Design Example Report Title 150 W Power Factor Corrected LLC Power Supply Using HiperPLC (PLC810PG) Specification 140 – 265 VAC Input; 150 W (48 V at 0.05 A – 3.125 A) Output Application LED Street Light Author Applications Engineering Department Document Number DER-212 Date June 1, 2009 Revision 1.1 Summary and Features • Integrated PFC and LLC controller • Continuous mode PFC using small low-cost ferrite core and magnet wire • Frequency and Phase locked PFC and LLC for ripple cancellation in bulk capacitor for reduced ripple current, reduced bulk capacitor size and reduced EMI filter cost • Tight LLC duty-cycle matching • Tight LLC dead-time control • >95% full load PFC efficiency at 140 VAC using conventional ultrafast rectifier • >95% full load LLC efficiency • >92% full load system efficiency PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 Table of Contents 1 2 3 4 Introduction.................................................................................................................4 Power Supply Specification ........................................................................................7 Schematic...................................................................................................................8 Circuit Description ....................................................................................................10 4.1 Input Filter / Boost Converter / Bias Supply.......................................................10 4.1.1 EMI Filtering ...............................................................................................10 4.1.2 Inrush Limiting............................................................................................10 4.1.3 Main PFC Stage .........................................................................................10 4.1.4 Primary Bias Supply / Start-up ...................................................................11 4.2 Controller / Main LLC Output.............................................................................11 4.2.1 LLC Input Stage .........................................................................................11 4.2.2 LLC Outputs ...............................................................................................11 4.2.3 Controller....................................................................................................11 4.2.4 PFC Control ...............................................................................................12 4.2.5 Bypassing / Ground Isolation .....................................................................12 4.2.6 LLC Control ................................................................................................12 4.3 LLC Secondary Control Circuits ........................................................................12 4.3.1 Voltage Feedback ......................................................................................12 5 PCB Layout ..............................................................................................................13 6 Bill of Materials .........................................................................................................15 7 Magnetics .................................................................................................................19 7.1 Main LLC 48 V Transformer (T1) Specification .................................................19 7.1.1 Electrical Diagram ......................................................................................19 7.1.2 Electrical Specifications..............................................................................19 7.1.3 Materials.....................................................................................................19 7.1.4 Winding Diagram........................................................................................20 7.1.5 Winding Instructions ...................................................................................20 7.2 Transformer Illustrations....................................................................................21 7.3 PFC Choke (L4) Specification ...........................................................................25 7.3.1 Electrical Diagram ......................................................................................25 7.3.2 Electrical Specification ...............................................................................25 7.3.3 Materials.....................................................................................................25 7.3.4 Build Diagram.............................................................................................26 7.3.5 Winding Instructions ...................................................................................26 8 LLC Transformer Design Spreadsheet .....................................................................28 9 Performance Data ....................................................................................................34 9.1 LLC Stage Efficiency .........................................................................................34 9.2 Total Efficiency ..................................................................................................35 9.3 THD and Power Factor......................................................................................36 9.4 Output Regulation .............................................................................................37 10 Waveforms............................................................................................................38 10.1 Input Voltage and Current .................................................................................38 10.2 LLC Primary Voltage and Current .....................................................................38 10.3 PFC Switch Voltage and Current - Normal Operation .......................................39 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 10.4 AC Input Current and PFC Output Voltage During Start-up...............................39 10.5 LLC Start-up ......................................................................................................40 10.6 LLC Output Short Circuit....................................................................................41 10.7 Output Voltage During Start-up .........................................................................42 10.8 Output Ripple Measurements ............................................................................43 10.8.1 Ripple Measurement Technique.................................................................43 10.8.2 Full Load Output Ripple Results .................................................................44 10.8.3 Output Load Step Response ......................................................................45 11 Temperature Profiles.............................................................................................46 11.1 Thermal Results Summary ................................................................................47 11.1.1 Testing Conditions......................................................................................47 11.2 140 VAC, 60 Hz, 150 WOUT................................................................................48 11.3 230 VAC, 60 Hz, 150 WOUT................................................................................49 12 LLC Gain-Phase....................................................................................................50 13 Conducted EMI .....................................................................................................52 14 Line Surge.............................................................................................................53 15 Revision History ....................................................................................................54 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 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 1 Introduction This engineering report describes a 150 W reference design power supply for 230 VAC input LED street lights and also serves as a general purpose evaluation board for the PLC810PG The design is based on the PLC810PG controller IC which integrates both continuous current mode (CCM) boost PFC and resonant half-bridge (LLC) control functions together with high-side and low side drivers for the LLC stage MOSFETs. To allow optimum design of the LLC transformer (T1) for high efficiency (high k factor – the ratio of parallel to series inductance) the design operates in burst mode at zero load. The supply is thus protected against output overvoltage at low/zero load, but it will not deliver a steady output voltage at zero load. A practical LED street light power supply design that includes an auxiliary output winding to power the LED driver circuitry may not have this limitation. DER-212 demonstrates a design using the commonly employed single transformer and resonant inductor magnetic component (integrated magnetics) for the LLC stage (common in display applications). However, the PLC810 may as easily be used with separated transformer and resonating inductor. PI design materials support both approaches. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Figure 1 – DER-212 Photograph, Top View. Page 5 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 Figure 2 – DER-212 Photograph, Bottom View. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 2 Power Supply Specification Description Symbol Min Typ Max Units Comment VIN fLINE PF 140 47 0.97 265 64 VAC Hz 3 Wire input. 50/60 Output Voltage VLG 45.6 48 Output Ripple VRIPPLE(LG) Input Voltage Frequency Power Factor Full load, 230 VAC Main Converter Output Output Current ILG * 0.05 50.4 V 150 mV P-P 48 VDC ± 5% 20 MHz bandwidth * 3.13 3.13 A Supply is protected under no-load conditions Total Output Power Continuous Output Power Efficiency POUT Total system at Full Load ηMain 150 W 91 92 % Measured at 140 VAC, Full Load Measured at 230 VAC, Full Load Environmental Conducted EMI Safety Surge Differential Common Mode 100 kHz Ring Wave Ambient Temperature Page 7 of 55 Meets CISPR22B / EN55022B Designed to meet IEC950 / UL1950 Class II TAMB 1 2 2 0 60 kV kV kV o C 1.2/50 µs surge, IEC 1000-4-5, Differential Mode: 2 Ω Common Mode: 12 Ω 500 A short circuit current See thermal section for conditions Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 3 Schematic Figure 3 – Schematic of PLC810PG LCD Street Light Power Supply Application Circuit, Input Circuit and PFC Power Stage. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Figure 4 – Schematic of PLC810PG LCD Street Light Power Supply Application Circuit, PFC Circuit Control Inputs and LLC Stage. Page 9 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 4 Circuit Description The main converter uses the PLC810PG in a primary-side-control, PFC + LLC configuration. 4.1 Input Filter / Boost Converter / Bias Supply The schematic in Figure 3 shows the input EMI filter, main PFC stage, and primary bias supply/start-up circuit. 4.1.1 EMI Filtering Capacitors C1 and C5 are connected directly from Line and Neutral to protective Earth ground and are used to control common mode noise at frequencies greater than 30 MHz. Common mode inductors L1 and L2 control EMI at low frequencies and mid-band (<10 MHz), respectively. Capacitors C2 and C6 control resonant peaks in the mid-band region. PFC inductor L4 has a grounded shield band to prevent electrostatic and magnetic noise coupling to the EMI filter components. Capacitors C3 and C4 provide differential mode EMI filtering. To meet safety requirements resistors R1, R2 and R3 discharge these capacitors when AC is removed. The heat sink for PFC switch FET Q2 and PFC output diode D2 is tied to primary return at the cathode of D3 via capacitor C80 to eliminate the heat sink as a source of conducted noise into the chassis/protective Earth ground. 4.1.2 Inrush Limiting Thermistor RT1 provides inrush limiting. It is shorted by relay RL1 during normal operation, increasing efficiency by approximately 1 - 1.5%. 4.1.3 Main PFC Stage Components C9, C11, L4, Q2, and D2 form a continuous mode power factor correction circuit. Components Q1, Q3, R7, R9 and bead 1 buffer the PWM drive signal for Q2 from the PLC810 controller. Resistor R7 allows the turn-off speed of Q2 to be adjusted to optimize the losses between D2 and Q2. In this design it was found that efficiency and EMI were both improved by reducing the value of R7 and adding ferrite beads to the gate and drain of Q2 (bead 1 and bead 2 respectively). In general, increasing MOSFET turn on drive current reduces MOSFET switching losses but increases the reverse recovery current through D2 and associated ringing. An ultra fast diode was selected for D2 as a lower cost alternative to a silicon carbide or other proprietary diode technology. These may provide higher efficiency by reducing reverse recovery charge, but significantly increase solution cost. A 220 MΩ, 500 V power MOSFET was selected for Q2 to maximize the efficiency of the PFC stage. A TO-247 package device was selected for better heat transfer. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Capacitor C10 provides local bypassing for the drive circuit. Current sensing for the PFC stage is provided by R6 and R8. The sense voltage is clamped to two diode drops by D3 and D4, protecting the current sense input of the controller IC during fault conditions. Diode D1 charges the PFC output capacitor (C9) when AC is first applied. This routes the inrush current around the PFC inductor L4 preventing it from saturating and causing stress in Q2 and D2 when the PFC stage begins to operate. Capacitor C11 is used to shrink the high frequency loop around components Q2, D2 and C9 to reduce EMI. The incoming AC is rectified by BR1 and filtered by C7. Capacitor C7 was selected as a lowloss polypropylene type due to its low loss and low impedance characteristics. This capacitor provides the high instantaneous current through L4 during Q2 on-time. 4.1.4 Primary Bias Supply / Start-up Components D22, D23, C75, C76, and R109 act as a voltage doubler circuit to rectify and filter the output of a floating bias winding on PFC choke L4, providing a bias voltage relatively independent of input voltage. Components Q24, Q25, Q27, VR9, VR10, VR11, D24, C70, R103, R111, R113, R114, and R117 constitute the bias regulator and start-up functions. Resistor R113 charges capacitor C70 through mosfet Q24 to provide start-up bias for controller U1. The Q24 output voltage is clamped by VR10. Transistor Q25 shuts off the start-up circuit when the primary bias supply reaches regulation. Darlington transistor Q27, R111, and VR9 form a simple emitter-follower voltage regulator. Transistor Q26 switches on relay RL1 when the primary bias supply reaches regulation, shorting out thermistor RT1. 4.2 Controller / Main LLC Output Figure 4 shows the schematic of the main controller circuit and LLC converter stage. 4.2.1 LLC Input Stage MOSFETs Q10 and Q11 are the switch MOSFETs for the LLC converter. They are driven directly by the controller IC via resistors R56 and R58. Capacitor C39 is the primary resonating capacitor, and should be a low-loss type rated for the RMS current at maximum load. Capacitor C40 is used for local bypassing, and is positioned adjacent to Q10 and Q11. Resistor R59 provides primary current sensing to the controller for overpower protection. 4.2.2 LLC Outputs The secondaries of transformer T1 are rectified and filtered by D9, and C37-38 to provide the +48 V output. 4.2.3 Controller Figure 4 also shows the circuitry around the main controller IC U1, which provides control functions for the input PFC and output LLC stages. Page 11 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 4.2.4 PFC Control The PFC boost stage output voltage is fed back to the boost voltage sense pin (FBP of U13) via resistors R39-41, R43, R46, and R50. Capacitor C25 filters noise. Components C26, C28 and R48 provide frequency compensation for the PFC. Transistor Q20 turns on during large signal excursions, bypassing C26. This allows fast slewing of the PFC control loop in response to a large load step. The PFC current sense signal from resistors R6 and R8 is filtered by R45 and C73. The PFC drive signal from the GATEP pin is routed to the main switching FET via R44. This damps any ringing in the PFC drive signal caused by the trace length from U1 to PFC switch MOSFET Q2. 4.2.5 Bypassing / Ground Isolation Capacitors C29, C31, and C32 provide supply bypassing for the analog and digital supply rails for U1. Resistor R55 and ferrite bead L7 provide ground isolation between the PFC and LLC ground systems. Resistors R37 and R38 isolate the IC analog and digital supply rails. Ferrite bead L6 provides high frequency isolation between the LLC stage high side MOSFET drive return and the controller IC. 4.2.6 LLC Control Feedback from the LLC output sense/feedback circuit is provided by U2, which develops a feedback voltage across resistor R54. Capacitor C77 filters the feedback signal. Resistors R49, R51, and R53 set the lower frequency limit for the LLC converter stage. Capacitor C27 is used to provide output soft start. Resistor R52 sets the LLC upper frequency limit. Capacitors C30 and C36 are noise filters. The LLC overload sense signal from resistor R59 is filtered by R47 and C35. Components C23, R42, and D8 provide bootstrapping for the LLC top side MOSFET drive. Resistors R52 and R53 were selected to force the LLC converter into burst mode at low/zero output load, protecting the output from overvoltage. This operation mode was selected (vs. allowing operation at a higher frequency at no-load) to give adequate dead time and ensure ZVS operation. The alternative would be to adjust the ratio of parallel and series inductance (k factor) however this reduces full load efficiency. 4.3 LLC Secondary Control Circuits Figure 4 shows the secondary control schematic for the LLC stage. 4.3.1 Voltage Feedback The LLC converter 48 V output is sensed by resistors R67 and R68. Zener diode VR12 drops the 48 V output to protect regulator U3. Components C24, C44, C51, R30, R70, and R107 provide frequency compensation for the LLC stage. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 5 PCB Layout Figure 5 – Printed Circuit Layout, Top Side. Page 13 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 Figure 6 – Printed Circuit Layout, Bottom Side. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 6 Bill of Materials Item Qty Ref Des 1 4 BEAD1 BEAD2 BEAD3 BEAD4 2 1 BR1 3 4 C1 C2 C5 C6 4 2 C3 C4 5 1 6 Description Mfg Part Number Mfg 3.5 mm D x 3.25 L mm, 21 Ω at 25 MHz, 1.6mm (.063) hole, Ferrite Bead 2643001501 Fair-Rite 600 V, 8 A, Bridge Rectifier, GBJ Package GBJ806-F Diodes Inc Vishay 330 pF, Ceramic Y1 440LT33-R 470 nF, 275 VAC, Film, X2 PX474K31D5 Carli C7 470 nF, 630 V, Polypropylene Film ECW-F6474JL Panasonic 1 C9 100 µF, 450 V, Electrolytic, Low ESR, (18 x 30) EPAG451ELL101MM35S 7 4 1 µF, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E105K 8 1 C10 C23 C31 C33 C11 Nippon ChemiCon Panasonic 20 nF, 500 V, Disc Ceramic D203Z59Z5UL63L0R Vishay/BC 9 3 C24 C28 C51 22 nF, 200 V, Ceramic, X7R, 0805 08052C223KAT2A AVX Corp 10 2 C25 C77 10 nF, 200 V, Ceramic, X7R, 0805 08052C103KAT2A AVX Corp 11 2 C26 C29 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) EKMG500ELL100ME11D Nippon ChemiCon 12 1 C27 2.2 µF, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E225K Panasonic 13 5 C30 C34 C36 C44 C73 2.2 nF, 200 V, Ceramic, X7R, 0805 08052C222KAT2A AVX Corp 14 1 C32 100 nF, 50 V, Ceramic, X7R, 1206 ECJ-3VB1H104K Panasonic 15 1 C35 1 nF, 200 V, Ceramic, X7R, 0805 08052C102KAT2A AVX Corp 16 2 C37 C38 680 µF, 63 V, Electrolytic, Low ESR, 50 mΩ, (16 x 25) EEU-FC1J681 Panasonic 17 1 C39 18 nF, 1600 V, Film 2222 383 50183 Vishay 18 1 C40 100 nF, 630 V, Film ECQ-E6104KF Panasonic 19 1 C68 1 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) EKMG500ELL1R0ME11D Nippon ChemiCon 20 3 C70 C75 C76 ELXZ250ELL151MF15D 21 2 C74 C78 150 uF, 25 V, Electrolytic, Low ESR, 180 mΩ, (6.3 x 15) 1 nF, Ceramic, Y1 440LD10-R Nippon ChemiCon Vishay 22 1 C80 3.3 nF, Ceramic, Y1 440LD33-R Vishay 23 1 D1 600 V, 3 A, Recitifier, DO-201AD 1N5406 Vishay 24 1 D2 600 V, 8 A, Ultrafast Recovery, 12 ns, TO-220AC STTH8S06D ST Semiconductor 25 2 D3 D4 1000 V, 1 A, Rectifier, DO-41 1N4007-E3/54 Vishay 26 1 D8 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 UF4005-E3 Vishay 27 1 D9 200 V, 10 A, Dual Ultrafast Recovery, 25 ns, TO220AB STTH1002CT ST 28 5 D16 D19 D20 D24 D25 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diode Inc. 29 2 D22 D23 200 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC ES1D Vishay 30 1 DER-212 PRIMARY INSULATOR Thermal Conductive insulator, DER-212 Pri Htsnk, 0.5mm Silicone Power Integrations 31 1 DER-212 SECONDARY INSULATOR Thermal Conductive insulator, DER-212 Sec Htsnk, 0.5mm Silicone Power Integrations 32 1 F1 Page 15 of 55 5 A, 250 V, Slow, TR5 