Design Example Report Title High Efficiency 3.8 W Dimmable Power Factor Corrected LED Driver Using LinkSwitchTM-PL LNK457DG in a Non-Isolated Buck Topology Specification 190 VAC – 265 VAC Input; 42 V – 54 V, 80 mA Output Application LED Driver for Candelabra Lamp Replacement Author Applications Engineering Department Document Number DER-301 Date November 10, 2011 Revision 1.0 Summary and Features Single-stage power factor corrected and accurate constant current (CC) output Dimmable Low cost, low component count and small PCB footprint Highly energy efficient, >83.5% at 230 VAC input for 48 V Fast start-up time (<300 ms) – no perceptible delay Integrated protection and reliability features Output short-circuit protected with auto-recovery Disconnected load protection with auto-recovery Auto-recovering thermal shutdown with large hysteresis protects both components and PCB No damage during brown-out conditions PF >0.91 at 230 VAC % ATHD <25% at 230 VAC; 48 V LED Meets IEC ring wave, differential line surge and EN55015 conducted EMI 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-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 3 Power Supply Specifications ...................................................................................... 5 Schematic ................................................................................................................... 6 Circuit Description ...................................................................................................... 7 4.1 Input EMI Filtering ............................................................................................... 7 4.2 Dimmable Buck using LinkSwitch-PL .................................................................. 7 4.3 Output Feedback ................................................................................................. 7 4.4 Disconnected Load Protection............................................................................. 8 5 PCB Layout ................................................................................................................ 9 6 Bill of Materials ......................................................................................................... 10 7 Performance Data .................................................................................................... 11 7.1 Active Mode Efficiency ...................................................................................... 11 7.2 Line Regulation ................................................................................................. 12 7.3 Power Factor ..................................................................................................... 13 7.4 %THD ................................................................................................................ 14 8 Thermal Scans ......................................................................................................... 15 9 Waveforms ............................................................................................................... 16 9.1 Drain Voltage and Current, Normal Operation................................................... 16 9.2 Drain Voltage and Current Start-up Profile ........................................................ 17 9.3 Output Voltage Start-up Profile.......................................................................... 18 9.4 Input and Output Voltage and Current Profiles .................................................. 18 9.5 Drain Voltage and Current Profile with Output Shorted ..................................... 19 9.6 Line Transient Response................................................................................... 20 9.7 Brown-out .......................................................................................................... 21 9.8 Start-up No-load ................................................................................................ 22 9.9 Normal Operation then No-load......................................................................... 22 9.10 Line Surge Waveform ........................................................................................ 23 10 Dimming Sample Waveform ................................................................................. 25 11 Dimming Compatibility .......................................................................................... 27 12 Line Surge............................................................................................................. 