Design Example Report Title 14 W PW M -Analog Dim m able LED Driver Using LinkSw itch TM -PH LNK 406EG Specification 90 VAC – 265 VAC Input; 28 V, 500 mA Output Application LED Driver Author Applications Engineering Department Document Number DER-263 Date June 23, 2015 Revision 1.4 Summary and Features • High efficiency, power factor corrected • >87% at 230 VAC and >86% at 115 VAC • >0.9 PF, meets EN61000-3-2 Class C • 0-10 V analog dimming • >1000:1 dimming range • Low cost, low component count and small printed circuit board footprint • No current sensing required • Frequency jitter for smaller, lower cost EMI filter components • Integrated protection and reliability features • Output open circuit / output short-circuit protected with auto-recovery • Line input overvoltage shutdown extends voltage withstand during line faults. • Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 Table of Contents 1 2 3 4 5 Introduction .........................................................................................................4 Power Supply Specification ...................................................................................6 Schematic ............................................................................................................7 PCB Layout ..........................................................................................................8 Circuit Description ................................................................................................9 5.1 PWM-Analog Dimming ...................................................................................9 5.2 Analog-PWM Converter ................................................................................ 11 5.3 Active Load Circuit ....................................................................................... 12 6 Bill of Materials .................................................................................................. 13 7 Transformer Specification ................................................................................... 15 7.1 Electrical Diagram ........................................................................................ 15 7.2 Electrical Specifications ................................................................................ 15 7.3 Materials ..................................................................................................... 15 7.4 Transformer Build Diagram .......................................................................... 16 7.5 Transformer Construction ............................................................................. 16 8 Transformer Design Spreadsheet ........................................................................ 17 9 Performance Data .............................................................................................. 20 9.1 Efficiency – Full Brightness ........................................................................... 20 9.2 Line and Load Regulation – Full Brightness.................................................... 21 9.3 Power Factor – Full Brightness...................................................................... 22 9.4 A-THD – Full Brightness ............................................................................... 23 9.5 115 VAC Dimming Characteristic ................................................................... 24 9.5.1 Output Current vs. Control Voltage ........................................................ 24 9.5.2 Dimming Ratio vs. Control Voltage ......................................................... 25 9.6 230 VAC Dimming Characteristic ................................................................... 26 9.6.1 Output Current vs. Control Voltage ........................................................ 26 9.6.2 Dimming Ratio vs. Control Voltage ......................................................... 27 9.7 Harmonics – Full Brightness ......................................................................... 28 9.7.1 8 LED Load ........................................................................................... 28 9.7.2 9 LED Load ........................................................................................... 30 9.7.3 10 LED Load ......................................................................................... 32 9.8 Test Data .................................................................................................... 34 9.8.1 Efficiency, Regulation, Power Factor, and THD - Non-Dimming ................ 34 9.8.2 115 VAC Dimming Test Data .................................................................. 35 9.8.3 230 VAC, 50 Hz Dimming Test Data ....................................................... 36 10 Waveforms ..................................................................................................... 37 10.1 Input Line Current ....................................................................................... 37 10.2 Drain Voltage and Current Normal Operation ................................................. 38 10.3 Drain Voltage and Current Start-up Operation ............................................... 39 10.4 Output Current and Output Voltage .............................................................. 40 10.5 Output Current and Voltage at Power-up, Power-down .................................. 41 10.6 Output Short ............................................................................................... 