Title Reference Design Report for a 150 W Power

Title
Reference Design Report for a 150 W Power
Factor Corrected LLC Power Supply for LED
Street Lighting
Specification
90 VAC – 265 VAC Input;
150 W (48 V at 0 - 3.125 A) Output
Application
LED Streetlight
Author
Applications Engineering Department
Document
Number
RDR-292
Date
November 19, 2013
Revision
6.1
Summary and Features
 Integrated PFC stage using
 PFS708EG from HiperPFS family of ICs
 LQA05TC600 ultrafast soft recovery QSpeed diode
 Integrated LLC stage using
 LCS702HG from HiperLCS family of ICs
 Simple snubberless bias supply using
 LNK302DG from LinkSwitch-TN family of ICs
 CAPZero (CAP002DG) IC used to discharge X capacitors for higher efficiency compared to
resistive solution
 High frequency (250 kHz) LLC for small transformer size
 >95% full load PFC efficiency at 115 VAC
 >95% full load LLC efficiency
 System efficiency 91% / 93% at 115 VAC / 230 VAC
PATENTINFORMATION
Theproductsandapplicationsillustratedherein(includingtransformerconstructionandcircuitsexternaltotheproducts)maybe
coveredbyoneormoreU.S.andforeignpatents,orpotentiallybypendingU.S.andforeignpatentapplicationsassignedtoPower
Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its
customersalicenseundercertainpatentrightsassetforthat<http://www.powerint.com/ip.htm>.
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RDR-292, 150 W Street Light Power Supply
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Table of Contents
1 2 3 4 Introduction ................................................................................................................. 5 Power Supply Specification ........................................................................................ 7 Schematic ................................................................................................................... 8 Circuit Description ...................................................................................................... 9 4.1 Input Filter / Boost Converter / Bias Supply ......................................................... 9 4.1.1 EMI Filtering ................................................................................................. 9 4.1.2 Inrush limiting ............................................................................................... 9 4.1.3 Main PFC Stage ........................................................................................... 9 4.1.4 Primary Bias Supply / Start-up ................................................................... 10 4.2 LLC Converter ................................................................................................... 10 4.3 Primary .............................................................................................................. 10 4.4 Output Rectification ........................................................................................... 12 4.5 Secondary EMI Components............................................................................. 13 5 PCB Layout .............................................................................................................. 14 6 Bill of Materials ......................................................................................................... 16 7 Heat Sink Assemblies ............................................................................................... 19 7.1 Diode Heat Sink Assembly ................................................................................ 19 7.1.1 Diode Heat Sink Drawing ........................................................................... 19 7.1.2 Diode Heat Sink Fabrication Drawing......................................................... 20 7.1.3 Diode and Heat Sink Assembly Drawing .................................................... 21 7.2 Primary Heat Sink Assembly ............................................................................. 22 7.2.1 Primary Heat Sink Drawing ........................................................................ 22 7.2.2 Primary Heat Sink Fabrication Drawing...................................................... 23 7.2.3 Primary and Heat Sink Assembly Drawing ................................................. 24 8 Magnetics ................................................................................................................. 25 8.1 PFC Choke (L2) Specification ........................................................................... 25 8.1.1 Electrical Diagram ...................................................................................... 25 8.1.2 Electrical Specifications.............................................................................. 25 8.1.3 Materials..................................................................................................... 25 8.1.4 Winding Instructions ................................................................................... 26 8.2 LLC Transformer (T2) Specification .................................................................. 30 8.2.1 Electrical Diagram ...................................................................................... 30 8.2.2 Electrical Specification ............................................................................... 30 8.2.3 Materials..................................................................................................... 30 8.2.4 Build Diagram ............................................................................................. 31 8.2.5 Winding Instructions ................................................................................... 31 8.2.6 Winding Illustrations ....................................................................................... 32 8.3 Bias Transformer (T1) Specification .................................................................. 36 8.3.1 Electrical Diagram ...................................................................................... 36 8.3.2 Electrical Specifications.............................................................................. 36 8.3.3 Materials List .............................................................................................. 36 8.3.4 Transformer Build Diagram ........................................................................ 37 8.3.5 Transformer Build Instructions ................................................................... 37 8.3.6 Transformer Build Illustrations .................................................................... 38 Power Integrations
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RDR-292, 150 W Street Light Power Supply
8.4 Output Inductor (L3) Specification .....................................................................41 8.4.1 Electrical Diagram ......................................................................................41 8.4.2 Electrical Specifications ..............................................................................41 8.4.3 Material List ................................................................................................41 8.4.4 Construction Details ...................................................................................41 9 LLC Transformer Design Spreadsheet .....................................................................42 10 Bias Transformer Design Spreadsheet .................................................................49 11 Power Factor Controller Design Spreadsheet .......................................................53 12 Performance Data .................................................................................................57 12.1 LLC Stage Efficiency .........................................................................................57 12.2 Total Efficiency ..................................................................................................58 12.3 No-Load Power ..................................................................................................59 12.4 Power Factor .....................................................................................................60 12.5 THD ...................................................................................................................61 12.6 Output Regulation ..............................................................................................62 12.6.1 Output Line Regulation ...............................................................................62 12.6.2 Output Load Regulation ..............................................................................63 13 Input Current Harmonics vs. EN 61000-3-2 Class C Limits...................................64 14 Waveforms ............................................................................................................66 14.1 Input Voltage and Current..................................................................................66 14.2 LLC Primary Voltage and Current ......................................................................66 14.3 PFC Switch Voltage and Current - Normal Operation........................................67 14.4 AC Input Current and PFC Output Voltage during Start-up ...............................68 14.5 Bias Supply Drain Waveforms ...........................................................................68 14.6 LLC Start-up ......................................................................................................69 14.7 LLC Brownout ....................................................................................................69 14.8 LLC Output Short-Circuit ...................................................................................70 14.9 Output Ripple Measurements ............................................................................71 14.9.1 Ripple Measurement Technique .................................................................71 14.9.2 Full Load Output Ripple Results .................................................................72 14.9.3 No-Load Ripple Results ..............................................................................72 14.10 Output Load Step Response ..........................................................................73 14.10.1 100% to 0% Load Step ...........................................................................74 14.10.2 0% to 100% Load Step ...........................................................................75 14.10.3 Temperature Profiles ..............................................................................76 14.11 Thermal Results Summary .............................................................................77 14.11.1 Testing Conditions ..................................................................................77 14.11.2 90 VAC, 60 Hz, 150 W Output ................................................................77 14.11.3 115 VAC, 60 Hz, 150 W Output ..............................................................81 14.11.4 230 VAC, 150 W, Room Temperature ....................................................85 15 Conducted EMI .....................................................................................................88 15.1 EMI Set-up .........................................................................................................88 15.1.1 Power Supply Preparation for EMI Test .....................................................88 15.1.2 EMI Test Set-up..........................................................................................89 16 Gain-Phase Measurement ....................................................................................92 17 Input Surge Testing ...............................................................................................93 Page 3 of 97
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17.1 Surge Test Set-up ............................................................................................. 93 17.2 Differential Mode Surge, 1.2 / 50 sec .............................................................. 94 17.3 Common Mode Surge, 1.2 / 50 sec ................................................................. 95 18 Revision History .................................................................................................... 96 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.
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1
RDR-292, 150 W Street Light Power Supply
Introduction
This engineering report describes a 48 V, 150 W reference design power supply for
90 VAC - 265 VAC LED street lights which can also serve as a general purpose
evaluation board for the combination of a PFS power factor stage with an LCS output
stage using devices from the Power Integration’s HiperPFS and HiperLCS device
families.
The design is based on the PFS708EG IC and LQA05TC600 diode for the PFC front end,
with a LNK302DG utilized in a non-isolated flyback bias supply. An LCS702HG IC is used
for the LLC output stage.
Figure 1 – RD-292 Photograph, Top View.
Figure 2 – RD-292 Photograph, Bottom View.
The circuit shown in this report is optimized for >0.9 power factor, over an input voltage
range of 90 VAC - 230 VAC, at both 100% load and 50% load. If >0.9 power factor is not
Page 5 of 97
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RDR-292, 150 W Street Light Power Supply
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required at 50% load, the circuit can be cost reduced by downsizing common mode filter
L1 and PFC input capacitor C6. Contact Power Integrations for more details.
This power supply is designed to be mounted inside a grounded enclosure for streetlight
service, with the input AC safety ground connected to the chassis. EMI and line surge
tests should be performed with the supply screwed down to a ground plane with the input
AC safety ground connected to this plane. See set-up photographs in sections 14.1 and
16.1.
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RDR-292, 150 W Street Light Power Supply
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
Symbol
Min
Typ
VIN
fLINE
90
47
50/60
THD
Power Factor
PF
0.97
Output Voltage
VLG
45.6
Output Ripple
VRIPPLE(LG)
Max
Units
Comment
265
64
<10
<15
VAC
Hz
%
%
3 Wire input.
Full Load, 115 VAC
Full Load, 230 VAC
Full load, 230 VAC
Main Converter Output
Output Current
ILG
0.00
48
3.13
50.4
V
480
mV P-P
20 MHz bandwidth
3.13
A
Supply is protected under no-load
conditions
N/A
W
W
48 VDC ± 5%
Total Output Power
Continuous Output Power
Peak Output Power
Efficiency
POUT
POUT(PK)
Total system at Full Load
Main
150
91
93
%
Measured at 115 VAC, Full Load
Measured at 230 VAC, Full Load
Environmental
Conducted EMI
Meets CISPR22B / EN55022B
Safety
Surge
Differential
Common Mode
100 kHz Ring Wave
Harmonic Currents
Ambient Temperature
Page 7 of 97
Designed to meet IEC950 / UL1950 Class II
kV
kV
kV
2
4
4
1.2/50 s surge, IEC 1000-4-5,
Differential Mode: 2 
Common Mode: 12 
500 A short circuit current
EN 61000-3-2 Class C
TAMB
0
60
o
C
See thermal section for conditions
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3 Schematic
Figure 3 – Schematic RD-292 Streetlight Power Supply Application Circuit - Input Filter, PFC Power Stage,
and Bias Supply.
Figure 4 – Schematic of RD-292 Streetlight Power Supply Application Circuit, LLC Stage.
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RDR-292, 150 W Street Light Power Supply
4 Circuit Description
The circuit shown in Figures 3 and 4 utilizes the PFS708EG, the LQA05TC600, the
LCS702HG, the LNK302DG, and the CAP002DG (optional) devices from Power
Integrations in a 48 V, 150 W power factor corrected LLC power supply intended to
power an LED streetlight.
4.1
Input Filter / Boost Converter / Bias Supply
The schematic in Figure 3 shows the input EMI filter, PFC stage, and primary bias
supply/start-up circuit. The power factor corrector utilizes the PFS708EG PFC controller
with integrated power MOSFET and the LQA05TC600 low QRR, soft switching diode. The
bias supply is a non-isolated flyback using the LNK302DG. The CAP002DG discharges X
capacitors C1 and C2 only when the AC input voltage is not present, eliminating the static
power loss of resistors R1, R3, R50, and R51.
4.1.1 EMI Filtering
Capacitors C3 and C4 are used to control common mode noise. Inductor L1 controls EMI
at low and mid-band (~10 MHz) frequencies. Capacitors C1 and C2 together with
leakage reactance of inductor L1 provide differential mode EMI filtering. To meet safety
requirements resistors and to increase system efficiency, R1, R3 and R50-51 discharge
these capacitors via U6 only when AC is removed. If U6 is not used, resistor R2 (390 k,
1206) can be added for conventional resistive discharge (place is reserved for R2 on
PCB). The primary heat sink for U1, U3, D3 and BR1 is connected to primary return to
eliminate the heat sink as a source of radiated/capacitively coupled noise and EMI.
4.1.2 Inrush limiting
Thermistor RT1 provides inrush limiting. It is shorted by relay RL1 during normal
operation, gated by activation of the internal bias supply (see components Q1, R20-21),
increasing efficiency by approximately 1 - 1.5%. Capacitor C5 and resistor R15 are used
to provide a short pulse of higher current to close relay RL1, followed by a smaller
holding current determined by the value of R25. This reduces the power consumption of
the relay coil.
4.1.3 Main PFC Stage
Components C6, C10, L4, U1, and D3 form a boost power factor correction circuit.
Components Q3-4, D4, and R16 form a non-linear feedback sense circuit (R11-13, R1719, C11, and C16) to drive the U1 feedback pin. This configuration achieves extremely
fast transient response while simultaneously enabling a slow feedback loop to achieve
the low gain-bandwidth product for high power factor. A Qspeed ultrafast soft recovery
diode was selected for D3 as a lower cost alternative to a silicon carbide diode.
Capacitor C6 is used to filter the output of diode bridge BR1, and was chosen for
optimum power factor at 50% load. Components R7 and C12 filter the VCC supply for
U10. Diode D2 charges the PFC output capacitor (C10) when AC is first applied. This
routes the inrush current around the PFC inductor L4, preventing it from saturating and
causing stress to U1 when the PFC stage begins to operate. It also routes the bulk of the
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RDR-292, 150 W Street Light Power Supply
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inrush current away from PFC rectifier D3. Capacitor C9 and R9 are used to shrink the
high frequency loop around components U1, D3 and C10 to reduce EMI. A resistor in
series with C9 damps mid-band EMI peaks. The incoming AC is rectified by BR1 and
filtered by C6. Capacitor C6 was selected as a low-loss polypropylene type to provide the
high instantaneous current through L4 during U1 on-time.