29 13 Conducted EMI ..................................................................................................... 30 13.1 Equipment ......................................................................................................... 30 13.2 EMI Test Set-up ................................................................................................ 30 13.3 EMI Test Result ................................................................................................. 31 14 Revision History .................................................................................................... 33 Important Note: Although this board is designed to satisfy safety requirements for non-isolated LED drivers, 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 2 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 1 Introduction This document is an engineering report describing a non-isolated dimmable LED driver (power supply) utilizing a LNK457DG from the LinkSwitch-PL family of devices. The DER-301 provides a single constant current output with an output power of 3.8 W output. The key design goals were high efficiency, dimmable and compact size, enabling the driver to fit into candelabra and B10 sized lamps and maximize efficacy. Figure 1 – Populated Circuit Board Photograph. The board was optimized to operate over the high AC input voltage range (190 VAC to 265 VAC, 47 Hz to 63 Hz). LinkSwitch-PL based designs provide a high power factor (>0.91) meeting current international requirements. The form factor of the board was chosen to meet the space limitations of standard Candelabra 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. The document contains the power supply specification, schematic, bill of materials, printed circuit layout and performance data. Page 3 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 Figure 2 – Populated Circuit Mounted in the B10 Casing. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 2 Power Supply Specifications The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Input Voltage Frequency Power Factor %ATHD Output Output Voltage Output Current Total Output Power Continuous Nominal Output Power Efficiency Nominal Symbol Min Typ Max Units Comment VIN fLINE 190 47 0.92 265 63 VAC Hz 2 Wire – no P.E. 50/60 At 230 V; nominal load 25 VOUT IOUT 75 70 48 80 85 90 V mA mA POUT 3.8 W 83 % 230 VAC 190 VAC - 265 VAC o Measured at POUT 25 C at 230 VAC Environmental Conducted EMI Meets CISPR22B / EN55015 Line Surge Differential Mode (L1-L2) 1 Ring Wave (100 kHz) Differential Mode (L1-L2) 2.5 Harmonic Currents Operating Ambient Page 5 of 34 kV 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 kV 2 short-circuit Series Impedance EN 61000-3-2 Class D (C) Section 7.3.b - Second Clause 0 70 Class C specifies Class D Limits when PIN <25 W See Section 9.4 ºC Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 3 Schematic Figure 3 – Schematic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 4 Circuit Description The LinkSwitch-PL (U1) is a highly integrated primary side controller intended for use in LED driver applications. The LinkSwitch-PL provides high power factor in a single-stage conversion topology while regulating the output current across a range of input (190 VAC to 265 VAC) and output voltage variations typically encountered in LED driver applications. All of the control circuitry responsible for these functions plus the highvoltage power MOSFET are incorporated into the IC. 4.1 Input EMI Filtering The maximum input voltage is clamped by RV1 and by VR2 (TVS) during differential line surges. Varistor RV1 can be removed for a differential line surge requirement of ≤500 V. The AC input is full wave rectified by BR1 (vs. half wave) to achieve good power factor and dimmability. Inductor L1 and L4 are positioned before the bridge to avoid an imbalance in the EMI scan between line and neutral and filters the differential noise. Capacitor C1, C2, and differential choke L2 perform EMI filtering while the limited total capacitance maintains high power factor. This input filter network plus the frequency jittering feature of LinkSwitch-PL allows compliance with Class B emission limits. EMI inductor L1 and L4 are also used as a protection against component failure (providing a fusing function). RC bleeder R6 and C8 are located near the switching node to reduce radiated and conducted noise. Shielded inductor L3 was selected to reduce conducted and radiated noise. 