3721500041 Wickman Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG Thermal Grease, Silicone, 5 oz Tube 01-Jun-09 33 1 GREASE1 CT40-5 ITW Chemtronics 34 1 35 1 36 2 GND CABLE ASSY, DER212 HS/BRACKET, DER-212 HS3 HS4 37 1 J3 38 1 J4 3 Position (1 x 3) header, 0.156 pitch, Vertical B3P-VH JST 39 1 JP38 Wire Jumper, Non insulated, 22 AWG, 1.4 in 298 Alpha 40 1 JP39 Wire Jumper, Non insulated, 22 AWG, 0.3 in 298 Alpha 41 2 L1 L2 Common Mode Choke Toroidal P/N T22148-902S (Order PI Taiwan) Fontaine Tech CO. LTD 42 1 L4 CC Mode PFC Choke, PQ32/20 43 2 L6 L7 3.5 mm x 4.45 mm, 68 Ohms at 100 MHz, 22 AWG hole, Ferrite Bead 2743001112 Fair-Rite 44 4 Hardware, Heatsink MaxClip, TO220/Max247 11.2lb 0.87 x 12 mm MAX07G Aavid Thermalloy 45 1 MAX CLIP1 MAX CLIP2 MAX CLIP3 MAX CLIP4 MAX CLIP5 Hardware, Heatsink MaxClip, TO218/TO247 16.9lb 0.93 x 18 mm MAX08G Aavid Thermalloy 46 1 NUT1 Nut, Hex, Kep 4-40, S ZN Cr3 plateing RoHS 4CKNTZR Olander 47 6 Nut, Hex, Kep 6-32, Zinc Plate 6CKNTZR Olander 48 1 NUT2 NUT3 NUT4 NUT5 NUT6 NUT7 Q1 NPN, 60 V 1000 MA, SOT-23 FMMT491TA Zetex Inc 49 1 Q2 500 V, 20 A, 220 mOhm, N-Channel, TO-247AC STW20NM50FD ST 50 1 Q3 PNP, 60 V 1000 MA, SOT-23 FMMT591TA Zetex Inc 51 2 Q10 Q11 500 V, 6.8 A, 320 mOhm. N-Channel, TO-247AC IRFIB7N50LPBF IR/Vishay 52 1 Q20 PNP, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3906LT1G On Semiconductor 53 1 Q24 600 V, 400 mA, 8.5 Ohm, N-Channel, SOT 223 STN1HNK60 ST 54 2 Q25 Q26 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3904LT1G On Semiconductor 55 1 Q27 56 3 R1 R2 R3 57 2 R6 R8 58 1 R7 2.2 Ω, 5%, 1/8 W, Metal Film, 0805 59 2 R9 R103 4.7 kΩ, 5%, 1/8 W, Metal Film, 0805 60 1 R30 7.5 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ752V Panasonic 61 2 R37 R38 4.7 Ω, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ4R7V Panasonic 62 2 R39 R40 768 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-768K Yageo 63 3 R41 R43 R46 768 kΩ, 1%, 1/4 W, Metal Film, 1206 ERJ-8ENF7683V Panasonic 64 1 R42 10 Ω, 5%, 1/4 W, Carbon Film CFR-25JB-10R Yageo 65 3 R44 R56 R58 10 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ100V Panasonic 66 1 R45 150 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ151V Panasonic 67 2 R47 R68 1 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ102V Panasonic 68 1 R48 2.2 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ222V Panasonic Cable ASSY, 18 GA GRN/YEL, 6 in, with ring terminal Heatsink/Mounting Bracket, DER-212 HEATSINK, Custom, Al, 1100, 0.090" Thk 8 Position (1 x 8) header, 0.156 pitch, Vertical Power Integrations 26-48-1081 Molex NPN, DARL 80 V 500 MA, SOT-89 BST52TA Zetex Inc 680 kΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ684V Panasonic 0.33 Ω, 5%, 2 W, Metal Oxide MO200J0R33B ERJ-6GEYJ2R2V Synton-Tech corporation Panasonic ERJ-6GEYJ472V Panasonic Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 69 1 R49 57.6 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF5762V Panasonic 70 1 R50 22.1 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF2212V Panasonic 71 2 R51 R52 15 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF1502V Panasonic 72 1 R53 8.25 kΩ, 1%, 1/8 W, Metal Film, 0603 ERJ-3EKF8251V Panasonic 73 1 R54 1.8 kΩ, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ182V Panasonic 74 1 R55 1 Ω, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ1R0V Panasonic 75 1 R59 0.22 Ω, 5%, 2 W, Metal Oxide MO200J0R22B 76 1 R66 182 kΩ, 1%, 1/4 W, Metal Film, 1206 ERJ-8ENF1823V Synton-Tech Corporation Panasonic 77 1 R67 10 kΩ, 1%, 1/8 W, Metal Film, 0805 ERJ-6ENF1002V Panasonic 78 1 R70 470 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ474V Panasonic 79 1 R107 2 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ202V Panasonic 80 1 R109 2.2 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ2R2V Panasonic 81 1 R111 22 kΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ223V Panasonic 82 2 R112 R117 22 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ223V Panasonic 83 1 R113 10 kΩ, 5%, 2 W, Metal Oxide RSF200JB-10K Yageo 84 1 R114 2 MΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ205V Panasonic 85 1 RL1 SPST-NO, 5A 12VDC, PC MNT G6B-1114P-US-DC12 OMRON 86 1 RT1 NTC Thermistor, 5 Ohms, 4.7 A CL150 Thermometrics 87 1 RV1 320 V, 84J, 15.5 mm, RADIAL S14K320 Epcos 88 1 SCREW1 SCREW MACHINE PHIL 4-40X1/2 SS PMSSS 440 0050 PH 89 5 SCREW2 SCREW3 SCREW4 SCREW5 SCREW6 SCREW MACHINE PHIL 6-32X1/2 SS PMSSS 632 0050 PH Building Fasteners Building Fasteners 90 1 SCREW7 SCREW MACHINE PHIL 6-32X1/4 SS PMSSS 632 0025 PH 91 4 SCREW8 SCREW9 SCREW10 SCREW11 SCREW MACHINE PHIL Flat head, Undercut 6-32 X ¼” Zinc Plated 6C25PFUZR Building Fasteners Olander 92 2 STDOFF1 STDOFF3 Standoff Hex,6-32, .375L,Alum 2209 Keystone Elect 93 2 Standoff Hex, 6-32/snap, .375L,Nylon FTA-A 375 Eagle Hardware 94 1 STDOFF2 STDOFF4 T1 95 4 TUBE-TO-220 Heatpad, TO-220 Tube 13.5 x 25 mm SPT400-12-11-25 Bergquist 96 1 TUBE-TO-247 Heatpad, TO-247 Tube 13.5 x 25 mm SPT400-12-13.5-25 Bergquist 97 1 U1 Controller, PFC/LLC, 24-pin DIP PLC818PG 98 1 U2 Opto coupler, 35 V, CTR 80-160%, 4-DIP LTV-817A Power Integrations Liteon 99 1 U3 IC, REG ZENER SHUNT ADJ SOT-23 LM431AIM3/NOPB National Semiconductor 100 1 VR9 15 V, 5%, 500 mW, DO-213AA (MELF) ZMM5245B-7 Diodes Inc 101 1 VR10 17 V, 5%, 500 mW, DO-213AA (MELF) ZMM5247B-7 Diodes Inc 102 1 VR11 12 V, 5%, 500 mW, DO-213AA (MELF) ZMM5242B-7 Diodes Inc 103 1 VR12 22 V, 5%, 500 mW, DO-35 1N5251B Microsemi Page 17 of 55 Custom Transformer, LLC, ETD39,Vertical, 14Pins Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 104 2 WASHER1 WASHER2 WASHER FLAT #4 SS FWSS 004 Building Fasteners 105 11 WASHER3 WASHER4 WASHER5 WASHER6 WASHER7 WASHER8 WASHER9 WASHER10 WASHER11 WASHER12 WASHER13 Washer Flat #6, SS FWSS 006 Building Fasteners 106 1 WASHER14 Bushing Nylon #4 X 0.125 MNI#4-8 107 5 WASHER15 WASHER16 WASHER17 WASHER18 WASHER19 Bushing Nylon #6 X 0.125 MNI#6-8 Richco Plastic Co. Richco Plastic Co. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 7 Magnetics 7.1 Main LLC 48 V Transformer (T1) Specification 7.1.1 Electrical Diagram Figure 7 – Transformer Electrical Diagram. 7.1.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 60 second, 60 Hz, from pins 1 - 9 to pins 10 - 18 Pins 7 - 9, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 7- 9, all other windings open Pins 7 - 9, with pins 10 - 18 shorted, measured at 100 kHz, 0.4 VRMS 3000 VAC 820 µH ±10% 700 kHz (Min.) 100 µH ±10% 7.1.3 Materials Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core: ETD39, Ferroxcube 3F3 material or equivalent, gap for inductance coefficient (AL) of 539 nH/t². Bobbin: ETD39 vertical, flanged Pinshine P-3907 Tape: Polyester film, 3M 1350F-1 or equivalent, 10.6 mm wide. Wire: Litz, 75 strands 40WAG, solderable single coated. Wire: Litz, 175 strands 40WAG, solderable single coated. Tape: Copper foil 9.0 mm wide. Tape: Polyester film, 10.0 mm wide. Copper bus wire #24 AWG. Page 19 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 7.1.4 Winding Diagram 13 12 9 WD2: 39T – (75/40AWG_Litz wire) 7 WD1B: 9T - (175/40AWG_Litz wire) WD1A: 9T - (175/40AWG_Litz wire) 11 10 Figure 8 – LLC Transformer Winding Diagram. 