4.1.4 Primary Bias Supply / Start-up
Components U2, T1, D5, C14-16, R22-R24, Q2, and VR1 comprise a simple low power
non-isolated flyback supply to provide auxiliary power. Transformer T1 is very small,
utilizing an EE10 core. Careful transformer design allows operation without a drain
snubber for U2. Components Q2, VR1 R22-24, and C16 comprise the voltage sense,
error amplifier, and feedback for U2. Capacitor C13 provides local high-voltage bypassing
for U2.
Transistor Q1 switches on relay RL1 when the primary bias supply reaches regulation,
shorting out thermistor RT1.
4.2
LLC Converter
The schematic in Figure 4 depicts a 24 V, 150 W LLC DC-DC converter implemented
using the LCS702HG.
4.3 Primary
Integrated circuit U3 incorporates the control circuitry, drivers and output MOSFETs
necessary for an LLC resonant half-bridge (HB) converter. The HB output of U3 drives
output transformer T2 via a blocking/resonating capacitor (C30). This capacitor was rated
for the operating ripple current and to withstand the high voltages present during fault
conditions.
Transformer T2 was designed for a leakage inductance of 50 H. This, along with
resonating capacitor C30, sets the primary series resonant frequency at ~286 kHz
according to the equation:
fR 
1
6.28 LL  CR
R is the series resonant frequency in Hertz, LL is the transformer leakage inductance in
Henries, and CR is the value of the resonating capacitor (C30) in Farads.
The transformer turns ratio was set by adjusting the primary turns such that the operating
frequency at nominal input voltage and full load is close to, but slightly less than, the
previously described resonant frequency.
An operating frequency of 250 kHz was found to be a good compromise between
transformer size, output filter capacitance (enabling ceramic capacitors), and efficiency.
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RDR-292, 150 W Street Light Power Supply
The number of secondary winding turns was chosen to provide a good compromise
between core and copper losses. AWG #44 Litz wire was used for the primary and AWG
#42 Litz wire, for the secondary, this combination providing high-efficiency at the
operating frequency (~250 kHz). The number of strands within each gauge of Litz wire
was chosen as a balance between winding fit and copper losses.
The core material selected was NC-2H (from Nicera). This material yielded acceptable
(low-loss) performance. However, selecting a material more suited for high-frequency
operation, such as PC95 (from TDK), would further reduce core loss and increase
efficiency.
Components D7, R35, and C28 comprise the bootstrap circuit to supply the internal highside driver of U1.
Components C25 and R34, provide filtering and bypassing of the +12 V input which is the
VCC supply for U3. Note: VCC voltage of >15 V may damage U3.
Voltage divider R26-29 sets the high-voltage turn-on, turn-off, and overvoltage thresholds
of U3. The voltage divider values are chosen to set the LLC turn-on point at 360 VDC and
the turn-off point at 285 VDC, with an input overvoltage turn-off point at 473 VDC.
Capacitor C29 is a high-frequency bypass capacitor for the +380 V input, connected with
short traces between the D and S1/S2 pins of U3.
Capacitor C31 forms a current divider with C30, and is used to sample a portion of the
primary current. Resistor R40 senses this current, and the resulting signal is filtered by
R39 and C27. Capacitor C31 should be rated for the peak voltage present during fault
conditions, and should use a stable, low-loss dielectric such as metalized film, SL
ceramic, or NPO/COG ceramic. The capacitor used in the RD-292 is a ceramic disc with
“SL” temperature characteristic, commonly used in the drivers for CCFL tubes. The
values chosen set the 1 cycle (fast) current limit at 5.5 A, and the 7-cycle (slow) current
limit at 3 A, according to the equation:
I CL 
0.5
 C 31 

  R 40
 C 30  C 31 
ICL is the 7-cycle current limit in Amperes, R40 is the current limit resistor in Ohms, and
C30 and C31 are the values of the resonating and current sampling capacitors in
nanofarads, respectively. For the one-cycle current limit, substitute 0.9 V for 0.5 V in the
above equation.
Resistor R39 is set to 220  the minimum recommended value. The value of C27 is set
to 1 nF to avoid nuisance tripping due to noise, but not so high as to substantially affect
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the current limit set values as calculated above. These components should be placed
close to the IS pin for maximum effectiveness. The IS pin can tolerate negative currents,
the current sense does not require a complicated rectification scheme.
The Thevenin equivalent combination of R33 and R38 sets the dead-time at 290 ns and
maximum operating frequency for U1 at 934 kHz. The FMAX input of U1 is filtered by C23.
The combination of R33 and R138 also selects burst mode “2” for U3. This sets the lower
and upper burst threshold frequencies at 366 kHz and 427 kHz, respectively.
The FEEDBACK pin has an approximate characteristic of 2.6 kHz per A into the
FEEDBACK pin. As the current into the FEEDBACK pin increases so does the operating
frequency of U3, reducing the output voltage. The series combination of R30 and R31
sets the minimum operating frequency for U3 to ~187 kHz. This value was set to be lower
than the frequency required for regulation a full load and minimum bulk capacitor voltage.
Resistor R30 is bypassed by C21 to provide output soft start during start-up by initially
allowing a higher current to flow into the FEEDBACK pin when the feedback loop is open.
This causes the switching frequency to start high and then decrease until the output
voltage reaches regulation. Resistor R31 is typically set at the same value as the
combination of R33 and R38 so that the initial frequency at soft-start is equal to the
maximum switching frequency as set by R33 and R38. If the value of R31 is less than
this, it will cause a delay before switching occurs when the input voltage is applied.
Optocoupler U4 drives the U3 FEEDBACK pin through R32 which limits the maximum
optocoupler current into the FEEDBACK pin. Capacitor C26 filters the FEEDBACK pin.
Resistor R36 loads the optocoupler output to force it to run at a relatively high quiescent
current, increasing its gain. Resistors R32 and R36 also improve large signal step
response and burst mode output ripple. Diode D8 isolates R36 from the FMAX/soft start
network.
4.4 Output Rectification
The output of transformer T1 is rectified and filtered by D9 and C34-35. These capacitors
are X5R dielectric, carefully chosen for output ripple current rating. Standard Z5U
capacitors will not work in this application. Output Rectifier D9 is a 150 V Schottky
rectifier chosen for high efficiency, Intertwining the transformer secondary halves (see
transformer construction details in section 8) reduces leakage inductance between the
two secondary halves, reducing the worst-case PIV and allowing use of a 150 V rated
Schottky diode with consequent higher efficiency. Additional output filtering is provided by
L3 and C37. Capacitor C37 also damps the LLC output impedance peak at ~30 kHz
caused by the LLC “virtual” output series R-L and ceramic output capacitors C34 and
C35. It also improves the response to fast, high amplitude load steps. Resistors R48-49
force equal voltage across C34 and C35 by swamping out the effects of any internal or
external leakage currents.
Resistors R46 and R47, along with the U5 reference voltage, set the output voltage of the
supply. Error amplifier U5 drives the feedback optocoupler U4 via R41. Zener diode VR2
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RDR-292, 150 W Street Light Power Supply
clamps the voltage across U5 to a value below its maximum 35 V rating. Components
C20, C36, and C41, R37, R42, R45, and R41 determine the gain-phase characteristics of
the supply. These values were chosen to provide stable operation at nominal and
extreme load/input voltage combinations. Resistor R43 allows the minimum required
operating current to flow in U5 when no current flow occurs in the LED of optocoupler U4.
Components C40, R44 and D10-11 are a soft finish network used to eliminate output
overshoot at turn-on.
4.5
Secondary EMI Components
Capacitor C42 is a Y1 capacitor that provides common mode filtering for frequencies up
to ~15 MHz.Capacitors C32 and C33 couple a small amount of signal from the output of
T1 into the secondary side of C42 to provide partial neutralization of the fundamental and
harmonic frequencies of the LLC converter. This allows use of a smaller, less
complicated EMI filter. Capacitors C30 and C39 are connected from the +48 V output and
return to chassis ground through an aluminum standoff which would be fixed to the
streetlight enclosure in the end application. These capacitors suppress common mode
mid-to-high frequencies.
Page 13 of 97
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5 PCB Layout
Figure 5 – Printed Circuit Layout, Top Side.
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RDR-292, 150 W Street Light Power Supply
Figure 6 – Printed Circuit Layout, Bottom Side.
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6 Bill of Materials
Item
Qty
Ref Des
1
1
BR1
2
2
C1 C2
3
3
C3 C4 C42
Description
600 V, 8 A, Bridge Rectifier, GBJ
Package
220 nF, 275 VAC, Film, X2
1 nF, Ceramic, Y1
Mfg Part Number
Mfg
GBJ806-F
Diodes, Inc.
ECQ-U2A224ML
Panasonic
440LD10-R
Vishay
EKMG160ELL101ME11D
Nippon Chemi-Con
ECW-F4105JL
Panasonic
4
1
5
1
C6
100 F, 16 V, Electrolytic, Gen.
Purpose, (5 x 11)
1 F, 400 V, Polypropylene Film
6
2
C7 C16
10 nF, 50 V, Ceramic, X7R, 0805
C0805C103K5RACTU
Kemet
7
1
C8
100 nF, 50 V, Ceramic, X7R, 0805
CC0805KRX7R9BB104
Yageo
C5
8
1
C9
10 nF, 1000 V, Disc Ceramic
9
1
C10
120 F, 450 V, Electrolytic, (22 x 430)
100 nF, 200 V, Ceramic, X7R, 1206
S103K75Y5PN83K0R
Vishay
EET-ED2W121BA
Panasonic
10
1
C11
11
3
C12 C24 C25
12
1
C13
4.7 nF, 1 kV, Thru Hole, Disc Ceramic
562R5GAD47
Vishay
13
1
C14
GRM188R61C105KA93D
Murata
14
1
C15
ELXZ250ELL151MF15D
Nippon Chemi-Con
15
1
C17
1 F, 16 V, Ceramic, X5R, 0603
150 F, 25 V, Electrolytic, Low ESR,
180 m, (6.3 x 15)
4.7 F, 25 V, Ceramic, X7R, 1206
ECJ-3YB1E475M
Panasonic
16
1
C18
470 pF, 100 V, Ceramic, X7R, 0805
08051C471KAT2A
AVX
17
1
C20
33 nF, 50 V, Ceramic, X7R, 0805
ECJ-2VB1H333K
Panasonic
18
2
C21 C28
330 nF, 50 V, Ceramic, X7R, 1206
12065C334KAT2A
AVX
19
2
C22 C40
22 nF, 200 V, Ceramic, X7R, 0805
08052C223KAT2A
AVX
20
2
C23 C26
4.7 nF, 200 V, Ceramic, X7R, 0805
08052C472KAT2A
AVX
21
1
C27
1 nF, 200 V, Ceramic, X7R, 0805
08052C102KAT2A
AVX
22
1
C29
22 nF, 630 V, Ceramic, X7R, 1210
GRM32QR72J223KW01L
Murata
23
1
C30
6.2 nF, 1600 V, Film
B32672L1622J000
Epcos
24
1
C31
47 pF, 1 kV, Disc Ceramic
DEA1X3A470JC1B
Murata
AVX
1 F, 25 V, Ceramic, X7R, 1206
C1206C104K2RACTU
Kemet
HMK316B7105KL-T
Taiyo Yuden
25
1
C32
33 pF, 1000 V, Ceramic, COG, 0805
0805AA330KAT1A
26
3
C33 C36 C41
2.2 nF, 200 V, Ceramic, X7R, 0805
08052C222KAT2A
AVX
27
2
C34 C35
GMK325BJ106KN-T
Taiyo Yuden
28
1
C37
EKZE630ELL121MJ16S
United Chemi-con
29
2
C38 C39
08052C103KAT2A
AVX
30
5
D1 D4 D8 D10 D11
LL4148-13
Diodes, Inc.
31
1
D2
10 F, 35 V, Ceramic, X5R, 1210
120 F, 63 V, Electrolytic, Gen.
Purpose, (10 x 16)
10 nF, 200 V, Ceramic, X7R, 0805
75 V, 0.15 A, Fast Switching, 4 ns,
MELF
1000 V, 3 A, Recitifier, DO-201AD
32
1
D3
33
1
D5
34
1
D6
35
1
D7
36
1
37
2
38
1
D9
ESIPCLIP M4 METAL1
ESIPCLIP M4 METAL2
F1
39
1
HS1
40
1
41
1
HS2
HSPREADER_ESIPPF
ISW1
1N5408-T
600 V, 5 A, TO-220AC
LQA05TC600
200 V, 1 A, Ultrafast Recovery, 50 ns,
UF4003-E3
DO-41
130 V, 5%, 250 mW, SOD-123
BAV116W-7-F
600 V, 1 A, Ultrafast Recovery, 75 ns,
UF4005-E3
DO-41
150 V, 20 A, Schottky, TO-220AB
DSSK 20-015A
Heat sink Hardware, Edge Clip, 20.76
NP975864
mm L x 8 mm W x 0.015 mm Thk
5 A, 250V, Slow, TR5
37215000411
Heat sink, RDK292-Diode, Alum 1.300
61-00071-01
H x 2.270 W x 0.062" Thk"
Heat sink, RDK292-eSIP,Alum 1.85 L x 2.840 W x 0.062" Thk"
Heat Spreader, Custom, Al, 3003,
61-00040-00
0.030 Thk"
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
Diodes, Inc.
Power Integrations
Vishay
Diodes, Inc.