42 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 2 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 10.7 Open Load/LED Condition ............................................................................ 42 11 Thermals ........................................................................................................ 43 11.1 115 VAC Thermal Measurements .................................................................. 43 11.2 230 VAC Thermal Measurements .................................................................. 44 12 Conducted EMI ............................................................................................... 45 12.1 Conducted EMI Test Setup ........................................................................... 45 12.2 115 VAC, 60 Hz Conducted EMI Measurements ............................................. 45 12.3 230 VAC, 60 Hz Conducted EMI Measurements ............................................. 46 13 Revision History .............................................................................................. 47 Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Page 3 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 1 Introduction The document describes a high power-factor secondary referenced, analog dimmable LED driver. The circuit is designed to drive a nominal LED string voltage of 28 V at 500 mA from an input voltage range of 90 VAC to 265 VAC. The LED driver utilizes the LNK406EG from the LinkSwitch-PH family of ICs. Analog dimming is controlled by an external secondary referenced analog control signal of 0-10 V. 0 volts correspond to minimum light output and 10 V corresponds to maximum brightness. The analog controlled signal is transferred to the primary-side and controls the feedback current IFB of LNK406EG which in turn controls the output power/light output of the driver while maintaining high power factor and low THD. An active load circuit and control are also included to extend dimming ratio beyond 1000:1 but may be omitted if extended dimming operation is not required. This document contains the LED driver specification, schematic, PCB diagram, bill of materials, conducted EMI measurements, thermal measurements, transformer documentation and typical performance characteristics. Figure 1 – Top View. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 4 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG Figure 2 – Bottom Side. Page 5 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 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 Power Factor Output Voltage Current Ripple Power Dimming Range Efficiency 115 VAC 230 VAC Environmental Symbol Min Typ Max Units VIN fLINE PF 90 115 / 230 60 / 50 265 VAC Hz 28 500 60 14 31 V mA % W VOUT IOUT IRIPPLE POUT η115 η230 Conducted EMI 0.92 25 1000:1 ±5% IO(PK-PK) / IO VIN(TYP) 86 87 % % VOUT = 28 V VOUT = 28 V Meets EN55015B Harmonic Currents Temperature Comment EN 61000-3-2 Class D (C) TAMB Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 40 °C Class C specifies Class D Limits when PIN <25 W May be increased with larger heat sink Page 6 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 3 Schematic Figure 3 – Schematic. Page 7 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 4 PCB Layout Figure 4 – PCB Showing Top, Bottom Traces and Dimensions in Inches [mm]. Figure 5 – PCB Bottom Side. Figure 6 – PCB Top Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 8 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 5 Circuit Description The LinkSwitch-PH device is a controller and integrated 725 V MOSFET intended for use in LED driver applications. The LinkSwitch-PH is configured for use in a single-stage continuous conduction mode flyback topology and provides a primary-side regulated constant current output while maintaining high power factor from the AC input. Controlling the IFB current with an external control signal regulates the output power and thus the output current to the LED Load. 5.1 P W M -Analog Dim m ing Figure 7 – PWM-Analog Dimming. Dimming is controlled by an external analog secondary reference control signal of 0-10 V magnitude. 0 V corresponds to full dimming or minimum light output and 10 V corresponds to maximum brightness. Resistor RF and CF (Figure 7) form a simple low pass filter to provide noise filtering of the incoming control signal. The PWM generator block converts the analog signal to PWM. Conversion to PWM preserves the integrity of the analog control signal information when it is transferred from the secondary to the primary-side. If 0 V to 10 V dimming is not required and a PWM source is already present, for example from a micro controller, then the PWM generator block may be omitted and U2A driven directly. Optocoupler U2 is switched on and off with a duty cycle proportional to the control voltage. Diode D1 prevents C6 from pulling down the FB pin during start-up condition. Resistors R6 and R12 sets the IFB current at maximum brightness. The equation for operating IFB with U2 open (maximum brightness) is Page 9 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG I FB = 23-Jun-12 VBIAS − VFB VR 4 − VFB + R6 + R12 R10 During full dimming, transistor U2 is fully on and voltage across C6 falls to VFB + 0.6 V approximately 3 V. Resistor R11 is then selected based on the following relationship: R11 = 3V × R6 ; VBIAS ( FD ) − 3V where VBIAS(FD) is the minimum bias voltage at full dimming. PWM filter capacitor C6 is chosen to be greater than: 5 f PWM × R11 Resistor R10 provides a stable current of approximately 20 µA into the FB pin from the bias winding through VR4 biased by R7. This prevents the FB pin current from entering into auto-restart region (i.e. IFB <20 µA) thus allowing operation in deep dimming mode operation. However, during short-circuit condition the VR4 bias voltage will collapse and allows IFB current to fall below 20 µA thus enabling auto-restart protection mode. Resistor R10 also guarantees that the unit starts-up normally while the PWM filter capacitor C6 charges up and causes delay for the feedback current to cross the autorestart region from the bias supply during initial start-up. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 10 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 5.2 Analog-P W M Converter Figure 8 – Analog Signal to PWM Converter. The PWM converter uses 2 comparator circuits implemented using LM393. The first comparator circuit is a relaxation oscillator that produces a nearly triangular waveform at the inverting input. The frequency of the sawtooth and the PWM output at pin 7 is given by the following relation 1 FPWM ≈ 2 × ln(2) × R 21× C 22 where R21 = R22 = R23 = R24. The approximation was used to simplify the formula and ignore the small effect of the pull-up resistor R20. Resistor R20 would not be necessary if U3 is an op-amp with an output that saturates to its rail voltage. The oscillating frequency for this design is approximately 150 Hz. The second comparator circuitry compares the triangular waveform with the scaled analog input. The minimum control signal is scaled to VCC/3 and maximum control signal is scaled to approximately 2×(VCC/3) to produce a 0-100% duty cycle. The scaling is done by resistors R26-R28. Page 11 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 5.3 Active Load Circuit Figure 9 – Active Load Circuit. The active load circuit is designed such that: 1. At full dimming, the active load circuit dissipates the minimum output power when IFB is at minimum (IFB ~20 µA) thereby reducing the LED load current. 2. Without dimming, or full brightness, the active load is inactive. VAL (active load control voltage) is at its minimum value and set such that Q1 is off. This disconnects the active load from the output and does not affect the full load efficiency of the converter The emitter follower configuration formed by Q1, R13, R14, D10 and D9 draws a current proportional to VAL once VAL exceeds 1.8 V threshold. Resistor R14 sets the ratio between VAL and desired offset current. Resistor R13 is used to proportion the power dissipated between Q1 and R13 and thus enable the use of a lower power rating transistor. The network formed by R32-R35 and U4 is configured as an inverting amplifier to satisfy relationship between control signal and VAL as shown on the figure above. Resistor R30, R31, and Q2 comprise the pull-up circuit and ensure that if the analog control signal is not present, the active load circuit is not connected to the output. The active load circuit is optional for designs where a reduced dimming range is acceptable. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 12 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 6 Bill of Materials Item Qty 1 1 Part Ref BR1 2 1 C1 47 nF, 275 VAC, Film, X2 3 1 C2 100 nF, 630 V, Film ECQ-E6104KF Panasonic 4 1 C3 1 µF, 400 V, Electrolytic, (6.3 x 11) EKMG401ELL1R0MF11D United Chemi-Con 5 1 C4 ECJ-3YB1E106M Panasonic 6 1 C5 ELXZ500ELL220MEB5D Nippon Chemi-Con 7 1 C6 10 µF, 25 V, Ceramic, X5R, 1206 22 µF, 50 V, Electrolytic, Low ESR, 900 mΩ, (5 x 11.5) 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) KME50VB10RM5X11LL Nippon Chemi-Con 8 1 C7 440LD10-R Vishay 9 2 C8 C10 EKZE500ELL331MJ25S Nippon Chemi-Con 10 1 C9 1 nF, Ceramic, Y1 330 µF, 50 V, Electrolytic, Very Low ESR, 28 mΩ, (10 x 25) 1000 pF, 630 V, Ceramic, X7R, 1206 ECJ-3FB2J102K Panasonic 11 1 C13 100 nF, 25 V, Ceramic, X7R, 0805 ECJ-2VB1E104K Panasonic 12 2 C14 C20 13 1 C21 14 1 15 1 16 4 17 1 D2 18 1 D3 1000 V, 1 A, Rectifier, Glass Passivated, DO-213AA (MELF) 600 V, 1 A, Ultrafast Recovery, 35 ns, SMB Case 19 1 D4 200 V, 2 A, Ultrafast Recovery, 20 ns, DO-214AA 20 1 D6 DIODE ULTRA FAST, SW, 200 V, 1 A, SMA 21 1 D8 200 V, 4 A, Schottky, SMC, DO-214AB 22 1 F1 3.15 A, 250V, Slow, RST 23 2 J1 J2 24 3 L1 L2 L3 25 1 Q1 NPN, Power BJT, 70 V, 1 A, TO-92 ZTX692B Zetex 26 1 Q2 PNP, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3906LT1G On Semi 27 2 Q3 Q4 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3904LT1G On Semi 28 2 R2 R3 2.00 MΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF2004V Panasonic 29 1 R4 24.9 kΩ, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF2492V Panasonic 30 1 R5 3 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ302V Panasonic 31 1 R6 24 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ243V Panasonic 32 1 R7 10 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ103V Panasonic 33 1 R8 150 Ω, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ151V Panasonic 34 2 R9 R15 390 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ394V Panasonic 35 1 R10 174 kΩ, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1743V Panasonic 36 1 R11 3.6 kΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ362V Panasonic 37 1 R12 150 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ154V Panasonic 38 1 R13 130 Ω, 5%, 1 W, Metal Oxide RSF100JB-130R Yageo 39 1 R14 200 Ω, 5%, 1 