7.1.5 Winding Instructions General note WD1A and 1B WD2 Assembly 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. For WD1A and WD1B use two ~60 cm lengths of Litz wire (item [5]). Mark start and finish of one strand using a tape flag or other means. This strand will be used for WD 1A. Route start and finish leads as shown in illustrations. Start flagged wire strand at pin 10, start unflagged strand at pin 11. Wind 9 simultaneous bifilar turns of Litz wire (item [5]) from left to right, then from right to left, and continue with tight tension about 4 layers. Finish flagged wire at pin12 and unflagged wire at pin 13. Use 2 layers of tape (item [3]) for finish wrap. Starting at pin 7, shield start lead where it enters bobbin with 2cm piece of tape (item [3]) at side of bobbin, then wind 39 turns of Litz wire (item [4]) on bobbin from left to right, then from right to left, and continue with tight tension in 6 layers. Use 2 layers of tape (item [3]) for finish wrap. Route start and finish leads as shown in illustrations. Grind core halves for specified primary inductance, insert bobbin, and secure core halves with one turn of copper tape (item [6]) as shown. Make sure that start and finis of copper tape overlap. Solder at overlap, attach wire (item [8]) and connect this wire to pin 2. Use tape (item [7]) to secure core halves and insulate. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 55 01-June-09 7.2 DER-212, 150 W Street Light Power Supply Using PLC810PG Transformer Illustrations 1 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. General note 9 For WD1A and WD1B use two ~60 cm lengths of Litz wire (item [5]). Mark start and finish of one strand using a tape flag or other means. The marked strand will be used for WD 1A. Route start and finish leads as shown in illustrations. Start flagged wire strand at pin 10, start unflagged strand at pin 11. WD1A and 1B: 10 WD1A and 1B: (Cont’d) 18 Page 21 of 55 Wind 9 simultaneous bifilar turns of Litz wire (item [5]) from left to right, then from right to left, and continue with tight tension about 4 layers. Finish flagged wire at pin 12 and unflagged wire at pin 13. Use 2 layers of tape (item [3]) for finish wrap. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 Use 2 layers of tape (item [3]) for finish wrap. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG WD2: Starting at pin 7, shield start lead where it enters bobbin with 2cm piece of tape (item [3]) at side of bobbin, then wind 39 turns of Litz wire (item [4]) on bobbin from left to right, then from right to left, and continuing for 6 layers. Finish at Pin 9. Route start and finish leads as shown in illustration. WD2: (Cont’d) Use 2 layers of tape (item [3]) for finish wrap. Route start and finish leads as shown in illustrations. Page 23 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG Assembly Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 01-Jun-09 Grind core halves for specified primary inductance, insert bobbin, and secure cores with one turn of copper Tape (item [6]). Overlap start and finish of copper tape. Solder at overlap, attach wire (item [8]) and connect this wire to pin 2. Use tape (item [7]) to secure core halves and insulate. Page 24 of 55 01-June-09 7.3 DER-212, 150 W Street Light Power Supply Using PLC810PG PFC Choke (L4) Specification 7.3.1 Electrical Diagram Figure 9 – PFC Choke Schematic. 7.3.2 Electrical Specification Inductance: Pins 1-6, 100 kHz, 0.4 V - 580 µH ± 10% 7.3.3 Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description 2 Ferrite core pair, PQ32/20, TDK PC44PQ32/20Z-12 or equivalent, gap for AL of 473 nH/T . Bobbin, PQ32/20, 12 pin, TDK CPH-E41/12-1S-12PD-Z or equivalent. Magnet Wire: #20AWG, solderable double coated. Magnet Wire: #28AWG, solderable double coated. Tape Polyester Film, 3M 1350F-1 or equivalent, 7.5 mm wide. Tape Polyester Film, 3M 1350F-1 or equivalent, 10 mm wide. Tape, Copper Foil, 3M 1125 or equivalent, 6.5 mm wide. Wire, tinned bus, #24 AWG. Transformer Varnish, Dolph BC-389 or equivalent (must be baking vs. air-dry varnish). Page 25 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 7.3.4 Build Diagram Core [1] Solder wire [7] here Bus Wire [8] Pin 7 Copper Tape [7] Overlap and solder ends Figure 10 – PFC Choke Build Diagram. 7.3.5 Winding Instructions Bobbin Preparation Main Winding Insulation Bias Winding Finish Wrap Core Assembly Shield Shield Insulation Varnish Pull pins 2, 3, 10, and 11 on bobbin [2]. Starting on pin 1, wind 35 turns of wire [3] on bobbin [2]. Finish on pin 6. Use 1 layer of tape [5] for insulation. Starting on pin 8, wind 2 turns of wire [4], finishing on pin 7. Use 3 layers of tape [5] for finish wrap. Assemble bobbin and core halves. Secure core with two wraps of tape (Item 5). Apply 1 turn of copper tape (Item [7]) as shown in Figure 1, centered in bobbin window. Overlap start and finish ends as shown in Figure 1, and solder to form a shorted turn. Take 3 cm of hook-up wire [7], solder 1 end of wire to copper foil as shown in Figure 1. Terminate other end on pin 9 of bobbin. Apply 3 turns of tape (item [6]) to insulate copper shield. Dip varnish finished assembly. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Figure 11 – Finished PFC Choke, Front and Back View. Page 27 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 8 LLC Transformer Design Spreadsheet ACDC_PLC810_031209; Rev.1.4; Copyright Power Integrations 2008 Enter Input Parameters INPUTS INFO OUTPUTS UNITS 140 V Vacmin ACDC_PLC810_031209_Rev1-4.xls; PLC810 Half-Bridge, Continuous mode LLC Resonant Converter Design Spreadsheet Minimum AC input voltage Vacmax 265 V Maximum AC input voltage Iacinmax 1.19 A Maximum input AC rms current at Vacmin Vbulk 385.00 V Nominal PFC output voltage Vbulkmax 411.95 V 300.00 300.00 V 50.00 Hz Peak PFC OVP voltage (typical is 7% above Vbulk) Minimum bulk capacitor voltage at the specified holdup time. Typical value is between 250 - 320 VDC. Max holdup time is at 250 V AC Line input frequency 18.00 18.00 ms Bulk capacitor hold up time CIN_MIN 98.28 uF bulk ripple 8.16 V Vbulkmin fL Holdup time 389.08 V Minimum value of bulk cap to meet holdup time requirement; Adjust holdup time and Vbulkmin to change bulk cap value Bulk capacitor peak to peak voltage (low freq ripple) Bulk cap peak value of ripple voltage IAC 1.19 A AC input rms current at VACMIN IAC_PEAK 1.68 A Peak AC input current at full load and VACMIN V The spreadsheet assumes AC stacking of the secondaries Main Output Voltage. Spreadsheet assumes that this is the regulated output Main output maximum current Vrippeak Enter LLC (secondary) outputs Vo1 48.00 Io1 3.13 Vd1 0.90 Po1 A 0.90 V Forward voltage of diode in main output 150.24 W Output Power from first LLC output Vo2 0.00 V Second Output Voltage Io2 0.00 A Second output current Vd2 0.00 Po2 0.00 V Forward voltage of diode used in second output 0.00 