Vishay
IXYS
Aavid Thermalloy
Wickman
Custom
Custom
Custom
Page 16 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
3 Position (1 x 3) header, 0.156 pitch,
Vertical
4 Position (1 x 4) header, 0.156 pitch,
Vertical
16 mH, 2 A, Common Mode Choke
Custom, 300 nH, ±15%, constructed
on Micrometals T30-26 toroidal core
Custom, 1.8 mH, constructed on VTM1050-10 base
Post, Circuit Board, Female, Hex, 632, snap, 0.375L, Nylon
Nut, Hex, Kep 4-40, S ZN Cr3 plateing
RoHS
NPN, Small Signal BJT, GP SS, 40 V,
0.6 A, SOT-23
PNP, Small Signal BJT, 40 V, 0.6 A,
SOT-23
390 k, 5%, 1/4 W, Thick Film, 1206
42
1
J1
43
1
J2
44
1
L1
45
1
L3
46
1
L4
47
4
48
5
49
2
Q1 Q3
50
2
Q2 Q4
51
4
R1 R3 R50 R51
52
3
R4 R5 R6
53
2
R7 R34
4.7 , 5%, 1/4 W, Thick Film, 1206
54
1
R8
55
1
R9
56
1
57
MTG1 MTG2 MTG3
MTG4
NUT1 NUT2 NUT3
NUT4 NUT5
B3P-VH
JST
26-48-1045
Molex
ELF-22V020C
Panasonic
SNX-R1621
Santronics USA
SNX-R1623
Santronics USA
561-0375A
Eagle Hardware
4CKNTZR
Any RoHS
Compliant Mfg.
MMBT4401LT1G
Diodes, Inc.
MMBT4403-7-F
Diodes, Inc.
ERJ-8GEYJ394V
Panasonic
CFR-25JB-1M3
Yageo
ERJ-8GEYJ4R7V
Panasonic
10 , 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ100V
Panasonic
1 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ1R0V
Panasonic
R11
1.60 M, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF1604V
Panasonic
1
R12
732 k, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF7323V
Panasonic
58
1
R13
1.50 M, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF1504V
Panasonic
59
1
R14
2 k, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ202V
Panasonic
60
1
R15
3 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ302V
Panasonic
61
1
R16
160 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ164V
Panasonic
62
1
R17
2.21 k, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF2211V
Panasonic
63
1
R18
57.6 k, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF5762V
Panasonic
64
1
R19
2.21 k, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF2211V
Panasonic
65
1
R20
22 k, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ223V
Panasonic
66
1
R21
2.2 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ222V
Panasonic
67
1
R22
15 k, 5%, 1/4 W, Carbon Film
68
1
R23
69
1
70
2
71
1
R26
72
2
73
1.3 M, 5%, 1/4 W, Carbon Film
CFR-25JB-15K
Yageo
100 , 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ101V
Panasonic
R24
1 k, 5%, 1/10 W, Thick Film, 0603
ERJ-3GEYJ102V
Panasonic
R25 R32
1 k, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ102V
Panasonic
976 k, 1%, 1/4 W, Metal Film
MFR-25FBF-976K
Yageo
R27 R28
976 k, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF9763V
Panasonic
1
R29
20 k, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF2002V
Panasonic
74
1
R30
36.5 k, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF3652V
Panasonic
75
1
R31
5.11 k, 1%, 1/4 W, Thick Film, 1206
ERJ-8ENF5111V
Panasonic
76
1
R33
5.9 k, 1%, 1/4 W, Metal Film
MFR-25FBF-5K90
Yageo
77
1
R35
2.2 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ2R2V
Panasonic
78
1
R36
4.7 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ472V
Panasonic
79
1
R37
1 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ102V
Panasonic
80
1
R38
52.3 k, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF5232V
Panasonic
81
1
R39
220 , 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ221V
Panasonic
82
1
R40
24 , 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ240V
Panasonic
83
1
R41
10 k, 5%, 1/4 W, Carbon Film
CFR-25JB-10K
Yageo
84
1
R42
2.2 k, 5%, 1/4 W, Carbon Film
CFR-25JB-2K2
Yageo
85
1
R43
680 , 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ681V
Panasonic
86
1
R44
10 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ103V
Panasonic
87
1
R45
22 k, 5%, 1/8 W, Thick Film, 0805
ERJ-6GEYJ223V
Panasonic
Page 17 of 97
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
88
1
R46
182 k, 1%, 1/4 W, Metal Film
MFR-25FBF-182K
Yageo
89
1
R47
10 k, 1%, 1/8 W, Thick Film, 0805
ERJ-6ENF1002V
Panasonic
90
2
R48 R49
1 M, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ105V
Panasonic
91
1
R52
33 k, 5%, 1/4 W, Thick Film, 1206
ERJ-8GEYJ333V
Panasonic
92
1
RL1
SPST-NO, 5 A 12 VDC, PC MNT
G6B-1114P-US-DC12
OMRON
93
1
NTC Thermistor, 5 Ohms, 4.7 A
CL-150
Thermometrics
94
5
Thermally conductive Silicone Grease
120-SA
Wakefield
95
1
V320LA20AP
Littlefuse
96
3
Screw Machine Phil 4-40 X 5/16 SS
PMSSS 440 0031 PH
Building Fasteners
97
2
RT1
RTV1 RTV2 RTV3
RTV4 RTV5
RV1
SCREW1 SCREW2
SCREW3
SCREW4 SCREW5
Screw Machine Phil 4-40 X 3/8 SS
PMSSS 440 0038 PH
Building Fasteners
98
2
SCREW6 SCREW7
Screw Machine Phil 4-40 X 1/4 SS
PMSSS 440 0025 PH
Building Fasteners
99
2
STDOFF1 STDOFF2
1892
Keystone
100
1
T1
SNX-R1619
Santronics USA
101
1
T2
SNX-R1620
Santronics USA
102
1
TO-220 PAD3
SPK10-0.006-00-90
Bergquist
103
1
TO-220 PAD1
K10-104
Bergquist
104
1
TP1
5012
Keystone
105
5
TP2 TP4 TP6 TP7 TP9
5011
Keystone
106
2
TP3 TP8
5010
Keystone
107
1
TP5
Standoff Hex, 4-40, 0.375 L
Custom Transformer, LinkSwitch,
EE10, Vertical, pins 3, 6 & 7 removed
Custom Transformer, LLC, 48V,
EEL25.4, Vertical
THERMAL PAD TO-118, TO-220, TO247, .006 K10"
HEATPAD TO-247 .006" K10
Test Point, WHT,THRU-HOLE
MOUNT
Test Point, BLK,THRU-HOLE MOUNT
Test Point, RED,THRU-HOLE
MOUNT
Test Point, YEL,THRU-HOLE MOUNT
5014
Keystone
108
1
U1
HiperPFS, eSIP7/6-TH
PFS708EG
Power Integrations
109
1
U2
LinkSwitch-TN, SO-8
LNK302DG
Power Integrations
110
1
U3
LCS702HG
Power Integrations
111
1
U4
LTV-817A
Liteon
112
1
U5
HiperLCS, Overmolded, ESIP16/13,
Optocoupler, 35 V, CTR 80-160%, 4DIP
IC, REG ZENER SHUNT ADJ SOT-23
113
1
U6
114
1
VR1
115
1
VR2
116
2
WASHER1 WASHER3
117
1
WASHER2
118
5
WASHER4 WASHER5
WASHER6 WASHER7
WASHER8
320 V, 80 J, 14 mm, RADIAL
CAPZero, SO-8C
12 V, 5%, 500 mW, DO-213AA
(MELF)
33 V, 5%, 500 mW, DO-35
Washer,Shoulder, #4, 0.095 Shoulder
x 0.117 Dia , Polyphenylene Sulfide
PPS
Washer Teflon #6, ID 0.156, OD
0.312, Thk 0.031
Washer FLAT #4 SS
Power Integrations
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LM431AIM3/NOPB
National Semic
CAP002DG
Power Integrations
ZMM5242B-7
Diodes, Inc.
1N5257B-T
Diodes, Inc.
7721-10PPSG
Aavid Thermalloy
FWF-6
See Distributor
FWSS 004
Building Fasteners
Page 18 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
7 Heat Sink Assemblies
7.1
Diode Heat Sink Assembly
7.1.1 Diode Heat Sink Drawing
Page 19 of 97
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
7.1.2 Diode Heat Sink Fabrication Drawing
Power Integrations
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Page 20 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
7.1.3 Diode and Heat Sink Assembly Drawing
Page 21 of 97
Power Integrations
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RDR-292, 150 W Street Light Power Supply
7.2
19-Nov-13
Primary Heat Sink Assembly
7.2.1 Primary Heat Sink Drawing
Power Integrations
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Page 22 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
7.2.2 Primary Heat Sink Fabrication Drawing
Page 23 of 97
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
7.2.3 Primary and Heat Sink Assembly Drawing
Note: The above heat sink drawing is designed for the overmolded version of the LCS IC.
A SIL pad must be substituted, instead of thermal grease (Item 13) if the exposed-pad
version of the LCS IC is used. The picture below identifies the two versions of the IC.
Overmolded LCS IC
Power Integrations
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Exposed Pad LCS IC
Page 24 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
8 Magnetics
8.1
PFC Choke (L2) Specification
8.1.1 Electrical Diagram
Figure 7 – Transformer Electrical Diagram.
8.1.2 Electrical Specifications
Inductance
Pins 1-5 measured at 100 kHz, 0.4 VRMS
1.8 mH, ±8%
8.1.3 Materials
Item
[1]
[2]
[3]
[4]
[5]
Description
Core: Chang Sung, Inc.: Sendust core: CS270090;
Alternate: Magnetics Inc., Mfg: 77934-A7.
Magnet wire: 22AWG insulated magnet wire. VTM1050-1D.
Base: Toroid mounting base, Lodestone Pacific, P/N VTM160-4, or similar. See Figure 2.
PI P/N: 76-00019-00.
High Temperature Epoxy, Mfg: MG Chemicals, P/N: 832HT-375ML, Digikey: 473-1085-ND, or
similar, PI P/N: 66-00087-00.
Divider: Tie-wrap, Panduit, P/N: PLT.7M-M or similar.
Page 25 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
Figure 8 – Top View of Toroid mounting Base Item [3].
8.1.4 Winding Instructions


Insert 2 dividers item [5] in the core item [1] to divide into 2 sections equally. See photo. Superglue
dividers in place if necessary to prevent slipping.
Take approximately 17ft of wire item [2]. Align center of wire with 1 divider. This location on the
inductor is your ‘top’ reference point.
Center of wire


Start winding on the left section with approximately 24 turns of wire item [2], for the 1st layer, wind
wire laminar fashion and ensure that turns do not overlap.
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Page 26 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply

Next, wind another 24 turns on the right hand side of the core.

Continue winding on the right hand side for the 2nd layer approximately 22 turns, spread wire
evenly and try to ensure that turns do not overlap.
Page 27 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13

Continue winding on the right section on the 3rd layer the remaining [approximately 17] turns,
distributing wire evenly and try to ensure that turns do not overlap.

Wind the same as above for the 2nd and 3rd layers on the left section. Inductor leads will finish at
the ‘bottom’ of the inductor after all turns are wound.
Power Integrations
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Page 28 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply

Invert toroid with ‘top’ side down for mounting.



Remove pins 2, 3, 4, and 8 on base (item [3]).
Place wound toroid into the mount with ‘top’ side down
Solder the leads to pins 1 and 5 of mounting base item [3].
Secure the ‘top’ side of the inductor to the base by using high temperature epoxy item [4].
Front view
Back view
Figure 9 – Front and Back Views of Finished PFC Inductor
Page 29 of 97
Power Integrations
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RDR-292, 150 W Street Light Power Supply
8.2
19-Nov-13
LLC Transformer (T2) Specification
8.2.1 Electrical Diagram
Figure 9 – PFC Electrical Diagram.
8.2.2 Electrical Specification
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage
Inductance
1 second, 60 Hz, from pins 1-6 to FL1, Fl2, FL3, FL4.
Pins 2-5, all other windings open, measured at 100 kHz,
0.4 VRMS
Pins 2-5, all other windings open
Pins 2-5, with FL1, FL2, FL3, FL4 shorted, measured at
100 kHz, 0.4 VRMS
3000 VAC
340 H, ±10%
1800 kHz (Min)
50 H ±5%
8.2.3 Materials
Item
[1]
[2]
[3]
[4]
[5]
[6]
[7]
Description
Core Pair: EEL25.4 Nippon Ceramic FEEL25.4-NC-2H, ungapped.
Bobbin: EEL25 Vertical, 3 chamber, 5 pins, PI P/N 25-00960-05.
Bobbin EEL25 Cover, PI P/N 25-00961-00.
Tape: Polyester Film, 3M 1350F-1 or equivalent, 7.0 mm wide.
Litz wire: 165/#42 Single Coated, Unserved.
Litz wire: 125/#44 Single Coated, Served.
Transformer Varnish: Dolph BC-359 or equivalent.
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Page 30 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
8.2.4 Build Diagram
Figure 10 – PFC Choke Build Diagram.
8.2.5 Winding Instructions
Secondary Wire
Preparation
WD1 (Primary)
WD2A & WD2B
(Secondary)
Bobbin Cover
WD 3
(Primary)
Finish
Page 31 of 97
Prepare 2 strands of wire item [5] 26” length, tin ends, and label one strand to
distinguish from other and designate it as FL1, FL2. Other strand will be
designated as FL3 and FL4. Twist these 2 strands together ~60 twists evenly
along length leaving 1” free at each end. See pictures below.
Place the bobbin item [2] on the mandrel with pin side on the left side.
Starting on pin 5, wind 24 turns of served Litz wire [6] in 5 layers, and finish on
pin 1. Secure winding with one turn of tape [4].
