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Title
Reference Design Report for a 5 W Dimmable
Power Factor Corrected LED Driver (Non-
Isolated) Using LinkSwitchTM-PL LNK457DG
Specification 90 VAC – 265 VAC, >0.9 PF Input;
12 V – 18 V, 350 mA 8% Output
Application LED Driver for A19 Incandescent Lamp
Replacement
Author Applications Engineering Department
Document
Number RDR-251
Date February 15, 2011
Revision 1.92
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 >100:1 dimming range even with low cost leading edge TRIAC dimmers
o Clean monotonic start-up – no output blinking
o Fast start-up (<300 ms) – no perceptible delay
o Consistent dimming performance unit to unit
Highly energy efficient
o >73% at 115 VAC / 230 VAC (dimmable configuration)
o >78% at 115 VAC / 230 VAC (non-dimmable configuration)
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
Meets IEC ringwave and EN55015 conducted EMI
PF >0.9 at 115 VAC / 230 VAC
%ATHD <10% at 115 VAC and <15% at 230 VAC
Meets EN61000-3-2 harmonics contents
RDR-251 – 5 W, PFC, Dimmable LED Power Supply 15-Feb-11
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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>.
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Table of Contents
1Introduction ................................................................................................................. 5
2Power Supply Specification ........................................................................................ 7
3Schematic ................................................................................................................... 8
4Circuit Description ....................................................................................................... 9
4.1Dimming Performance Circuit Design Considerations ......................................... 9
4.2Input EMI Filtering and Input Rectification ......................................................... 10
4.3Active Damper ................................................................................................... 10
4.4Bleeder .............................................................................................................. 10
4.5LinkSwitch-PL Primary ....................................................................................... 11
4.6Output Rectification ........................................................................................... 11
4.7Output Feedback ............................................................................................... 11
5PCB Layout ............................................................................................................... 12
6Bill of Materials ......................................................................................................... 13
7Transformer Design Spreadsheet ............................................................................. 14
8Transformer Specification ......................................................................................... 17
8.1Electrical Diagram .............................................................................................. 17
8.2Electrical Specifications ..................................................................................... 17
8.3Materials ............................................................................................................ 17
8.4Transformer Build Diagram ................................................................................ 18
8.5Transformer Construction .................................................................................. 19
8.6Winding Illustrations ........................................................................................... 20
9Performance Data ..................................................................................................... 23
9.1Active Mode Efficiency ....................................................................................... 23
9.2Non-Dimmable Configuration ............................................................................ 24
9.3Dimmable .......................................................................................................... 24
9.4Harmonics ......................................................................................................... 25
9.5Power Factor ..................................................................................................... 27
9.6Line Regulation .................................................................................................. 28
9.7Dimming Performance ....................................................................................... 29
9.7.1Dimming Range .......................................................................................... 29
9.7.2Unit to Unit Tracking ................................................................................... 33
10Thermal Performance ............................................................................................ 35
10.1Thermal Set-up .................................................................................................. 35
10.2Equipment Used ................................................................................................ 36
10.3Thermal Result .................................................................................................. 36
10.4Thermal Scan .................................................................................................... 37
11Waveforms ............................................................................................................ 38
11.1Drain Voltage and Current ................................................................................. 38
11.1.1Normal Steady State Operation .................................................................. 38
11.1.2AC Start-up ................................................................................................. 40
11.1.3115 V TRIAC in Series with AC Input ......................................................... 40
11.1.4230 V TRIAC in Series with AC Input ......................................................... 42
11.1.5Fault Conditions (Output Shorted / Open Circuit) ....................................... 43
11.2Output Current Start-up Profile .......................................................................... 44
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11.3Input and Output Waveforms ............................................................................. 45
11.3.1Normal Operation (VIN, IIN, VO and IO) ........................................................ 45
11.4Dimming Operation (VIN, IIN, VO and IO) ............................................................. 46
11.5Line Transient Response ................................................................................... 48
12Line Surge ............................................................................................................. 52
13Conducted EMI ..................................................................................................... 53
13.1Equipment: ........................................................................................................ 53
13.2EMI Test Set-up ................................................................................................ 53
14Dimming Compatibility .......................................................................................... 56
15Output Current Production Distribution ................................................................. 57
16Revision History .................................................................................................... 59
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.
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1 Introduction
This document is an engineering report describing a non-isolated LED driver (power
supply) utilizing a LNK457DG from the LinkSwitch-PL family of devices.
