Using LV5012MD in 220VAC, 14W Flyback for TRIAC dimming

LV5012MD-A19-220VEVM03
[ For A19/E27 LED Bulb Application ]
The single stage flyback converter for phase cut dimming
with High Power Factor
Application Note
Ver1.03
LV5012MD-A19-220VEVM03
Application Note
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1. Introduction
2. Features
3. Performance Specifications
3.1. Application constitution
3.2. Electrical characteristics
4. Schematic
5. Evaluation Board



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6. Test Setup
7. Test Procedure
7.1 Line/Load Regulation and Efficiency Measurement Procedure
7.2 Equipment Shutdown





7.3 Phase Angle Decode vs LED Current (at dimming)
8. Performance Data
8.1 Efficiency
8.2 Power factor
8.3 Line regulation



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

8.4 Output voltage/current operation waveform (No dimming)
8.5 Input voltage/current operation waveform (No dimming)
8.6 Switching operation waveform
8.7 LED current vs Phase angle
8.8 Dimming operation waveform
8.9 EMI data
9. Board Layout
10. Bill of materials
11. Transformer specification







12. Detailed Descriptions for Application Circuit Setting
12.1 Transformer design
12.2 REF_IN pin and ALC_C pin setting
12.3 CS pin setting
12.4 ACS pin and DML pin setting
12.5 HV pin setting
12.6 Protection function
1. Introduction
The LV5012MD-A19-220VEVM03 is a 14W, 220VAC isolated dimmable LED driver for A19 and
E27 applications. The LV5012MD-A19-220VEVM03 is a primary-side power regulated PFC
controller used for commercial and residential phase-cut dimmer compatible LED lamp drivers.
2. Features
・Primary Side Flyback Control With Integrated PFC
・Compatible With Leading and Trailing Edge Dimmer
・Constant Current & Improved THD
・Short Protection - [latch off]
・Over Voltage Protection -[auto recovery]
・2 Stage Thermal Protection -[auto recovery]
3. Performance Specifications
3.1.
Application constitution
Isolation Flyback with Phase Cut Dimming
3.2.
Electrical characteristics (Operating Temperature = 25C)
Table1. LV5012MD-A19-220VEVM03 Electrical Performance Specifications
Description
Min
Typ
Max
Units
Input AC voltage
198
220
264
VAC
Output voltage
20
V
Output current
550
mA
Efficiency
82
%
Power Factor
0.95
Comment
2parallel of 6LEDs series
VAC=220V, 50Hz
VAC=220V, 50Hz
4. Schematic
AC1
F1
33/1W
AC INPUT
R1
47/2W
VR1
C1
0.033uF
/AC275V
R21
Open
AC2
R2
R3
56/2W
0
D1
S1ZB60
R4
L2
10/1W
4.7mH
C3
0.1uF/630V
C2
D2
MRA4005
R13
820/2W
C5
4.7nF
/630V
47nF/630V
L1
4.7mH
D3
R5
R7
680k
470k
R9
1.2k
R10
12k
U1
LV5012MD
1
2
Transformer T1 specifications
Inductance value
1-3 inductance Lp = 2.0mH
S-F inductance Ls = 42uH
Turns ratio
(4-6) : (S-F) = 1 : 1.18
3
4
5
6
C7
150pF
R6
R8
2.7k
12k
R11
0
7
C12
4.7uF
/50V
MMSD103
OUT
14
DML
GND
13
VIN
12
GND
CS
ENB
REF_IN
ACS
TRC
REF_OUT
ALC_C
T1
F
1
3
R15
C10
1000uF
/35V
6
0
11
22
27k
Q1
NDD03N60
R12
C11
2.2nF/AC250V
10
9
R18
8
0.1uF
R20
LED-
4.7Meg
C8
LED+
S
R16
R17
100k
D5
MBRS4201
2
4
HV
NC
R14
100k
/1W
D4