Using unserved Litz assembly prepared in step 1, start with FL1 and FL3
inserted into hole 1 and hole 4 of bobbin [2] bottom flange (see illustration).
Tightly wind 12 turns in bobbin center chamber. Finish with FL2 in hole 3 of
bobbin bottom flange, and FL4 in hole 1. Secure winding with one turn of tape
[4].
Slide bobbin cover [3] into grooves in bobbin flanges as shown, with closed end
of cover pointed to pin 1-5 side of bobbin see illustration. Make sure cover is
securely seated.
Start on pin 1 of bobbin [2], wind 25 turns of served Litz wire [6], finishing on pin
2. Secure and insulate winding start lead using tape [4] per illustration. Secure
winding with one turn of tape [4].
Grind core halves [1] for inductance of 270 H ±10%. Assemble and secure
core halves. Tin all secondary wires to ~ ¼” from bobbin holes per illustration,
and trim to ½”.
Dip varnish [7].
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
8.2.6 Winding Illustrations
FL1
FL2
FL3
Secondary Wire
Preparation
FL4
Make 2 strands of wire item
[5] 26” length, tin ends, label
one cable to distinguish
from other and designate it
as FL1, FL2. Other strand
will be designated as FL3
and FL4. Twist these 2
cables together ~60 twists
evenly along length leaving
1” free at each end. See
pictures below.
FL4
FL1
FL2
Video 1.wmv
FL3
WD1
(Primary)
Place the bobbin item [2] on
the mandrel with pin side on
the left side.
Starting on pin 5.
WD1
(Primary)
(Cont’d)
Wind 24 turns of served Litz
wire [6] in 5 layers, and
finish on pin 1. Secure
winding with one turn of
tape [4].
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Page 32 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
Hole 1
Hole 2
Hole 3
Hole 4
FL1
WD2A & WD2B
(Secondary)
Page 33 of 97
FL3
Using unserved Litz
assembly prepared in step
1, start with FL1 and FL3
inserted into hole 2 and hole
4 of bobbin [2] bottom flange
(see illustration). Tightly
wind 12 turns in bobbin
center chamber. Finish with
FL2 in hole 3 of bobbin
bottom flange, and FL4 in
hole 1. Secure winding with
one turn of tape [4].
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
FL4
FL1
FL3
FL2
Bobbin Cover
Slide bobbin cover [3] into
grooves in bobbin flanges
as shown, with closed end
of cover pointed to pin 1-5
side of bobbin, see
illustration. Make sure cover
is securely seated.
WD 3
(Primary)
Start on pin 1 of bobbin [2],
wind 25 turns of served Litz
wire [6] in 5 layers, finish on
pin 2.
Secure and insulate winding
start lead using tape [4] per
illustration. Secure winding
with one turn of tape [4].
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Page 34 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
Front
Grind core halves [1] for
inductance of 270 H ±10%.
Assemble and secure core
halves. Tin all secondary
wires to ~ ¼” from bobbin
holes per illustration, and
trim to ½”.
Dip varnish [7].
Finish
Back
Page 35 of 97
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RDR-292, 150 W Street Light Power Supply
8.3
19-Nov-13
Bias Transformer (T1) Specification
8.3.1 Electrical Diagram
1
WDG#3
76T
#38 AWG
2
WDG#1
80T
#38 AWG
4
8
WDG #2
26T
#32 AWG T.I.
5
Figure 11 – Transformer Electrical Diagram.
8.3.2 Electrical Specifications
Electrical Strength
Primary Inductance
Resonant Frequency
Primary Leakage Inductance
1 second, 60 Hz, from pins 1-4 to pins 5-8.
Pins 1-4, all other windings open, measured at
100 kHz, 0.4 VRMS.
Pins 1-4, all other windings open.
Pins 1-4, with pins 5-8 shorted, measured at 
100 kHz, 0.4 VRMS.
500 V
1880 H ±10%
1000 kHz (Min.)
20 H ±10%
8.3.3 Materials List
Item
[1]
[2]
[3]
[4]
[5]
[6]
Description
Core: EE10, TDK PC40 material or equivalent.
Gap for inductance coefficient (AL) of 77 nH/T².
Bobbin, EE10 vertical, 8 Pin. TDK BE10-118CPSFR, Taiwan Shulin TF-10, or equiv.
Tape, Polyester film, 3M 1350F-1 or equivalent, 7.1 mm wide.
Wire, Magnet #38 AWG, solderable double coated.
Wire, Triple Insulated, Furukawa TEX-E or equivalent, #32 AWG.
Transformer Varnish, Dolph BC-359 or equivalent.
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Page 36 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
8.3.4 Transformer Build Diagram
Tape
1
2
5
8
½ Primary
Secondary
2
4
½ Primary
Figure 12 – Bias Transformer Build Diagram.
8.3.5 Transformer Build Instructions
General Note
WD1 (1/2 Primary)
Tape
WD2 (Secondary)
Tape
WD3 (1/2 Primary)
Tape
Assembly
Page 37 of 97
For the purpose of these instructions, bobbin is oriented on winder such that pin
side is on the left side (see illustration). Winding direction as shown is counterclockwise.
Starting at pin 4, wind 80 turns of wire (Item [4]) in ~1 1/2 layers. Finish at pin 2.
Use 1 layer of tape (Item [3]) for insulation.
Starting at pin 8, wind 26 turns of triple insulated wire (Item [5]) in two layers.
Finish at pin 5.
Use 1 layer of tape (Item [3]) for insulation.
Starting at pin 2, wind 76 turns of wire (Item [4]) in ~ 1 1/2 layers. Finish at pin 1.
Use 3 layer of tape (Item [3]) for finish wrap.
Grind core halves for specified primary inductance, insert bobbin, and secure core
halves. Remove pin 3, 6, 7. Dip varnish [6].
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
8.3.6 Transformer Build Illustrations
Bobbin
Preparation
General
Note
For the purpose of
these instructions,
bobbin is oriented
on winder such that
pin side is on the
left side (see
illustration).
Winding direction
as shown is
counter-clockwise.
WD1
(1/2 Primary)
Starting at pin 4,
wind 80 turns of
wire (Item [4]) in ~1
1/2 layers. Finish at
pin 2.
Apply one layer of
tape (item [3]) for
insulation.
Tape
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Page 38 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
WD2
(Secondary)
Starting at pin 8,
wind 26 turns of
triple insulated wire
(Item [5]) in ~1 1/2
layers. Finish at pin
5.
Tape
Use 1 layer of tape
(Item [3]) for
insulation.
WD3
(1/2 Primary)
Tape
Page 39 of 97
Starting at pin 2,
wind 76 turns of
wire (Item [4]) in
two layers. Finish
at pin 1.
Use 3 layer of tape
(Item [3]) for finish
wrap.
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RDR-292, 150 W Street Light Power Supply
Assembly
19-Nov-13
Grind core halves
for specified
primary inductance,
insert bobbin, and
secure core halves.
Remove pin 3, 6, 7.
Dip varnish [6].
Finished
Transformer
Note that Pins 3, 6,
7 are removed.
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Page 40 of 97
19-Nov-13
8.4
RDR-292, 150 W Street Light Power Supply
Output Inductor (L3) Specification
8.4.1 Electrical Diagram
Figure 13 – Inductor Electrical Diagram.
8.4.2 Electrical Specifications
Pins FL1-FL2, all other windings open, measured at 100 kHz,
0.4 VRMS
Inductance
300 nH, ±15%
8.4.3 Material List
Item
[1]
[2]
Description
Powdered Iron Toroidal Core: Micrometals T30-26.
Magnet wire: #19 AWG Solderable Double Coated.
8.4.4 Construction Details
Figure 14 – Finished Part, Front View. Tin Leads to within ~1/8” of Toroid Body.
Page 41 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
9 LLC Transformer Design Spreadsheet
HiperLCS_120611;
Rev.1.2; Copyright
INPUTS
Power Integrations
2011
Enter Input Parameters
Vbulk_nom
380
OUTPUTS
UNITS
380
V
Vbrownout
280
V
Vbrownin
VOV_shut
VOV_restart
353
465
448
V
V
V
120
uF
25.5
ms
CBULK
120.00
tHOLDUP
INFO
Enter LLC (secondary) outputs
VO1
48.00
48.0
V
IO1
VD1
PO1
VO2
IO2
VD2
PO2
P_LLC
LCS Device Selection
Device
RDS-ON (MAX)
Coss
Cpri
Pcond_loss
Tmax-hs
3.13
0.70
3.1
0.70
150
0.0
0.0
0.70
0.00
150
A
V
W
V
A
V
W
W
Theta J-HS
Expected Junction
temperature
Ta max
LCS702
HiperLCS_120611_Rev1-2.xls; HiperLCS Half-Bridge,
Continuous mode LLC Resonant Converter Design
Spreadsheet
Nominal LLC input voltage
Brownout threshold voltage. HiperLCS will shut down if
voltage drops below this value. Allowable value is
between 65% and 76% of Vbulk_nom. Set to 65% for max
holdup time
Startup threshold on bulk capacitor
OV protection on bulk voltage
Restart voltage after OV protection.
Minimum value of bulk cap to meet holdup time
requirement; Adjust holdup time and Vbrownout to change
bulk cap value
Bulk capacitor hold up time
The spreadsheet assumes AC stacking of the
secondaries
Main Output Voltage. Spreadsheet assumes that this is the
regulated output
Main output maximum current
Forward voltage of diode in Main output
Output Power from first LLC output
Second Output Voltage
Second output current
Forward voltage of diode used in second output
Output Power from second LLC output
Specified LLC output power
LCS702
1.39
ohms
250
pF
40
pF
1.5
W
90
deg C
deg
9.1
C/W
LCS Device
RDS-ON (max) of selected device
Equivalent Coss of selected device
Stray Capacitance at transformer primary
Conduction loss at nominal line and full load
Maximum heatsink temperature
Thermal resistance junction to heatsink (with grease and
no insulator)
104
Expected Junction temperature
deg C
50
deg C
Expected max ambient temperature
deg
Theta HS-A
26
Required thermal resistance heatsink to ambient
C/W
LLC Resonant Parameter and Transformer Calculations (generates red curve)
Desired Input voltage at which power train operates at
Vres_target
395
V
resonance. If greater than Vbulk_nom, LLC operates below
resonance at VBULK.
Po
152
W
LLC output power including diode loss
Main Output voltage (includes diode drop) for calculating
Vo
48.70
V
Nsec and turns ratio
Desired switching frequency at Vbulk_nom. 66 kHz to 300
f_target
250
kHz
kHz, recommended 180-250 kHz
Parallel inductance. (Lpar = Lopen - Lres for integrated
Lpar
229
uH
transformer; Lpar = Lmag for non-integrated low-leakage
transformer)
Primary open circuit inductance for integrated transformer;
Lpri
280.00
280
uH
for low-leakage transformer it is sum of primary inductance
and series inductor. If left blank, auto-calculation shows
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19-Nov-13
Lres
RDR-292, 150 W Street Light Power Supply
51.00
Kratio
Cres
51.0
uH
4.5
6.20
Lsec
m
n_eq
6.2
nF
14.100
uH
94
%
4.03
Npri
49.0
49.0
Nsec
12.0
12.0
f_predicted
262
kHz
f_res
283
kHz
value necessary for slight loss of ZVS at ~80% of Vnom
Series inductance or primary leakage inductance of
integrated transformer; if left blank auto-calculation is for
K=4
Ratio of Lpar to Lres. Maintain value of K such that 2.1 < K
< 11. Preferred Lres is such that K<7.
Series resonant capacitor. Red background cells produce
red graph. If Lpar, Lres, Cres, and n_RATIO_red_graph
are left blank, they will be auto-calculated
Secondary side inductance of one phase of main output;
measure and enter value, or adjust value until f_predicted
matches what is measured ;
Leakage distribution factor (primary to secondary). >50%
signifies most of the leakage is in primary side. Gap
physically under secondary yields >50%, requiring fewer
primary turns.
Turns ratio of LLC equivalent circuit ideal transformer
Primary number of turns; if input is blank, default value is
auto-calculation so that f_predicted = f_target and m=50%
Secondary number of turns (each phase of Main output).
Default value is estimate to maintain BAC<=200 mT, using
selected core (below)
Expected frequency at nominal input voltage and full load;
Heavily influenced by n_eq and primary turns
Series resonant frequency (defined by series inductance
Lres and C)
Expected switching frequency at Vbrownout, full load. Set
HiperLCS minimum frequency to this value.
Parallel resonant frequency (defined by Lpar + Lres and C)
LLC full load gain inversion frequency. Operation below
this frequency results in operation in gain inversion region.