4.2 Dimmable Buck using LinkSwitch-PL The buck power train is composed of U1 (power switch + control), D2 (free-wheeling diode), C7 (output capacitor), and L3 (inductor). Diode D1 was used to prevent negative voltage appearing across the drain-source of U1 especially near the zero-crossing of the input voltage. The bypass capacitor C4 provides the internal supply for the device when the power MOSFET is on. The integrated device enables a very low component count and high efficiency that makes it ideal for candelabra B10 or other compact applications. 4.3 Output Feedback The output current feedback is sensed on the voltage drop across R3 and R5 then filtered by a low pass filter (R4 and C5) to keep the LinkSwitch-PL operating point such that the average FEEDBACK (FB) pin voltage is 290 mV in steady-state operation. The output inductor is operated in DCM for better CC control and the current regulation is sampled during the discharge in the energy of the output inductor. Page 7 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 4.4 Disconnected Load Protection The LED driver is protected in the event of accidental open load operation by monitoring the voltage across the output inductor during energy decay. The threshold is limited by VR1 and the discharge resistor (R9) in the output. Want More? Use your smartphone and free software from www.neoreader.com (or any other free QR Code Reader from your smartphone’s App Store) and you will be connected to related content Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 5 PCB Layout Figure 4 – Top Printed Circuit Layout (Diameter = .68” [17.3 mm]). Figure 5 – Bottom Printed Circuit Layout. Page 9 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 6 Bill of Materials The table below is the reference design BOM. Item Qty Ref Des 1 1 BR1 2 1 C1 Description 600 V, 0.5 A, Bridge Rectifier, SMD, MBS-1, 4SOIC 10 nF, 630 V, Ceramic, X7R, 1206 Mfg Part Number Manufacturer MB6S-TP Micro Commercial 3 1 C2 47 nF, 400 V, Film 4 1 C4 10 F, 16 V, Ceramic, X5R, 0805 GRM21BR61C106KE15L Murata 5 1 C5 GRM188R61A225KE34D 6 1 C7 C1206C103KBRACTU Kemet ECQ-E4473KF Panasonic 7 1 C8 2.2 F, 10 V, Ceramic, X5R, 0603 22 F, 63, Electrolytic, Low ESR, 1000 m, (6.3 x 11.5) 100 nF, 500 V, Ceramic, X7R, 1812 VJ1812Y104KXEAT Murata Nippon ChemiCon Vishay 8 1 D1 60 V, 1 A, Diode Schottky, PWRDI 123 DFLS160-7 Diodes, Inc. 9 1 D2 800 V, 1 A, Fast Recovery, 500 ns, SMA US1K-13-F Diodes, Inc. 10 1 D3 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diode Inc. 11 2 JP1 JP2 Wire Jumper, Insulated, TFE, #22 AWG, 0.6 in C2004-12-02 Alpha 12 3 L1 L2 L4 3300 H, 62 mA, 59.5 , Axial Ferrite Inductor B78108S1335J Epcos 13 1 L3 1 mH, 0.23 A, Ferrite Core CTSCH875DF-102K CT Parts 14 1 R3 6.2 , 1%, 1/8 W, Thick Film, 0805 RL1220S-6R2-F Susumu 15 1 R4 3.3 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ332V Panasonic 16 1 R5 17.4 , 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF17R4V Panasonic 17 1 R6 1 k, 5%, 1/2 W, Carbon Film CFR-50JB-1K0 Yageo 18 1 R7 47 , 5%, 1/2 W, Carbon Film CFR-50JB-47R Yageo 19 1 R8 47 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ473V Panasonic 20 1 R9 100 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1003V Panasonic 21 1 RV1 22 1 U1 23 1 VR1 68 V, 2%, 300 mW, SSMINI-2 24 1 VR2 350 V, 400 W, 5%, DO214AC (SMA) 320 V, 26 J, 7 mm, RADIAL LinkSwitch-PL, SO-8C Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com ELXZ630ELL220MFB5D V320LA7 Littlefuse LNK457DG Power Integrations BZX585-B68,115 NXP Semi SMAJ350A LittleFuse Page 10 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 7 Performance Data All measurements performed at 25 ºC room temperature, 60 Hz input frequency unless otherwise specified. 7.1 Active Mode Efficiency 85.0 54 V OUTPUT 48 V OUTPUT 42 V OUTPUT 84.5 Efficiency (%) 84.0 83.5 83.0 82.5 82.0 81.5 81.0 180 190 200 210 220 230 240 250 260 270 AC Input Voltage (VRMS), 50 Hz Figure 6 – Efficiency with Respect to AC Input Voltage. Page 11 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 7.2 Line Regulation The LinkSwitch-PL device regulates the output by controlling the power MOSFET on-time and switching frequency to maintain the average FB pin at its 0.29 V threshold. Slight changes in output current may be observed when input or output conditions are changed, or after AC cycling due to the device selecting a slightly different operating state (selection of on-time and frequency). 