MURA160
C4
0.1Fu/630V
(6 LEDs in series)×2parallel
[LED: NICHIA NS6W083AT]
C9
1uF
Figure1. LV5012MD-A19-220VEVM03 Schematic
0.91
R19
Open
5. Evaluation Board
LEDAC
INPUT
LED+
Figure2. LV5012MD-A19-220VEVM03 Transformer Side
64mm
24mm
Figure3. LV5012MD-A19-220VEVM03 IC Side
6. Test Setup
6.1 Test Equipment
Voltage Source: 220VAC AC source, NF EPO2000S
Power Meter: HIOKI 3332
Volt Meter: ADVANTEST R6441D DIGITAL MULTIMETER
AMP Meter: Agilent DIGITAL MULTIMETER 34401A
Output Load: 2 Parallel of 6 LEDs series (LED: NICHIA NS6W083AT)
Oscilloscope: LeCroy WaveRunner 6050A
Operating Temperature: 25℃
6.2 Recommended Test Setup
Volt Meter
+
Power Meter
AMP
Meter
Neutral
AC Source
AC
INPUT
LED
+
LV5012MD-A19-220VEVM03
Line
Dimmer
Min
At No Dimming,
Connect this line
LED-
Max
2 Parallel of 6 LEDs series
Figure4. LV5012MD-A19-220VEVM03 Recommended Test Set Up
6.3 List of Test Points
Table2. Test Points Functions
TEST POINTS NAME
DESCRIPTION
Neutral
220VAC neutral connection
Line
220VAC line voltage
LED+
LED anode connection
LED-
LED cathode connection
7. Test Procedure
7.1 Line/Load Regulation and Efficiency Measurement Procedure
1. Connect LV5012MD-A19-220VEVM like upper Figure4. An external LED load must be used
to start up the EVM.
2. Prior to turning on the AC source, set the voltage to 220VAC.
3. Turn on the AC Source.
4. Record the output voltage readings from Volt Meter and the output current reading from
AMP Meter. And Record the input power reading from Power Meter.
5. Change VAC from 198VAC to 264VAC and perform “4”.
6. Refer to Section 7.2 for shutdown procedure.
7.2 Equipment Shutdown
1. Turn off equipment.
2. Make sure capacitors are discharged.
7.3 Phase Angle Decode vs LED Current (at dimming)
1. Connect LV5012MD-A19-220VEVM like upper Figure4. An external LED load must be used
to start up the EVM.
2. Prior to turning on the AC source, set the voltage to 220VAC.
3. Monitor the Dimmer output AC voltage between the neutral and the line by using the
oscilloscope differential probe.
4. Turn on the AC Source.
5. Maximize the dimmer ratio.
6. Record the output voltage readings from Volt Meter and the output current reading from
AMP Meter. And Record the input power reading from Power Meter. And Record the phase
angle of Dimmer output reading from the oscilloscope differential probe.
7. Gradually lower the Dimming ratio and perform "6". Repeat it until the Dimming ratio is
minimized.
8. Refer to Section 7.2 for shutdown procedure.
8. Performance Data
8.1 Efficiency
Efficiency vs Input Voltage
87
50Hz
86
60Hz
Efficiency [ % ]
85
84
83
82
81
80
79
78
77
190
200
210
220
230
240
250
260
270
Input Voltage [ VAC ]
Figure5. Efficiency vs Input voltage
8.2 Power factor
Power Factor vs Input Voltage
1.00
50Hz
60Hz
Power Factor
0.98
0.96
0.94
0.92
0.90
0.88
0.86
190
200
210
220
230
240
250
Input Voltage [ VAC ]
Figure6. Power factor vs Input voltage
260
270
8.3 Line regulation
LED Current (Output current)
LED Current vs Input Voltage
600
50Hz
590
60Hz
LED Current [ mA ]