LLC full load gain inversion point input voltage
Expected value of input voltage at which LLC operates at
resonance.
f_brownout
187
kHz
f_par
121
kHz
f_inversion
166
kHz
Vinversion
240
V
Vres_expected
393
V
1.04
A
Primary winding RMS current at full load, Vbulk_nom and
f_predicted
2.4
A
Winding 1 (Lower secondary Voltage) RMS current
1.4
A
Lower Secondary Voltage Capacitor RMS current
0.0
A
Winding 2 (Higher secondary Voltage) RMS current
0.0
A
Higher Secondary Voltage Capacitor RMS current
102
V
Resonant capacitor AC RMS Voltage at full load and
nominal input voltage
RMS Currents and Voltages
IRMS_LLC_Primary
Winding 1 (Lower
secondary Voltage)
RMS current
Lower Secondary
Voltage Capacitor
RMS current
Winding 2 (Higher
secondary Voltage)
RMS current
Higher Secondary
Voltage Capacitor
RMS current
Cres_Vrms
Virtual Transformer Trial - (generates blue curve)
New primary turns
49.0
New secondary turns
12.0
New Lpri
280
uH
New Cres
6.2
nF
51.0
229
14.100
4.5
uH
uH
uH
New estimated Lres
New estimated Lpar
New estimated Lsec
New Kratio
Page 43 of 97
Trial transformer primary turns; default value is from
resonant section
Trial transformer secondary turns; default value is from
resonant section
Trial transformer open circuit inductance; default value is
from resonant section
Trial value of series capacitor (if left blank calculated value
chosen so f_res same as in main resonant section above
Trial transformer estimated Lres
Estimated value of Lpar for trial transformer
Estimated value of secondary leakage inductance
Ratio of Lpar to Lres for trial transformer
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RDR-292, 150 W Street Light Power Supply
New equivalent circuit
transformer turns ratio
V powertrain inversion
new
f_res_trial
f_predicted_trial
IRMS_LLC_Primary
Winding 1 (Lower
secondary Voltage)
RMS current
Lower Secondary
Voltage Capacitor
RMS current
Winding 2 (Higher
secondary Voltage)
RMS current
Higher Secondary
Voltage Capacitor
RMS current
4.03
19-Nov-13
Estimated effective transformer turns ratio
240
V
Input voltage at LLC full load gain inversion point
283
262
kHz
kHz
1.04
A
2.4
A
RMS current through Output 1 winding, assuming half
sinusoidal waveshape
1.4
A
Lower Secondary Voltage Capacitor RMS current
2.4
A
RMS current through Output 2 winding; Output 1 winding is
AC stacked on top of Output 2 winding
0.0
A
Higher Secondary Voltage Capacitor RMS current
New Series resonant frequency
New nominal operating frequency
Primary winding RMS current at full load and nominal input
voltage (Vbulk) and f_predicted_trial
Expected value of input voltage at which LLC operates at
resonance.
Transformer Core Calculations (Calculates From Resonant Parameter Section)
Transformer Core
Auto
EEL25
Transformer Core
Ae
0.40
cm^2
Enter transformer core cross-sectional area
Ve
3.01
cm^3
Enter the volume of core
Aw
107.9
mm^2
Area of window
Bw
22.0
mm
Total Width of Bobbin
mW/cm
Enter the loss per unit volume at the switching frequency
Loss density
200.0
^3
and BAC (Units same as kW/m^3)
MLT
3.1
cm
Mean length per turn
Nchambers
2
Number of Bobbin chambers
Winding separator distance (will result in loss of winding
Wsep
3.0
mm
area)
Ploss
0.6
W
Estimated core loss
Bpkfmin
134
mT
First Quadrant peak flux density at minimum frequency.
AC peak to peak flux density (calculated at f_predicted,
BAC
192
mT
Vbulk at full load)
Primary Winding
Number of primary turns; determined in LLC resonant
Npri
49.0
section
Primary gauge
44
AWG
Individual wire strand gauge used for primary winding
Equivalent Primary
0.050
mm
Equivalent diameter of wire in metric units
Metric Wire gauge
Number of strands in Litz wire; for non-litz primary winding,
Primary litz strands
125
125
set to 1
Primary Winding
Primary window allocation factor - percentage of winding
50
%
Allocation Factor
space allocated to primary
AW_P
47
mm^2
Winding window area for primary
Fill Factor
43%
%
% Fill factor for primary winding (typical max fill is 60%)
Resistivity_25
m75.42
Resistivity in milli-ohms per meter
C_Primary
ohm/m
Primary DCR 25 C
114.42
m-ohm
Estimated resistance at 25 C
Estimated resistance at 100 C (approximately 33% higher
Primary DCR 100 C
153.32
m-ohm
than at 25 C)
Primary RMS current
1.04
A
Measured RMS current through the primary winding
Measured AC resistance (at 100 kHz, room temperature),
ACR_Trf_Primary
245.31
m-ohm
multiply by 1.33 to approximate 100 C winding temperature
Primary copper loss
0.27
W
Total primary winding copper loss at 85 C
Secondary Winding 1 (Lower secondary voltage OR Single
Note - Power loss calculations are for each winding
output)
half of secondary
Output Voltage
48.00
V
Output Voltage (assumes AC stacked windings)
Vres_expected_trial
393
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V
Page 44 of 97
19-Nov-13
Sec 1 Turns
Sec 1 RMS current
(total, AC+DC)
Winding current (DC
component)
Winding current (AC
RMS component)
Sec 1 Wire gauge
Equivalent secondary
1 Metric Wire gauge
Sec 1 litz strands
RDR-292, 150 W Street Light Power Supply
12.00
42
165
Secondary winding turns (each phase )
RMS current through Output 1 winding, assuming half
sinusoidal waveshape
2.4
A
1.56
A
DC component of winding current
1.85
A
AC component of winding current
42
AWG
0.060
mm
Individual wire strand gauge used for secondary winding
Equivalent diameter of wire in metric units
Number of strands used in Litz wire; for non-litz nonintegrated transformer set to 1
165
Resistivity_25 C_sec1
35.93
DCR_25C_Sec1
13.35
mohm/m
m-ohm
DCR_100C_Sec1
17.89
m-ohm
DCR_Ploss_Sec1
0.35
W
ACR_Sec1
28.62
m-ohm
ACR_Ploss_Sec1
Total winding 1
Copper Losses
Capacitor RMS
current
Co1
Capacitor ripple
voltage
Output rectifier RMS
Current
0.20
W
0.55
W
1.4
A
Output capacitor RMS current
1.3
uF
3.0
%
2.4
A
Secondary 1 output capacitor
Peak to Peak ripple voltage on secondary 1 output
capacitor
Schottky losses are a stronger function of load DC current.
Sync Rectifier losses are a function of RMS current
Note - Power loss calculations are for each winding
half of secondary
Output Voltage (assumes AC stacked windings)
Secondary winding turns (each phase) AC stacked on top
of secondary winding 1
RMS current through Output 2 winding; Output 1 winding is
AC stacked on top of Output 2 winding
Secondary Winding 2 (Higher secondary voltage)
Output Voltage
0.00
Sec 2 Turns
0.00
Sec 2 RMS current
(total, AC+DC)
Winding current (DC
component)
Winding current (AC
RMS component)
Sec 2 Wire gauge
Equivalent secondary
2 Metric Wire gauge
Sec 2 litz strands
Resistivity_25 C_sec2
V
Estimated resistance per phase at 25 C (for reference)
Estimated resistance per phase at 100 C (approximately
33% higher than at 25 C)
Estimated Power loss due to DC resistance (both
secondary phases)
Measured AC resistance per phase (at 100 kHz, room
temperature), multiply by 1.33 to approximate 100 C
winding temperature. Default value of ACR is twice the
DCR value at 100 C
Estimated AC copper loss (both secondary phases)
Total (AC + DC) winding copper loss for both secondary
phases
2.4
A
0.0
A
DC component of winding current
0.0
A
AC component of winding current
42
AWG
0.060
mm
Individual wire strand gauge used for secondary winding
Equivalent diameter of wire in metric units
Number of strands used in Litz wire; for non-litz nonintegrated transformer set to 1
0
59292.53
mohm/m
Transformer
Secondary MLT
DCR_25C_Sec2
3.10
cm
0.00
m-ohm
DCR_100C_Sec2
0.00
m-ohm
DCR_Ploss_Sec1
0.00
W
ACR_Sec2
0.00
m-ohm
ACR_Ploss_Sec2
Total winding 2
0.00
0.00
W
W
Page 45 of 97
Resistivity in milli-ohms per meter
Resistivity in milli-ohms per meter
Mean length per turn
Estimated resistance per phase at 25 C (for reference)
Estimated resistance per phase at 100 C (approximately
33% higher than at 25 C)
Estimated Power loss due to DC resistance (both
secondary halves)
Measured AC resistance per phase (at 100 kHz, room
temperature), multiply by 1.33 to approximate 100 C
winding temperature. Default value of ACR is twice the
DCR value at 100 C
Estimated AC copper loss (both secondary halves)
Total (AC + DC) winding copper loss for both secondary
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RDR-292, 150 W Street Light Power Supply
Copper Losses
Capacitor RMS
current
Co2
Capacitor ripple
voltage
Output rectifier RMS
Current
Transformer Loss
Calculations
Primary copper loss
(from Primary section)
Secondary copper
Loss
Transformer total
copper loss
AW_S
Secondary Fill Factor
19-Nov-13
halves
0.0
A
Output capacitor RMS current
N/A
uF
N/A
%
0.0
A
Secondary 2 output capacitor
Peak to Peak ripple voltage on secondary 1 output
capacitor
Schottky losses are a stronger function of load DC current.
Sync Rectifier losses are a function of RMS current
Does not include fringing flux loss from gap
0.27
W
Total primary winding copper loss at 85 C
0.55
W
Total copper loss in secondary winding
0.81
W
Total copper loss in transformer (primary + secondary)
46.59
mm^2
40%
%
187
kHz
ns
Area of window for secondary winding
% Fill factor for secondary windings; typical max fill is 60%
for served and 75% for unserved Litz
Signal Pins Resistor Values
f_min
Dead Time
290
290
Burst Mode
Auto
2
Minimum frequency when optocoupler is cut-off. Only
change this variable based on actual bench measurements
Dead time
Select Burst Mode: 1, 2, and 3 have hysteresis and have
different frequency thresholds
Max internal clock frequency, dependent on dead-time
setting. Is also start-up frequency
Lower threshold frequency of burst mode, provides
hysteresis. This is switching frequency at restart after a
bursting off-period
Upper threshold frequency of burst mode; This is switching
frequency at which a bursting off-period stops
f_max
934
kHz
f_burst_start
366
kHz
f_burst_stop
427
kHz
5.84
k-ohms
Resistor from DT/BF pin to VREF pin
53
k-ohms
Resistor from DT/BF pin to G pin
Rstart
5.09
k-ohms
Start up delay
0.0
ms
Rfmin
36.8
k-ohms
0.22
uF
DT/BF pin upper
divider resistor
DT/BF pin lower
divider resistor
C_softstart
0.22
Ropto
1.0
OV/UV pin lower
20.00
20.0
resistor
OV/UV pin upper
2.92
resistor
LLC Capacitive Divider Current Sense Circuit
k-ohms
Start-up resistor - resistor in series with soft-start capacitor;
equivalent resistance from FB to VREF pins at startup. Use
default value unless additional start-up delay is desired.
Start-up delay; delay before switching begins. Reduce
R_START to increase delay
Resistor from VREF pin to FB pin, to set min operating
frequency; This resistor plus Rstart determine f_MIN.
Includes 7% HiperLCS frequency tolerance to ensure
f_min is below f_brownout
Soft start capacitor. Recommended values are between
0.1 uF and 0.47 uF
Resistor in series with opto emitter
k-ohm
Lower resistor in OV/UV pin divider
M-ohm
Total upper resistance in OV/UV pin divider
Slow current limit
2.92
A
Fast current limit
5.26
A
LLC sense capacitor
47
pF
RLLC sense resistor
22.8
ohms
220
ohms
1.0
nF
IS pin current limit
resistor
IS pin noise filter
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8-cycle current limit - check positive half-cycles during
brownout and startup
1-cycle current limit - check positive half-cycles during
startup
HV sense capacitor, forms current divider with main
resonant capacitor
LLC current sense resistor, senses current in sense
capacitor
Limits current from sense resistor into IS pin when voltage
on sense R is < -0.5V
IS pin bypass capacitor; forms a pole with IS pin current
Page 46 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
capacitor
IS pin noise filter pole
frequency
Loss Budget
LCS device
Conduction loss
Output diode Loss
Transformer
estimated total copper
loss
Transformer
estimated total core
loss
Total transformer
losses
Total estimated losses
Estimated Efficiency
PIN
limit capacitor
724
kHz
1.5
W
Conduction loss at nominal line and full load
2.2
W
Estimated diode losses
0.81
W
Total copper loss in transformer (primary + secondary)
0.6
W
Estimated core loss
1.4
W
Total transformer losses
5.1
97%
155
W
%
W
Total losses in LLC stage
Estimated efficiency
LLC input power
This is to help you choose the secondary turns Outputs not connected to any other part of
spreadsheet
Target regulated output voltage Vo1. Change to see effect
on slave output
Diode drop voltage for Vo1
Total number of turns for Vo1
Expected output
Target output voltage Vo2
Diode drop voltage for Vo2
Total number of turns for Vo2
Expected output voltage
Not applicable if using integrated magnetics - not
connected to any other part of spreadsheet
Desired inductance of separate inductor
Inductor core cross-sectional area
Number of primary turns
AC flux for core loss calculations (at f_predicted and full
load)
Secondary Turns and Voltage Centering Calculator
V1
48.00
V
V1d1
0.70
V
N1
12.00
V1_Actaul
48.00
V
V2
0.00
V
V2d2
0.70
V
N2
0.00
V2_Actual
-0.70
V
Separate Series Inductor (For Non-Integrated Transformer
Only)
Lsep
51.00
uH
Ae_Ind
0.53
cm^2
Inductor turns
10
BP_fnom
Expected peak
primary current
BP_fmin
Inductor Litz gauge
Equivalent Inductor
Metric Wire gauge
Inductor litz strands
Inductor parallel wires
Resistivity_25
C_Sep_Ind
Inductor MLT
Inductor DCR 25 C
152
mT
2.9
A
284
44
mT
AWG
0.050
mm
125.00
1
7.00
52.8
Inductor DCR 100 C
70.7
m-ohm
ACR_Sep_Inductor
113.2
m-ohm
Inductor copper loss
Feedback section
VMAIN
ITL431_BIAS
0.12
W
48.0
1.0
mA
VF_MIN
1.1
V
VCE_SAT
0.3
V
Page 47 of 97
Auto
Expected peak primary current
Peak flux density, calculated at minimum frequency fmin
Individual wire strand gauge used for primary winding
Equivalent diameter of wire in metric units
Number of strands used in Litz wire
Number of parallel individual wires to make up Litz wire
mohm/m
cm
m-ohm
75.4
This pole attenuates IS pin signal
Resistivity in milli-ohms per meter
Mean length per turn
Estimated resistance at 25 C (for reference)
Estimated resistance at 100 C (approximately 33% higher
than at 25 C)
Measured AC resistance (at 100 kHz, room temperature),
multiply by 1.33 to approximate 100 C winding temperature
Total primary winding copper loss at 85 C
Output voltage rail that optocoupler LED is connected to
Minimum operating current in TL431 cathode
Maximum Optocoupler LED forward voltage at
IOPTO_BJTMAX (max current)
Optocoupler transistor saturation voltage
Power Integrations
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RDR-292, 150 W Street Light Power Supply
CTR_MIN
0.8
VTL431_SAT
2.5
V
RLED_SHUNT
1.1
k-ohms
ROPTO_LOAD
4.70
k-ohms
382.98
uA
IOPTO_BJT_MAX
0.99
mA
RLED_SERIES_MAX
17.86
k-ohms
IFMAX
Power Integrations
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19-Nov-13
Optocoupler minimum CTR at VCE_SAT and at
IOPTO_BJT_MAX
TL431 minimum cathode voltage when saturated
Resistor across optocoupler LED to ensure minimum
TL431 bias current is met
Resistor from optocoupler emitter to ground, sets load
current
FB pin current when switching at FMAX (e.g. startup) Sameer should we show this?
