Title Reference Design Report for a 1.1 W Power Factor Corrected LED Driver (Non-Isolated) Using LinkSwitchTM-PL LNK454DG Specification 85 VAC – 265 VAC, >0.85 PF Input; 2.5 V – 3.5 V, 366 mA 10% Output Application LED Driver for Candelabra Lamp Replacement Author Applications Engineering Department Document Number RDR-268 Date April 4, 2011 Revision 1.2 Summary and Features Single stage power factor correction and accurate constant current (CC) output Low cost, low component count and small PCB footprint solution Superior performance and end user experience o Clean monotonic start-up – no output blinking o Fast start-up (<300 ms) – no perceptible delay Universal input Integrated protection and reliability features o Output open-circuit protected / output short-circuit protected with auto-recovery o Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board o No damage during brown out conditions o Extended pin creepage distance between device DRAIN pin and other pins for reliable operation in high pollution and humid environments Surge protected for high reliability o Meets IEC ringwave and differential mode surge Meets EN55015 conducted EMI PF >0.9 at 115 VAC and PF>0.85 at 230 VAC %ATHD <15% at 115 VAC and <25% at 230 VAC Meets EN61000-3-2 harmonic current requirements Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Table of Contents 1 2 3 4 Introduction .................................................................................................................5 Power Supply Specification ........................................................................................8 Schematic ...................................................................................................................9 Circuit Description.....................................................................................................10 4.1 Input EMI Filtering and Input Rectification .........................................................10 4.2 LinkSwitch-PL Primary.......................................................................................10 4.3 Output Rectification ...........................................................................................11 4.4 Output Feedback ...............................................................................................11 5 PCB Layout...............................................................................................................12 6 Bill of Materials .........................................................................................................16 7 Transformer Design Spreadsheet .............................................................................17 8 Transformer Specification .........................................................................................19 8.1 Electrical Diagram..............................................................................................19 8.2 Electrical Specifications .....................................................................................19 8.3 Materials ............................................................................................................19 8.4 Transformer Build Diagram................................................................................20 8.5 Transformer Construction ..................................................................................20 8.6 Winding Illustrations...........................................................................................21 9 Performance Data.....................................................................................................23 9.1 Active Mode Efficiency.......................................................................................23 9.2 Harmonics .........................................................................................................24 9.3 Power Factor .....................................................................................................27 9.4 Line Regulation..................................................................................................28 10 Thermal Performance............................................................................................30 10.1 Thermal Set-up ..................................................................................................30 10.2 Equipment Used ................................................................................................31 10.3 Thermal Result ..................................................................................................31 10.3.1 Startup at Low Temperatures .....................................................................31 10.3.2 Operation at Maximum Ambient .................................................................31 10.4 Thermal Scan ....................................................................................................32 10.4.1 Load: 3 V / 366 mA.....................................................................................32 11 Waveforms ............................................................................................................33 11.1 Drain Voltage and Current .................................................................................33 11.1.1 Normal Steady-State Operation..................................................................33 11.1.2 AC Start-up.................................................................................................35 11.1.3 Fault Conditions (Output Shorted / Open Circuit) .......................................36 