The RD-251 provides a single constant current output of 350 mA over an LED string
voltage of 12 V and 18 V. The output current can be reduced using a standard AC mains
TRIAC dimmer down to 1% (3 mA) without instability and flickering of the LED load. The
board is compatible with both low cost leading edge and more sophisticated trailing edge
dimmers.
The board was optimized to operate over the 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. LinkSwitch-
PL based designs provide a high power factor (>0.9) meeting current international
requirements and enabling a single design to be used worldwide.
The form factor of the board was chosen to meet the requirements for standard pear
shaped (A19) 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 – Populated Circuit Board Photograph (Top).
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Figure 2 – Populated Circuit Board Photograph (Bottom).
Figure 3 – Example of RD-251 Used in an A19 LED Replacement Lamp (board removed from housing).
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2 Power Supply Specification
The table below represents the minimum acceptable performance of the design. Actual
performance is listed in the results section.
Description Symbol Min Typ Max Units Comment
Input
Voltage VIN(NOM) 115/230 VAC
Nominal line voltages
VIN(EXT) 90 265 VAC
Normal operating range
VIN(ND) 0 300 VAC
Voltage range over which no damage to
the supply shall occur
Frequency fLINE 47 50/60 63 Hz
Output
Output Voltage VOUT 12 15 18 V
Thermal results were verified with 15 V
LED string
Output Current IOUT(N) 322 350 378 mA
(+/-8%) at VIN(NOM) after reaching thermal
equilibrium
I
OUT(E) 315 350 385 mA
(+/-10%) Extended 90-265 VAC Input, -
20 oC to 80 oC
Output Power POUT 5 W
Efficiency
Dimmable
configuration 73 % Measured at POUT 25 oC
Non-dimmable
configuration 78
Environmental
Conducted EMI Meets CISPR22B / EN55015
Mounted into A19 metal finned enclosure
and measured on ground plane (to
simulate end application)
%ATHD 230 V < 18
Safety
Non-isolated
Line Surge
Differential Mode
(L1-L2)
500
V
1.2/50 s surge, IEC 1000-4-5, Series
Impedance:
Differential Mode: 2
Ring Wave (100 kHz)
Differential Mode
(L1-L2)
2500
V
200 A short-circuit
Series Impedance:
Differential Mode
Dimensions 0.83” (20.86 mm) x 2.52” (63.9 mm)
Board Level Ambient
Temperature TAMB -20 80
oC Free convection, sea level
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3 Schematic
Note:
C1, R22 and C12 are not populated.
For non-dimming application, the Active Damper and Bleeder blocks can be removed
allowing the following parts can be deleted: Q3, R20, R3, R4, R10, R11 C6 and C3. Replace 0
for the following locations: R7, R8, and R20.
For high line only application and to match high leakage dimmer such as REV 300 W,
Busch 2250 (600 W) or alike the following parts can be tuned. Replace F1 to 47 / 2 W fusible
resistors, R7 and R8 to 20, C6 to 220 nF, R10 and R11 to 510 / 0.5 W minimum, C3 to 150nF
and R16 to 1 k / 0.25 W.
Figure 4 – Schematic (highlighted blocks may be removed for non-dimming applications.)
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4 Circuit Description
This circuit is configured as non-isolated discontinuous flyback converter designed to
drive LED strings at voltages of 12 V to 18 V with an output current of 350 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 bulb replacement applications.
4.1 Dimming Performance Circuit Design Considerations
The requirement to provide output dimming with low cost, TRIAC base, leading edge
phase dimmers introduces a number of trade offs in the design.
Due to the much lower power consumed by LED based lighting the line current drawn by
the overall lamp is typically below the holding current of the TRIAC within the dimmer.
This causes undesirable behaviors such as limited dim range and/or flickering. The
relatively large impedance the LED driver presents to the line allows significant ringing to
occur when the TRIAC turns on. At the instant the TRIAC conducts, a large inrush current
flows into the input capacitance of the driver, exciting the line inductance and causing
current ringing. This too can cause similar undesirable behavior as the ringing may cause
the TRIAC current to fall to zero and turn off, also generating flicker.
To overcome these issues the circuit includes two circuit blocks labeled active damper
and bleeder. The drawback of these blocks is increased dissipation and therefore
reduced efficiency of the supply.
The values used for the damper and bleeder in this design allow correct operation of a
single board with the widest range of 600 W dimmer models including low cost leading
edge TRIAC models across the full input voltage range. The trade off decision was to
give flicker free operation for a single lamp connected to a dimmer operating at high line.