580
570
560
550
540
530
520
510
500
190
200
210
220
230
240
250
260
270
Input Voltage [ VAC ]
Fgure7. LED current vs Input voltage
Output Voltage
Output Voltage vs Input Voltage
20.5
50Hz
20.4
60Hz
Output Voltage [ V ]
20.3
20.2
20.1
20.0
19.9
19.8
19.7
19.6
19.5
190
200
210
220
230
240
250
260
Input Voltage [ VAC ]
Figure8. Output voltage vs Input voltage
270
8.4 Input voltage/current operation waveform (No dimming)
CH1
Input voltage (VAC)
[200V/div]
CH4
Input current
[100mA/div]
5msec/div
Figure9. Input waveform
8.5 Output voltage/current operation waveform (No dimming)
CH1
Output voltage
[5V/div]
CH4
Output current
(LED current)
[200mA/div]
5msec/div
Figure10. Output waveform
8.6 Switching operation waveform
CH1
Q1 Drain voltage
[200V/div]
CH4
Q1 current
[500mA/div]
10usec/div
Figure11. Switching operation waveform
8.7 LED Current vs Phase angle
[ Measurement condition: V AC=230V, 50Hz, Dimmer= MERTEN 572599 ]
LED Current vs Phase angle
600
LED Current [mA]
500
400
300
200
100
0
0
20
40
60
80
100 120 140 160 180
phase angle [ deg ]
Figure12. LED current vs Phase angle
8.8 Dimming operation waveform
[ Measurement condition: V AC=230V, 50Hz, Dimmer= MERTEN 572599 ]
Phase angle = 120 degree
CH1
Input voltage
=Dimmer output
[200V/div]
CH4
Input current
[100mA/div]
5msec/div
Figure13. Dimming operation waveform at phase angle=120degree
Phase angle = 60 degree
CH1
Input voltage
=Dimmer output
[200V/div]
CH4
Input current
[100mA/div]
5msec/div
Figure14. Dimming operation waveform at phase angle=60degree
8.9 EMI data
Conducted Emission
QP Measurement
[ Measurement condition: V AC=230V, 50Hz ]
Phase1
Phase2
Figure15. Conducted Emission, QP Measurement
9. Board Layout
Figure16. Transformer Side Layout
Figure17. IC Side Layout
Figure18. Board Size
10.Bill of materials
No
Designator
Description
Value
Footprint
Manufacturer
Manufacturer Part Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
C1
C2
C3
C4
C5
C7
C8
C9
C10
C11
C12
D1
D2
D3
D4
D5
F1
L1
L2
Q1
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
T1
U1
VR1
Metallized Polyester Film Capacitor
Capacitor,Ceramic,X7R
Capacitor,Ceramic,X7R
Capacitor,Ceramic,X7R
Capacitor,Ceramic,X7R
Capacitor,Ceramic,CH
Capacitor,Ceramic,X7R
Capacitor,Ceramic,X7R
Aluminum Electrolytic Capacitor
Capacitor,Ceramic,E
Capacitor,Ceramic,X7R
Diode,Bridge
Diode,STD Recovery
Diode
Diode,Ultrafast
Diode,Schottky
Metal Film Fuse Resistor
Power Inductor
Power Inductor
N-Channel Power MOSFET
Metal Film Resistor
Metal Film Resistor
Jumper
Metal Film Resistor
Chip Resistor
Chip Resistor
Chip Resistor
Chip Resistor
Anti-surge Chip Resistor
Anti-surge Chip Resistor
Jumper
Chip Resistor
Metal Film Resistor
Metal Film Resistor
Jumper
Chip Resistor
Chip Resistor
Low Ohmic Chip Resistor
Open
Anti-surge Chip Resistor
Open
Transformer
LED Driver
Varistor
0.033uF/275VAC
47nF/630V
0.1uF/630V
0.1uF/630V
4.7nF/630V
150pF/50V
0.1uF/50V
1uF/25V
1000uF/35V
2.2nF/250VAC
4.7uF/50V
0.8A,600V
1A,600V
0.2A,250V
1A,600V
4A,200V
33,1W
4.7mH
4.7mH