11.2 Output Current Start-up Profile ..........................................................................37 11.3 Input and Output Waveforms.............................................................................38 11.3.1 Normal Operation (VIN, IIN, VO and IO).........................................................38 11.4 Line Transient Response...................................................................................39 11.5 Brownout ...........................................................................................................44 12 Line Surge.............................................................................................................45 12.1 Line Surge Drain Voltage waveforms. ...............................................................45 12.2 Conducted EMI ..................................................................................................46 Page 3 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 12.3 Equipment: ........................................................................................................46 12.4 EMI Test Set-up ................................................................................................46 13 Output Current Production Distribution .................................................................51 14 Revision History ....................................................................................................53 Important Note: This board is designed for non-isolated application and the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 1 Introduction This document is an engineering report describing a non-isolated LED driver (power supply) utilizing a LNK454DG from the LinkSwitchTM-PL family of devices. It contains the power supply specification, schematic, bill of materials, transformer documentation, printed circuit layout, and performance data. The RD-268 provides a single constant current output of 366 mA with a nominal LED voltage of 3 V. The board was optimized to operate over a universal AC input voltage range (85 VAC to 265 VAC, 47 Hz to 63 Hz) but suffers no damage over an input range of 0 VAC to 300 VAC. This increases field reliability and lifetime during line sags and swells. Key benefits of this design are the very high power factor (>0.85), low THD (<25%) and low harmonic content (a significant challenge due to the low output power) and the ability to fit inside the limited space of a candelabra size lamp base. High PF is a requirement or desire in many commercial applications, for example large chandeliers in hotel foyers. Here a large number of lamps (25 to >200) are connected in parallel however by using individual lamps that have PFC allows the overall fixture to meet PFC and THD requirements with the large energy savings that come from using LEDs vs. incandescent lamps. The form factor of the board was chosen to meet the requirements for standard candelabra shaped LED replacement lamps. The output is non-isolated and requires the mechanical design of the enclosure to isolate the output of the supply and the LED load from the user. Figure 1 – RD-268 (Top View). Page 5 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 Figure 2 – RD-268 (Bottom View). The board is provided with break out locations that allow the driver board to be removed and inserted into a candelabra base as show in Figure 3. Figure 3 – RD-268 Driver Board Removed and Inserted into a Typical Candelabra Base (Metal Part Forms LED Heat Sink). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Figure 4 – Size Comparison of RD-268 Used in a Candelabra LED Replacement Lamp. Page 7 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 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 Symbol Voltage VIN(NOM) Min Typ Max 115/230 Units Comment VAC Nominal line voltages VIN(EXT) 85 265 VAC Normal operating range VIN(ND) 0 300 VAC Voltage range over which no damage to the supply shall occur 25 % THD ATHD Frequency fLINE 47 50/60 63 Hz Output Voltage VOUT 2.5 3 3.5 V Thermal results were verified with 3 V LED string Output Current IOUT(N) 336 366 395 mA (±8%) Nominal 115 VAC / 230 VAC input, after reaching thermal equilibrium IOUT(E) 336 366 395 mA (±10%) Extended 90 VAC-265 VAC o o Input, -20 C to 80 C Output Output Power POUT 1.1 W 50 % Efficiency o Measured at POUT 25 C Environmental Conducted EMI Mounted into candelabra metal finned enclosure and measured on ground plane (to simulate end application) Meets CISPR22B / EN55015 Safety Non-isolated Line Surge Differential Mode (L1-L2) 500 Ring Wave (100 kHz) Differential Mode (L1-L2) Dimensions Board Level Ambient Temperature 2500 V V 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Common Mode: N/A 200 A short-circuit Series Impedance: Differential Mode: 12.5 Common Mode: N/A 23 x 21 mm TAMB -20 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 80 o C Free convection, sea level Page 8 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 3 Schematic Figure 5 – Schematic. Notes: Replace fusible resistor F1 with a slow blow 2 A fuse for differential line surge withstand levels above 500 V. The PCB has optional location for secondary rectifier RC snubber (R4 and C7). Populate if increased radiated EMI margin is required. Page 9 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 4 Circuit Description This circuit is configured as non-isolated discontinuous flyback converter designed to drive LED strings at voltages of 2.5 V to 3.5 V with an output current of 366 mA. The driver is guaranteed to operate across a wide range input voltage range and provide high power factor. The circuit meets both line surge and EMI requirements and the low component count allows board dimensions required for LED candelabra bulb replacement applications. 