A single lamp operating at high line results in the lowest current drawn from the line and
the highest inrush current (when the TRIAC fires) and represents the worst case. As a
result the active damper and bleeder networks were designed to be aggressive; lower
impedance for the bleeder and higher impedance for the damper. This increases
dissipation and therefore lowers efficiency of the driver and efficacy of the overall system.
Requiring multiple lamps to be connected to a single dimmer for correct operation
reduces the current required through the bleeder, allowing increasing the values of R10
and R11 and reducing the value of C6.
Limiting operation to low line only (85 VAC to 132 VAC) allows the values of R7 and R8
to be reduced as the peak currents that occur when a leading edge dimmer TRIAC fires
are significantly lower.
Both changes reduce dissipation and improve efficiency.
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For non-dimming application these components can simply be omitted and jumpers used
to replace R7 and R8 giving higher efficiency with no change in other performance
characteristics.
4.2 Input EMI Filtering and Input Rectification
The EMI filter was optimized to minimize the impact on dimming performance. Resistor
R20 is a fusible resistor. Fusible types are selected to fail open-circuit should a
component failure cause excessive input current. Film types (vs. wirewound) are
acceptable compared to a non or passive PFC solution. This reduces the instantaneous
dissipation as the input capacitance charges, however, a 2 w rating is recommended for
designed that operate at high line. In addition they limit the inrush current caused when a
phase leading TRIAC dimmer turns on and capacitors C4 and C5 charge. The worst case
condition (maximum inrush current) occurs when the TRIAC turns on at 90 or 270
degrees, which correspond to the peaks of the AC waveform. Finally they act to damp
any current ringing between the AC line impedance and the input stage of the supply
again caused by the inrush current when leading edge TRIAC dimmers turn on.
Two differential pi (π) filter EMI stages are used with C1, R2, L1 and C2 forming one
stage and C4, L2, R9 and C5 the second. It was found during testing that C1 was not
required to meet conducted EMI limits and was therefore not populated.
The incoming AC is rectified by BR1 and filtered by C4 and C5. The total effective input
capacitance, the sum of C4, C5 and C6, was selected to assure correct zero crossing
detection of the AC input by the LinkSwitch-PL device, necessary correct operation and
best performance during dimming.
4.3 Active Damper
The active damper network is used to limit the inrush current, associated voltage spikes
and ringing when the TRIAC within a dimmer turns on. This connects a resistance (R7
and R8) in series with the input rectifier for a short period of each AC half-cycle, it is then
bypassed for the remainder of the AC cycle by a parallel SCR (Q3). Resistor R3, R4 and
C3 determines the delay before the turn-on of Q3.
4.4 Bleeder
Resistor R10, R11 and C6 form a bleeder network which ensures the initial input current
is high enough meet the TRIAC holding current requirement, especially during small
TRIAC conduction angles.
For non-dimming application, both the active damper and bleeder network may be
removed. To achieve this, the following parts can be deleted: Q3, R20, R3, R4, R10, R11,
C6 and C3. Replace 0 for the following locations: R7, R8, and R20.
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4.5 LinkSwitch-PL Primary
The LNK457DG 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
C9. At start-up, C9 is charged by U1 from an internal current source via the DRAIN pin
and then during normal operation it is supplied by the output via R15 and D4.
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 drain voltage spike is limited by an RCD-R clamp
consisting of D2, R13, R12, and C7.
Diode D6 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.
4.6 Output Rectification
The secondary of the transformer is rectified by D5 and filtered by C11. A Schottky
barrier type was selected for higher efficiency. As C11 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. For the 680 F value shown the output ripple is 50% of IO.
Resistor R17 and C10 damp high frequency ringing and improve conducted and radiated
EMI.
4.7 Output Feedback
The CC mode set-point is determined by the voltage drop that appears across R18 which
is then fed to the FB pin of U1. Output overvoltage protection is provided by VR2 and
R14 (the effect of R14 on the current sense signal in negligible and can be ignored).
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5 PCB Layout
Figure 5 – Top Printed Circuit Layout 0.83” (20.86 mm) x 2.52” (63.9 mm).
Figure 6 – Bottom Printed Circuit Layout.