Optocoupler transistor maximum current - when bursting at
FMAX (e.g. startup)
Maximum value of gain setting resistor, in series with
optocoupler LED, to ensure optocoupler can deliver
IOPTO_BJT_MAX. Includes -10% tolerance factor.
Page 48 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
10 Bias Transformer Design Spreadsheet
ACDC_LinkSwitchTN_Flyback_103007;
Rev.1.9; Copyright
INPUT
Power Integrations
2007
ENTER APPLICATION VARIABLES
VACMIN
85
VACMAX
280
fL
50
INFO
OUTPUT
UNIT
Volts
Volts
Hertz
VO
12.60
Volts
IO
0.05
Amps
CC Threshold Voltage
0.00
Volts
Output Cable Resistance
0.17
Ohms
PO
0.63
Watts
Feedback Type
Add Bias Winding
OPTO
Opto
NO
No
n
0.6
Z
0.5
tC
CIN
Input Rectification Type
2.90
mSeconds
100.00
uFarads
F
F
ACDC_LinkSwitch-TN
Flyback_103007; Copyright
Power Integrations 2007
Minimum AC Input Voltage
Maximum AC Input Voltage
AC Mains Frequency
Output Voltage (main) (For CC
designs enter upper CV tolerance
limit)
Power Supply Output Current
(For CC designs enter upper CC
tolerance limit)
Voltage drop across sense
resistor.
Enter the resistance of the output
cable (if used)
Output Power (VO x IO + CC
dissipation)
Choose 'BIAS' for Bias winding
feedback and 'OPTO' for
Optocoupler feedback from the
'Feedback Type' drop down box
at the top of this spreadsheet
Choose 'YES' in the 'Bias
Winding' drop down box at the
top of this spreadsheet to add a
Bias winding. Choose 'NO' to
continue design without a Bias
winding. Addition of Bias winding
can lower no load consumption
Efficiency Estimate at output
terminals.
Loss Allocation Factor (suggest
0.5 for CC=0 V, 0.75 for CC=1
V)
Bridge Rectifier Conduction Time
Estimate
Input Capacitance
Choose H for Half Wave Rectifier
and F for Full Wave Rectification
from the 'Rectification' drop down
box at the top of this spreadsheet
ENTER LinkSwitch-TN VARIABLES
LinkSwitch-TN
Chosen Device
ILIMITMIN
ILIMITMAX
LNK302
User selection for LinkSwitch-TN.
Ordering info - Suffix P/G
indicates DIP 8 package; suffix D
indicates SO8 package; second
suffix N indicates lead free RoHS
compliance
LNK302
LNK302
0.126
0.146
Amps
Amps
62000
Hertz
984.312
A^2Hz
VOR
80
Volts
VDS
10
Volts
fSmin
I^2fmin
Page 49 of 97
Minimum Current Limit
Maximum Current Limit
Minimum Device Switching
Frequency
I^2f (product of current limit
squared and frequency is
trimmed for tighter tolerance)
Reflected Output Voltage
LinkSwitch-TN on-state Drain to
Source Voltage
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
VD
0.7
KP
4.72
Volts
Output Winding Diode Forward
Voltage Drop
Ripple to Peak Current Ratio (0.6
< KP < 6.0).
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type
EE10
EE10
Core
EE10
Bobbin
EE10_BOBBIN
P/N:
P/N:
AE
0.121
cm^2
LE
2.61
cm
AL
850
nH/T^2
BW
6.6
mm
0
mm
3
26
N/A
N/A
N/A
Volts
Volts
User-Selected transformer core
PC40EE10-Z
EE10_BOBBIN
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
Bias winding not used
Bias winding not used
N/A - Bias Winding not in use
120
396
Volts
Volts
Minimum DC Input Voltage
Maximum DC Input Voltage
0.13
0.01
0.13
0.13
0.03
Amps
Amps
Amps
Amps
Maximum Duty Cycle
Average Primary Current
Minimum Peak Primary Current
Primary Ripple Current
Primary RMS Current
1879
uHenries
LP_TOLERANCE
10
%
NP
156
ALG
77
nH/T^2
BM
1449
Gauss
BAC
725
Gauss
ur
1459
LG
BWE
0.18
19.8
mm
mm
OD
0.13
mm
INS
0.03
mm
DIA
0.10
mm
AWG
39
AWG
CM
13
Cmils
CMA
467
Cmils/Amp
TRANSFORMER SECONDARY DESIGN PARAMETERS
Lumped parameters
ISP
ISRMS
IRIPPLE
0.76
0.19
0.18
Amps
Amps
Amps
M
L
3.00
NS
NB
VB
PIVB
DC INPUT VOLTAGE PARAMETERS
VMIN
VMAX
CURRENT WAVEFORM SHAPE PARAMETERS
DMAX
IAVG
IP
IR
IRMS
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP
Power Integrations
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Typical Primary Inductance. +/10%
Primary inductance tolerance
Primary Winding Number of
Turns
Gapped Core Effective
Inductance
Maximum Operating Flux
Density, BM<1500 is
recommended
AC Flux Density for Core Loss
Curves (0.5 X Peak to Peak)
Relative Permeability of
Ungapped Core
Gap Length (Lg > 0.1 mm)
Effective Bobbin Width
Maximum Primary Wire Diameter
including insulation
Estimated Total Insulation
Thickness (= 2 * film thickness)
Bare conductor diameter
Primary Wire Gauge (Rounded to
next smaller standard AWG
value)
Bare conductor effective area in
circular mils
Primary Winding Current
Capacity (150 < CMA < 500)
Peak Secondary Current
Secondary RMS Current
Output Capacitor RMS Ripple
Page 50 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
CMS
38
Cmils
AWGS
34
AWG
DIAS
0.16
mm
ODS
0.25
mm
INSS
0.05
mm
VDRAIN
584
Volts
PIVS
78
Volts
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
Maximum Secondary Insulation
Wall Thickness
VOLTAGE STRESS PARAMETERS
Maximum Drain Voltage Estimate
(Includes Effect of Leakage
Inductance)
Output Rectifier Maximum Peak
Inverse Voltage
FEEDBACK COMPONENTS
Recommended Bias
Diode
1N4003 - 1N4007
R1
500 - 1000
ohms
R2
200 - 820
ohms
Recommended diode is 1N4003.
Place diode on return leg of bias
winding for optimal EMI. See
LinkSwitch-TN Design Guide
CV bias resistor for CV/CC
circuit. See LinkSwitch-TN
Design Guide
Resistor to set CC linearity for
CV/CC circuit. See LinkSwitchTN Design Guide
TRANSFORMER SECONDARY DESIGN PARAMETERS (MULTIPLE OUTPUTS)
1st output
VO1
12.60
Volts
IO1
PO1
0.05
0.63
Amps
Watts
VD1
0.70
Volts
NS1
ISRMS1
26.00
0.19
Amps
IRIPPLE1
0.18
Amps
78.43
Volts
PIVS1
Recommended Diodes
Pre-Load Resistor
MUR110, UF4002,
SB1100
4
k-Ohms
CMS1
38.28
Cmils
AWGS1
34.00
AWG
DIAS1
0.16
mm
ODS1
0.25
mm
2nd output
VO2
IO2
PO2
0.00
Volts
Amps
Watts
VD2
0.70
Volts
NS2
ISRMS2
IRIPPLE2
1.37
0.00
0.00
Amps
Amps
Page 51 of 97
Main Output Voltage (if unused,
defaults to single output design)
Output DC Current
Output Power
Output Diode Forward Voltage
Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple
Current
Output Rectifier Maximum Peak
Inverse Voltage
Recommended Diodes for this
output
Recommended value of pre-load
resistor
Output Winding Bare Conductor
minimum circular mils
Wire Gauge (Rounded up to next
larger standard AWG value)
Minimum Bare Conductor
Diameter
Maximum Outside Diameter for
Triple Insulated Wire
Output Voltage
Output DC Current
Output Power
Output Diode Forward Voltage
Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple
Power Integrations
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RDR-292, 150 W Street Light Power Supply
PIVS2
19-Nov-13
3.46
Volts
CMS2
0.00
Cmils
AWGS2
N/A
AWG
DIAS2
N/A
mm
ODS2
N/A
mm
3rd output
VO3
IO3
PO3
0.00
Volts
Amps
Watts
VD3
0.70
Volts
NS3
ISRMS3
1.37
0.00
Amps
IRIPPLE3
0.00
Amps
PIVS3
3.46
Volts
CMS3
0.00
Cmils
AWGS3
N/A
AWG
DIAS3
N/A
mm
Recommended Diode
Recommended Diode
ODS3
N/A
mm
Total power
0.63
Watts
Power Integrations
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Current
Output Rectifier Maximum Peak
Inverse Voltage
Recommended Diodes for this
output
Output Winding Bare Conductor
minimum circular mils
Wire Gauge (Rounded up to next
larger standard AWG value)
Minimum Bare Conductor
Diameter
Maximum Outside Diameter for
Triple Insulated Wire
Output Voltage
Output DC Current
Output Power
Output Diode Forward Voltage
Drop
Output Winding Number of Turns
Output Winding RMS Current
Output Capacitor RMS Ripple
Current
Output Rectifier Maximum Peak
Inverse Voltage
Recommended Diodes for this
output
Output Winding Bare Conductor
minimum circular mils
Wire Gauge (Rounded up to next
larger standard AWG value)
Minimum Bare Conductor
Diameter
Maximum Outside Diameter for
Triple Insulated Wire
Total Output Power
Page 52 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
11 Power Factor Controller Design Spreadsheet
ACDC_PFS_041411;
Rev.1.1; Copyright Power
Integrations 2011
Enter Applications Variables
Input Voltage Range
VACMIN
VACMAX
VBROWNIN
VBROWNOUT
VO
PO
fL
TA Max
INPUT
OUTPUT
50.00
Universal
90
265
77.77
70.42
380.00
157.00
50
50
n
0.950
0.95
KP
0.445
0.445
18.00
361
20
18
VO_MIN
VO_RIPPLE_MAX
tHOLDUP
Universal
INFO
380.00
157.00
UNITS
V
V
V
V
W
Hz
deg C
V
V
ms
VHOLDUP_MIN
310
V
I_INRUSH
40
A
Forced Air Cooling
no
no
Auto
PFS708
5.50
5.85
6.20
0.73
4.00
1.00
100.00
10.00
A
A
A
ohms
Mohms
uF
nF
nF
FS_PK
72.7
kHz
FS_AVG
59.2
kHz
IP
PFS_IRMS
PCOND_LOSS_PFS
PSW_LOSS_PFS
PFS_TOTAL
3.34
1.74
2.21
1.07
3.28
A
A
W
W
W
TJ Max
100
deg C
Rth-JS
3.00
degC/W
HEATSINK Theta-CA
12.25
degC/W
LPFC
705
uH
LPFC (0 Bias)
1820
uH
PFS Parameters
PFS Part Number
IOCP min
IOCP typ
IOCP max
RDSON
RV
C_VCC
C_V
C_FB
ACDC_HiperPFS_041411_Rev11.xls; Continuous Mode Boost
Converter Design Spreadsheet
Select Universal or High_Line option
Minimum AC input voltage
Maximum AC input voltage
Expected Minimum Brown-in Voltage
Specify brownout voltage.
Nominal Output voltage
Nominal Output power
Line frequency
Maximum ambient temperature
Enter the efficiency estimate for the
boost converter at VACMIN
Ripple to peak inductor current ratio at
the peak of VACMIN
Minimum Output voltage
Maximum Output voltage ripple
Holdup time
Minimum Voltage Output can drop to
during holdup
Maximum allowable inrush current
Enter "Yes" for Forced air cooling.