4.1 Input EMI Filtering and Input Rectification The EMI filter was optimized to meet high power factor and low THD. Fuse (F1) provides protection from component failure that causes excessive input current. A 10 , 2 W rated fusible resistor was selected. Film types (vs. wirewound) are acceptable in this design due to the lower instantaneous resistor dissipation when AC is applied and the small input capacitance charges. For ring wave surge withstand >2 kV or differential surge >500 V a fuse should be substituted as the increased instantaneous dissipation in the resistor causes it to fail open circuit. Two differential pi (π) filter EMI stages are used with C1, R1, L1 and C2 forming one stage and C2, L2, R2 and C3 the second. The incoming AC is rectified by BR1 and filtered by C1, C2 and C3. The total effective input capacitance, the sum of C1, C2 and C3, was selected to assure correct zero crossing detection of the AC input by the LinkSwitch-PL device and to meet high power factor and low THD. Due to the limited input capacitance (to meet PF) RV1 and VR1 are used to limit component voltage stress during line surges. 4.2 LinkSwitch-PL Primary The LNK454DG device (U1) incorporates the power switching device, oscillator, output constant current control, start-up, and protection functions. The integrated 725 V MOSFET provides extended voltage margin and ensures high reliability even during line surge events. The device is powered from the BYPASS pin via the decoupling capacitor C5. During start-up and normal operation C5 is supplied via the DRAIN pin. This self powered operation simplifies the design and reduces component count. The rectified and filtered input voltage is applied to one end of the primary winding of T1. The other side of the transformer’s primary winding is driven by the integrated MOSFET in U1. The leakage inductance generated drain voltage spike is limited by an RCD clamp consisting of D1, R3, and C4. Diode D2 is used to protect the IC from negative ringing (drain voltage ringing below source voltage) when the MOSFET is off due to the reflected output voltage exceeding the DC bus voltage, the result of minimal input capacitance to give high power factor. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 10 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 4.3 Output Rectification The secondary of the transformer is rectified by D3 and filtered by C6. A Schottky barrier type was selected for higher efficiency. As C6 provides energy storage during AC zero crossings its value determines the magnitude of the line frequency output ripple (2 x fL due to full wave rectification). The value may therefore be adjusted based on the desired output ripple. The value of 1000 F chosen provided good regulation and acceptable output current ripple. Lower values may be used providing the resultant LED current ripple is acceptable. Provision is made on the PCB for optional snubber components R4 and C7. These damp high frequency ringing and improve conducted and radiated EMI margin. 4.4 Output Feedback The output current is directly sensed via R5. The average output current (constant current operation) is determined by the value of R5 and the threshold voltage of the FEEDBACK (FB) pin of U1 (290 mV). Disconnected load (output overvoltage protection) is provided by VR2. Under this condition the output voltage is regulated at a value equal to the FB pin voltage and the voltage rating of VR2. Page 11 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 5 PCB Layout Figure 6 – Top Printed Circuit Layout (3.94” x 1.77”). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Figure 7 – Bottom Printed Circuit Layout. Page 13 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 Figure 8 – Bottom Silkscreen. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Figure 9 – Top Silkscreen. Page 15 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 6 Bill of Materials Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 24 25 26 2 1 1 Ref Des BR1 C1 C2 C3 C4 C5 C6 D1 D2 D3 F1 L1 L2 R1 R2 R3 R5 R6 RV1 T1 U1 VR1 VR2 D4 TP5 TP8 TP6 TP7 Description 600 V, 0.5 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC 10 nF, 1 kV, Disc Ceramic, X7R 22 nF, 630 V, Ceramic, X7R, 1210 47 nF, 500 V, Ceramic, X7R, 1812 1 nF, 1000 V, Ceramic, X7R, 0805 4.7 F, 10 V, Ceramic, X7R, 0805 1000 F, 6.3 V, Electrolytic, Gen Purpose, (8 x 11.5) 800 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 40 V, 1 A, Schottky, DO-214AC 10 , 5%, 2 W, Metal Film, Fusible 2200 H, 80 mA, 34.7 Ohm, Axial Ferrite Inductor 3300 H, 62 mA, 59.5 Ohm, Axial Ferrite Inductor 4.7 k, 5%, 1/4 W, Thick Film, 1206 200 k, 5%, 1/4 W, Thick Film, 1206 0.82 , 1%, 1/2 W, Thick Film, 1206 1 k, 5%, 1/10 W, Thick Film, 0603 275 V, 23 J, 7 mm, RADIAL Bobbin, EE10, Vertical, 8 pins LinkSwitch-PL, SO-8C 350 V, 400 W, 5%, DO214AC (SMA) 6.2 V, 5%, 150 mW, SSMINI2 LED, SMD, Luxeon Rebel, Neutral-White Test Point, BLK,THRU-HOLE MOUNT Test Point, WHT,THRU-HOLE MOUNT Test Point, RED,THRU-HOLE MOUNT Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Manufacturer P/N MB6S-TP SV01AC103KAR GRM32QR72J223KW01L VJ1812Y473KXEAT C0805C102KDRACTU C0805C475K8PACTU ECA-0JHG102 UF4006-E3 BAV21WS-7-F SS14 NFR0200001009JR500 B78108S1225J B78108S1335J ERJ-8GEYJ472V ERJ-8GEYJ204V RL1632R-R820-F ERJ-3GEYJ102V V275LA4P SNX R1568 LNK454DG SMAJ350A DZ2S06200L LXML-PWN1-0100 Manufacturer Micro