W Output Power from second LLC output Enter stand-by (auxiliary) outputs Vo3 12.00 V Auxiliary Output 1 Voltage Io3 0.05 A Auxiliary Output 1 maximum current Vo4 V Auxiliary Output 2 Voltage Io4 A Auxiliary Output 2 maximum current Specified LLC output power Efficiciency and Loss Allocation P_LLC 150.24 W P_AUX 0.60 W Auxiliary output power P_PFC 158.95 W PFC output power P_TOTAL 150.84 W 0.95 Total output power (Includes Output power from LLC stage and auxiliary stage) Efficiency of LLC stage 0.75 Efficiency of auxiliary output LLC_n_estimated 0.95 AUX_n_estimated PFC_n_estimated PIN 0.96 0.96 166.44 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Minimum efficiency of PFC front end stage W AC input power Page 28 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Overall efficiency 0.91 Ploss_PFC 7.49 W PFC stage power loss Ploss_LLC 7.91 W LLC stage power loss Ploss_AUX 0.20 W Auxiliary power loss Ploss_TOTAL 15.60 W Total power loss Enter PFC Design Parameters f_nominal_desired 100.00 kHz Krp Minimum system efficiency Desired full load switching frequency. Recommended value 66 kHz to 132 kHz PFC choke ripple current factor. Actual Krp tends to increase at higher current when using iron powder/Sendust cores, due to drop in inductance at higher current Forward voltage drop of diode bridge 0.98 0.98 0.70 V 0.22 0.22 ohms Coss 18.18 pF tON 20.00 ns Qrr 26.49 nC PFC MOSFET Rdson - use high temp value from datasheet PFC MOSFET high voltage Coss from datasheet MOSFET turnon current rise time. Check actual value Average Qrr of boost diode over AC sinusoid Lpfc 583.79 uH PFC choke inductance ILpk 3.33 A PFC choke peak current at VACMIN Diode bridge Vf Rdson PFC CHOKE Parameters AL 470.00 n MLT AWG_Choke nH/t^2 35.24 5.00 turns cm 20 Equivalent Choke Metric Wire gauge Wire length nH per turn^2 (from magnetics datasheet). Note - This value decreases by as much as 15% if a belly-band is added to reduce EMI PFC choke number of turns Mean length per turn PFC choke wire gauge 0.80 mm 1.76 m DCR 21.21 m-ohms DC resistance of wire at 25 C DCR at 85 C 26.72 m-ohms DC resistance of wire at 85 C Irms_CHOKE 1.36 A PFC choke rms current DCR Cu loss 0.05 W ACR_PFC_Choke 53.45 m-ohms HF Irms 0.58 A PFC choke DC Copper loss for reference at 85 C Measure or calculate; add 26% to measured value to get 85 C value RMS current of switching component HF Cu loss 0.02 W tot Cu loss 0.07 W Strands LM 3 Equivalent diameter of wire in metric units Length of wire used on PFC choke Number of wires 10.00 Copper loss due to switching component at 85 C Total copper loss at 85 C cm Magnetic path length of core used Hpk 14.74 Oe Peak MMF in Oersteds, calculated at low line Hpk_SI 1174 A/m Peak MMF in A/m, calculated at low line Isense_R 0.16 ohms Sense resistor power dissipation Irms_FET 0.30 W PFC sense resistor power dissipation at Vacmin 1.11 A Conduction loss 0.27 W PFC MOSFET RMS current measured at VACMIN PFC MOSFET conduction loss PFC FET, Diode and Output Parameters Page 29 of 55 Maximum value of PFC current sense resistor Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 Trrloss 0.89 W PFC MOSFET loss due to diode Trr Cossloss 0.15 W MOSFET Coss loss Crossover loss 0.01 W MOSFET crossover turnon loss Total PFC loss 1.17 W MOSPFC FET total loss Diode bridge Ploss 1.51 W Diode bridge estimated loss PFC Diode RMS current 0.65 A Bulk capacitor RMS current 0.72 A Approximate PFC Diode RMS current at nominal AC input voltage (VACMIN) (includes 100/120 Hz component) Approximate Bulk Capacitor RMS current at nominal AC input voltage (VACMIN) (includes 100/120 Hz component and LLC input current) Po 153.06 W Output from LLC converter including diode loss Vo 48.90 V Output at transformer windings (includes diode drop) Transformer core cross-sectional area LLC TRANSFORMER CALCULATIONS Ae 2.10 cm^2 Lpar 704.00 704.00 uH Lser 116.00 116.00 uH 820.00 uH Lopen C 18.00 Parallel inductance. (Lpar = Lopen - Lser for integrated transformer; Lpar = Lmag for nonintegrated transformer) Leakage inductance of integrated transformer; Leakage + external inductor for non-integrated transformer Primary open circuit inductance for integrated transformer Series resonant capacitor 18.00 nF 100.00 kHz Desired full load switching frequency. Recommended value 66 kHz to 132 kHz fnominal_actual 87.0 kHz IRMS_LLC_Primary 0.94 A IRMS_LLC_Q1 0.67 A VMIN 295.1 V f_AT_VMIN Expected frequency at nominal input voltage (VBULK) and full load Primary winding RMS current at full load and nominal input voltage (VBULK) RMS current through upper MOSFET in LLC half bridge Minimum Voltage on Bulk Capacitor at minimum switching frequency Frequency at minimum Bulk capacitor voltage fnominal_desired 49.00 kHz fpar 45 kHz fser 110 kHz fmin 55 kHz 39 Parallel resonant frequency (defined by Lpar + Lser and C) Series resonant frequency (defined by series inductance Lser and C) Min frequency, at VBULK _MIN and full load. Set PLC810 minimum frequency to this value. Operation below this frequency results in loss of ZVS Primary winding number of turns NS_1 9.00 9 Secondary winding number of turns n_RATIO 4.30 4.30 NP_1 Transformer turns ratio. Adjust this value so that fnominal_actual is close to fnominal_desired Bpkfmin 1186 Gauss BAC 1487 Gauss 0.22 ohms 0.20 W LLC sense resistor 0.22 Pdiss_LLC_senseR PRIMARY Primary gauge Equivalent Primary Metric Wire gauge 40.00 AWG 0.08 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com mm First Quadrant peak flux excursion at minimum frequency. AC peak to peak flux density (calculated at fnominal_actual, VBULK at full load) LLC current sense resistor Power dissipation in LLC sense resistor Individual wire strand gauge used for primary winding Equivalent diameter of wire in metric units Page 30 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Primary litz strands 75.00 Number of strands used in Litz wire; for non-litz non-integrated transformer set to 1 Primary parallel wires 1.00 Number of parallel individual wires to make up Litz wire Resistivity in milli-ohms per meter Resistivity_25 C_Primary Transformer primary MLT 49.72 5.00 Primary turns m-ohm/m cm 38.70 Mean length per turn Number of primary turns Primary DCR 25 C 96.21 m-ohm Estimated resistance at 25 C Primary DCR 100 C 128.92 m-ohm Estimated resistance at 100 C (approximately 33% higher than at 25 C) Measured RMS current through the primary winding 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 Primary RMS current 1.50 ACR_Trf_Primary Primary copper loss A 206.27 m-ohm 0.46 W Separate Series Inductor (For non-integrated transformer only) Lsep 116.00 Ae_Ind 0.53 Inductor turns 15.00 Ignore this section if using integrated magnetics uH Desired inductance from separate inductor cm^2 Inductor core cross-sectional area mm AC flux for core loss calculations (at fnom and full load) Peak flux density, calculated at minimum frequency fmin Individual wire strand gauge used for primary winding Equivalent diameter of wire in metric units 29.83 m-ohm/m Number of parallel individual wires to