600V,2.6A
47,2W
56,2W
0
10,1W
680k
2.7k,1%
470k
12k,1%
1.2k
12k
0
4.7Meg
820,2W
100k,1W
0
22
100k
0.91,1%
27k
-
Radial
Radial
Radial
Radial
1206
0603
0603
0603
Radial
Radial
1206
1Z(SMD)
SMA
SOD-123
SMA
SMC
Axial
Radial
Radial
DPAK
Axial
Axial
Axial
1206
0603
1206
0603
1206
1206
0603
0603
Axial
Axial
0603
0603
0603
0805
1206
RM6
MFP14S
Radial
OKAYA
MURATA
MURATA
MURATA
MURATA
MURATA
MURATA
MURATA
Rubycon
MURATA
MURATA
SHINDENGEN
ON Semiconductor
ON Semiconductor
ON Semiconductor
ON Semiconductor
Panasonic
Sumida
Sumida
ON Semiconductor
Panasonic
Panasonic
Panasonic
Rohm
KOA
Rohm
KOA
Rohm
Rohm
KOA
Panasonic
Panasonic
Panasonic
KOA
KOA
KOA
Rohm
Rohm
WE-Midcom
ON Semiconductor
Nippon Chemi-con
LE333
RDER72J473K3K1C11B
RDER72J104K8K1C11B
RDER72J104K8K1C11B
GRM31BR72J472KW01L
GRM1882CH1H151JA01
GRM188R71H104KA93D
GRM188R71E105KA12D
35ZLH1000
DE1E3KX222MA4BL01
GRM31CR71H475KA12L
S1ZB60
MRA4005T3G
MMSD103T1G
MURA160T3G
MBRS4201T3G
ERQ1ABJ330
RCH895NP-472K
RCH895NP-472K
NDD03N60Z
ERG2SJ470
ERG2SJ560
ERG1SJ100
KTR18EZPJ684
RK73H1JTTD272
KTR18EZPJ474
RK73H1JTTD123
ESR18EZPJ122
ESR18EZPJ123
RK73Z1JTTD000
ERJ3GEYJ475V
ERG2SJ821
ERG1SJ104
RK73Z1JTTD000
RK73B1JTTD220
RK73B1JTTD104
MCR10EZHFLR910
ESR18EZPJ273
750341585 Rev.6A
LV5012MD
TND05V-471KB00AAA0
470V
11.Transformer specification
12.Detailed Descriptions for Application Circuit Setting
The LV5012MD-A19-220VEVM03 is the isolated flyback converter with phase cut dimming. The explanation of each parts of the application
circuit is described in figure19. How to set this application circuit is described below.
AC1
F1
33/1W
R1
Filter for EMI and TRIAC dimming
47/2W
Snubber circuit for TRIAC dimming
Snubber circuit
AC INPUT
VR1
C1
0.033uF
/AC275V
R21
Open
AC2
R2
56/2W
D1
S1ZB60
L2
R4
4.7mH
10/1W
C2
47nF/630V
R13
C3
0.1uF/630V
820/2W
Start up resistor
for HV regulator
L1
4.7mH
Filter for EMI and TRIAC dimming
Resistors
for ALC function
R5
R7
680k
470k
R9
1.2k
12k
U1
LV5012MD
1
2
Resistor
for bleeder
current
Resistors
for TRIAC ON/OFF detection setting
and bleeder current setting
3
4
5
6
Transformer T1 specifications
Inductance value
1-3 inductance Lp = 2.0mH
S-F inductance Ls = 42uH
Turns ratio
(4-6) : (S-F) = 1 : 1.18
C7
150pF
R6
R8
2.7k
12k
R11
7
D3
C12
4.7uF
/50V
HV
OUT
DML
GND
NC
VIN
GND
CS
ENB
REF_IN
ACS
TRC
REF_OUT
D4
MURA160
ALC_C
MMSD103
Secondary side
rectifier diode
T1
F
3
C10
1000uF
/35V
6
0
4
R17
100k
13
R12
12
11
LED+
R20
27k
S
LED-
R16
14
D5
MBRS4201
2
R15
(6 LEDs in series)×2parallel
[LED: NICHIA NS6W083AT]
Transformer
1
Auxiliary winding
for VIN supply
Capacitor
for VIN supply
R10
R14
100k
/1W
C5
4.7nF
/630V
C4
0.1uF/630V
R3
0
D2
MRA4005
22
Q1
NDD03N60
Power
MOSFET
Capacitor
for smoothing output voltage
4.7Meg
C11
2.2nF/AC250V
10
9
R18
8
0
C8
C9
0.1uF
1uF
Capacitor
for ALC function
Figure19. The description of each parts of LV5012MD-A19-220VEVM03
0.91
R19
Open
Current sense resistor
Capacitor
for noise reduction
12.1 Transformer design
At first calculate about primary inductance and secondary inductance.