Commercial AVX Murata Vishay Kemet Kemet Panasonic Vishay Diodes, Inc. Vishay Vishay Epcos Epcos Panasonic Panasonic Susumu Panasonic Littlefuse Santronics Power Integrations LittlelFuse Panasonic-SSG Luxeon 5011 5012 5010 Keystone Keystone Keystone Page 16 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 7 Transformer Design Spreadsheet ACDC_LinkSwitch-PLFlb_101210; Rev.2.0; Copyright Power Integrations 2010 INPUT INFO OUTPUT UNIT ENTER APPLICATION VARIABLES VACMIN VACMAX FL VO VO_MIN VO_MAX IO n Z Enclosure Dimming Application 85 265 47 3.50 0.35 Retrofit Lamp No PO VD LinkSwitch-PL DESIGN VARIABLES Device LNK454 85 265 47 3.50 3.5 3.50 0.350 0.7 0.5 V V Hz V V V A %/100 Retrofit Lamp No 1.23 0.5 W V LNK454 VOR Turns Ratio 104.0 26.0 V TON 2.61 us FSW 122.1 kHz Duty Cycle 31.9 % VDRAIN 572 V IRMS IPK ILIM_MAX 0.031 0.253 0.325 A A A KDP 1.85 LinkSwitch-PL EXTERNAL COMPONENT CALCULATIONS RSENSE 0.829 Standard RSENSE 0.83 PSENSE 0.102 ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type EE10 EE10 Core Part Number #N/A Bobbin Part Number #N/A AE 12.10 12.10 LE 26.10 26.10 AL 850 850 BW 6.00 6 L 3.00 3 NS 7 TRANSFORMER PRIMARY DESIGN PARAMETERS LP 2.000 LP Tolerance 10 NP 180 ALG 62 BM 2325 BAC 1163 Page 17 of 54 Ohms Ohms W mm^2 mm nH/T^2 mm Turns mH % Turns nH/T^2 Gauss Gauss ACDC_LinkSwitch-PL_Flb_101210; LinkSwitch-PL Flyback Transformer Design Spreadsheet Reference Design Report for a 1.2 W NonDimmable Power Factor Corrected LED TM Driver (Non-Isolated) Using LinkSwitch PL LNK454DG Minimum AC input voltage Maximum AC input voltage Minimum line frequency Nominal Output Voltage Minimum output voltage tolerance Maximum output voltage tolerance Average output current Total power supply efficiency Loss allocation factor. Enclosure selections determines thermal conditions and maximum power Dimming applications generally require lower flux density to avoid audible noise problems Average output power Output diode forward voltage drop Chose device PO max in Open Frame: 2.46W, PO Max in Retrofit Lamp: 1.54 W. Reflected output voltage Primary to secondary turns ratio Expected on-time of MOSFET at low line and PO Expected switching frequency at low line and PO Expected operating duty cycle at low line and PO Estimated worst case drain voltage at VACMAX and VO_MAX Worst case primary RMS current at VO Worst case peak primary current at VO Device peak current Ratio between off-time of switch and reset time of core at VACMIN Output current sense resistor Closest 1% value for RSENSE Power dissipated by RSENSE Core Type Core Part Number (if Available) Bobbin Part Number (if available) Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Number of primary winding layers Number of Secondary Turns Primary Inductance Tolerance of Primary Inductance Primary Winding Number of Turns Gapped Core Effective Inductance Operating Flux Density Worst case AC Flux Density for Core Loss Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 BP 3283 Gauss LG BWE 0.246 18 mm mm OD 0.10 mm INS 0.02 mm DIA 0.08 mm AWG 41 AWG CM 8 Cmils 261 Cmils/Amp 7.71 A/mm^2 6.51 1.18 0.35 A A A PIVS 17.9 V CMS1 235 Cmils AWGS 26 AWG 0.41 2.57 mm mm CMA Primary Current Density (J) SECONDARY DESIGN PARAMETERS ISP ISRMS IO DIAS ODS Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Curves (0.5 X Peak to Peak) Calculated Worst Case Peak Flux Density (BP < 3600 G ) Gap Length (Lg > 0.1 mm) Effective Bobbin Width Maximum Primary Wire Diameter including insulation Estimated Total Insulation Thickness (= 2 * film thickness) Bare conductor diameter Primary Wire Gauge (Rounded to next smaller standard AWG value) Bare conductor effective area in circular mils Primary Winding Current Capacity (200 < CMA < 500) Primary Winding Current density (3.8 < J < 9.75 A/mm^2) Worst Case Peak Secondary Current Worst Case Secondary RMS current Output Current Peak Inverse Voltage at VO_MAX on output diode Output Winding Bare Conductor minimum circular mils Wire Gauge (Rounded up to next larger standard AWG value) Minimum Bare Conductor Diameter Maximum Outside Diameter for Wire Page 18 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 8 Transformer Specification 8.1 Electrical Diagram Figure 10 – Transformer Electrical Diagram. 8.2 Electrical Specifications 500 VAC Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 8.3 Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS Pins 1-2, all other windings open Pins 1-2, with pins 7-9 shorted, measured at 100 kHz, 0.4 VRMS 2 mH ±10% 1.2 MHz 270 H (Max.) Materials Item [1] [2] [3] [4] [5] [6] [7] [8] [9] Description Core: EE10/PC40 Bobbin: EE10, Vertical, 8 pins, (4/4) Magnet Wire: #34 AWG. Magnet Wire: #40 AWG Magnet Wire #26 AWG Tape: 3M 1298 Polyester Film, 6.5 mm wide. Copper Foil Tape, 6.5 mm Bus Wire: #24 AWG Varnish. Page 19 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 8.4 04-Apr-11 Transformer Build Diagram 8 7 Secondary: 7T – #26 AWG 1 50T 65T 3 8 Primary: 180T – #40 AWG 65T Cancellation: 32T – #34 AWG Figure 11 – Transformer Build Diagram. 8.5 Transformer Construction Winding Preparation General Note WD1 Insulation WD2 Insulation WD3 Insulation Core Assembly Copper Shielding Finish Place bobbin on the mandrel such that primary on the left and secondary on the right. Winding direction is clock-wise direction. For the purpose of these instructions, Bobbin is oriented on winder such that pin 1 side is on the left side (see illustration). Winding direction as shown is clockwise. Start on a temporary pin on secondary side, wind 32 turns of #34 AWG item [3] from left to right one layer. Finish at pin 8. 