Title Reference Design Report for 4.5 W Power Factor Corrected LED Driver (Non-Isolated Buck Boost) Using LinkSwitchTM-PL LNK458KG Specification 85 VAC - 135 VAC Input; 35 V, 130 mA Output Application LED Driver for E17 Lamp Replacement Author Applications Engineering Department Document Number RDR-271 Date June 8, 2011 Revision 1.0 Summary and Features Single-stage power factor corrected and accurate constant current (CC) output Low cost, low component count and small PCB footprint solution Highly energy efficient, >85 % at 115 VAC input Superior performance and end user experience Fast start-up time (<300 ms) - no perceptible delay Integrated protection and reliability features Single shot no-load protection / output short-circuit protected with auto-recovery Auto-recovering thermal shutdown with large hysteresis protects both components and PCB No damage during brown-out conditions PF >0.95 at 115 VAC Meets EN55015 conducted EMI %A THD <15% at 115 VAC Meets IEC ring wave, differential line surge and EN55015 conducted EMI No potting required up to 90 C internal ambient 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 . Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Table of Contents 1 2 3 4 Introduction ................................................................................................................. 4 Power Supply Specification ........................................................................................ 7 Schematic ................................................................................................................... 8 Circuit Description ...................................................................................................... 9 4.1 Input EMI Filtering ............................................................................................... 9 4.2 Buck Boost using LinkSwitch-PL ......................................................................... 9 4.3 Output Feedback ............................................................................................... 10 4.4 Disconnected Load Protection........................................................................... 10 4.5 Reference Design Kit ........................................................................................ 10 5 PCB Layout .............................................................................................................. 12 6 Bill of Materials ......................................................................................................... 15 6.1 Lamp Bill of Materials ........................................................................................ 15 6.2 LED Load Bill of Materials ................................................................................. 15 7 Inductor Specification ............................................................................................... 16 7.1 Electrical Diagram ............................................................................................. 16 7.2 Electrical Specifications ..................................................................................... 16 7.3 Materials ............................................................................................................ 16 7.4 Inductor Build Diagram ...................................................................................... 17 7.5 Inductor Construction ........................................................................................ 17 8 Inductor Illustration ................................................................................................... 18 9 Inductor Design Spreadsheet ................................................................................... 21 10 Performance Data ................................................................................................. 23 10.1 Active Mode Efficiency ...................................................................................... 23 10.2 Line Regulation ................................................................................................. 24 10.3 Power Factor ..................................................................................................... 