The primary inductance Lp is calculated
(VAC peak) 2 × Dp2 × η × 0.565
Lp =
2 × POUT × f
where,
Lp : Primary side inductance
VAC peak : Input peak voltage
η : Conversion efficiency of transformer
f : Switching frequency = 70k [Hz]
POUT : Output power of secondary side
Transformer
current
Is peak
Primary
current
Secondary
current
Ip peak
POUT = VOUT × IOUT
VOUT : Output voltage (LED voltage)
IOUT : Output current (LED current)
Dp : Duty of primary side current
Tp
Dp = T
Time
Tp
Ts
T
Figure20. Transformer current
Tp : Time of primary side current
T : Switching period = 1/70k [sec]
The secondary inductance Ls is calculated
(VOUT + Vf ) 2 × Ds 2
Ls = L × (I peak) 2 × f 2
p
p
where,
Ls : Secondary side inductance
Vf : Forward voltage of the rectifier diode
Ip peak : Peak current of Primary side inductance “Lp”
LED+
Transformer
Rectified AC voltage
Lp
[Turns: Np]
Vf
Ls
[Turns: Ns]
[Turns: Nd]
(*Refer to section “12.3”)
Ds : Duty of secondary side current
LED-
Ts
Ds = T
Ts : Time of secondary side current
Figure21. Transformer Turns
Next calculate about Turns Raito by primary inductance and secondary inductance.
Np
Ns =
Lp
Ls
where,
Np : Turns of primary side
Ns : Turns of secondary side
Design the most suitable transformer with the winding turns ratio and the inductance value.
Confirm that the operation with the designed transformer is a current discontinuous mode.
The auxiliary winding turns Nd is calculated
Nd
VIN
=
Ns
VOUT
where,
Nd : Turns of auxiliary winding
VIN : VIN pin voltage
12.2 REF_IN pin and ALC_C pin setting
 R5, R6 setting
Please set R5, R6 so that the voltage peak of the REF_IN pin is around 1.1V to 1.9V.
e.g. VAC=220V → R5=680kΩ, R6=2.7kΩ
REF_IN peak = (220V×√2) ×2.7k / (680k+2.7k) = 1.23V
 C8 setting
Please connect capacitor of about 0.1uF to an ALC_C pin.
By the above setting, ALC function of LV5012MD becomes effective. Thereby the application of
LV5012MD can achieve good line regulation and total harmonic distortion.
12.3 CS pin setting
 R18, R19 setting
The output power of second side is set by the current sense resistor (R18, R19) connected to
CS pin. The current sense resistor is calculated,
0.141 × Lp × f × η
2 × POUT
R18 × R19
R18 + R19 =
Figure22 is the operation outline diagram.
Rectified
AC voltage
LV5012MD
inside
ALC_out
Auto
Level
Control
VREF
(0.45Vtyp)
+
CLK
Q
RESET
Q1 current
(Primary side current)
ALC_out
Lp
VREF
(0.45Vtyp)
OUT
0.5Vtyp
Reference
Q1
Q1
current
CS
T
R18
R19
ON
OUT
(Q1 Gate)
OFF
Ton
Toff
Reference=ALC_out
Reference
=0.45V
Figure22. Operation outline diagram (No dimming)
The peak current of Lp “Ip peak” is the following expression.
R18 + R19
Ip peak = R18 × R19 × 0.45
( In the case of ALC_out > VREF(0.45V) )
Reference=ALC_out
12.4 ACS pin and DML pin setting
LV5012MD contains the function for TRIAC dimming. This function is operated by setting ACS
pin and DML pin.
Figure23 is the outline diagram of TRIAC dimming operation.
Please set the TRIAC ON/OFF threshold and the Bleeder operation threshold in tune with the
characteristic of TRIAC dimmer. The TRIAC ON/OFF threshold and the Bleeder operation
threshold are calculated as follow.
The TRIAC ON threshold of the rectified AC is determined below.
R7 + R8
Vac_triac on =
× 1.7
R8
The TRIAC OFF threshold of the rectified AC is determined below.
R7 + R8
Vac_triac off =
× 1.3
R8
The Bleeder operation threshold of the rectified AC is determined below.
R7 + R8
× 0.85
R8
Vac_bleeder =
Please set R7, R8 on the basis of these expressions according to TRIAC dimmer.