1 layers of tape item [6] for insulation. Start at pin 3, wind 180 turns of #40 AWG [4] wire from left to right three layers 65T + 65T + 50T. Use 2 layers of tape item [6] between each layer. Finish at pin 1. 2 layers of tape [6] for insulation. Start at pin 7, wind 7 turns of #26 AWG [5] from left to right one layer. Finish at pin 8. 3 layers of tape [6] for insulation. Grind and assemble core. 1 turn of 6.5 mm copper foil tape [7] around assembly and solder the tape seal. Solder #24 AWG buss wire [8] to the copper shield and terminate at pin 8 2 layers of tape item [6] for insulation over copper shield and varnish using item [9]. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 54 04-Apr-11 8.6 RDR-268 1.1 W PF Corrected LED Power Supply Winding Illustrations Bobbin Preparation For the purpose of these instructions, Bobbin is oriented on winder such that pin 1 side is on the left side (see illustration). Winding direction as shown is clockwise. WD1 Start on a temporary pin on the secondary side and wind 32 turns of #34 AWG item [3] from left to right one layer. Finish at pin 8. Remove wire from temporary pin and cut off excess leaving on a small portion to be terminated under the insulation tape. Insulation WD2 Page 21 of 54 1 Layers of tape item [6] for insulation. Start at pin 3, wind 180 turns of #40 AWG item [4] in 3 layers: 65T + 65T + 50T, place 2 layers of tape item [6] between layers. Finish at pin 1. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 2 layers of tape item [6] for insulation. Insulation Start at pin 7, wind 7 turns of #26 AWG item [5] from left to right one layer. Finish at pin 8. WD3 3 layers of tape item [6] for insulation. Insulation Core Assembly Grind core halves to get 2 mH, between cores, refer to section 1.3 for electrical specifications, and assemble with tape. Copper Shielding Wind 1 turn of 6.5 mm copper foil tape item [7] around the core assembly. Solder the tape seal. Solder #24 AWG buss wire item [8] to the copper shield and terminate at pin 8 Finish Add 2 Layers of tape item [6] over copper shield and varnish with item [9]. Figure 12 – Transformer Construction. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 9 Performance Data All measurements performed at room temperature otherwise specified. 9.1 Active Mode Efficiency 58.0 57.5 57.0 Efficiency (%) 56.5 56.0 55.5 55.0 54.5 54.0 53.5 53.0 80 100 120 140 160 180 200 220 240 260 280 AC Input Voltage (VAC) Figure 13 – Nominal Load (3 V, 366 mA) Efficiency with Respect to Line Input Voltage. Input Input Measurement VAC (VRMS) Freq (Hz) 90 100 115 132 180 190 220 230 265 47 60 60 60 50 50 50 50 50 Page 23 of 54 IIN (mARMS) PIN (W) PF 21.61 19.48 17.40 14.43 11.80 10.90 10.03 9.68 9.02 1.93 1.92 1.95 1.82 1.98 1.90 2.00 2.01 2.04 0.99 0.98 0.97 0.95 0.93 0.92 0.90 0.90 0.85 Load Measurement %THD VO (VDC) IO (mADC) Po (W) 6.15 8.04 10.52 14.58 15.09 17.51 20.26 21.1 25.59 2.86 2.85 2.86 2.85 2.85 2.85 2.85 2.85 2.85 371.80 370.50 385.30 358.10 379.00 365.60 372.40 383.30 376.30 1.08 1.07 1.12 1.04 1.10 1.06 1.08 1.11 1.09 Efficiency (%) 56.22 56.07 57.41 57.00 55.73 55.72 54.08 55.41 53.55 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 9.2 04-Apr-11 Harmonics Meets EN61000-3-2 Harmonics content limits. Order 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 Input Current Harmonics (mA) Measured Limits 115 V 230 V 115 V 230 V 17.71 9.60 0.43 0.84 13.5728 6.9360 1.18 1.02 7.5848 3.8760 0.61 0.87 3.9920 2.0400 0.51 0.64 1.9960 1.0200 0.49 0.43 1.3972 0.7140 0.54 0.34 1.1822 0.6042 0.33 0.36 1.0246 0.5236 0.16 0.36 0.9041 0.4620 0.17 0.33 0.8089 0.4134 0.18 0.26 0.7319 0.3740 0.27 0.24 0.6682 0.3415 0.18 0.24 0.6148 0.3142 0.17 0.23 0.5692 0.2909 0.12 0.21 0.5300 0.2708 0.17 0.21 0.4958 0.2534 0.12 0.18 0.4657 0.2380 0.15 0.17 0.4391 0.2244 0.20 0.17 0.4154 0.2123 0.14 0.15 0.3941 0.2014 0.07 0.13 0.10 0.14 0.07 0.12 0.04 0.12 0.08 0.16 EN 61000-3-2 P P P P P P P P P P P P P P P P P P P P: Pass Table 1 – Measured Harmonic Input Current. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 16 Class D Limits RD-268 Harmonic Data at 115 VAC 14 Harmonic Content 12 10 8 6 4 2 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order Figure 14 – 115 V UUT Harmonic Content. Page 25 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 8 04-Apr-11 Class D Limits RD-268 Harmonic Data at 230 VAC 7 Harmonic Content 6 5 4 3 2 1 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order Figure 15 – 230 V UUT Harmonic Content. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 54 04-Apr-11 9.3 RDR-268 1.1 W PF Corrected LED Power Supply Power Factor 1.00 0.95 0.90 Power Factor 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 80 100 120 140 160 180 200 220 240 260 Input Voltage (VAC) Figure 16 – Power Factor with Respect to AC Input at Full Load. Page 27 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 9.4 Line Regulation Output current vs. line voltage measurements were taken by directly applying the AC input at the line voltages indicated, removing the AC power, adjusting the AC voltage (via an AC source) and reapplying AC at the new voltage. This approach was taken to ensure repeatability as variations in the operating state of the LinkSwitch-PL can occur when the AC input voltage is swept. 