10.0 54 V OUTPUT 48 V OUTPUT 42 V OUTPUT 8.0 6.0 Regulation (%) 4.0 2.0 0.0 -2.0 -4.0 -6.0 -8.0 -10.0 180 190 200 210 220 230 240 250 260 270 280 AC Input Voltage (VRMS), 60 Hz Figure 7 – Line Regulation, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 34 10-Nov-11 7.3 DER-301 3.8 W Buck Power Supply Using LNK457DG Power Factor 1.00 54 V OUTPUT 48 V OUTPUT 42 V OUTPUT 0.95 Power Factor 0.90 0.85 0.80 0.75 0.70 180 190 200 210 220 230 240 250 260 270 AC Input Voltage (VRMS), 50 Hz Figure 8 – High Power Factor within the Operating Range. Page 13 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 280 DER-301 3.8 W Buck Power Supply Using LNK457EG 7.4 10-Nov-11 %THD 45 42 V OUTPUT 48 V OUTPUT 54 V OUTPUT 40 35 ATHD (%) 30 25 20 15 10 5 0 180 190 200 210 220 230 240 250 260 270 280 AC Input Voltage (VRMS), 50 Hz Figure 9 – Very Low %ATHD within the Operating Range. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 8 Thermal Scans The scan is conducted at ambient temperature of 25 ºC, 190 VAC / 50 Hz input and 48 V LED string voltage. Figure 10 – LNK457DG (U1) Case Temperature. Figure 11 – Output Diode (D2) Case Temperature. Figure 12 – L3 Output Inductor Temperature. Figure 13 – L1 EMI Inductor Temperature. Page 15 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 9 Waveforms 9.1 Drain Voltage and Current, Normal Operation Figure 14 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.2 A / div. F1: VDS, 200 V / div. Time Scale: 5 ms / div. Figure 15 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 5 ms / div. Figure 16 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.2 A / div. F1: VDS, 200 V / div. Time Scale: 5 s / div. Figure 17 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 5 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 34 10-Nov-11 9.2 DER-301 3.8 W Buck Power Supply Using LNK457DG Drain Voltage and Current Start-up Profile Figure 18 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 5 ms / div. Figure 19 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 5 ms / div. Figure 20 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 10 s / div. Figure 21 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VBULK, 200 V / div. Ch1: VS PIN, 200 V / div. Ch3: IDRAIN, 0.5 A / div. F1: VDS, 200 V / div. Time Scale: 10 s / div. Page 17 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 9.3 Output Voltage Start-up Profile Figure 22 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VIN, 200 V / div. Ch1: VOUT, 200 V / div. Ch3: IIN, 0.5 A / div. Ch4: IOUT, 0.05 A / div. Time Scale: 100 ms / div. 9.4 10-Nov-11 Figure 23 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VIN, 200 V / div. Ch1: VOUT, 200 V / div. Ch3: IIN, 0.5 A / div. Ch4: IOUT, 0.05 A / div. Time Scale: 100 ms / div. Input and Output Voltage and Current Profiles Figure 24 – 190 VAC / 50 Hz, 48 V LED String. Ch1: VIN, 200 V / div. Ch1: VOUT, 200 V / div. Ch3: IIN, 0.1 A / div. Ch4: IOUT, 0.05 A / div. Time Scale: 10 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 25 – 265 VAC / 50 Hz, 48 V LED String. Ch1: VIN, 200 V / div. Ch1: VOUT, 200 V / div. Ch3: IIN, 0.1 A / div. Ch4: IOUT, 0.05 A / div. Time Scale: 10 ms / div. Page 18 of 34 10-Nov-11 9.5 DER-301 3.8 W Buck Power Supply Using LNK457DG Drain Voltage and Current Profile with Output Shorted Figure 26 – 190 VAC / 50 Hz, Output Shorted. Ch1: VDS, 200 V / div. Ch4: VSOURCE , 200 V / div. Ch3: IDRAIN, 0.5 A / div., 500 s / div. Figure 27 – 265 VAC / 50 Hz, Output Shorted. Ch1: VDS, 200 V / div. Ch4: VSOURCE , 200 V / div. Ch3: IDRAIN, 0.5 A / div., 500 s / div. Figure 28 – 190 VAC / 50 Hz, Output Shorted. Ch1: VDS, 200 V / div. Ch4: VSOURCE , 200 V / div. Ch3: IDRAIN, 0.5 A / div., 20 s / div. Figure 29 – 265 VAC / 50 Hz, Output Shorted. Ch1: VDS, 200 V / div. Ch4: VSOURCE , 200 V / div. Ch3: IDRAIN, 0.5 A / div., 20 s / div. Page 19 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 9.6 10-Nov-11 Line Transient Response Figure 30 – 230 VAC / 50 Hz, 300 ms On – 300 ms Off. Load: 48 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 50 mA / div., 1 s / div. Figure 32 – 1 s at 230 VAC, 1 s at 190 VAC / 50 Hz, Load: 48 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 50 mA / div., 500 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 31 – 230 VAC / 50 Hz, 1 s On – 1 s Off. Load: 48 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 50 mA / div., 5 s / div. Figure 33 – 1 s at 230 VAC, 1 s at 265 VAC / 50 Hz, Load: 48 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 50 mA / div., 500 ms / div. Page 20 of 34 10-Nov-11 9.7 DER-301 3.8 W Buck Power Supply Using LNK457DG Brown-out Input voltage slew rate of 0.02 V / ms from 230 VAC / 50 Hz line input variation; no failure observed. Figure 34 – 230 VAC / 50 Hz, 0.02 V / ms Slew Rate. Load: 48 V LED String. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 50 mA / div., 1 s / div. Page 21 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 9.8 Start-up No-load Figure 35 – 190 VAC / 50 Hz, Start-up No-load. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 100 mA / div., 100 ms / div. 9.9 10-Nov-11 Figure 36 – 265 VAC / 50 Hz, Start-up No-load. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 100 mA / div., 100 ms / div. Normal Operation then No-load Figure 37 – 190 VAC / 50 Hz, Normal Operation then No-load. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 100 mA / div., 100 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 38 – 265 VAC / 50 Hz, Normal Operation then No-load. Ch1: VIN, 200 V / div. Ch2: VOUT, 20 V / div. Ch4: IOUT, 100 mA / div., 100 ms / div. Page 22 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 9.10 Line Surge Waveform Figure 39 – 230 VAC / 60 Hz, 48 V Load, VDS=422 VPK. (+)2.5 kV Differential Ring Surge at 0º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 40 – 230 VAC / 60 Hz, 48 V Load, VDS=422 VPK. (+)2.5 kV Differential Ring Surge at 90º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 41 – 230 VAC / 60 Hz, 48 V Load, VDS=422 VPK. (-)2.5 kV Differential Ring Surge at 0º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 42 – 230 VAC / 60 Hz, 48 V Load, VDS=422 VPK. (-)2.5 kV Differential Ring Surge at 90º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Page 23 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 Figure 43 – 115 VAC / 60 Hz, 48 V load, VDS=506 VPK. (+)1 kV Differential Surge at 0º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 44 – 230 VAC / 60 Hz, 48 V Load, VDS=512 VPK. (+)1kV Differential Surge at 90º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 45 – 115 VAC / 60 Hz, 48 V Load, VDS=493 VPK. (-)1 kV Differential Surge at 0º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Figure 46 – 115 VAC / 60 Hz, 48 V Load, VDS=474 VPK. (-)1 kV Differential Surge at 90º. Ch1: VIN, 200 V / div. Ch2: VS PIN, 200 V / div. F1: VDS, 500 V / div., 10 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 10 Dimming Sample Waveform The input voltage waveform varies depending on the internal circuitry and leakage of the dimmer especially at full dim. Figure 47 – 230 VAC / 50 Hz, Dimming at Full Conduction from Relco-RTM34LED DAXS Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Figure 49 – 230 VAC / 50 Hz, Dimming at Full Conduction from Sen Bo Lang Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Page 25 of 34 Figure 48 – 230 VAC / 50 Hz, Dimming at Full Dim from Relco-RTM34LED DAXS Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Figure 50 – 230 VAC / 50 Hz, Dimming at Full Dim from Sen Bo Lang Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 Figure 51 – 230 VAC / 50 Hz, Dimming at Full Conduction from Mank Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Figure 52 – 230 VAC / 50 Hz, Dimming at Full Dim from Mank Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Figure 53 – 230 VAC / 50 Hz, Dimming at Full Conduction from Anam Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Figure 54 – 230 VAC / 50 Hz, Dimming at Full Dim from Anam Dimmer. Ch1: VIN, 100 V / div. Ch2: IIN, 100 mA / div. Ch4: IOUT, 50 mA / div., 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 11 Dimming Compatibility The LED driver was verified to the following list of 230 V dimmers. This table does not limit the types and models of dimmers to be matched in the LED driver instead these are the only available dimmers in the laboratory by the time the UUT was evaluated. Most of the dimmers are high power rated wherein the holding current is way above the instantaneous drawn current of the driver. For this reason and in some cases it will require for this application to parallel the UUT in order to reach the minimum holding current of the dimmers in order to avoid shimmer. Brand Model Relco RH34LEDPLT Power (W) 300 Italian No. of Units to Satisfy Holding Current of TRIAC 3 IOUT Max mAAVG 70.60 IOUT Min mAAVG 2.80 Relco RM34DMA 160 Relco RTM34LED DAXS 500 Italian 1 75.00 10.29 Italian 1 53.73 Relco RM34DMA 13.19 300 Italian 2 81.10 Relco 7.42 RTS34.43RLI 300 Italian 2 81.60 11.62 Relco RT34DSL 500 Italian 2 