25 10.4 %THD ................................................................................................................ 26 10.5 Harmonic Measurements .................................................................................. 27 11 Thermal Performance ........................................................................................... 29 11.1 Equipment Used ................................................................................................ 29 11.2 Thermal Results ................................................................................................ 30 12 Thermal Scans ...................................................................................................... 31 13 Waveforms ............................................................................................................ 32 13.1 Drain Voltage and Current, Normal Operation................................................... 32 13.2 Drain Voltage and Current Start-up Profile ........................................................ 33 13.3 Output Voltage Start-up Profile.......................................................................... 35 13.4 Drain Voltage and Current Start-up Short Profile .............................................. 36 13.5 Line Transient Response................................................................................... 37 13.6 Brown-out .......................................................................................................... 39 13.7 Start-up No-load ................................................................................................ 40 13.8 Line Surge Waveform ........................................................................................ 41 14 Line Surge............................................................................................................. 42 15 Conducted EMI ..................................................................................................... 43 15.1 Equipment: ........................................................................................................ 43 15.2 EMI Test Set-up ................................................................................................ 43 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 47 08-Jun-11 16 4.5 W Buck Boost Power Supply Using LNK458KG Revision History ....................................................................................................46 Important Note: Although this board is designed to satisfy safety requirements for non-isolated LED driver, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. Page 3 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 1 Introduction This document is an engineering report describing a non-isolated LED driver (power supply) utilizing a LNK458KG from the LinkSwitch-PL family of devices. The RD-271 provides a single constant current output of 130 mA over an LED string voltage of 35 V. The board was optimized to operate over the low AC input voltage range (85 VAC to 135 VAC, 47 Hz to 63 Hz). LinkSwitch-PL based designs provide a high power factor (>0.9) meeting current international requirements. The form factor of the board was chosen to meet the requirements for standard pear shaped (E17) 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, transformer documentation, printed circuit layout, and performance data. Figure 1 - Size of Populated Circuit Board Photograph. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 4 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG Figure 2 - Populated Circuit Board Retrofitted Inside A17 Bulb. Figure 3 - Reference Design Test Board with LED Load for Ease of Testing, Top. Page 5 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Figure 4 - Reference Design Test Board with LED Load for Ease of Testing, Bottom. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 6 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 2 Power Supply Specification The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Input Voltage Frequency Power Factor > %ATHD < Output Output Voltage Output Current Total Output Power Continuous Output Power Efficiency Nominal Symbol Min Typ Max Units Comment VIN fLINE 85 47 0.9 135 63 VAC Hz 2 Wire - no P.E. 50/60 At any line input voltage 15 VOUT IOUT 120 35 130 140 V A POUT 4.5 W 85 % o Measured at POUT 25 C at 115 VAC Environmental Conducted EMI Meets CISPR22B / EN55015 Line Surge 0.5 (OPTION 1: VR2 not populated) Differential Mode (L1-L2) >0.7 Line Surge (OPTION 2: VR2 populated-TVS) Differential Mode (L1-L2) 1 >1.5 Ring Wave (100 kHz) Differential Mode (L1-L2) 2.5 >3 Internal Ambient Temperature Page 7 of 47 TAMB -40 kV kV kV 90 o C 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 1.2/50 s surge, IEC 1000-4-5, Series Impedance: Differential Mode: 2 Above 1.7 kV, F1 opens 2 short circuit Series Impedance Board level, free convection, sea level Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 3 Schematic Figure 5 - Schematic. Remove VR2 for Differential Line Surge Requirement of 500 V Only. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 8 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 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 in a wide range of input (85 VAC 135 VAC) and output voltage variations typical in LED driver application environment. All of the control circuitry responsible for these functions plus a high-voltage power MOSFET is incorporated into the device. 4.1 Input EMI Filtering Fuse F1 provides protection against component failure. A fast 5 A rating (this being relatively high) was needed to prevent false opening during line surges. The maximum input voltage is clamped by RV1 and by VR2 (TVS) during differential line surges. Zener diode VR2 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 THD. Capacitor C1, C2, C3 and differential choke L1 and L2 perform EMI filtering while the limited total capacitance maintains high power factor. This input 2- filter network plus the frequency jittering feature of LinkSwitch-PL allows compliance to Class B emission limits. Resistor R1 and R2 were used to damp the resonance of the EMI filter, preventing peaks in the EMI spectrum. Inductor L1 and L2 are positioned after the bridge to avoid an imbalance in the EMI scan between line and neutral. This gives also leeway to use small high-voltage ceramic capacitors in the input filter. Capacitor C2 is a film capacitor to achieve more than 10 dBV design margin. It may be replaced by X7R high-voltage ceramic capacitor if EMI design margin requirement is relaxed (<4 dBV margin) 4.2 Buck Boost using LinkSwitch-PL The buck boost power train is composed of U1 (power switch + control), D2 (freewheeling diode), C6 and 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. Diode D1 and D2 are low drop diodes (Schottky) to maximize efficiency. Inductor L3 winding construction and wire gauge are optimized to minimize interwinding capacitance and reduces AC losses. Page 9 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 4.3 Output Feedback The output current feedback is sensed on the voltage drop across R3 and 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 steady-state. Resistor R5 is provisioned in parallel with R3 to allow centering of the output current. 4.4 Disconnected Load Protection The system is protected by VR1 if the load is not connected in order to avoid catastrophic failure of C7 (output capacitor). Zener diode VR1 will short the output it the load is not connected; this protection is not auto-recovering. Replace VR1 if this occurs in order to reuse the LED driver. Note that at the system level the LED load is always connected. If the system will be potted or enclosed tightly, VR1 might not be required. Replace VR1 with an SCR clamp circuit it auto-recovery is required. 4.5 Reference Design Kit The reference design is mounted with LED load as a complete kit. The load is for illustration and can be operated at 25 C ambient maximum only. A loop wire can be used for monitoring the output current via current probe or clamp. The board can be dismantled to fit to common E17 lamps and for higher operating temperature test condition. 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 10 of 47 08-Jun-11 Page 11 of 47 4.5 W Buck Boost Power Supply Using LNK458KG Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 5 PCB Layout Figure 6 - Top Printed Circuit Layout. Figure 7 - Bottom Printed Circuit Layout. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 12 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG Figure 8 - Top Printed Circuit Layout of the Kit. Note: Operate LED loads at 25C ambient only. Remove LED driver from the kit to test at higher ambient temperature. Make sure LED is connected before power-up to avoid fusing the non-resettable OVP protection (replace VR1 to reset the driver). Page 13 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Figure 9 - Bottom Printed Circuit Layout of the Kit. Note: Operate LED loads at 25C ambient only. Remove LED driver from the kit to test at higher ambient temperature. Make sure LED is connected before power-up to avoid fusing the non-resettable OVP protection (replace VR1 to reset the driver). Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 14 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 6 Bill of Materials The table below is divided into two sections namely: reference design BOM and additional parts for load. 6.1 6.2 Lamp Bill of Materials Item Qty Ref Des 1 1 BR1 2 3 4 5 1 1 1 2 C1 C2 C3 C4 C5 6 1 C7 7 1 D1 8 1 D2 9 10 1 2 F1 L1 L2 11 1 L3 12 13 14 15 2 1 1 1 R1 R2 R3 R4 RV1 16 1 U1 17 18 1 1 VR1 VR2 Description 600 V, 0.5 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC 33 nF, 630 V, Ceramic, X7R, 1210 68 nF, 250 V, Polyester Film 100 nF, 500 V, Ceramic, X7R, 1812 1 F, 16 V, Ceramic, X5R, 0603 22 F, 50 V, Electrolytic, Low ESR, 900 m, (5 x 11.5) 60 V, 1 A, Diode Schottky, PWRDI 123 200 V, 1 A, Diode Schottky 1 A 200 V PWRDI 123 5 A, 250V, Fast, Microfuse, Axial 1200 H, 0.018 A Mfg Part Number DFLS160-7 Manufacturer Micro Commercial Murata Panasonic Vishay Murata Nippon ChemiCon Diodes, Inc DFLS1200-7 Diodes, Inc 0263005.MXL RL-5480-1-1200 RLPI-1002 SNX-R1577 ERJ-6GEYJ332V ERJ-8ENF2204V ERJ-3GEYJ332V V140LA2P MB6S-TP GRM32DR72J333KW01L ECQ-E2683KB VJ1812Y104KXEAT GRM188R61C105KA93D ELXZ500ELL220MEB5D LinkSwitch-PL, eSOP-12P LNK458KG 47 V, 5%, 1 W, DO-41 350 V, 400 W, 5%, DO214AC (SMA) 1N4756A-T SMAJ350A Littelfuse Renco Renco Santronics Panasonic Panasonic Panasonic Littlefuse Power Integrations Diodes Inc LittlelFuse Mfg Part Number 5010 MX3SWT-A1-0000-000AE7 C2003A-12-02 5011 5012 3748 Vo-TC Manufacturer Keystone Cree Gen Cable Keystone Keystone 3M 330 H EE10 inductor 3.3 k, 5%, 1/8 W, Thick Film, 0805 2.2 , 1%, 1/4 W, Thick Film, 1206 3.3 k, 5%, 1/10 W, Thick Film, 0603 140 V, 12 J, 7 mm, RADIAL LED Load Bill of Materials Item 1 2 3 4 5 6 Qty 2 3 1 2 1 1 ml Page 15 of 47 Ref Des +LED LED+ D3 D4 D5 JP1 LINE NEUT Glue Description Test Point, RED, THRU-HOLE MOUNT LED, SMD, 87.4 lm, Cree, Warm-White Wire Jumper, Insulated, 24 AWG, 2.2 in Test Point, BLK, THRU-HOLE MOUNT Test Point, WHT, THRU-HOLE MOUNT Hot Melt Adhesive V0 5/8"X2) Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 7 Inductor Specification 7.1 Electrical Diagram Figure 10 - Inductor Electrical Diagram. 7.2 Electrical Specifications Primary Inductance 7.3 Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS 330 H 10% Materials Item [1] [2] [3] [4] Description Core: EE10/PC40 Bobbin: EE10, Horizontal, 8 pins, (4/4), Taiwan Shulin Enterprise Co., Ltd. or Kunshan Fengshunhe Electronics Co., Ltd Equivalent Magnet Wire: 2 X #33 AWG Loctite Super Glue Control Gel Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 16 of 47 08-Jun-11 7.4 4.5 W Buck Boost Power Supply Using LNK458KG Inductor Build Diagram 1 80T -2 X #33 AWG 3 Figure 11 - Inductor Build Diagram. 7.5 Inductor Construction General Note WD1 Finish Page 17 of 47 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 counter-clockwise. Start at pin 3. Wind 80 turns of item [3]. Continue winding up to 5 1/2 layers and terminate it at pin 1. Grind the core to get 330 H, 10%. Apply tape to secure both cores. Cut pins 2, 4, 5, 6, 7 and 8. Apply adhesive item [4] to core and bobbin to prevent core from any movement (see illustration). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 8 Inductor Illustration Bobbin Preparation General Note 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 counter-clockwise. WD1 Start at pin 3. Wind 80 turns of item [3]. Continue winding up to 5 1/2 layers and terminate it at pin 1. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 18 of 47 08-Jun-11 Finish Page 19 of 47 4.5 W Buck Boost Power Supply Using LNK458KG Grind the core to get 330 H, 10%. Apply tape to secure both cores. Cut pins 2, 4, 5, 6, 7 and 8. Apply adhesive item [4] to core and bobbin to prevent core from any movement (see illustration). Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Arrow shows where adhesive applies. Figure 12 - Inductor Assembly. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 20 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 9 Inductor Design Spreadsheet Power Supply INFO OUTPUT UNIT LinkSwitch-PL Buck-boost Inductor Design Spreadsheet VACMIN 85 85 V Minimum AC input voltage VACNOM 115 115 V Nominal AC input voltage VACMAX 132 132 V Maximum AC input voltage FL 60 60 Hz Minimum line frequency VO_MIN 30.00 30.0 V Minimum output voltage tolerance VO_NOM 35.00 35.00 V Nominal Output Voltage VO_MAX 38.00 38.00 V Maximum output voltage tolerance IO 0.130 0.130 A Average output current specification n 0.85 0.850 %/100 Open Frame 0.5 Open Frame 4.55 W Loss allocation factor Enclosure selections determines thermal conditions and maximum power Total output power 0.40 0.4 V Output diode forward voltage drop Z Enclosure PO VD Total power supply efficiency LinkSwitch-PL DESIGN VARIABLES Device LNK458 LNK458 Chosen LinkSwitch-PL Device TON 1.67 us Expected on-time of MOSFET at low line and PO FSW 88.9 kHz Expected switching frequency at low line and PO Duty Cycle 14.8 % Expected operating duty cycle at low line and PO VDRAIN 245 V Estimated worst case drain voltage at VACMAX and VO_MAX IRMS 0.129 A Nominal RMS current through the switch IPK 0.938 A Worst Case Peak current ILIM_MIN 1.012 A Minimum device current limit KDP Device 1.25 1.25 LNK458 LNK458 Ratio between off-time of switch and reset time of core at VACNOM Chosen LinkSwitch-PL Device LinkSwitch-PL EXTERNAL COMPONENT CALCULATIONS RSENSE Standard RSENSE PSENSE 2.231 Ohms Output current sense resistor 2.21 Ohms Closest 1% value for RSENSE 37.7 mW Power dissipated by RSENSE ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES Core Type Core Part Number Bobbin Part Number AE EE10 12.10 12.10 LE 26.10 26.10 mm AL 850 850 nH/T^2 BW 6.00 6 mm 5 5 L EE10 Core Type Custom Core Part Number (if Available) Custom Bobbin Part Number (if available) mm^2 Core Effective Cross Sectional Area Core Effective Path Length Ungapped Core Effective Inductance Bobbin Physical Winding Width Number of winding layers TRANSFORMER PRIMARY DESIGN PARAMETERS LP LP Tolerance 330.7 uH Primary Inductance 5.00 5 % Tolerance of Primary Inductance 80 80 Turns N Page 21 of 47 Number of Turns Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG ALG BM Info BAC BP Warning LG BWE 08-Jun-11 52 nH/T^2 3205 Gauss 1603 Gauss 4620 Gauss 0.294 mm Gapped Core Effective Inductance Reduce BM < 3000 G. Decrease BP (increase NP) or increase core size. Worst case AC Flux Density for Core Loss Curves (0.5 X Peak to Peak) !!! Reduce peak flux density (BP < 3600 G) by increasing NP, selecting a bigger core or decreasing KDP; See note below Gap Length (Lg > 0.1 mm) 30 mm Effective Bobbin Width L_IRMS 0.333 A OD 0.38 mm RMS Curren through the inductor Maximum Primary Wire Diameter including insulation INS 0.06 mm Estimated Total Insulation Thickness (= 2 * film thickness) DIA 0.32 mm Bare conductor diameter AWG 29 AWG Primary Wire Gauge (Rounded to next smaller standard AWG value) CM 128 Cmils Bare conductor effective area in circular mils CMA Current Density (J) 384 5.19 Cmils/Amp Primary Winding Current Capacity (200 < CMA < 500) A/mm^2 Inductor Winding Current density (3.8 < J < 9.75 A/mm^2) Output Parameters IO 0.130 A Expected Output Current PIVS 42.2 V Peak Inverse Voltage at VO_MAX on output diode Note: Peak flux density is limited by slowly increasing the duty cycle of LinkSwitch-PL family during start-up. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 22 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 10 Performance Data All measurements performed at 25 C room temperature, 60 Hz input frequency otherwise specified. 