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6 Bill of Materials
Item Qty Ref
Des Description Manufacturer P/N Manufacturer
1 1
BR1 Bridge Rectifier Diode MBS GPP 0.8A 1000V B10S-G Comchip Technology
BR1
(sub)
600 V, 0.5 A, Bridge Rectifier, SMD, MBS-1,
4-SOIC MB6S-TP Micro Commercial
2 1 C3 22 nF, 50 V, Ceramic, Y5V, 0603 ECJ-1VF1H223Z Panasonic
3 1 C4 22 nF, 630V, Film ECQ-E6223KZ Panasonic
4 1 C5 C6 68 nF, 400 V, Film ECQ-E4683KF Panasonic
5 1 C7 1000 pF, 630 V, Ceramic, X7R, 1206 ECJ-3FB2J102K Panasonic
6 1 C8 10 nF, 50 V, Ceramic, X7R, 0805 ECJ-2VB1H103K Panasonic
7 1 C9
1 F, 25 V, Ceramic, X7R, 0805 ECJ-2FB1E105K Panasonic
8 1 C10 1 nF, 100 V, Ceramic, X7R, 0805 ECJ-2VB2A102K Panasonic
9 1 C11
680 F, 25 V, Electrolytic, Very Low ESR,
32 m, (10 x 16) 25ZLH680MEFC10X16 Rubycon
10 0 C1 Do not mount (unstalled/optional location only)
11 0 C12 Do not mount (unstalled/optional location only)
12 1 D4 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diode Inc.
13 1 D2 DIODE ULTRA FAST, SW 600V, 1A, SMA US1J-13-F Diodes, Inc
14 1 D5 100 V, 1 A, Schottky, DO-214AC (SMA) SS110-TP Micro commercial
15 1
D6 800 V, 1 A, Rectifier, Glass Passivated, DO-
213AA (MELF) DL4006-13-F Diodes Inc
D6
(sub) 200 V, 1 A, Fast Recovery, 150ns, SMA RS1D-13-F Diodes Inc
16 1 F1 3.15 A, 250V, Slow, RST 507-1181 Belfuse
17 2 L1 L2 2.2 mH, 0.15 A, Ferrite Core CTSCH875DF – 222K CTParts
18 1 Q3 SCR, 400 V, 0.8 A, SMD, SOT-223 P0102DN 5AA4 ST Microelectroics
19 2 R2 R9
4.7 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ472V Panasonic
20 2 R3 R4
750 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ754V Panasonic
21 2 R7 R8
240 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ241V Panasonic
22 2 R10
R11 510 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ511V Panasonic
23 1 R12
100 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ104V Panasonic
24 1 R13
4.7 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ4R7V Panasonic
25 1 R14
R21 1 k, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ102V Panasonic
26 1 R15
3.3 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ332V Panasonic
27 1 R16
10 k, 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ103V Panasonic
28 1 R17
27 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ270V Panasonic
29 1 R18
0.82 , 1%, 1/2 W, Thick Film, 1206 RL1632R-R820-F Susumu Co Ltd
30 2 R19
R20 47 , 5%, 2 W, MF Fusible NFR0200004709JR500 Vishay/BC Components
31 0 R22 Do not mount (unstalled/optional location only)
32 1 RV1 275 V, 23 J, 7 mm, RADIAL V275LA4P Littlefuse
33 1 T1
Custom transformer, EE16. See report for
specifications SNX-R1536 Santronics
34 1 U1 LinkSwitch-PL, LNK457DG, SO-8C LNK457DG Power Integrations
35 1 VR2 20 V, 5%, 150 mW, SSMINI-2 MAZS2000ML Panasonic-SSG
36 1 J1 J2
Test point, WHT, Miniature THRU-HOLE
MOUNT 5002 Keystone
37 1 J3
Test point, RED, Miniature THRU-HOLE
MOUNT 5000 Keystone
38 1 J4
Test point, BLK, Miniature THRU-HOLE
MOUNT 5001 Keystone
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7 Transformer Design Spreadsheet
ACDC_LinkSwitch-PL-
Flb_042910; Rev.1.0;
Copyright Power
Integrations 2010 INPUT INFO OUTPUT UNIT
ACDC_LinkSwitch-PL_Flb_042910;
LinkSwitch-PL Flyback Transformer
Design Spreadsheet
ENTER APPLICATION VARIABLES
5 W Dimmable Power Factor Corrected
LED Driver (Non-Isolated) Using
LinkSwitch-PL LNK457DG
VACMIN 85 85 V Minimum AC input voltage
VACMAX 265 265 V Maximum AC input voltage
FL 50 50 Hz Minimum line frequency
VO_MAX 18 18 V Maximum Output Voltage
VO_MIN 10.0 V
Minimum output voltage before device
operates in cycle skipping at VACMAX
IO 0.35 0.350 A Average output current
N 0.7 0.7 %/100 Total power supply efficiency
Z 0.7 0.7
Loss allocation factor. Larger value of Z
means losses are more on secondary
side, smaller value of Z means more
losses on primary side.