10 8 Regulation Band (%) 6 4 2 0 -2 -4 -6 -8 -10 80 90 100 110 120 130 140 Input Voltage (VAC) Figure 17 – Low Line Regulation Band, Room Temperature, Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 10 8 Regulation Band (%) 6 4 2 0 -2 -4 -6 -8 -10 180 190 200 210 220 230 240 250 260 270 Input Voltage (VAC) Figure 18 – High Line Regulation Band, Room Temperature, Full Load. Page 29 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 10 Thermal Performance 10.1 Thermal Set-up The unit was verified inside a cardboard box to avoid the influence of circulating air inside the thermal chamber. Figure 19 – Thermal Chamber Set-up Showing Box Used to Prevent Airflow Over UUT. Figure 20 – UUT Within Box. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 10.2 Equipment Used Chamber: Tenney Environmental Chamber Model No: TJR-17 942 AC Source: Chroma Programmable AC Source Model No: 6415 Wattmeter: Yokogawa Power Meter Model No: WT2000 Data Logger: Monogram SN:1290492 10.3 Thermal Result Load: 3 V / 366 mA LED load. 10.3.1 Startup at Low Temperatures Unit was soaked at -30°C with no AC applied. AC was then applied and supply correctly started up and operated. 10.3.2 Operation at Maximum Ambient Operation at an ambient of 80°C was verified. This simulates operation inside sealed candelabra enclosure. Component Ambient (ºC) Bridge Pin (BR1) Input Inductor (L1) LNK454DG SOURCE Pin (U1) Transformer Core (T1) Output Diode (D3) Output Case Capacitor (C6) 90 V / 50 Hz Input Device Temperature (ºC) 80 97 96 106 100 110 98 265 / 63 Hz Input Device Temperature (ºC) 80 102 100 109 105 109 103 Table 2 – Thermal Measurement at 80ºC Ambient (Board Temperature). Page 31 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 10.4 Thermal Scan 10.4.1 Load: 3 V / 366 mA Figure 21 – LNK454DG Device Temperature at 25ºC Open Air. Figure 22 – Transformer (T1) Temperature at 25ºC Open Air. Figure 23 – Clamp Diode (D1) Temperature at 25ºC Open Air. Figure 24 – Output Diode D3 Temperature at 25ºC Open Air. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 11 Waveforms 11.1 Drain Voltage and Current 11.1.1 Normal Steady-State Operation Figure 25 – 90 VAC / 50 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 100 V / div., 1 ms / div. Lower: IDRAIN, 0.1 A / div. Figure 26 – 90 VAC / 50 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 100 V / div., 2 s / div. Lower: IDRAIN, 0.1 A / div. Figure 27 – 115 VAC / 60 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 100 V / div., 1 ms / div. Lower: IDRAIN, 0.1 A / div. Figure 28 – 115 VAC / 60 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 100 V / div., 2 s / div. Lower: IDRAIN, 0.1 A / div. Page 33 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 Figure 29 – 230 VAC / 50 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 200 V / div., 1 ms / div. Lower: IDRAIN, 0.1 A / div. Figure 30 – 230 VAC / 50 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 200 V / div., 5 s / div. Lower: IDRAIN, 0.1 A / div. Figure 31 – 265 VAC / 63 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 200 V / div., 1 ms / div. Lower: IDRAIN, 0.1 A / div. Figure 32 – 265 VAC / 63 Hz, LED = 3 V / 366 mA. Upper: VDRAIN, 200 V / div., 5 s / div. Lower: IDRAIN, 0.1 A / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 11.1.2 AC Start-up Figure 33 – 265 VAC / 63 Hz, LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VO, 1 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 100 mA / div. Time Scale: 20 ms / div. Page 35 of 54 Figure 34 – 265 VAC / 63 Hz, LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VO, 1 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 100 mA / div. Time Scale: 1 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 11.1.3 Fault Conditions (Output Shorted / Open Circuit) Figure 35 – 265 VAC. Load Shorted. Upper: VDRAIN, 100 V / div. Lower: IDRAIN, 50 m A / div., 1 ms / div. Figure 36 – 265 VAC. Load Shorted. Upper: VDRAIN, 100 V / div. Lower: IDRAIN, 50 mA / div., 1 s / div. Figure 37 – 265 VAC. Load Shorted. Upper: VDRAIN, 100 V / div. Lower: IDRAIN, 50 mA / div., 20 s / div. Figure 38 – 265 VAC. Load Open. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VO, 1 V / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 11.2 Output Current Start-up Profile Figure 39 – 90 VAC / 47 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 20 mA / div. Time Scale:100 ms / div. Figure 40 – 115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 20 mA / div. Time Scale:100 ms / div. Figure 41 – 230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 20 mA / div. Time Scale:100 ms / div. Figure 42 – 265 VAC / 63 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 20 mA / div. Time Scale:100 ms / div. Page 37 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 11.3 Input and Output Waveforms 11.3.1 Normal Operation (VIN, IIN, VO and IO) Figure 43 – 90 VAC / 47 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 10 mA / div., 5 ms / div. Figure 44 – 115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 10 mA / div., 5 ms / div. Figure 45 – 230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 10 mA / div., 5 ms / div. Figure 46 – 265 VAC / 63 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 100 V / div. Ch2(Red): VO, 500 mV / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IIN, 10 mA / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 11.4 Line Transient Response In the figures shown below, signal averaging was used to better enable viewing the load transient response. The oscilloscope was triggered using the load current step as a trigger source. Since the output switching and line frequency occur essentially at random with respect to the load transient, contributions to the output ripple from these sources will average out, leaving the contribution only from the load step response. Figure 47 – 115-0-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 