Otherwise enter "No"
Selected PFS device
Minimum Current limit
Typical current limit
Maximum current limit
Typical RDSon at 100 'C
Line sense resistor
Supply decoupling capacitor
V pin decoupling capacitor
Feedback pin decoupling capacitor
Estimated frequency of operation at
crest of input voltage (at VACMIN)
Estimated average frequency of
operation over line cycle (at VACMIN)
MOSFET peak current
PFS MOSFET RMS current
Estimated PFS conduction losses
Estimated PFS switching losses
Total Estimated PFS losses
Maximum steady-state junction
temperature
Maximum thermal resistance (Junction
to heatsink)
Maximum thermal resistance of
heatsink
Basic Inductor Calculation
Page 53 of 97
Value of PFC inductor at peak of
VACMIN and Full Load
Value of PFC inductor at No load. This
is the value measured with LCR meter
Power Integrations
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RDR-292, 150 W Street Light Power Supply
LPFC_RMS
LP_TOL
Inductor Construction Parameters
Core Type
Sendust
19-Nov-13
2.07
A
10
%
6.38
A/mm^2
BM_TARGET
N/A
Gauss
BM
2892
Gauss
BP
1793
Gauss
LPFC_CORE_LOSS
LPFC_COPPER_LOSS
LPFC_TOTAL LOSS
Critical Parameters
IRMS
IO_AVG
Output Diode (DO)
Part Number
1.33
1.39
2.73
W
W
W
Enter "Sendust", "Pow Iron" or "Ferrite"
Select from 60u, 75u, 90u or 125 u for
Sendust cores. Fixed at PC44 or
equivalent for Ferrite cores. Fixed at 52
material for Pow Iron cores.
Select from Toroid or EE for Sendust
cores and from EE, or PQ for Ferrite
cores
Core part number
Core cross sectional area
Core mean path length
Core AL value
Core volume
Core height/Height of window
Mean length per turn
Bobbin width
Inductor turns
Gap length (Ferrite cores only)
Inductor RMS current
Select between "Litz" or "Regular" for
double coated magnet wire
!!! Info. Selected wire gauge is too thick
and may cause increased proximity
losses. Selecta thinner wire gauge
Inductor wire number of parallel
strands
Outer diameter of single strand of wire
Ratio of AC resistance to the DC
resistance (using Dowell curves)
!!! Warning Current density is too high
and may cause heating in the inductor
wire. Reduce J
Target flux density at VACMIN (Ferrite
cores only)
Maximum operating flux density
Peak Flux density (Estimated at
VBROWNOUT)
Estimated Inductor core Loss
Estimated Inductor copper losses
Total estimated Inductor Losses
1.84
0.41
A
A
AC input RMS current
Output average current
V
A
ns
V
W
PFC Diode Part Number
Diode Type - Special - Diodes specially
catered for PFC applications, SiC Silicon Carbide type, UF - Ultrafast
recovery type
Diode Manufacturer
Diode rated reverse voltage
Diode rated forward current
Diode Reverse recovery time
Diode rated forward voltage drop
Estimated Diode conduction losses
Core Material
Core Geometry
Core
AE
LE
AL
VE
HT
MLT
BW
NL
LG
ILRMS
Wire type
Sendust
Inductor RMS current (calculated at
VACMIN and Full Load)
Tolerance of PFC Inductor Value
90u
90u
TOROID
TOROID
77934(OD=27.7)
77934(OD=27.7)
65.4
63.5
116
4150
11.94
41
N/A
125
N/A
2.07
regular
AWG
22
Filar
1
mm
A
regular
Info
22
AWG
1
OD
0.643
AC Resistance Ratio
3.42
J
mm^2
mm
nH/t^2
mm^3
mm
cm
mm
Warning
LQA05TC600
Type
mm
LQA05TC600
SPECIAL
Manufacturer
VRRM
IF
TRR
VF
PCOND_DIODE
Power Integrations
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Qspeed
600
5
24
1.1
0.45
Page 54 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
PSW_DIODE
P_DIODE
0.71
1.16
W
W
TJ Max
125
deg C
Rth-JS
2.90
degC/W
HEATSINK Theta-CA
61.21
degC/W
120.00
uF
VO_RIPPLE_EXPECTED
11.5
V
T_HOLDUP_EXPECTED
18.5
ms
ESR_LF
ESR_HF
IC_RMS_LF
1.38
0.553
0.29
ohms
ohms
A
IC_RMS_HF
0.83
A
CO_LF_LOSS
0.12
W
CO_HF_LOSS
0.38
W
Total CO LOSS
0.50
W
Input Bridge (BR1) and Fuse (F1)
I^2t Rating
Fuse Current rating
VF
IAVG
PIV_INPUT BRIDGE
8.43
2.85
0.90
1.77
375
A^2s
A
V
A
V
PCOND_LOSS_BRIDGE
2.98
W
CIN
0.47
uF
8.54
1N5407
ohms
R2
1.50
Mohms
R3
1.54
Mohms
R4
698.00
kohms
C2
100.00
nF
R5
2.20
kohms
R6
2.20
kohms
R7
57.60
kohms
C3
470.00
pF
R8
160.00
kohms
R9
2.21
kohms
R10
10.00
kohms
C4
10.00
uF
Output Capacitor
CO
RT
D_Precharge
Feedback Components
Page 55 of 97
120
Estimated Diode switching losses
Total estimated Diode losses
Maximum steady-state operating
temperature
Maximum thermal resistance (Junction
to heatsink)
Maximum thermal resistance of
heatsink
Minimum value of Output capacitance
Expected ripple voltage on Output with
selected Output capacitor
Expected holdup time with selected
Output capacitor
Low Frequency Capacitor RMS current
High Frequency Capacitor RMS
current
Estimated Low Frequency ESR loss in
Output capacitor
Estimated High frequency ESR loss in
Output capacitor
Total estimated losses in Output
Capacitor
Minimum I^2t rating for fuse
Minimum Current rating of fuse
Input bridge Diode forward Diode drop
Input average current at 70 VAC.
Peak inverse voltage of input bridge
Estimated Bridge Diode conduction
loss
Input capacitor. Use metallized
polypropylene or film foil type with high
ripple current rating
Input Thermistor value
Recommended precharge Diode
Feedback network, first high voltage
divider resistor
Feedback network, second high
voltage divider resistor
Feedback network, third high voltage
divider resistor
Feedback network, loop speedup
capacitor
Feedback component, NPN transistor
bias resistor
Feedback component, PNP transistor
bias resistor
Feedback network, lower divider
resistor
Feedback component- noise
suppression capacitor
Feedback network - pole setting
resistor
Feedback network - zero setting
resistor
Feedback pin filter resistor
Feedback network - compensation
capacitor
Power Integrations
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
D3
1N4148
D4
1N4001
Q1
2N4401
Q2
2N4403
Feedback network reverse blocking
Diode
Feedback network - capacitor failure
detection Diode
Feedback network - speedup circuit
NPN transistor
Feedback network - speedup circuit
PNP transistor
Loss Budget (Estimated at VACMIN)
PFS Losses
Boost diode Losses
3.28
1.16
W
W
Input Bridge losses
2.98
W
Inductor losses
2.73
W
Output Capacitor Loss
0.50
W
Total losses
10.65
W
Efficiency
0.94
Total estimated losses in PFS
Total estimated losses in Output Diode
Total estimated losses in input bridge
module
Total estimated losses in PFC choke
Total estimated losses in Output
capacitor
Overall loss estimate
Estimated efficiency at VACMIN. Verify
efficiency at other line voltages
Note: There is a warning in the spreadsheet for current density in PFC choke. Whenever
such a warning is issued, thermal performance of the PFC choke should be checked
while operating continuously at the lowest input voltage. In this design, it was found that
the temperature rise of the choke was within acceptable limits when operating
continuously at 90 VAC and full load (see page 80 and Figure 52).
Power Integrations
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Page 56 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
12 Performance Data
All measurements were taken at room temperature and 60 Hz input frequency unless
otherwise specified, Output voltage measurements were taken at the output connectors.
12.1 LLC Stage Efficiency
To make this measurement, the LLC stage was supplied by connecting an external 380
VDC supply across bulk capacitor C23. The efficiency includes the losses from the bias
supply.
97
96
95
Efficiency (%)
94
93
92
91
90
89
88
0
20
40
60
80
100
120
140
Output Power (W)
Figure 15 – LLC Stage Efficiency vs. Load, 380 VDC Input.
Page 57 of 97
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160
RDR-292, 150 W Street Light Power Supply
19-Nov-13
12.2 Total Efficiency
Figures below show the total supply efficiency (PFC and LLC stages). AC input was
supplied using a sine wave source.
96
100% Load
50% Load
20% Load
10% Load
94
Efficiency (%)
92
90
88
86
84
82
80
80
100
120
140
160
180
200
220
240
260
280
AC Input Voltage
Figure 16 – Total Efficiency vs. Output Power.
Power Integrations
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Page 58 of 97
19-Nov-13
12.3
RDR-292, 150 W Street Light Power Supply
No-Load Power
0.83
No-Load Power
0.82
Input Power (W)
0.81
0.8
0.79
0.78
0.77
0.76
0.75
0.74
80
100
120
140
160
180
200
220
240
260
AC Input Voltage
Figure 17 – No-Load Input Power.
Page 59 of 97
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280
RDR-292, 150 W Street Light Power Supply
19-Nov-13
12.4 Power Factor
Power factor measurements were made using a sine wave AC source.
1.2
100% Load
50% Load
1.1
Power Factor
1
0.9
0.8
0.7
0.6
80
100
120
140
160
180
200
220
240
260
280
AC Input Voltage
Figure 18 – Power Factor vs. Input Voltage, 50% and 100% Load.
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19-Nov-13
RDR-292, 150 W Street Light Power Supply
12.5 THD
THD measurements were taken a 100% and 50% load using a sine wave source and a
Yokogawa WT210 power analyzer with harmonic measurement option.
80
100% Load
50% Load
70
60
THD (%)
50
40
30
20
10
0
80
100
120
140
160
180
200
220
240
260
AC Input Voltage
Figure 19 – THD vs. Input Voltage, 50% and 100% Load.
Page 61 of 97
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280
RDR-292, 150 W Street Light Power Supply
19-Nov-13
12.6 Output Regulation
The PFC regulates the LLC and standby supply input voltage under normal conditions so
the outputs will not be affected by the AC input voltage. Variations due to temperature
and component tolerances are not represented. The 48 V output varies by less than 1%
over a load range of 10% to 100% load.
12.6.1 Output Line Regulation
103
100% Load
50% Load
102
20% Load
Line Regulation (%)
101
10% Load
0% Load
100
99
98
97
96
95
80
100
120
140
160
180
200
220
240
260
280
AC Input Votage
Figure 20 – Output Voltage vs. Input Line Voltage (Line Regulation).
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RDR-292, 150 W Street Light Power Supply
12.6.2 Output Load Regulation
103
90 VAC
115 VAC
102
132 VAC
150 VAC
Load Regulation (%)
101
180 VAC
230 VAC
100
265 VAC
99
98
97
96
95
0
0.5
1
1.5
2
2.5
3
Load Current (A)
Figure 21 – Output Voltage vs. Output Load Current (Load Regulation).
Page 63 of 97
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3.5
RDR-292, 150 W Street Light Power Supply
19-Nov-13
13 Input Current Harmonics vs. EN 61000-3-2 Class C Limits
35%
Harmonics
Class C Limits
Harmonic Content and
EN 61000-3-2 Class C Limits (%)
30%
25%
20%
15%
10%
5%
0%
2
3
5
7
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic Order (115 V)
Figure 22 – AC Input Harmonics vs. EN 61000-3-2 Class C Limits, 115 VAC, 60 Hz, 100% Load.
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RDR-292, 150 W Street Light Power Supply
35%
Harmonics
Class C Limits
Harmonic Content and
EN 61000-3-2 Class C Limits (%)
30%
25%
20%
15%
10%
5%
0%
2
3
5
7
9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39
Harmonic Content (230 V)
Figure 23 – AC Input Harmonics vs. EN 61000-3-2 Class C Limits, 230 VAC, 60 Hz, 100% Load.
Page 65 of 97
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14 Waveforms
14.1
Input Voltage and Current
Figure 24 – 115 VAC, 150 W Load.
Upper: Input Current, 2 A / div.
Lower: Input Voltage, 100 V, 5 ms / div.
Figure 25 – 230 VAC, 150 W Load.
Upper: Input Current, 2 A / div.
Lower: Input Voltage, 200 V, 5 ms / div.
14.2 LLC Primary Voltage and Current
The LLC stage current was measured by adding a current sensing loop between C30 and
B- that measures the LLC transformer (T3) primary current. The primary voltage
waveform was measured at test point TP1.
Figure 26 – LLC Stage Primary Voltage and Current.
Upper: Current, 1 A / div.
Lower: Voltage, 200 V, 1 s / div.
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14.3
RDR-292, 150 W Street Light Power Supply
PFC Switch Voltage and Current - Normal Operation
Figure 27 – PFC Stage Drain Voltage and Current,
Full Load, 115 VAC
Upper: Drain Current, 1 A / div.
Lower: Drain Voltage, 200 V, 2 ms / div.
Figure 28 – PFC Stage Drain Voltage and Current,
Full Load, 115 VAC.
Upper: Drain Current, 1 A / div.
Lower: Drain Voltage, 200 V, 10 s /
div.
Figure 29 – PFC Stage Drain Voltage and Current,
Full Load, 230 VAC.