make up Litz wire Resistivity in milli-ohms per meter Inductor DCR 25 C 31.32 m-ohm Estimated resistance at 25 C (for reference) Inductor DCR 100 C 41.97 m-ohm ACR_Sep_Inductor 67.16 m-ohm Inductor copper loss 0.15 W 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 15 Number of primary turns BP_fnom 2086 Gauss BP_fmin 2629 Gauss Inductor gauge Equivalent Inductor Metric Wire gauge Inductor litz strands Inductor parallel wires 40.00 0.08 125.00 Number of strands used in Litz wire 1.00 Resistivity_25 C_Sep_Ind Inductor MLT AWG 7.00 cm Winding 1 (Vo1) Sec 1 Wire gauge Equivalent secondary 1 Metric Wire gauge Sec 1 litz strands Parallel wires sec 1 40 0.08 mm Note - Power loss calculations are for each winding half of secondary Individual wire strand gauge used for secondary winding Equivalent diameter of wire in metric units 175 Number of strands used in Litz wire; for non-litz non-integrated transformer set to 1 1 Number of parallel individual wires to make up Litz wire Resistivity in milli-ohms per meter Resistivity_25 C_sec1 Transformer Secondary MLT AWG Mean length per turn 21.31 5.00 m-ohm/m cm Mean length per turn Sec 1 Turns 9.00 DCR_25C_Sec1 9.59 m-ohm Estimated resistance at 25 C (for reference) DCR_100C_Sec1 12.85 m-ohm Sec 1 RMS current 4.92 A Estimated resistance at 100 C (approximately 33% higher than at 25 C) RMS current through Output 1 winding, Page 31 of 55 Secondary winding turns (each half) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 assuming half sinusoidal waveshape DCR_Ploss_Sec1 0.25 W ACR_Sec1 20.56 m-ohm ACR_Ploss_Sec1 1.00 W Total secondary winding Copper Losses 1.25 W Winding 2 (Vo2) Sec 2 Wire gauge Equivalent secondary 2 Metric Wire gauge Sec 2 litz strands Parallel wires sec 2 40 0.08 mm Note - Power loss calculations are for each winding half of secondary Individual wire strand gauge used for secondary winding Equivalent diameter of wire in metric units 175 Number of strands used in Litz wire; for non-litz non-integrated transformer set to 1 1 Number of parallel individual wires to make up Litz wire Resistivity in milli-ohms per meter Resistivity_25 C_sec2 Transformer Secondary 2 MLT Sec 2 Turns AWG Estimated Power loss due to DC resistance (both secondary halves) Measured AC resistance (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 halves 21.31 m-ohm/m cm 0.00 Mean length per turn Secondary winding turns (each half) DCR_25C_Sec2 0.00 m-ohm Estimated resistance at 25 C (for reference) DCR_100C_Sec2 0.00 m-ohm Sec 2 RMS current 4.92 Arms DCR_Ploss_Sec1 0.00 W ACR_Sec2 0.00 m-ohm ACR_Ploss_Sec2 0.00 W Total secondary winding Copper Losses 0.00 W Estimated resistance at 100 C for half secondary (approximately 33% higher than at 25 C) RMS current through Output 2 winding; Output 1 winding is AC stacked on top of Output 2 winding Estimated Power loss due to DC resistance (both secondary halves) Actual measured AC resistance (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 halves Total Copper loss calculation Does not include fringing flux loss from gap Primary copper loss (from Primary section) Secondary copper Loss 0.46 W Total primary winding copper loss at 85 C 1.25 W Total copper loss in secondary winding Transformer copper loss 1.71 W Total copper loss in transformer (primary + secondary) TURNS CALCULATOR This is to help you choose the secondary turns not connected to any other part of spreadsheet V1 48.00 V V1d1 0.90 V N1 4.00 V2 N2 V 2.00 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Diode drop voltage for Vo1 Total number of turns for Vo1 V V2d2 Target Output Voltage Vo1 Expected outputV Diode drop voltage for Vo2 Total number of turns for Vo2 Page 32 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Compared to the above spreadsheet, actual operating frequency is considerably higher than the expected operating frequency of 90 kHz shown. This is due to the effective turns ratio of the transformer, which results in an operating turns ratio lower than the ratio of primary turns to secondary turns (NP/NS). The graphs shown below were generated by adjusting the turns ratio in the spreadsheet until the expected operating frequency shown in the spreadsheet was identical to the actual operating frequency of the unit under test. VBULK vs Switching Frequency 500 450 VBULK (V) 400 350 Full load Min load 300 250 200 150 100 0 100 200 300 Switching Frequency (kHz) Full Load Primary and MOSFET RMS Currents 5 IRMS (A) 4 3 Primary MOSFET 2 1 0 30 130 230 Switching Frequency (kHz) Page 33 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 9 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. 9.1 LLC Stage Efficiency To make this measurement, the LLC stage was powered separately by connecting an external 385 VDC supply across bulk capacitor C9, and a 15 V source was applied between the collector of regulator transistor Q27 and controller ground. LLC Efficiency vs. Output Power, 385 VDC Input 98.00% 96.00% Efficiency (%) 94.00% 92.00% 90.00% 88.00% 86.00% 84.00% 82.00% 0 20 40 60 80 100 120 140 160 Output Power (W) Figure 12 – LLC Stage Efficiency vs. Load, 385 VDC Input. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 9.2 Total Efficiency Figures below show the total supply efficiency (PFC and LLC stages). AC input was supplied using a 60 Hz sine wave source. Total Efficiency vs. Input Voltage 0.94 0.92 0.9 Efficiency (%) 0.88 0.86 100% Load 50% Load 20% Load 10% Load 0.84 0.82 0.8 0.78 0.76 0.74 0.72 0.7 120 140 160 180 200 220 240 260 280 AC Input Voltage Figure 13 – Total Efficiency vs. Output Power. Page 35 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 9.3 THD and Power Factor THD and Power factor measurements were made using a 60 Hz sine wave AC source. THD vs. Input Voltage 12 10 THD (%) 8 1/2 Load Full Load 6 4 2 0 120 140 160 180 200 220 240 260 280 AC Input Voltage Figure 14 – Input Current THD vs. Input Voltage, 50% and 100% Load. Power Factor vs. Input Voltage 1 Power Factor 0.98 0.96 0.94 Full Load 1/2 Load 0.92 0.9 0.88 120 140 160 180 200 220 240 260 280 AC Input Voltage Figure 15 – Power Factor vs. Input Voltage, 50% and 100% Load. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 55 01-June-09 9.4 DER-212, 150 W Street Light Power Supply Using PLC810PG 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 2% to 100% load. Page 37 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 10 Waveforms All waveforms are measured at room temperature using a 60 Hz sine wave supply unless otherwise indicated. 