W, Metal Oxide RSF100JB-200R Yageo 40 2 R16 R17 4.7 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ472V Panasonic 41 2 R18 R40 1.5 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ152V Panasonic 42 1 R19 1 kΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ102V Panasonic 43 2 R20 R35 4.3 kΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ432V Panasonic 44 4 R21 R22 100 kΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ104V Panasonic Description 800 V, 1 A, Bridge Rectifier, SMD, DFS Mfg DF08S Diodes, Inc. ECQU2A473ML Panasonic 08055C102KAT2A AVX 100 nF, 25 V, Ceramic, X7R, 1206 ECJ-3VB1E104K Panasonic C22 47 nF, 50 V, Ceramic, X7R, 0805 ECJ-2YB1H473K Panasonic C23 D1 D5 D9 D10 2.2 µF, 50 V, Ceramic, Y5V, 1206 GRM31MF51H225ZA01L Murata LL4148-13 Diodes, Inc. DL4007-13-F Diodes, Inc. Page 13 of 48 1 nF, 50 V, Ceramic, X7R, 0805 Mfg Part Number 75 V, 0.15 A, Fast Switching, 4 ns, MELF PCB Terminal Hole, 30 AWG 1 mH, 0.30 A, Ferrite Core MURS160T3G On Semi ES2D Diodes, Inc. US1D-13-F Diodes, Inc. MBRS4201T3G ON Semi 507-1181 Belfuse N/A N/A CTCH895F-102K CTParts Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 R23 R24 45 2 R25 R31 10 kΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ103V Panasonic 46 1 R26 154 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1543V Panasonic 47 1 R27 22.1 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF2212V Panasonic 48 1 R28 47.5 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF4752V Panasonic 49 1 R29 3.3 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ332V Panasonic 50 1 R30 1 MΩ, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ105V Panasonic 51 1 R32 80.6 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF8062V Panasonic 52 1 R33 12.4 kΩ, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1242V Panasonic 53 1 100 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ104V Panasonic 54 3 1 kΩ, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ102V Panasonic 55 1 R34 R36 R37 R38 R39 56 1 RV1 57 1 T1 58 1 59 1 60 1 61 62 1 MΩ, 1%, 1/4 W, Metal Film MFR-25FBF-1M00 Yageo U1 275 V, 23 J, 7 mm, RADIAL Bobbin, RM8, Vertical, 12 pins Transformer LinkSwitch-PH, eSIP V275LA4P RM8/12/1 PNK-10012 LNK406EG Littlefuse Schwartzpunkt Premier Magnetics Power Integrations U2 Optocoupler, 35 V, CTR 80-160%, 4-DIP U3 Dual Diff Comparator, 8-SOIC 1 U4 1 VR3 63 1 VR4 16 V, 5%, 1 W, DO-41 64 1 VR5 6.2 V, 5%, 150 mW, SOD-323 LTV-817A Liteon LM393D National 1.24 V Shunt Reg IC LMV431ACZ National Semi 36 V, 5%, 500 mW, DO-213AA (MELF) ZMM5258B-7 Diodes, Inc. 1N4745A-T Diodes, Inc. MAZS0620ML Panasonic Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 14 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 7 Transformer Specification 7.1 Electrical Diagram W1 Primary 11 60T #31 AWG 1 FL1 20T #25 TIW W2 Output FL2 3 W3 Bias 20T #30 AWG 2 Figure 10 – Transformer Electrical Diagram. 7.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 second, 60 Hz, from pins 1, 2, 3, 11 to FL1, FL2. Pins 1-11, all other windings open, measured at 100 kHz, 0.4 VRMS. Pins 1-11, all other windings open. Pins 1-11, with FL1-FL2 shorted, measured at 100 kHz, 0.4 VRMS. 3000 VAC 1195 µH ±10% 750 kHz (Min.) 20 µH (Max.) 7.3 M aterials Item [1] [2] [3] [4] [5] [6] [7] Description Core: RM8/I, 3F3. Bobbin: 12 pin vertical, CSV-RM8-1S-12P Philips or equivalent with mounting clip, CLI/P-RM8. Tape: Polyester film, 3M 1350F-1 or equivalent, 9 mm wide. Wire: Magnet, #31 AWG, solderable double coated. Wire: Magnet, #30 AWG, solderable double coated. Wire: Triple Insulated, Furukawa TEX-E or Equivalent, #25 TIW. Transformer Varnish: Dolph BC-359 or equivalent. Page 15 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 7.4 Transform er Build Diagram Pins Side 3L Tape W3 - Finish (P2) W3 - Start (P3) 1L Tape 1L Tape W2 - Finish (FL2) W2 - Start (FL1) 1L Tape W1 - Finish (P11) W1 - Start (P1) Figure 11 – Transformer Build Diagram. 7.5 Transform er Construction Bobbin Preparation WD 1 (Primary) Insulation WD 2 (Secondary) Insulation WD 3 (Bias) Finish Wrap Final Assembly Place the bobbin item [2] on the mandrel such that pin side on the left side. Winding direction is the clockwise direction. Starting at pin 1, wind 60 turns of wire item [4] in two layers. Finish at pin 11. Apply one layer of tape item [3]. Leave about 1” of wire item [6], use small tape to mark as FL1, enter into slot of secondary side of bobbin, wind 20 turns in two layers. At the last turn exit the same slot, leave about 1”, and mark as FL2. Apply one layer of tape item [3]. Starting at pin 3, wind 20 turns of wire item [5], spreading the wire, finish at pin 2. Apply three layers of tape item [3] for finish wrap. Cut FL1 and FL2 to 0.75”. Grind core to get 1.15 mH inductance value. Assemble and secure core halves. Dip impregnate using varnish item [7]. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 16 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 8 Transformer Design Spreadsheet ACDC_LinkSwitchPH_032511; Rev.1.3; INPUT Copyright Power Integrations 2011 ENTER APPLICATION VARIABLES Dimming required VACMIN VACMAX fL VO VO_MAX VO_MIN V_OVP IO INFO NO OUTPUT UNIT NO 90 265 50 28.00 30.80 25.20 33.88 0.50 V V Hz V V V V A PO 14.0 W n 0.84 VB 25 ENTER LinkSwitch-PH VARIABLES LinkSwitch-PH LNK416 Chosen Device 0.84 25 V Power Out Universal 10W Current Limit Mode RED ILIMITMIN ILIMITMAX fS fSmin fSmax IV RV RV2 IFB RFB1 VDS LNK416 RED 1.19 1.38 66000 62000 70000 38.7 3.909 1.402 142.2 154.7 10 A A Hz Hz Hz uA M-ohms M-ohms uA k-ohms V VD 0.50 V VDB Key Design Parameters 0.70 V KP 0.88 LP VOR Expected IO (average) KP_VACMAX TON_MIN 85.00 0.88 1195 85 0.49 1.11 uH V A 1.90 us PCLAMP 0.11 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type RM8/I RM8/I Bobbin RM8/I_BOBBIN AE 0.63 LE 3.84 AL 3000 BW 8.6 M Page 17 of 48 0 W P/N: cm^2 cm nH/T^2 mm mm LinkSwitch-PH_032511: Flyback Transformer Design Spreadsheet Select 'YES' option if dimming is required. Otherwise select 'NO'. Minimum AC Input Voltage Maximum AC input voltage AC Mains Frequency Typical output voltage of LED string at full load Maximum expected LED string Voltage. Minimum expected LED string Voltage. Over-voltage protection setpoint Typical full load LED current !!! For Universal Input reduce Continuous Output Power PO_CONT below 10W (or use larger LinkSwitch-PH) Estimated efficiency of operation Bias Voltage 115 Doubled/230V 4.5W Select "RED" for reduced Current Limit mode or "FULL" for Full current limit mode Minimum current limit Maximum current limit Switching Frequency Minimum Switching Frequency Maximum Switching Frequency V pin current Upper V pin resistor Lower V pin resistor FB pin current (85 uA < IFB < 210 uA) FB pin resistor LinkSwitch-PH on-state Drain to Source Voltage Output Winding Diode Forward Voltage Drop (0.5 V for Schottky and 0.8 V for PN diode) Bias Winding Diode Forward Voltage Drop Ripple to Peak Current Ratio (For PF > 0.9, 0.4 < KP < 0.9) Primary Inductance Reflected Output Voltage. Expected Average Output Current Expected ripple current ratio at VACMAX Minimum on time at maximum AC input voltage Estimated dissipation in primary clamp * Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Safety Margin Width (Half the Primary to Secondary Creepage Distance) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG L 2.00 NS 20 DC INPUT VOLTAGE PARAMETERS VMIN VMAX CURRENT WAVEFORM SHAPE PARAMETERS DMAX IAVG 2 20 127 375 V V 0.42 0.18 A IP 0.91 A IRMS 0.30 A TRANSFORMER PRIMARY DESIGN PARAMETERS LP NP NB ALG 1195 60 18 336 uH 23-Jun-12 Number of Primary Layers Number of Secondary Turns Peak input voltage at VACMIN Peak input voltage at VACMAX Minimum duty cycle at peak of VACMIN Average Primary Current Peak Primary Current (calculated at minimum input voltage VACMIN) Primary RMS Current (calculated at minimum input voltage VACMIN) Primary Inductance Primary Winding Number of Turns Bias Winding Number of Turns nH/T^2 Gapped Core Effective Inductance Maximum Flux Density at PO, VMIN BM 2901 Gauss (BM<3100) BP 3511 Gauss Peak Flux Density (BP<3700) AC Flux Density for Core Loss Curves (0.5 X BAC 1277 Gauss Peak to Peak) ur 1455 Relative Permeability of Ungapped Core LG 0.21 mm Gap Length (Lg > 0.1 mm) BWE 17.2 mm Effective Bobbin Width Maximum Primary Wire Diameter including OD 0.29 mm insulation Estimated Total Insulation Thickness (= 2 * INS 0.05 mm film thickness) DIA 0.24 mm Bare conductor diameter Primary Wire Gauge (Rounded to next smaller AWG 31 AWG standard AWG value) CM 81 Cmils Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA CMA 272 Cmils/Amp < 600) LP_TOL 10 Tolerance of primary inductance TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT) Lumped parameters ISP 2.72 A Peak Secondary Current ISRMS 0.98 A Secondary RMS Current IRIPPLE 0.84 A Output Capacitor RMS Ripple Current Secondary Bare Conductor minimum circular CMS 196 Cmils mils Secondary Wire Gauge (Rounded up to next AWGS 27 AWG larger standard AWG value) DIAS 0.36 mm Secondary Minimum Bare Conductor Diameter Secondary Maximum Outside Diameter for ODS 0.43 mm Triple Insulated Wire VOLTAGE STRESS PARAMETERS Estimated Maximum Drain Voltage assuming VDRAIN 553 V maximum LED string voltage (Includes Effect of Leakage Inductance) Output Rectifier Maximum Peak Inverse PIVS 160 V Voltage (calculated at VOVP, excludes leakage inductance spike) Bias Rectifier Maximum Peak Inverse Voltage PIVB 144 V (calculated at VOVP, excludes leakage inductance spike) FINE TUNING (Enter measured values from prototype) V Pin Resistor Fine Tuning RV1 3.9 3.90 M-ohms Upper V Pin Resistor Value Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 18 of 48 23-Jun-12 RV2 VAC1 VAC2 IO_VAC1 IO_VAC2 RV1 (new) RV2 (new) DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 1.33 115 230 0.486 0.49 1.33 115.0 230.0 0.49 0.49 3.95 1.09 M-ohms V V A A M-ohms M-ohms V_OV 322.9 V V_UV 73.2 V 155 1E+012 22.5 27.5 0.50 0.50 154.7 1.00E+12 k-ohms k-ohms V V A A k-ohms k-ohms FB Pin Resistor Fine Tuning RFB1 RFB2 VB1 VB2 IO1 IO2 RFB1 (new) RFB2(new) Page 19 of 48 Lower V Pin Resistor Value Test Input Voltage Condition1 Test Input Voltage Condition2 Measured Output Current at VAC1 Measured Output Current at VAC2 New RV1 New RV2 Typical AC input voltage at which OV shutdown will be triggered Typical AC input voltage beyond which power supply can startup Upper FB Pin Resistor Value Lower FB Pin Resistor Value Test Bias Voltage Condition1 Test Bias Voltage Condition2 Measured Output Current at Vb1 Measured Output Current at Vb2 New RFB1 New RFB2 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9 Performance Data All measurements performed at room temperature and using strings of LEDs for the load. 9.1 Efficiency – Full Brightness 88.0 87.5 87.0 Efficiency (%) 86.5 86.0 85.5 85.0 84.5 8 LED 9 LED 84.0 10 LED 83.5 70 90 110 130 150 170 190 210 230 250 270 290 Input Voltage (VAC) Figure 12 – Efficiency at Full Brightness. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 20 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 9.2 Line and Load R egulation – Full Brightness 510 8 LED 505 9 LED 10 LED Output Current (mA) 500 495 490 485 480 475 470 465 70 90 110 130 150 170 190 210 230 250 270 Input Voltage (VAC) Figure 13 – Line and load Regulation. Page 21 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 290 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.3 P ow er Factor – Full Brightness 1.00 8 LED 0.99 9 LED 10 LED Power Factor 0.98 0.97 0.96 0.95 0.94 0.93 0.92 70 90 110 130 150 170 190 210 230 250 270 290 Input Voltage (VAC) Figure 14 – Power Factor at Full Brightness. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 22 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 9.4 A-THD – Full Brightness 34 31 A-THD (%) 28 25 22 19 16 8 LED 9 LED 13 10 LED 10 70 90 110 130 150 170 190 210 230 250 270 Input Voltage (VAC) Figure 15 – Total Harmonic Distortion. Page 23 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 290 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.5 115 VAC Dim m ing Characteristic 9.5.1 Output Current vs. Control Voltage 600 Output Current (mA) 500 400 300 200 100 0 0 1 2 3 4 5 6 7 8 9 10 Control Voltage (VDC) Figure 16 – 115 VAC Output Current vs. Control Voltage (9 LED Load). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 24 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 9.5.2 Dimming Ratio vs. Control Voltage 1000000 Dimming Ratio 100000 10000 1000 100 10 1 0 1 2 3 4 5 6 7 8 9 Control Voltage (VDC) Figure 17 – 115 VAC Dimming Ratio vs. Control Voltage (9 LED Load). Page 25 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 10 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.6 230 VAC Dim m ing Characteristic 9.6.1 Output Current vs. Control Voltage 600 Output Current (mA) 500 400 300 200 100 0 0 1 2 3 4 5 6 7 8 9 10 Control Voltage (VDC) Figure 18 – 230 VAC Output Current vs. Control Voltage (9 LED Load). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 26 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 9.6.2 Dimming Ratio vs. Control Voltage 10000 Dimming Ratio 1000 100 10 1 0 1 2 3 4 5 6 7 8 9 Control Voltage (VDC) Figure 19 – 230 VAC Dimming Ratio vs. Control Voltage (9 LED Load). Page 27 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 10 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.7 Harm onics – Full Brightness The design met the limits for Class C equipment for an active input power of <25 W. In this case IEC61000-3-2 specifies that harmonic currents shall not exceed the limits of Class D equipment 1. Therefore the limits shown in the charts below are Class D limits which must not be exceeded to meet Class C compliance. 9.7.1 8 LED Load 120 Class C limit 115 VAC Harmonics, 8 LED Load Harmonic Content (mA) 100 80 60 40 20 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 20 – 115 VAC Harmonics, 8 LED Load. 1 IEC6000-3-2 Section 7.3, table 2, column 2. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 28 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 60 Class C limit 230 VAC Harmonics, 8 LED Load Harmonic Content (mA) 50 40 30 20 10 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 21 – 230 VAC Harmonics, 8 LED Load. Page 29 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.7.2 9 LED Load 120 Class C limit 115 VAC Harmonics, 9 LED Load Harmonic Content (mA) 100 80 60 40 20 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 22 – 115 VAC Harmonics, 9 LED Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 30 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 60 Class C limit 230 VAC Harmonics, 9 LED Load Harmonic Content (mA) 50 40 30 20 10 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 23 – 230 VAC Harmonics, 9 LED Load. Page 31 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.7.3 10 LED Load 140 Class C limit 115 VAC Harmonics, 10 LED Load Harmonic Content (mA) 120 100 80 60 40 20 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 24 – 115 VAC Harmonics, 10 LED Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 32 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 70 Class C limit 230 VAC Harmonics, 10 LED Load Harmonic Content (mA) 60 50 40 30 20 10 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Number (N) Figure 25 – 230 VAC Harmonics 10 LED Load. Page 33 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.8 Test Data 9.8.1 Efficiency, Regulation, Power Factor, and THD - Non-Dimming Input Input Measurement VAC (VRMS) Freq (Hz) VIN (VRMS) IIN (mARMS) PIN (W) PF Load Measurement Calculation %ATHD VOUT (VDC) IOUT (mADC) POUT (W) PCAL (W) Efficiency (%) Loss (W) Regulation (%) 90 60 90.01 162.64 14.43 0.986 16.02 24.55 497 12.26 12.20 84.96 2.17 -0.60 100 60 99.98 146.84 14.41 0.982 18.56 24.51 499 12.31 12.23 85.42 2.10 -0.20 115 60 115.02 128.00 14.37 0.976 21.34 24.49 502 12.36 12.29 86.02 2.01 0.40 132 60 132.04 112.13 14.35 0.969 24.2 24.47 505 12.41 12.36 86.49 1.94 1.00 180 50 180.05 82.88 14.25 0.955 28.88 24.43 505 12.41 12.34 87.11 1.84 1.00 230 50 230.14 64.61 14.00 0.941 30.76 24.39 497 12.20 12.12 87.16 1.80 -0.60 240 50 240.10 61.83 13.93 0.939 30.85 24.37 495 12.13 12.06 87.07 1.80 -1.00 265 50 265.12 55.79 13.76 0.930 30.95 24.33 489 11.95 11.90 86.87 1.81 -2.20 Table 1 – 8 LED Load Measurement Data. Input Input Measurement VAC (VRMS) Freq (Hz) VIN (VRMS) IIN (mARMS) PIN (W) PF Load Measurement Calculation %ATHD VOUT (VDC) IOUT (mADC) POUT (W) PCAL (W) Efficiency (%) Loss (W) Regulation (%) 90 60 90.01 179.01 15.91 0.987 14.86 27.36 489 13.44 13.38 84.48 2.47 -2.20 100 60 99.98 161.04 15.83 0.983 17.61 27.35 490 13.47 13.40 85.12 2.36 -2.00 115 60 115.02 140.41 15.78 0.977 20.73 27.34 492 13.51 13.45 85.63 2.27 -1.60 132 60 132.04 122.87 15.74 0.970 23.71 27.34 494 13.56 13.51 86.14 2.18 -1.20 180 50 180.05 91.11 15.69 0.956 28.72 27.33 496 13.63 13.56 86.88 2.06 -0.80 230 50 230.15 71.09 15.45 0.944 30.58 27.30 489 13.42 13.35 86.88 2.03 -2.20 240 50 240.11 67.92 15.36 0.942 30.71 27.28 486 13.33 13.26 86.80 2.03 -2.80 265 50 265.13 61.14 15.14 0.934 30.96 27.25 479 13.12 13.05 86.65 2.02 -4.20 Table 2 – 9 LED Load Measurement Data. Input Input Measurement VAC (VRMS) Freq (Hz) VIN (VRMS) IIN (mARMS) PIN (W) PF Load Measurement Calculation %ATHD VOUT (VDC) IOUT (mADC) POUT (W) PCAL (W) Efficiency (%) Loss (W) Regulation (%) 90 60 90.00 195.02 17.354 0.989 14.02 30.31 479 14.57 14.52 83.96 2.78 -4.22 100 60 99.97 175.41 17.260 0.984 16.92 30.29 480 14.60 14.55 84.59 2.66 -3.96 115 60 115.01 152.62 17.161 0.978 20.42 30.28 482 14.63 14.58 85.25 2.53 -3.70 132 60 132.03 133.52 17.121 0.971 23.39 30.28 484 14.69 14.64 85.80 2.43 -3.28 180 50 180.04 99.53 17.166 0.958 28.36 30.28 489 14.87 14.81 86.62 2.30 -2.20 230 50 230.14 77.57 16.896 0.947 30.36 30.25 482 14.64 14.58 86.65 2.26 -3.58 240 50 240.10 74.05 16.787 0.944 30.55 30.23 479 14.54 14.48 86.61 2.25 -4.18 265 50 265.12 66.52 16.530 0.937 30.99 30.19 472 14.30 14.24 86.51 2.23 -5.66 Table 3 – 10 LED Load Measurement Data. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 34 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 9.8.2 115 VAC Dimming Test Data VDIM (VDC) 10 9.5 9 8.5 8 7.5 7 6.5 6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0.1 VIN (VRMS) 115.02 115.02 115.03 115.04 115.04 115.05 115.05 115.05 115.05 115.06 115.05 115.06 115.06 115.06 115.06 115.06 115.06 115.06 115.06 115.06 115.06 Input Measurement IIN PIN PF (mARMS) (W) 140.35 15.77 0.977 140.24 15.76 0.977 111.41 12.42 0.969 86.62 9.60 0.964 67.20 7.42 0.959 36.64 4.09 0.971 27.70 3.07 0.964 23.20 2.55 0.956 19.85 2.16 0.944 18.13 1.95 0.934 16.70 1.78 0.924 15.86 1.67 0.917 15.11 1.58 0.909 14.49 1.50 0.902 13.94 1.44 0.895 13.36 1.36 0.886 13.28 1.35 0.885 13.30 1.35 0.886 13.29 1.35 0.886 13.30 1.36 0.886 13.29 1.35 0.886 %ATHD 20.8 20.8 24.7 26.6 27.5 17.2 14.7 13.1 12.8 12.8 12.9 12.9 13.2 13.4 13.6 14.0 13.9 13.8 13.8 13.7 13.7 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 27.38 492.00 13.52 27.36 492.00 13.51 26.93 391.00 10.57 26.50 304.00 8.07 26.07 232.20 6.06 25.22 118.50 2.99 24.80 80.60 2.00 24.50 59.60 1.46 24.18 41.50 1.00 23.95 30.90 0.74 23.68 20.82 0.49 23.44 14.11 0.33 23.11 7.41 0.17 22.56 2.15 0.05 21.34 0.18 0.00 19.26 0.02 0.00 18.33 0.01 0.00 17.43 0.005 0.00 16.65 0.003 0.00 16.39 0.003 0.00 16.38 0.003 0.00 PCAL (W) 13.47 13.46 10.53 8.06 6.05 2.99 2.00 1.46 1.00 0.74 0.49 0.33 0.17 0.05 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Calculation Efficiency Loss (%) (W) 85.74 2.25 85.74 2.25 85.12 1.85 84.05 1.53 81.73 1.36 73.05 1.10 65.10 1.07 57.23 1.09 46.57 1.15 38.04 1.21 27.77 1.28 19.78 1.34 10.82 1.41 3.23 1.46 0.26 1.43 0.02 1.36 0.01 1.35 0.01 1.35 0.00 1.35 0.00 1.36 0.00 1.35 Table 4 – 115 VAC, 60 Hz Dimming Measurements. Page 35 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 9.8.3 230 VAC, 50 Hz Dimming Test Data VDIM (VDC) 10 9.5 9 8.5 8 7.5 7 6.5 6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 VIN (VRMS) 230.14 230.14 230.14 230.14 230.14 230.15 230.15 230.15 230.15 230.15 230.15 230.14 230.13 230.13 230.13 230.13 230.14 230.14 230.14 230.14 230.14 Input Measurement IIN PIN PF (mARMS) (W) 71.13 15.46 0.944 71.09 15.45 0.944 59.15 12.77 0.938 45.22 9.64 0.926 39.95 8.47 0.921 26.76 5.49 0.892 22.72 4.53 0.867 20.38 3.95 0.843 18.51 3.48 0.816 17.30 3.16 0.795 16.45 2.94 0.777 15.79 2.77 0.762 15.24 2.62 0.748 14.83 2.52 0.737 14.41 2.41 0.726 14.07 2.32 0.717 13.78 2.25 0.708 13.56 2.19 0.701 13.41 2.15 0.696 13.38 2.14 0.695 13.34 2.13 0.694 %ATHD 30.6 30.6 31.0 31.0 30.1 24.2 21.9 21.0 20.7 20.9 21.3 21.7 22.1 22.6 23.2 23.8 24.3 24.8 25.1 25.2 25.2 Load Measurement VOUT IOUT POUT (VDC) (mADC) (W) 27.38 488.00 13.43 27.36 488.00 13.42 27.01 405.00 10.99 26.51 305.00 8.11 26.29 264.90 6.98 25.57 163.60 4.19 25.32 126.40 3.20 25.09 103.30 2.59 24.86 82.90 2.06 24.67 68.40 1.69 24.52 57.10 1.40 24.36 47.70 1.16 24.19 38.90 0.94 24.05 32.10 0.77 23.84 24.47 0.58 23.63 17.92 0.42 23.39 11.97 0.28 23.10 6.90 0.16 22.75 3.21 0.07 22.31 1.11 0.02 21.60 0.26 0.01 PCAL (W) 13.36 13.35 10.94 8.09 6.96 4.18 3.20 2.59 2.06 1.69 1.40 1.16 0.94 0.77 0.58 0.42 0.28 0.16 0.07 0.02 0.01 Calculation Efficiency Loss (%) (W) 86.87 2.03 86.86 2.03 86.05 1.78 84.13 1.53 82.46 1.49 76.28 1.30 70.61 1.33 65.52 1.36 59.25 1.42 53.41 1.47 47.64 1.54 41.96 1.61 35.87 1.68 30.67 1.75 24.26 1.82 18.28 1.90 12.47 1.97 7.32 2.03 3.40 2.08 1.16 2.12 0.26 2.12 Table 5 – 230 VAC, 50 Hz Dimming Measurements. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 36 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 10 Waveforms 10.1 I nput Line Current Figure 26 – 90 VAC 60 Hz, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 27 – 115 VAC 60 Hz, Full Load. Upper: IIN, 100 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 28 – 230 VAC 50 Hz, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Figure 29 – 265 VAC 50 Hz, Full Load. Upper: IIN, 50 mA / div. Lower: VIN, 100 V, 10 ms / div. Page 37 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 10.2 Drain Voltage and Current Norm al Operation Figure 30 – 90 VAC 60 Hz, Full Load. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 31 – 90 VAC 60 Hz, Full Load. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 µs / div. Figure 32 – 265 VAC 50 Hz, Full Load. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Figure 33 – 265 VAC 50 Hz, Full Load. Upper: IDRAIN, 200 mA / div. Lower: VDRAIN, 100 V, 5 µs / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 38 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 10.3 Drain Voltage and Current Start-up Operation Figure 34 – 265 VAC 50 Hz, Full Load Start-Up. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 5 ms / div. Page 39 of 48 Figure 35 – 265 VAC 50 Hz, Full Load Start-Up. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 0.5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 10.4 Output Current and Output Voltage Figure 36 – 90 VAC 60 Hz, Full Load. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 5 ms / div. Figure 37 – 115 VAC 60 Hz, Full Load. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 5 ms / div. Figure 38 – 230 VAC 50 Hz, Full Load. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 5 ms / div. Figure 39 – 265 VAC 50 Hz, Full Load. Upper: IOUT, 100 mA / div. Lower: VOUT, 10 V, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 40 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 10.5 Output Current and Voltage at P ow er-up, P ow er-dow n Figure 40 – 90 VAC 60 Hz, Output Rise. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 500 ms / div. Figure 41 – 90 VAC 60 Hz, Output Fall. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 500 ms / div. Figure 42 – 265 VAC 50 Hz, Output Rise. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 500 ms / div. Figure 43 – 265 VAC 50 Hz, Output Fall. Upper: IOUT, 100 mA / div. Lower: VOUT, 5 V, 500 ms / div. Page 41 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 10.6 Output Short Figure 44 – 265 VAC 60 Hz, Output Short. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 500 ms / div. Figure 45 – 265 VAC 60 Hz, Output Short. Upper: IDRAIN, 500 mA / div. Lower: VDRAIN, 100 V, 20 ms / div. 10.7 Open Load/ LED Condition Figure 46 – 265 VAC 60 Hz, Open Load. CH1: VDRAIN, 100 V / div. CH4: VOUT, 10 V, 1 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Figure 47 – 265 VAC 60 Hz, Open Load Start-Up. CH1: VDRAIN, 100 V / div. CH4: VOUT, 10 V, 1 s / div. Page 42 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 11 Thermals The following measurements were taken at room temperature and using 9 LED Load, approximately 14 W output power. 11.1 115 VAC Therm al M easurem ents Figure 48 – 115 VAC, 60 Hz Top-Side Thermal Image. Figure 49 – 115 VAC, 60 Hz Bottom-Side Thermal Image. Page 43 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 11.2 230 VAC Therm al M easurem ents Figure 50 – 230 VAC, 50 Hz Top-Side Thermal Image. Figure 51 – 230 VAC, 50 Hz Bottom-Side Thermal Image. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 44 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 12 Conducted EMI 12.1 Conducted EM I Test Setup The unit was tested using 9 strings of LED load (~27 V VOUT) with input voltage of 115 VAC and 230 VAC, 60 Hz line frequency, and at room temperature. 12.2 115 VAC, 60 Hz Conducted EM I M easurem ents Power Integrations 05.Jul 11 18:14 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 E N55015Q 110 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 1 QP 100 CLRWR 90 2 AV CLRWR 80 TDF 70 60 50 EN55015A 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 52 – Conducted EMI, 9 LED Load, 115 VAC, 60 Hz, EN55015B Limits. Page 45 of 48 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 12.3 230 VAC, 60 Hz Conducted EM I M easurem ents Power Integrations 05.Jul 11 17:37 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 E N55015Q 110 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 1 QP 100 CLRWR 90 2 AV CLRWR 80 TDF 70 60 50 EN55015A 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 53 – Conducted EMI, 9 LED Load, 230 VAC, 60 Hz, EN55015B Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 46 of 48 23-Jun-12 DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 13 Revision History Date 09-Sep-11 17-Nov-11 09-May-12 16-Oct-12 23-Jun-12 Page 47 of 48 Author CA KM KM KM Revision 1.0 1.1 1.2 1.3 KM 1.4 Description and Changes Initial Release Updated Harmonics text on page 6 and 28 Updated Figure 7 Updated Power Supply Specification Updated Brand Style and Added Transformer Supplier Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com DER-263 14 W PWM-Analog Dimmable LED Driver Using LNK406EG 23-Jun-12 For the latest updates, visit our website: www.power.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.power.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.power.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, LYTSwitch, InnoSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, FluxLink, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2015 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Lindwurmstrasse 114 80337, Munich Germany Phone: +49-895-52739110 Fax: +49-895-527-39200 e-mail: [email protected] JAPAN Kosei Dai-3 Building 2-12-11, Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033 Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu District Taipei 11493, Taiwan R.O.C. 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