RDK-290 Power Integrations

Reference Design Report for a >92% Efficient Title 75 W Power Factor Corrected LED Driver TM Using LinkSwitch -PH LNK420EG 190 VAC 300 VAC Input Specification 29 V 36 V, 2.1 A Output Application LED Driver for Industrial High Bay Light Author Applications Engineering Department Document RDR-290 Number Date October 12, 2012 Revision 1.2 Summary and Features Single-stage combined power factor correction and accurate constant current (CC) output Low cost, low component count and small PCB footprint Highly energy efficient, >92 % at 230 VAC input 36 V LED Fast start-up time (<300 ms) no perceptible delay Integrated protection features Single shot no-load latching protection / output short-circuit protected with auto-recovery Auto-recovering thermal shutdown with large hysteresis protects both components and printed circuit board No damage during brown-out conditions PF >0.95 at 230 VAC Meet Class C Harmonics Limits EN61000-3-2 Meet EN55015 conducted EMI %A THD <20% at 230 VAC Meets IEC ring wave (2.5 kV), differential line surge (2 kV), common mode line surge (4 kV) 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 <RDR-290 LNK420EG (29 V 36 V / 2.1 A 75 W Output) 12-Oct-12 Table of Contents 1 Introduction ................................................................................................................. 4 2 Power Supply Specification ........................................................................................ 6 3 Schematic ................................................................................................................... 7 4 Circuit Description ...................................................................................................... 8 4.1 Input EMI Filtering ............................................................................................... 8 4.2 Flyback Using LinkSwitch-PH .............................................................................. 8 4.3 Output Rectification ............................................................................................. 9 4.4 Protection ............................................................................................................ 9 5 PCB Layout .............................................................................................................. 10 6 Bill of Materials ......................................................................................................... 11 6.1 Electrical Bill of Materials ................................................................................... 11 6.2 Mechanical Bill of Materials ............................................................................... 12 7 Transformer Specification ......................................................................................... 13 7.1 Electrical Diagram ............................................................................................. 13 7.2 Electrical Specifications ..................................................................................... 13 7.3 Materials ............................................................................................................ 13 7.4 Transformer Build Diagram ............................................................................... 14 7.5 Transformer Construction .................................................................................. 14 7.6 Transformer Core Wrapping Process ................................................................ 15 8 Transformer Design Spreadsheet ............................................................................. 18 9 Heat Sink Assemblies ............................................................................................... 21 9.1 Diode Heat Sink ................................................................................................ 21 9.1.1 Diode Heat Sink Drawing ........................................................................... 21 9.1.2 Diode Heat Sink Fabrication Drawing ......................................................... 22 9.1.3 Diode and Heat Sink Assembly Drawing .................................................... 23 9.2 eSIP Heat Sink .................................................................................................. 24 9.2.1 eSIP Heat Sink Drawing ............................................................................. 24 9.2.2 eSIP Heat Sink Fabrication Drawing .......................................................... 25 9.2.3 eSIP and Heat Sink Assembly Drawing ..................................................... 26 10 Performance Data ................................................................................................. 27 10.1 Active Mode Efficiency ...................................................................................... 27 10.2 Line Regulation ................................................................................................. 28 10.3 Power Factor ..................................................................................................... 29 10.4 %THD ................................................................................................................ 30 10.5 Harmonic Currents ............................................................................................ 31 11 Thermal Performance ........................................................................................... 33 11.1 Equipment Used ................................................................................................ 33 11.2 Thermal Result .................................................................................................. 33 11.3 Thermal Scan .................................................................................................... 34 12 Waveforms ............................................................................................................ 36 12.1 Drain Voltage and Current, Normal Operation ................................................... 36 12.2 Drain Voltage and Current, Start-up Operation ................................................. 36 12.3 Drain Voltage and Current, Output Short .......................................................... 37 12.4 Output Voltage and Output Current Start-up Profile .......................................... 37 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Page 2 of 50