10.1 Active Mode Efficiency 86.5 36 V LED 39 V LED Efficiency (%) 86.0 85.5 85.0 84.5 84.0 80 85 90 95 100 105 110 115 120 125 130 135 AC Input (VRMS), 60 Hz Figure 13 - Efficiency with Respect to AC Input Voltage. Page 23 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 140 RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 10.2 Line Regulation 8 Regulation Band (%) 6 4 2 0 -2 -4 -6 85 - 135 VAC 50 Hz 115 VAC 60 Hz 85 - 135 VAC 47 - 63 Hz -8 VAC Input Figure 14 - Line Regulation, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 24 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 10.3 Power Factor 0.99 33 V LED 36 V LED 39 V LED Power Factor 0.98 0.97 0.96 0.95 0.94 0.93 80 85 90 95 100 105 110 115 120 125 130 135 AC Input Voltage (VRMS), 60 Hz Figure 15 - High Power Factor within the Operating Range. Page 25 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 140 RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 10.4 %THD 33 V LED 36 V LED 39 V LED 30 % ATHD 25 20 15 10 5 0 80 85 90 95 100 105 110 115 120 125 130 135 140 AC Input Voltage (VRMS), 60 Hz Figure 16 - Very Low %ATHD within the Operating Range. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 26 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 10.5 Harmonic Measurements Page 27 of 47 VAC (VRMS) 115 Freq (Hz) 60 nth order mA content 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 38 39 48.67 1.38 1.67 2.09 2.20 2.36 1.82 1.67 1.00 0.79 0.40 0.10 0.24 0.24 0.49 0.33 0.18 0.19 0.10 0.27 V (VRMS) 114.97 Base Limit mA/W IIN (mARMS) 50.51 PIN (W) 5.58000 Actual Limit Remarks 3.40000 1.90000 1.00000 0.50000 0.35000 0.29615 0.25667 0.22647 0.20263 0.18333 0.16739 0.15400 0.14259 0.13276 0.12419 0.11667 0.11000 0.10405 0.09872 37.9440 21.2040 11.1600 5.5800 3.9060 3.3051 2.8644 2.5274 2.2614 2.0460 1.8681 1.7186 1.5913 1.4816 1.3860 1.3020 1.2276 1.1612 1.1017 Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Pass Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 40 08-Jun-11 Limits Measured 35 Harmonic Content 30 25 20 15 10 5 0 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order Figure 17 - Meets EN61000-3-2 Harmonics Contents Standards for <25 W Rating. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 28 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 11 Thermal Performance 11.1 Equipment Used Chamber: AC Source: Wattmeter: Data Logger: Tenney Environmental Chamber Model No: TJR-17 942 Chroma Programmable AC Source Model No: 6415 Yokogawa Power Meter Model No: WT2000 Monogram SN:1290492 Figure 18 - Thermal Chamber Set-up Showing Box Used to Prevent Airflow Over UUT. Page 29 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 11.2 Thermal Results Load: 36 V / 130 mA LED load. Ambient of 90 C simulates operation inside sealed LED replacement enclosure. Normal Operation Component Box Internal Ambient (C) Bridge (BR1) Blocking Diode (D1) LNK458KG (U1) Inductor Core (L3) Output Diode (D2) Device Temperature (C) 85 V/50 Hz 100 V/50Hz 115V/60Hz Normal OTP Normal OTP Normal OTP 90 106 90 113 90 113 108 120 103 125 102 125 113 125 107 130 106 129 120 134 112 134 111 134 116 126 108 130 105 130 126 138 110 132 109 132 Table 1 - Thermal Data if U1 Exposed Pad is Soldered. Normal Operation Component Box Internal Ambient (C) Bridge (BR1) Blocking Diode (D1) LNK458KG (U1) Inductor Core (L3) Output Diode (D2) Device Temperature (C) 85 V/50 Hz 100 V/50Hz 115V/60Hz Normal OTP Normal OTP Normal OTP 90 104 90 107 90 107 108 118 104 120 104 120 112 124 109 126 110 126 125 133 117 135 118 135 115 124 108 126 110 126 122 127 112 129 113 129 Table 2 - Thermal Data if U1 Exposed Pad is Unsoldered. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 30 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 12 Thermal Scans The scan is conducted at ambient temperature of 25 C, 85 VAC / 47 Hz input and 35 V LED string load. Figure 19 - U1 Case Temperature. Figure 20 - D2 Case Temperature. Figure 21 - L3 Temperature. Figure 22 - BR1 Case Temperature. Page 31 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 13 Waveforms 13.1 Drain Voltage and Current, Normal Operation Figure 23 - 85 VAC / 47 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 s / div. Figure 24 - 85 VAC / 47 Hz, 35 V LED String. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 ms / div. Figure 25 - 100 VAC / 50 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 s / div. Figure 26 - 115 VAC / 60 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 32 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG Figure 27 - 135 VAC / 63 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 5 s / div. Figure 28 - 355 VAC / 63 Hz, 35 V LED String. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div F1: VD-S, 250 V / div., 1 ms / div. 13.2 Drain Voltage and Current Start-up Profile Figure 29 - 85 VAC / 47 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 10 ms / div. Page 33 of 47 Figure 30 - 135 VAC / 63 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 200 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Figure 31 - 135 VAC / 63 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 10 ms / div. Figure 32 - 135 VAC / 63 Hz, 35 V LED String. Ch1: VDRAIN, 50 V / div. Ch2: VSOURCE, 50 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 s / div. Figure 33 - 125 C Start-up; 135 VAC / 63 Hz; 85 Phase Angle, 35 V LED String. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 500 s / div. Z4: IDRAIN, 305 mA / div.; 500 ns / div. Figure 34 - 150 C Start-up; 135 VAC / 63 Hz; 85 Phase Angle, 35 V LED String. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 500 s / div. Z4: IDRAIN, 305 mA / div.; 500 ns / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 34 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 13.3 Output Voltage Start-up Profile Figure 35 - 85 VAC / 47 Hz, 35 V LED String. Ch1: VIN, 50 V / div. Ch2: VOUT, 10 V / div. Ch3: IIN, 50 mA / div. Ch4: IOUT, 50 mA / div., 50 ms / div. Page 35 of 47 Figure 36 - 135 VAC / 63 Hz, 35 V LED String. Ch1: VIN, 50 V / div. Ch2: VOUT, 10 V / div. Ch3: IIN, 50 m A / div. Ch4: IOUT, 50 mA / div., 50 ms / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 13.4 Drain Voltage and Current Start-up Short Profile Figure 37 - 135 VAC / 63 Hz, Output Shorted. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 1 s / div. Figure 38 - 135 VAC / 63 Hz, Output Shorted. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 10 s / div. Figure 39 - 135 VAC / 63 Hz, Output Shorted. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 20 ms / div. Figure 40 - 135 VAC / 63 Hz, Output Shorted. Ch1: VDRAIN, 100 V / div. Ch2: VSOURCE, 100 V / div. Ch4: IDRAIN, 0.5 A / div. F1: VD-S, 100 V / div., 2 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 36 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 13.5 Line Transient Response Figure 41 - 115 VAC / 50 Hz, 300 ms On - 300 ms Off. Load: 35V LED String. Ch1: VIN, 50 V / div. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 1 s / div. Page 37 of 47 Figure 42 - 115 VAC / 50 Hz, 1 s On - 1 s Off. Load: 35 V LED String. Ch1: VIN, 50 V / div. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 5 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 Figure 43 - 115 VAC / 50 Hz, 0.5 Cycle-Skip. Load: 35 V LED String. Ch1: VIN, 50 V / div. Ch3: IIN, 50 mA / div,100 ms / div. Figure 44 - 115 VAC / 50 Hz, 0.25 Cycle-Skip. Load: 35 V LED String. Ch1: VIN, 50 V / div. Ch3: IIN, 50 mA / div.,100 ms / div. Figure 45 - 115 VAC / 50 Hz, 1 Cycle-Skip. Load: 35 V LED String. Ch1: VIN, 50 V / div. Ch3: IIN, 50 mA / div.,100 ms / div. Figure 46 - 115 VAC / 50 Hz, 2 Cycle-Skip. Load: 35 V LED String. Ch1: VIN, 50 V / div. Ch3: IIN, 50 mA / div.,100 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 38 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 13.6 Brown-out Input voltage slew rate of 0.1 V / s from 85-0-85 VAC / 50 Hz line input variation; no failure observed. Figure 47 - 85 VAC / 50 Hz, 35 V LED String. Below 75 VAC the peak current of the load is higher than normal but the average current is regulated at 130 mA. Ch1: VIN, 50 V / div. Ch2: VOUT, 5 V / div. Ch3: IIN, 50 mA / div.,200 s / div. Page 39 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 13.7 Start-up No-load This LED driver is protected by VR1 in case of no-load condition occurs in order to avoid leakage from the output capacitor. This protection is not auto-recover; replace VR1 in case this condition occurs. Figure 48 - 185 VAC / 63 Hz, Start-up No-load. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 1 s / div. Figure 49 - 85 VAC / 63 Hz, Start-up No-load. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 200 ms / div. Figure 50 - 135 VAC / 63 Hz, Start-up No-load. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 1 s / div. Figure 51 - 135 VAC / 63 Hz, Start-up No-load. Ch2: VOUT, 10 V / div. Ch4: IOUT, 100 mA / div., 500 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 40 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 13.8 Line Surge Waveform Figure 52 - 115 VAC / 60 Hz, 500 V Differential Surge. Ch1: VIN, 200 V / div. Ch2: VDRAIN, 10 V / div. Ch3: VSOURCE, 10 V / div. F1: VDS, 500 V / div., 50 s / div. Page 41 of 47 Figure 53 - 115 VAC / 60 Hz, 1 kV Differential Surge; VR2 Installed. Ch1: VIN, 200 V / div. Ch2: VDRAIN, 10 V / div. Ch3: VSOURCE, 10 V / div. F1: VDS, 500V / div., 50 s / div. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 14 Line Surge Input voltage was set at 115 VAC / 60 Hz. Output was loaded with 35 V LED string and operation was verified following each surge event. Differential input line 1.2 / 50 s surge testing was completed on two test unit to IEC61000-4-5. Surge Level (V) Input Voltage (VAC) +500 -500 +500 -500 115 115 115 115 +1200 -1200 +1200 -1200 115 115 115 115 Injection Phase () Option 1: VR2 not installed L to N 0 L to N 0 L to N 90 L to N 90 Option 2: VR2 installed L to N 0 L to N 0 L to N 90 L to N 90 Injection Location Test Result (Pass/Fail) Pass Pass Pass Pass Pass Pass Pass Pass Differential input line ring surge testing was completed on two test unit to IEC61000-4-5. Surge Level (V) Input Voltage (VAC) +2500 -2500 +2500 -2500 +3000 -3000 +3000 -3000 115 115 115 115 115 115 115 115 Injection Phase () Option 1: VR2 not installed L to N 0 L to N 0 L to N 90 L to N 90 L to N 0 L to N 0 L to N 90 L to N 90 Injection Location Test Result (Pass/Fail) Pass Pass Pass Pass Pass Pass Pass Pass Unit passes under all test conditions. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 42 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 15 Conducted EMI 15.1 Equipment: Receiver: Rohde & Schwartz ESPI - Test Receiver (9 kHz - 3 GHz) Model No: ESPI3 LISN: Rohde & Schwartz Two-Line-V-Network Model No: ENV216 15.2 EMI Test Set-up LED driver is placed in a conical metal housing (for self-ballasted lamps; CISPR15 Edition 7.2). Figure 54 - Conducted Emissions Measurement Set-up Showing Conical Ground Plane Inside which UUT was Mounted. Page 43 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG Power Integrations 24.Mar 11 13:18 RBW MT 08-Jun-11 9 kHz 500 ms Att 10 dB AUTO dBV 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 55 - Conducted EMI, Maximum Steady-State Load, 115 VAC, 60 Hz, and EN55015 Limits. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 44 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG Trace1: EDIT PEAK LIST (Final Measurement Results) EN55015Q Trace2: EN55015A Trace3: --- TRACE FREQUENCY LEVEL dBV 2 Average 95.14984736 kHz 2 Average 99.0133127137 kHz 1 Quasi Peak 190.46019728 kHz 2 Average 192.364799253 kHz 37.68 1 Quasi Peak 283.569280422 kHz 2 Average 1 DELTA LIMIT dB 14.69 L1 gnd 8.86 N gnd 45.86 N gnd -18.15 N gnd -16.25 42.86 N gnd -17.84 289.269022958 kHz 36.17 N gnd -14.36 Quasi Peak 378.424303998 kHz 43.21 N gnd -15.09 2 Average 389.890938834 kHz 33.37 N gnd -14.69 1 Quasi Peak 881.64914842 kHz 42.69 N gnd -13.30 2 Average 881.64914842 kHz 30.42 N gnd -15.57 1 Quasi Peak 983.628047757 kHz 36.36 N gnd -19.63 1 Quasi Peak 1.17656420634 MHz 42.34 N gnd -13.65 2 Average 1.17656420634 MHz 31.30 N gnd -14.69 2 Average 1.23658080545 MHz 31.28 N gnd -14.71 1 Quasi Peak 1.27405044044 MHz 41.86 N gnd -14.13 2 Average 1.33903981723 MHz 31.57 N gnd -14.42 1 Quasi Peak 1.37961406273 MHz 36.63 N gnd -19.36 1 Quasi Peak 1.43563192593 MHz 44.42 N gnd -11.57 2 Average 1.43563192593 MHz 31.34 N gnd -14.65 1 Quasi Peak 1.57012949439 MHz 40.49 N gnd -15.51 Figure 56 - Conducted EMI, Maximum Steady-State Load, 115 VAC, 60 Hz, and EN55015 Limits. Line and Neutral Scan Design Margin Measurement. Page 45 of 47 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com RDR-271 4.5 W Buck Boost Power Supply Using LNK458KG 08-Jun-11 16 Revision History Date 08-Jun-11 Author JDC Revision 1.0 Description & changes Initial Release Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Reviewed Apps & Mktg Page 46 of 47 08-Jun-11 4.5 W Buck Boost Power Supply Using LNK458KG 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. 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