Upper: Drain Current, 1 A / div.
Lower: Drain Voltage, 200 V, 2 ms / div.
Figure 30 – PFC Stage Drain Voltage and Current,
Full Load, 230 VAC.
Upper: Drain Current, 1 A / div.
Lower: Drain Voltage, 200 V, 10 s /
div.
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RDR-292, 150 W Street Light Power Supply
14.4
AC Input Current and PFC Output Voltage During Start-up
Figure 31 – AC Input Current vs. PFC Output Voltage
at Start-up, Full Load, 115 VAC.
Upper: AC Input Current, 2 A / div.
Lower: PFC Voltage, 200 V, 20 ms / div
14.5
19-Nov-13
Figure 32 – AC Input Current vs. PFC Output Voltage
at Start-up, Full Load, 230 VAC.
Upper: AC Input Current, 2 A / div.
Lower: PFC Voltage, 200 V, 20 ms / div.
Bias Supply Drain Waveforms
Figure 33 – Bias Supply LNK302 Drain Voltage,
100 V, 50 s / div.
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Figure 34 – Bias Supply LNK302 Drain Voltage,
100 V, 2 s / div.
Page 68 of 97
19-Nov-13
14.6
RDR-292, 150 W Street Light Power Supply
LLC Start-up
Figure 35 – LLC Start-up. 115 VAC, 100% Load.
Upper: LLC Primary Current, 1 A / div.
Lower: LLC Output Voltage, 20 V,
10 ms / div.
14.7
Figure 36 – LLC Start-up. 115 VAC, 0% Load.
Upper: LLC Primary Current, 1 A / div.
Lower: LLC Output Voltage, 20 V,
10 ms / div.
LLC Brown-Out
Figure 37 – LLC Brown-out.
Upper: Primary Current, 2 A / div.
Middle: Output Voltage, 20 V / div.
Lower: B+ Voltage, 200 V, 1 ms / div
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19-Nov-13
14.8 LLC Output Short-Circuit
The figure below shows the effect of an output short circuit on the LLC primary current. A
mercury displacement relay was used to short the output to get a fast, bounce-free
connection.
Figure 38 – Output Short Circuit Test.
Upper: LLC Primary Current, 2 A / div.
Lower: 48 V Output, 20 V, 10 s / div.
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14.9
RDR-292, 150 W Street Light Power Supply
Output Ripple Measurements
14.9.1 Ripple Measurement Technique
For DC output ripple measurements, use a modified oscilloscope test probe to reduce
spurious signals. Details of the probe modification are provided in figures below.
Tie two capacitors in parallel across the probe tip of the 4987BA probe adapter. Use a
0.1 F / 50 V ceramic capacitor and 1.0 F / 100 V aluminum electrolytic capacitor. The
aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across
DC outputs.
Probe Ground
Probe Tip
Figure 39 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).
Figure 40 – Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe
Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added).
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14.9.2 Full Load Output Ripple Results
Figure 41 – 48 V Output Ripple,
100 mV, 2 ms / div.
Figure 42 – 48 V Output Ripple, 100 mV, 1 s / div.
14.9.3 No-Load Ripple Results
Figure 43 – 48 V No-Load Output Ripple, 200 mV, 10 ms / div.
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RDR-292, 150 W Street Light Power Supply
14.10 Output Load Step Response
The figures below show transient response with a 75%-100%-75% load step for the 48 V
output. The oscilloscope was triggered using the rising edge of the load step, and
averaging was used to cancel out ripple components asynchronous to the load step in
order to better ascertain the load step response.
Figure 44 – Output Transient Response 3.13 A – 2.3 A – 3.13 A Load Step.
Upper: Output Load Step, 1 A / div.
Lower: 48 V Transient Response, 100 mV /,1 ms / div.
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14.10.1
100% to 0% Load Step
Figure 45 shows the response of the supply to a 100% to 0% load step. The LLC supply
enters burst mode to maintain regulation.
Figure 45 – Output Transient Response 3.13 A – 0 A Load Step.
500 mV, 10 ms / div.
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14.10.2
RDR-292, 150 W Street Light Power Supply
0% to 100% Load Step
Figure 46 – Output Transient Response 0 A – 3.13 A Load Step.
1 V, 5 ms / div.
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14.10.3
Temperature Profiles
The board was operated at room temperature in a vertical orientation as shown below.
For each test condition the unit was allowed to thermally stabilize (>1 hr) before
measurements were made.
Input bridge
rectifier
PFC
inductor
HiperPFS
IC
HiperLCS IC
PFC stage
boost diode
LLC
transformer
LLC output
rectifier
Figure 47 – Photograph of Board Used for Thermal Testing.
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RDR-292, 150 W Street Light Power Supply
14.11 Thermal Results Summary
14.11.1
Testing Conditions
Thermal Measurement data is presented below. The unit was allowed to thermally
stabilize (>1 hour in all cases) before gathering data.
14.11.2
90 VAC, 60 Hz, 150 W Output
Figure 48 – Overall Thermal Profile, Room Temperature, 90 VAC, 60 Hz, 150 W Load (1 hr).
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RDR-292, 150 W Street Light Power Supply
Figure 49 – Input Common Mode Choke
Temperature, 90 VAC, Full load.
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Figure 50 – Diode Bridge Case Temperature,
90 VAC, Full load.
Page 78 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
Figure 51 – PFC Choke Temperature, 90 VAC, Full
Load.
Figure 52 – PFS IC Case Temperature, 90 VAC,
Full Load.
Figure 53 – PFC Output Rectifier Case
Temperature, 115 VAC, Full Load.
Figure 54 – LCS IC Case Temperature, 90 VAC,
Full Load.
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RDR-292, 150 W Street Light Power Supply
Figure 55 – LLC Transformer Hot Spot
Temperature, 90 VAC, Full Load.
19-Nov-13
Figure 56 – LLC Transformer Hot Spot
Temperature, 90 VAC, Full Load.
Figure 57 – LLC Output Diode CaseTemperature,
90 VAC, Full Load (Viewed from
Above).
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14.11.3
RDR-292, 150 W Street Light Power Supply
115 VAC, 60 Hz, 150 W Output
Figure 58 – Overall Thermal Profile. Room Temperature, 115 VAC, 60 Hz, 150 W Load (1 hr).
Figure 59 – Input Common Mode Choke
Temperature, 115 VAC, Full Load.
Page 81 of 97
Figure 60 – Diode Bridge Case Temperature,
115 VAC, Full Load.
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19-Nov-13
Figure 61 – PFS IC CaseTemperature, 115 VAC,
Full Load.
Figure 62 – PFC Choke Temperature, 115 VAC,
Full Load.
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RDR-292, 150 W Street Light Power Supply
Figure 63 – PFC Output Rectifier Case
Temperature, 115 VAC, Full Load.
Figure 64 – LCS IC Case Temperature, 115 VAC,
Full Load.
Figure 65 – LLC Transformer Secondary Side Hot
Spot Temperature, 115 VAC, Full Load.
Figure 66 – LLC Transformer Primary Side Hot Spot
Temperature, 115 VAC, Full Load.
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
Figure 67 – LLC Output Rectifier Case
Temperature, 115 VAC, Full Load
(Viewed from Above).
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14.11.4
RDR-292, 150 W Street Light Power Supply
230 VAC, 150 W, Room Temperature
Figure 68 – Overall Temperature Profile, 230 VAC, Full Load.
Figure 69 – Input Common Mode FilterTemperature,
230 VAC, Full Load.
Page 85 of 97
Figure 70 – Bridge Rectifier Case Temperature,
230 VAC, Full Load.
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
Figure 71 – PFC ChokeTemperature, 230 VAC,
Full Load.
Figure 72 – PFS IC Case Temperature, 230 VAC,
Full Load.
Figure 73 – PFC Output Rectifier Case
Temperature, 115 VAC, Full Load.
Figure 74 – Hiper LCS CaseTemperature,
115 VAC, Full Load.
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RDR-292, 150 W Street Light Power Supply
Figure 75 – LLC Output Transformer Secondary
Side Hot Spot Temperature, 230 VAC,
Full Load.
Figure 76 – LLC Output Transformer Primary Side
Hot Spot Temperature, 230 VAC, Full
Load.
Figure 77 – LLC Output Rectifier Case
Temperature, 230 VAC, Full Load
(Viewed from Above).
Page 87 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
15 Conducted EMI
15.1
EMI Set-up
15.1.1 Power Supply Preparation for EMI Test
The picture below shows the power supply set-up for EMI and surge testing. The supply
is attached to a ground plane approximately the size of the power supply A piece of
single-sided copper clad printed circuit material was used in this case, but a piece of
aluminum sheet would also work. The supply is attached to the ground plane in two
places using ¼” 4-40 screws. Attachments points are the metal spacers marked as MH1
and MH2 on the top silk screen. An IEC AC connector was hard-wired to the power
supply AC input, with the safety ground connected to the ground plane. A Fair-Rite
2643250302 ferrite bead was placed over the safety ground connection, and can be seen
in the illustration below. This bead gives additional margin at ~20 MHz.
Figure 78 – RD-292 Set-up for EMI and Surge Testing.
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RDR-292, 150 W Street Light Power Supply
15.1.2 EMI Test Set-up
Figure 79 – EMI Room Set-up.
Conducted EMI tests were performed with a 16  resistive load on the 48 V main output.
The unit was attached to a metallic ground plane, which in turn was hard wired to the AC
cord ground. The resistive load was left floating.
Page 89 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
Figure 80 – Conducted EMI, 115 VAC.
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RDR-292, 150 W Street Light Power Supply
Figure 81 – Conducted EMI, 230 VAC.
Page 91 of 97
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
16 Gain-Phase Measurement
Figure 83 – RD-292 LLC Gain-Phase Measurement, Full Load Gain Crossover Frequency – 7.06 kHz,
Phase Margin, 57.8º.
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RDR-292, 150 W Street Light Power Supply
17 Input Surge Testing
17.1 Surge Test Set-up
The set-up for surge testing identical to that of EMI testing, with the UUT mounted on a
ground plane as shown below, with a 16  floating resistive load. An LED in series with a
680  resistor and a 39 V, 1 W Zener diode was used to monitor the output, in order to
detect dropouts/loss of function. The Zener diode provides extra sensitivity for dropout
testing, as the LED will shut off in response to a partial loss of output voltage.
The UUT was tested using a Key Tek EMC Pro Plus surge tester. The power supply was
configured on a ground plane as shown in Figure 84, with a floating 16  resistive load.
Results of common mode and differential mode surge testing are shown below. A test
failure was defined as a non-recoverable output interruption requiring supply repair or
recycling AC input voltage.
Figure 82 – RD-292 Set-up for Surge Testing.
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RDR-292, 150 W Street Light Power Supply
17.2
19-Nov-13
Differential Mode Surge, 1.2 / 50 sec
AC Input
Voltage
(VAC)
115
115
115
115
115
115
Surge
Voltage
(kV)
+2
-2
+2
-2
+2
-2
Phase
Angle
(º)
90
90
270
270
0
0
Generator
Impedance
()
2
2
2
2
2
2
AC Input
Voltage
(VAC)
230
230
230
230
230
230
Surge
Voltage
(kV)
+2
-2
+2
-2
+2
-2
Phase
Angle
(º)
90
90
270
270
0
0
Generator
Impedance
()
2
2
2
2
2
2
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Number of
Strikes
Test Result
10
10
10
10
10
10
PASS
PASS
PASS
PASS
PASS
PASS
Number of
Strikes
Test Result
10
10
10
10
10
10
PASS
PASS
PASS
PASS
PASS
PASS
Page 94 of 97
19-Nov-13
17.3
RDR-292, 150 W Street Light Power Supply
Common Mode Surge, 1.2 / 50 sec
AC Input
Voltage
(VAC)
115
115
115
115
115
115
Surge
Voltage
(kV)
+4
-4
+4
-4
+4
-4
Phase
Angle
(º)
90
90
270
270
0
0
Generator
Impedance
()
12
12
12
12
12
12
AC Input
Voltage
(VAC)
230
230
230
230
230
230
Surge
Voltage
(kV)
+4
-4
+4
-4
+4
-4
Phase
Angle
(º)
90
90
270
270
0
0
Generator
Impedance
()
12
12
12
12
12
12
Page 95 of 97
Number of
Strikes
Test Result
10
10
10
10
10
10
PASS
PASS
PASS
PASS
PASS
PASS
Number of
Strikes
Test Result
10
10
10
10
10
10
PASS
PASS
PASS
PASS
PASS
PASS
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RDR-292, 150 W Street Light Power Supply
19-Nov-13
18 Revision History
Date
01-Mar-12
19-Nov-13
Author
RH
KM
Revision
6.0
6.1
Description and Changes
Initial Release.
Updated Mfg Part Number for Q1 & Q3.
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Reviewed
Apps & Mktg
Apps & Mktg
Page 96 of 97
19-Nov-13
RDR-292, 150 W Street Light Power Supply
For the latest updates, visit our website: www.powerint.com
Power Integrations reserves the right to make changes to its products at any time to improve reliability or
manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit
described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS
ALL WARRANTIES
INCLUDING, WITHOUT LIMITATION,
THE
IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD
PARTY RIGHTS.
PATENT INFORMATION
The products and applications illustrated herein (including transformer construction and circuits’ external to the
products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign
patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at
www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at
http://www.powerint.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS,
HiperTFS, HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks
of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2012 Power
Integrations, Inc.
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China, 518040
Phone: +86-755-8379-3243
Fax: +86-755-8379-5828
e-mail:
[email protected]
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