Enclosure Open
Frame Open Frame Enclosure selections determines thermal
conditions and maximum power
PO
6.30 W Average output power
VD 0.7 V Output diode forward voltage drop
LinkSwitch-PL DESIGN VARIABLES
Device LNK457 LNK457
Chose device PO max in Open Frame:
7.357W, PO Max in Retrofit Lamp:
6.893125 W.
VOR 120.7 V Reflected output voltage
Turns Ratio 6.5 Primary to secondary turns ratio
TON 3.27 us
Expected on-time of MOSFET at low line
and PO
FSW
122.1 kHz
Expected switching frequency at low
line and PO
Duty Cycle 39.9 % Expected operating duty cycle at low
line and PO
VDRAIN
620 V Estimated drain voltage
IRMS 0.154 A Primary RMS current
IPK 0.595 A Peak primary current
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ACDC_LinkSwitch-PL-
Flb_042910; Rev.1.0;
Copyright Power
Integrations 2010 INPUT INFO OUTPUT UNIT
ACDC_LinkSwitch-PL_Flb_042910;
LinkSwitch-PL Flyback Transformer
Design Spreadsheet
ILIM_MAX 0.910 A Device peak current
KDP
1.51
Ratio between off-time of switch and
reset time of core
LinkSwitch-PL EXTERNAL COMPONENT CALCULATIONS
RSENSE 0.829 Ohms Output current sense resistor
Standard RSENSE 0.83 Ohms Closest 1% value for RSENSE
PSENSE 0.102 W Power dissipated by RSENSE
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES
Core Type EE16 EE16 Core Type
Core Part Number PC40EE16-Z Core Part Number (if Available)
Bobbin Part Number BE-16-
118CPH Bobbin Part Number (if available)
AE 19.20 mm^2 Core Effective Cross Sectional Area
LE 35.00 mm Core Effective Path Length
AL 1140 nH/T^2 Ungapped Core Effective Inductance
BW 8.6 mm Bobbin Physical Winding Width
L 3 Number of primary winding layers
NS 20 Turns Number of Secondary Turns
TRANSFORMER PRIMARY DESIGN PARAMETERS
LP 0.660 mH Primary Inductance
LP Tolerance 10 % Tolerance of Primary Inductance
NP 130 Turns Primary Winding Number of Turns
ALG 39 nH/T^2 Gapped Core Effective Inductance
BM
1574 Gauss Maximum (BM < 3000 G)
BAC
787 Gauss
AC Flux Density for Core Loss Curves
(0.5 X Peak to Peak)
BP_TARGET 2650 2650 Gauss
Target Peak Flux density.
Recommended value of BP_TARGET <
3700 G.
BP
2647 Gauss Peak Flux Density (BP < 3700 G )
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ACDC_LinkSwitch-PL-
Flb_042910; Rev.1.0;
Copyright Power
Integrations 2010 INPUT INFO OUTPUT UNIT
ACDC_LinkSwitch-PL_Flb_042910;
LinkSwitch-PL Flyback Transformer
Design Spreadsheet
LG
0.618 mm Gap Length (Lg > 0.1 mm)
BWE 25.8 mm Effective Bobbin Width
OD 0.20 mm
Maximum Primary Wire Diameter
including insulation
INS 0.04 mm
Estimated Total Insulation Thickness (=
2 * film thickness)
DIA 0.16 mm Bare conductor diameter
AWG 35 AWG
Primary Wire Gauge (Rounded to next
smaller standard AWG value)
CM 32 Cmils
Bare conductor effective area in circular
mils
CMA
208 Cmils/Amp
Primary Winding Current Capacity (200
< CMA < 500)
Primary Current Density (J) 9.61 A/ mm^2
Primary Winding Current density (3.8 < J
< 9.75 A/mm^2)
SECONDARY DESIGN PARAMETERS
ISP 3.87 A Peak Secondary Current
ISRMS 0.91 A Secondary RMS current
IO 0.35 A Output Current
PIVS 83.6 V
Peak Inverse Voltage experienced by
the output diode with added 10% margin
added for reverse recovery voltage
spike
CMS1 183 Cmils
Output Winding Bare Conductor
minimum circular mils
AWGS 27 AWG
Wire Gauge (Rounded up to next larger
standard AWG value)
DIAS 0.36 mm Minimum Bare Conductor Diameter
ODS 1.29 mm
Maximum Outside Diameter for Triple
Insulated Wire
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8 Transformer Specification
8.1 Electrical Diagram
2
1
7
3
6
130T - #35AWG 10T – 2 x #28AWG
10T – 2 x #28AWG
WD1: 1st half Secondary
WD2: Primary
WD3: 2nd half Seconadry
Figure 7 – Transformer Electrical Diagram.