2 s / div. Page 39 of 54 Figure 48 – 115-85-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 2 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 Figure 49 – 115-85-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 10 ms / div. Figure 50 – 115-85-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Figure 51 – 115-85-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 10 ms / div. Figure 52 – 115-85-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Figure 53 – 115-132-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 2 s / div. Figure 55 – 115-132-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Page 41 of 54 Figure 54 – 115-132-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Figure 56 – 115-132-115 VAC / 60 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 100 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply Figure 57 – 230-180-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 2 s / div. Figure 59 – 230-180-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 04-Apr-11 Figure 58 – 230-180-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 10 ms / div. Figure 60 – 230-180-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Page 42 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Figure 61 – 230-265-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 2 s / div. Figure 63 – 230-265-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Page 43 of 54 Figure 62 – 230-265-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 10 ms / div. Figure 64 – 230-265-230 VAC / 50 Hz. LED = 3 V / 366 mA. Ch1(Yellow): VDS, 200 V / div. Ch2(Red): VIN, 0.5 V / div. Ch3(Blue): IO, 100 mA / div. Ch4(Green): IDS, 50 mA / div., 50 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 11.5 Brown-Out AC input voltage is ramp up and ramp down slowly in a rate of 0.1 V / s to verify that no damage (e.g. overheating) or component failure occurs during this abnormal condition. Unit was not expected to operate normally below 85 VAC, turning off, low output current and flicker at extremely low input voltage is acceptable. Normal operation was verified once the AC input voltage was returned to specified range. Figure 65 – 90-0-90 VAC / 50 Hz at 0.1 V / s Slew Rate. LED = 3 V / 366 mA. Ch1(Yellow): VIN, 50 V / div. Ch3(Blue): IO, 100 mA / div. Time Scale: 200 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 44 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 12 Line Surge Differential input line 1.2 / 50 s 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 with 3 V / 366 mA and operation was verified following each surge event. Surge Level (V) Input Voltage (VAC) Injection Location Injection Phase (°) Surge Type Test Result (Pass/Fail) +500 +500 -500 -500 +2500 +2500 -2500 -2500 230 230 230 230 230 230 230 230 L1 to L2 L1 to L2 L1 to L2 L1 to L2 L1 to L2 L1 to L2 L1 to L2 L1 to L2 90 0 90 0 90 0 90 90 Line Line Line Line Ring Wave Ring Wave Ring Wave Ring Wave Pass Pass Pass Pass Pass Pass Pass Pass Unit passed all test conditions. 12.1 Line Surge Drain Voltage waveforms. Figure 66 – 500 V Differential Line Surge at 230 VAC / 60 Hz. LED = 3 V / 366 mA. Peak VDS = 573 V. Ch1(Yellow): VIN, 200 V / div. Ch2(Red): VBRIDGE, 200 V / div. Ch3(Blue): VBULK, 2000 V / div. Ch4(Green): VDS, 200 V / div., 50 s / div. Page 45 of 54 Figure 67 – 2.5 kV Ring Surge at 230 VAC / 60 Hz. LED = 3 V / 366 mA; Peak VDS = 700 V. Ch1(Yellow): VIN, 200 V / div. Ch2(Red): VBRIDGE, 200 V / div. Ch3(Blue): VBULK, 2000 V / div. Ch4(Green): VDS, 200 V / div., 50 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 12.2 Conducted EMI 12.3 Equipment: Receiver: Rohde and Schwarz ESPI - Test Receiver (9 kHz – 3 GHz) Model No: ESPI3 LISN: Rohde and Scharrz Two-Line-V-Network Model No: ENV216 12.4 EMI Test Set-up LED driver was placed within a candelabra base (Figure 3) with LED load and placed in a conical metal housing (for self-ballasted lamps; CISPR15 Edition 7.2). Figure 68 – Conducted Emissions Measurement Set-up Showing Conical Ground Plane Inside which UUT was Mounted. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 46 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Power Integrations 13.Jan 11 19:55 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 EN55015Q 110 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 69 – Pre-scan Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55015 Limits. Note Blue Line is Peak Result vs. QP Limit Line – Refer to Table for QP Margin. Page 47 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply Trace1: 04-Apr-11 EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 112.686385873 kHz 41.60 L1 gnd 1 Quasi Peak 223.329560038 kHz 53.71 L1 gnd 2 Average 227.818484195 kHz 46.44 L1 gnd -6.08 2 Average 342.582585749 kHz 33.21 L1 gnd -15.92 1 Quasi Peak 346.008411606 kHz 43.16 L1 gnd -15.89 2 Average 461.749566613 kHz 31.79 L1 gnd -14.86 2 Average 563.422222132 kHz 34.91 L1 gnd -11.08 1 Quasi Peak 580.494478884 kHz 45.93 L1 gnd -10.06 2 Average 687.48218373 kHz 35.17 L1 gnd -10.82 1 Quasi Peak 694.357005568 kHz 47.40 L1 gnd -8.59 2 Average 790.243042258 kHz 29.00 L1 gnd -16.99 1 Quasi Peak 814.188196682 kHz 41.27 L1 gnd -14.72 1 Quasi Peak 1.04414099339 MHz 43.78 L1 gnd -12.21 2 Average 1.04414099339 MHz 30.42 L1 gnd -15.58 1 Quasi Peak 1.91585637048 MHz 40.94 N gnd -15.05 1 Quasi Peak 3.24635311795 MHz 44.14 L1 gnd -11.85 2 Average 3.24635311795 MHz 32.10 L1 gnd -13.89 1 Quasi Peak 3.31160481562 MHz 43.42 N gnd -12.57 1 Quasi Peak 3.44606925067 MHz 42.44 N gnd -13.55 2 Average 3.44606925067 MHz 29.81 N gnd -16.18 -8.97 Table 3 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55015 Margin. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 48 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply Power Integrations 13.Jan 11 19:23 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 EN55015Q 110 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 1 QP CLRWR 100 90 2 AV CLRWR TDF 80 70 60 EN55015A 50 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 70 – Pre-scan Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 Limits. Note Blue Line is Peak Result vs. QP Limit Line – Refer to Table for QP Margin. Page 49 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply Trace1: 04-Apr-11 EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBµV DELTA LIMIT dB 2 Average 63.2749441994 kHz 11.22 N gnd 2 Average 123.243440661 kHz 23.41 N gnd 1 Quasi Peak 186.707378963 kHz 56.35 L1 gnd 2 Average 190.46019728 kHz 48.09 L1 gnd -5.92 1 Quasi Peak 249.161721009 kHz 50.27 L1 gnd -11.51 2 Average 251.653338219 kHz 42.25 L1 gnd -9.45 1 Quasi Peak 310.135545783 kHz 47.46 L1 gnd -12.50 2 Average 316.369270253 kHz 37.10 L1 gnd -12.70 1 Quasi Peak 370.967850209 kHz 47.19 L1 gnd -11.28 2 Average 374.677528711 kHz 35.01 L1 gnd -13.38 2 Average 448.169580165 kHz 29.85 L1 gnd -17.05 1 Quasi Peak 452.651275966 kHz 36.42 L1 gnd -20.40 2 Average 641.227045055 kHz 30.88 L1 gnd -15.11 1 Quasi Peak 647.639315505 kHz 34.20 L1 gnd -21.79 1 Quasi Peak 680.675429436 kHz 44.78 N gnd -11.21 2 Average 687.48218373 kHz 33.65 N gnd -12.34 1 Quasi Peak 1.75174377706 MHz 38.26 N gnd -17.73 1 Quasi Peak 3.08879360159 MHz 42.28 L1 gnd -13.71 2 Average 3.08879360159 MHz 30.28 L1 gnd -15.71 1 Quasi Peak 3.15087835298 MHz 42.36 N gnd -13.63 -7.82 Table 4 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 Margin. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 50 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 13 Output Current Production Distribution Figure 71 shows the production distribution of output current for 22 randomly selected RD-268 boards. The data was gathered using a NH Research 5600 series power supply test system, commonly used in the power supply industry for production testing of power supplies. The data is also summarized in Table 5. Measurements were made at room temperature, with a CV+CC load representing the characteristics of the included Luxeon Rebel LED. Measurements were after directly applying voltages of 115 VAC and 230 VAC. These distributions includes variations not only from the LinkSwitch-PL devices but also all the components of the driver. Figure 71 – Output Current Distribution Plot for RD-268 (Line Represents Nominal, Minimum and Maximum IO Specification) From the data it can be seen that the output current is not centered. This could be corrected by adjusting the output current sense resistor value, reducing it by 6% to Page 51 of 54 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 increase the output current by 6%. Therefore to correctly demonstrate the achievable tolerance of the design, CP values were calculated versus CPK. CP provides process capability when the distribution is centered (CP=CPK for a centered process) such as would be the case if the sense resistor were adjusted. Output current tolerance values are given based on CP of 1.33, 1.5, and 1.67. A value of 1.33 is typical for high volume production. A value of 1.5 is generally considered to indicate a 6 sigma process (allowing for a 1.5 sigma drift from the mean with a CP of 2). For reference Table 7 shows the expected PPM fallout rate for a given CP/CPK value. Input Voltage (VAC) Mean (mA) (mA) 115 351.2 230 115 - 230 IO Tolerance for Given CP Value CP=1.33 CP=1.5 CP=1.67 4.0 4.1% 4.% 5.9% 354.6 4.68 4.1% 4.7% 8% 352.9 4.16 Table 5 – Output Current Tolerance vs. CP Value. CPK Sigma PPM 1 3 2700 1.33 4 64 1.5 4.5 7 1.67 5 1 Table 6 – PPM Fallout Rate vs. CPK Value. The data in Table 6 shows that the design meets the 7% target specification with a CP of >1.33. In additional the design is capable of meeting a tolerance specification of < 5% at low line. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 52 of 54 04-Apr-11 RDR-268 1.1 W PF Corrected LED Power Supply 14 Revision History Date 28-Feb-11 04-Mar-11 04-Apr-11 Page 53 of 54 Author JDC PV KM Revision 1.0 1.1 1.2 Description & changes Initial Release Added Production IO Data Updated Figures 39 to 65 Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-268 1.1 W PF Corrected LED Power Supply 04-Apr-11 For the latest updates, visit our website: www.powerint.com Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS. PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm. The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, CAPZero, SENZero, LinkZero, HiperPFS, HiperTFS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies. ©Copyright 2011 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS 5245 Hellyer Avenue San Jose, CA 95138, USA. Main: +1-408-414-9200 Customer Service: Phone: +1-408-414-9665 Fax: +1-408-414-9765 e-mail: [email protected] GERMANY Rueckertstrasse 3 D-80336, Munich Germany Phone: +49-89-5527-3911 Fax: +49-89-5527-3920 e-mail: [email protected] JAPAN Kosei Dai-3 Building 2-12-11, Shin-Yokohama, Kohoku-ku, Yokohama-shi, Kanagawa 222-0033 Japan Phone: +81-45-471-1021 Fax: +81-45-471-3717 e-mail: [email protected] TAIWAN 5F, No. 318, Nei Hu Rd., Sec. 1 Nei Hu District Taipei 114, Taiwan R.O.C. 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Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com APPLICATIONS FAX World Wide +1-408-414-9760 Page 54 of 54