10.1 Input Voltage and Current Figure 16 – 140 VAC, 150 W Load. Top Trace: Input Current, 1 A / div. Bottom trace: Input Voltage, 200 V, 5 ms / div. Figure 17 – 230 VAC, 150 W Load. Top Trace: Input Current, 1 A / div. Bottom trace: Input Voltage, 200 V, 5 ms / div. 10.2 LLC Primary Voltage and Current The LLC stage current was measured by cutting the PC board trace in series with the T1 primary and adding a current sensing loop that measures the LLC transformer (T1) primary current. The primary voltage waveform was measured at the hot side of ferrite bead L6. Figure 18 – LLC Stage Primary Voltage and Current. Top Trace: Current, 1 A / div. Bottom Trace: Voltage, 100 V, 2 µs / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 10.3 PFC Switch Voltage and Current - Normal Operation Figure 19 – 140 VAC Input, 100% Load. Top Trace: Q2 Drain Current, 1 A / div, 5 µs / div Bottom Trace: Drain Voltage, 100 V, 5 µs/div. Figure 20 – 230 VAC Input, 100% Load. Top Trace: Q2 Drain Current, 1 A / div, 5 µs / div Bottom Trace: Drain Voltage, 100 V, 5 µs / div. 10.4 AC Input Current and PFC Output Voltage During Start-up Figure 21 – Full Load, 140 VAC. Top Trace: AC Input Current, 2 A / div. Bottom Trace: PFC Voltage, 100 V, 20 ms / div. Page 39 of 55 Figure 22 – Full Load, 230 VAC. Top Trace: AC Input Current, 2 A / div. Bottom Trace: PFC Voltage, 100 V, 20 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 10.5 LLC Start-up Figure 23 – LLC Start-up. 230 VAC, 100% Load. Top Trace: LLC Primary Current, 1 A / div. Bottom Trace: Output Voltage, 20 V, 10 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 10.6 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 24 – Output Short Circuit Test, 230 VAC. Top Trace: LLC Primary Current, 2 A / div. Bottom Trace: 48 V Output, 20 V, 50 µs / div. Page 41 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 10.7 Output Voltage During Start-up Figure 25 – 48 V Output at Start-up. 140 VAC Input, Full Load. 10 V, 20 ms/ div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 26 – 48 V Output at Start-up. 230 VAC Input, Full Load. 10 V, 20 ms / div. Page 42 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 10.8 Output Ripple Measurements 10.8.1 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 µF / 50 V ceramic capacitor and 1.0 µF / 100 V aluminum electrolytic capacitor. The aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across DC outputs. Probe Ground Probe Tip Figure 27 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 28 – Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added). Page 43 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 10.8.2 Full Load Output Ripple Results Figure 29 – 48 V Output Ripple, 200 mV, 2 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 30 – 48 V Output Ripple, 100 mV, 5 µs / div. Page 44 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 10.8.3 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 31 – Output Transient Response 3.13 A – 2.3 A – 3.13 A Load Step. Top Trace: 48 V Transient Response, 50 mV / div. Bottom Trace: Output Load Step, 1 A, 500 µs / div. Page 45 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 11 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. Infrared measurements were correlated to thermocouples attached using copper tape. LLC MOSFETs LLC transformer LLC rectifier PFC inductor PFC boost diode Input bridge PFC boost MOSFET Figure 32 – Photograph of Board Orientation Used for Thermal Testing. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 46 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 11.1 Thermal Results Summary 11.1.1 Testing Conditions The goal of this design is to maintain the temperature of components below 100 °C at rated ambient and 100% load (150 W), low line (140 VAC, 60 Hz). By extrapolating the data below from 21 °C to 60 °C this design meets these requirements. Measurement data is presented below. The unit was allowed to thermally stabilize (>1 hours in all cases) before gathering data. Semiconductor plastic and magnetics temperatures were correlated via thermocouples attached with copper tape. 140 VAC, 60 Hz 230 VAC, 60 Hz Output Power (W) 150.2 150.2 Input Power (W) 164.5 162.6 Efficiency (%) 91.3 92.37 Output Loading 48 V (A) 3.13 3.13 Ambient 21 21 LLC rectifier plastic package (D9) 47 48 Temperatures (°C) LLC Upper MOSFET (Q10) plastic package 42 43 LLC Lower MOSFET (Q11 ) plastic package 44 45 PFC diode plastic package (D2) 44 41 PFC MOSFET plastic package (Q2) 42 39 Bridge rectifier plastic package (BR1) 49 43 LLC transformer (T2) surface 47 40 49 PFC inductor (L4) surface Page 47 of 55 43 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 11.2 140 VAC, 60 Hz, 150 WOUT Figure 33 – Thermal Profile. Room Temperature, 140 VAC, 60 Hz, 150 W Load (1 hr) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 48 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 11.3 230 VAC, 60 Hz, 150 WOUT Figure 34 – Thermal Profile. Room Temperature, 230 VAC, 60 Hz, 150 W Load (1 hr) Page 49 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 12 LLC Gain-Phase Figure 35 – LLC Converter Gain-Phase, 100% Load Crossover Frequency – 2 kHz, Phase Margin - 45°. Figure 36 – LLC Converter Gain-Phase, 50% Load. Crossover Frequency ~1.8 kHz, Phase Margin - ~55°. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 50 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG Figure 37 – LLC Converter Gain-Phase, 10% Load. Gain Crossover – 600 Hz, Phase Margin - ~55°. Page 51 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 13 Conducted EMI Conducted EMI tests were performed with a 16 Ω resistive load on the 48 V main output. The unit was placed on a metallic ground plane, which in turn was hard wired to the AC cord ground. The resistive load was connected to the ground plane with a pair of 2.2 nF capacitors (one at the positive feed, and one at the return) to simulate the capacitive coupling of LED modules to a grounded street light casing. The peak shown at `90 MHz is actually 10 dB lower than shown in the graph, as the EMI receiver changes scale at 80 MHz. Figure 38 – Conducted EMI, 230 VAC. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 52 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG 14 Line Surge Differential input line 1.2/50 µs surge testing was completed on a single test unit to IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load and operation was verified following each surge event. During testing no output interruption was seen. Surge Level (kV) +1 kV -1 kV +2 kV -2 kV Generator Input Impedance Voltage (Ω) (VAC) 2 230 2 230 12 230 12 230 Injection Location L to N L to N L, N to G L, N to G Injection Phase (°) 90 270 90 270 Test Result (Pass/Fail) Pass Pass Pass Pass Notes: 1) A ground plane was placed under the PSU bracket and load resistors (load resistors are aluminum case units mounted on heat sinks). The resistive load was bypassed to the ground plane with (2) 2.2 nF capacitors (one at the +48 V input lead, one at return) to simulate the capacitance of LED arrays to a grounded street light case, but otherwise feft floating. The input AC safety ground wire was connected to the ground plane. Page 53 of 55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09 15 Revision History Date 11-May-09 01-Jun-09 Author RH Revision 1.0 1.1 Description and changes Initial Release Revised PCB Images Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Reviewed Page 54 of 55 01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. 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