80.90 5.56 TCL TCL 630 China 3 81.20 0.81 Sen Bo Lang SBL 300 China 1 80.70 0.41 Country Eba Huang - - China 1 79.50 0.29 SB Elect - 600 China 1 70.00 0.33 Myongbo - - China 1 79.90 0.42 KBE - 650 China 1 80.60 0.32 Clipmei - - China 1 79.60 0.51 Mank - 200 China 1 78.70 4.52 REV - 300 Germany 3 67.00 0.80 Busch 2250 600 Germany 4 72.90 2.59 Merten 572499 400 Germany 5 79.50 0.57 Busch 3513 420 Germany 1 81.60 43.40 Berker 2875 600 Germany 1 67.20 5.60 Anam - 500 Korea 2 775.70 14.45 Shin Sung - 500 Korea 3 78.50 6.00 Fantasia - 500 Korea 3 76.20 14.72 SS - 700 Korea 3 78.70 3.37 Aurora - 400 UK 5 65.60 0.47 Note: Shimmering can be observed if there is significant imbalance in the conduction of a dimmer. Page 27 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 90 80 Output Current (mA) 70 60 50 40 30 20 10 0 0 20 40 60 80 100 120 140 160 180 Conduction Angle (º) Figure 55 – Dimming Curve Characteristic; Measured from Controlled AC Source to Emulate the Dimmer Conduction Angle. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 12 Line Surge Input voltage was set at 230 VAC / 60 Hz. Output was loaded with 48 V LED string and operation was verified following each surge event. Differential input line 1.2 / 50 s surge testing was completed on one test unit to IEC61000-4-5. Surge Level (V) 10strikes/condition +1000 -1000 +1000 -1000 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L to N L to N Injection Phase (°) 0 0 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Differential input line ring surge testing was completed on one test unit to IEC61000-4-5. Surge Level (V) 10strikes/condition +2500 -2500 +2500 -2500 Input Voltage (VAC) 230 230 230 230 Injection Location L to N L to N L to N L to N Injection Phase (°) 0 0 90 90 Test Result (Pass/Fail) Pass Pass Pass Pass Unit passes under all test conditions. Page 29 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-11 13 Conducted EMI 13.1 Equipment Receiver: Rohde & Schwartz ESPI - Test Receiver (9 kHz – 3 GHz) Model No: ESPI3 LISN: Rohde & Schwartz Two-Line-V-Network Model No: ENV216 13.2 EMI Test Set-up LED driver is placed in a conical metal housing (for self-ballasted lamps; CISPR15 Edition 7.2). Figure 56 – 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 30 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 13.3 EMI Test Result Power Integrations 18.Oct 11 17:48 RBW MT 9 kHz 500 ms Att 10 dB AUTO dBµV 120 EN55015Q 110 1 QP CLRWR 100 kHz LIMIT CHECK 1 MHz PASS 10 MHz SGL 100 90 2 AV CLRWR TDF 80 70 60 50 EN55015A 6DB 40 30 20 10 0 -10 -20 9 kHz 30 MHz Figure 57 – Conducted EMI, 48 V / 80 mA Steady-State Load, 230 VAC, 60 Hz, and EN55015 Limits. Page 31 of 34 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG Trace1: 10-Nov-11 EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY 2 Average 9.64921816896 kHz 3 Quasi Peak 2 Average 1 LEVEL dBµV DELTA LIMIT dB 22.51 L1 gnd 90.5318149441 kHz 9.16 L1 gnd 133.454986145 kHz 34.00 N gnd Quasi Peak 151.5 kHz 45.23 L1 gnd 3 Quasi Peak 177.645664706 kHz 46.59 N gnd 2 Average 196.231331718 kHz 42.75 L1 gnd -11.01 1 Quasi Peak 225.562855639 kHz 47.76 N gnd -14.84 1 Quasi Peak 254.169871602 kHz 52.39 N gnd -9.22 2 Average 261.871472881 kHz 41.28 L1 gnd -10.09 3 Quasi Peak 267.135089486 kHz 51.59 N gnd 2 Average 325.955575511 kHz 35.12 L1 gnd 3 Quasi Peak 352.963180679 kHz 31.44 L1 gnd 2 Average 389.890938834 kHz 31.30 L1 gnd -16.76 1 Quasi Peak 401.705024172 kHz 39.76 L1 gnd -18.05 3 Quasi Peak 448.169580165 kHz 34.81 L1 gnd 2 Average 457.177788726 kHz 28.62 L1 gnd -18.11 1 Quasi Peak 466.367062279 kHz 38.33 L1 gnd -18.24 3 Quasi Peak 715.396717193 kHz 29.60 L1 gnd 3 Quasi Peak 798.145472681 kHz 33.36 N gnd 2 Average 864.277177159 kHz 29.94 N gnd -20.68 -14.43 -16.05 Figure 58 – Conducted EMI, 48 V / 80 mA Steady-State Load Steady-State Load, 230 VAC, 60 Hz, and EN55015 Limits. Line and Neutral Scan Design Margin Measurement. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 34 10-Nov-11 DER-301 3.8 W Buck Power Supply Using LNK457DG 14 Revision History Date 10-Nov-11 Page 33 of 34 Author JDC Revision 1.0 Description and Changes Initial Release Reviewed Apps and Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com DER-301 3.8 W Buck Power Supply Using LNK457EG 10-Nov-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, HiperLCS, Qspeed, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET, PI Expert and PI FACTS are trademarks of Power Integrations, Inc. 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