In addition, please set R9 between the rectified AC voltage and DML pin to satisfy the following
expression.
 R7 + R8

× 0.85  - ( R9 × 0.02 ) < 50 [V]
 R8


Rectified
TRIAC OUT
Rectified
AC voltage
ACS
Rectified AC voltage
Bleeder
current
R9
LV5012MD
inside
-
R7
0.85V +
ACS
+
Auto
Level
Control
1.7V
T
Lp
ALC_out
CLK
Q
RESET
0.1V
-
1.3V
VREF
(0.45Vtyp)
+
1.3V
0.85V
Built-in MOSFET
for Bleeder current
Bleeder MOS gate
-
R8
1.7V
DML
TRIAC OFF
TRIAC ON
OUT
ALC_out
Q1
VREF
(0.45Vtyp)
Q1
current
CS
R18
Q1 current
(Primary side
current)
Reference
R19
0.1V
T
TRIAC OFF
TRIAC ON
TRIAC
OFF
Bleeder MOS gate
Bleeder MOS ON
Bleeder MOS OFF
Figure23. Outline diagram of TRIAC dimming operation
Bleeder
MOS ON
12.5 HV pin setting
 R10 setting
LV5012MD has a high voltage regulator built-in for self-supplying from the rectified AC voltage. It
outputs 12V, and thereby the circuit in the IC starts. Please connect R10=12kΩ between HV pin
and the rectified AC voltage to operate HV regulator normally.
12.6 Protection function
1
2
3
4
tilte
UVLO
OCP
OVP
OTP
outline
Under Voltage Lock Out
Over Current Protection
Over Voltage Protection
Over Temperature Protection
monitor point
VIN voltage
CS voltage
VIN voltage
PN Junction temperature
1. UVLO(Under Voltage Lock Out)
If VIN voltage is 7.3V or lower, then UVLO operates and the IC stops. When UVLO operates,
the power supply current of the IC is about 80uA or lower. If VIN voltage is 9V or higher, then the IC
starts switching operation.
VIN
voltage
VIN
voltage
UVLOON
(9Vtyp)
UVLOOFF
(7.3Vtyp)
time
Output stage
on
off
on
2. OCP(Over Current Protection)
CS pin is used to sense current in primary winding of transformer via external MOSFET. This
provides an additional level of protection in the event of a fault. If the voltage of the CS pin exceeds
VCSOCP(1.9Vtyp.)(A), the internal comparator will detect the event and turn off the MOSFET. The
peak switch current is calculated
Iocp(peak)[A] = VCSOCP[V] / Rcs[Ω]
The VIN pin is pulled down to fixed level, keeping the controller latched off. The latch reset occurs
when the user disconnects LED from VAC and lets the VIN falls below the VIN reset
voltage,UVLOOFF(7.3Vtyp.)(B). Switching restarts when VIN rises UVLOON(9Vtyp.)(C).
CS
voltage
A
C
VCSOCP(1.9Vtyp)
time
VIN
voltage
B
UVLOON(9Vtyp)
UVLOFF(7.3Vtyp)
time
Output stage
on
off
on
3. OVP(Over Voltage Protection)
If the voltage of VIN pin is higher than the internal reference voltage VINOVP(27Vtyp), switching
operation is stopped. The stopping operation is kept until the voltage of VIN is lower than
VINOVP(27Vtyp). If the voltage of VIN pin is lower than VINOVP(27Vtyp), the switching operation
is restated. Please see OVP waveform chart.
OVP
VIN
voltage
OVP release
27Vtyp
time
Output stage
on
off
on
4. OTP(Over thermal protection)
LV5012MD has the gradually thermal protection system. If the junction temperature exceeds 140
degrees Celsius, 1st stage protection mode is started. At 1st stage protection mode, the internal
reference level compared with CS pin voltage is set to 0.1V. And the LED current is restricted to
low values (approximately 5%).
If the junction temperature exceeds 155 degrees Celsius, the switching operation and startup
circuit are stopped. Please see OTP waveform chart.
155℃
143℃
140℃
IC
Junction
Temperature
128℃
Time
100%
LED Current
Normal
Condition
Normal
Condition
1st Stage
Thermal
Protection
Normal
Condition
Thermal
Shut
Down
Time
Approximately
5%