39˚. IOUT: 31 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 20 mA / div., 10 ms / div. Figure 32 – Dimmer: MERTEN 572499. Conduction Angle: 40˚. IOUT: 14 mA. Upper: VIN, 50 V / div., IIN, 50 mA / div. Lower: IOUT, 10 mA / div., 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 11 Thermal Performance Images captured after running for >30 minutes at room temperature (25 °C), open frame for the conditions specified. 11.1 Non-Dimming VIN = 230 VAC, 50 Hz, 66 V LED Load Figure 33 – Top Side. Figure 34 – Bottom Side. 11.2 Dimming VIN = 230 VAC 50 Hz, 90˚ Conduction Angle, 66 V LED Load Figure 35 – Top Side. Page 37 of 52 Figure 36 – Bottom Side. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 11.3 Dimming VIN = 265 VAC 50 Hz, 90˚ Conduction Angle, 66 V LED Load Figure 37 – Top Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 38 – Bottom Side. Page 38 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 12 Waveforms 12.1 Input Line Voltage and Current without Dimmer Figure 39 – 176 VAC, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 40 – 220 VAC, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 41 – 230 VAC, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 42 – 265 VAC, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Page 39 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 12.2 Input Line Voltage and Current During Dimming 12.2.1 Dimmer: CLIPMEI-CHINA Figure 43 – 230 VAC, 50 Hz 169.2˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 20 mA, 5 ms / div. Figure 44 – 230 VAC, 50 Hz 135˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 20 mA, 5 ms / div. Figure 45 – 230 VAC, 50 Hz 90˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 20 mA, 5 ms / div. Figure 46 – 230 VAC, 50 Hz 28.8˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 20 mA, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 12.3 Output Current at Normal Operation Figure 47 – 176 VAC, Full Load. IOUT, 20 mA / div. Figure 48 – 220 VAC, Full Load. IOUT, 20 mA / div. Figure 49 – 230 VAC, Full Load. IOUT, 20 mA / div. Figure 50 – 265 VAC, Full Load. IOUT, 20 mA / div. Page 41 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 12.4 Output Current During Dimming Operation 12.4.1 Dimmer: CLIPMEI-CHINA Figure 51 – 230 VAC, 50 Hz 90 ˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 20 mA, 5 ms / div. Figure 52 – 230 VAC, 50 Hz 72˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 10 mA, 5 ms / div. Figure 53 – 230 VAC, 50 Hz 60˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 10 mA, 5 ms / div. Figure 54 – 230 VAC, 50 Hz 52.2˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 10 mA, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 42 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Figure 55 – 230 VAC, 50 Hz 43.2˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 10 mA, 5 ms / div. Figure 56 – 230 VAC, 50 Hz 28.8˚ Conduction Angle. Upper: VIN, 100 V / div. Lower: IIN, 10 mA, 5 ms / div. 12.5 Drain Voltage and Current at Normal Operation Figure 57 – 176 VAC, 50 Hz. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V, 5 ms / div. Page 43 of 52 Figure 58 – 176 VAC, 50 Hz. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V / div., 10 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG Figure 59 – 265 VAC, 50 Hz. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 03-Nov-11 Figure 60 – 265 VAC, 50 Hz. Upper: IDRAIN, 0.1 A / div. Lower: VDRAIN, 100 V / div., 10 s / div. Page 44 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 12.6 Start-Up Drain Voltage and Current Figure 61 – 176 VAC, 50 Hz. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 62 – 265 VAC, 50 Hz. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. 12.7 Output Diode PIV Figure 63 – 265 VAC, 50 Hz Normal Operation. PIV: 200 V, 5 ms / div. Page 45 of 52 Figure 64 – 265 VAC, 50 Hz Start-up. PIV: 200 V, 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 12.8 Output Current/Voltage Rise and Fall Figure 65 – 176 VAC Output Rise. Upper: IOUT, 20 mA / div. Lower: VOUT, 10 V, 500 ms / div. Figure 66 – 176 VAC Output Fall. Upper: IOUT, 20 mA / div. Lower: VOUT, 10 V, 500 ms / div. Figure 67 – 265 VAC Output Rise. Upper: IOUT, 20 mA / div. Lower: VOUT, 10 V, 500 ms / div. Figure 68 – 265 VAC Output Fall. Upper: IOUT, 20 mA / div. Lower: VOUT, 10 V, 500 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 46 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 12.9 Output Current and Drain Voltage During Output Short Condition Figure 69 – 230 VAC, 50 Hz Output Short Condition. Upper: IOUT, 200 mA / div. Lower: VDRAIN, 100 V, 1 s / div. Figure 70 – 265 VAC, 50 Hz Output Short Condition. Upper: IOUT, 200 mA / div. Lower: VDRAIN, 100 V, 1 s / div. 12.10 Open Load Output Voltage Figure 71 – 176 VAC, 50 Hz Open Load Characteristic. Upper: VOUT, 10 V / div., 1 s / div. Lower: VDRAIN, 100 V / div., 1 s / div. Page 47 of 52 Figure 72 – 265 VAC, 50 Hz Open Load Characteristic. Upper : VOUT, 10 V / div., 1 s / div. Lower: VDRAIN, 100 V / div., 1 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 13 Conducted EMI 13.1 Test Set-up The unit was tested using LED load (~66 V VOUT) with input voltage of 230 VAC, 60 Hz at room temperature. Figure 73 – EMI Test Set-up with the Unit and LED Load Placed Inside the Cone. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 48 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 13.2 Test Result Power Integrations 31.Aug 11 11:13 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 74 – Conducted EMI, 66 V LED Load, 230 VAC, 60 Hz, and EN55015 B Limits. Page 49 of 52 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-11 14 Line Surge The unit was subjected to ±2500 V 100 kHz ring wave and ±500 V Differential Surge at 230 VAC using 10 strikes at each condition. A test failure was defined as a nonrecoverable interruption of output requiring supply repair or recycling of input voltage. Level (V) Input Voltage (VAC) Injection Location Injection Phase (°) +2500 230 L1, L2 0 -2500 230 L1, L2 0 +2500 230 L1, L2 90 -2500 230 L1, L2 90 Level (V) +500 -500 +500 -500 Input Voltage (VAC) 230 230 230 230 Injection Location L1, L2 L1, L2 L1, L2 L1, L2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Injection Phase (°) 0 0 90 90 Type 100 kHz Ring Wave (200 A) 100 kHz Ring Wave (200 A) 100 kHz Ring Wave (200 A) 100 kHz Ring Wave (200 A) Test Result (Pass/Fail) Pass Pass Pass Pass Type Test Result (Pass/Fail) Surge (2) Surge (2) Surge (2) Surge (2) Pass Pass Pass Pass Page 50 of 52 03-Nov-11 DER-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 15 Revision History Date 03-Nov-11 Page 51 of 52 Author CA 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-296 7.4 W Tight CC Dimmable A19 LED Driver Using LNK403EG 03-Nov-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. 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 2011 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 Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 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. 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Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 Page 52 of 52