8.2 Electrical Specifications
Electrical Strength 3 second, 60 Hz, from pins 1-2 to pins 6-7 500 VAC
Primary Inductance Pins 1-2, all other windings open, measured at 100 kHz,
0.4 VRMS 660 H, 10 %
Resonant Frequency Pins 1-2, all other windings open 1200 kHz (Min.)
Primary Leakage
Inductance
Pins 1-2, with pins 7-9 shorted, measured at
100 kHz,
0.4 VRMS 15 H (Max.)
8.3 Materials
Item Description
[1] Core: EE16/PC40
[2] Bobbin: EE16, Horizontal, 10 pins, (5/5), TF1613 (Taiwan Shulin) or equivalent.
[3] Magnet wire: #28 AWG double coated.
[4] Magnet wire: #35 AWG double coated.
[5] Tape: 3M 1298 Polyester Film, 8.0 mm wide, 2.0mils thick or equivalent.
[6] Varnish.
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8.4 Transformer Build Diagram
WD1
WD2
WD3
10T – 2 x #28AWG
7
3
3
10T – 2 x #28AWG
130T - #35AWG
(wound in 3 layers: 44T+43T+43T)
2
1
6
Figure 8 – Transformer Build Diagram.
Figure 9 – Transformer Assembly.
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8.5 Transformer Construction
Winding
Preparation
Place bobbin on the mandrel such that primary on the left and secondary on the
right. Winding direction is clock-wise direction.
WD1
1st Half of
Secondary
Start at pin 7, wind 10 bifilar turns of wire item [3] from right to left, and terminate at
pin 3.
Insulation 1 layer of tape item [5].
WD2
Primary
Start at pin 2, wind 130 turns of wire item [4] in 3 layers: 44T+43T+43T, place 2
layers of tape item [5] between layers, see fig.7 above, and terminate at pin 1.
Insulation 1 layer of tape item [5].
WD3
2nd Half of
Secondary
Start at pin 3, wind 10 bifilar turns of wire item [3] from left to right, and terminate at
pin 6.
Insulation 2 layers of tape item [5].
Finish Grind core halves to get 660
H assemble with tape.
Varnish.
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8.6 Winding Illustrations
Winding Preparation
Place bobbin on the mandrel such that
primary on the left and secondary on
the right. Winding direction is clock-wise
direction.
WD1
1st Half of Secondary
Start at pin 7, wind 10 bifilar turns of
wire item [3] from right to left, and
terminate at pin 3.
Insulation 1 layer of tape item [5].
WD2
Primary
Start at pin 2, wind 130 turns of wire
item [4] in 3 layers: 44T+43T+43T,
place 2 layers of tape item [5] between
layers,
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WD2
Primary
(Cont’d)
Refer to fig.7 above, and terminate at
pin 1.
Insulation 1 layer of tape item [5].
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WD3
2nd Half of Secondary Start at pin 3, wind 10 bifilar turns of
wire item [3] from left to right, and
terminate at pin 6.
Insulation 2 layers of tape item [5].
Finish
Grind core halves to get 660H,
between cores see figure.3, and
assemble with tape.
Varnish.
Figure 10 – Transformer Construction.
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9 Performance Data
All measurements performed at room temperature otherwise specified.
9.1 Active Mode Efficiency
72
73
74
75
76
77
78
79
80
80 100 120 140 160 180 200 220 240 260 280
Input Voltage (VAC)
Efficiency (%)
Non-Dimmable
Dimmable
Figure 11 – Full Load (15 V, 350 mA) Efficiency with Respect to Line Input Voltage and Dimming or Non-
Dimming Configuration (active damper and bleeder removed).
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9.2 Non-Dimmable Configuration
Active Damper and Bleeder components removed.
Input Input Measurement Load Measurement Efficiency
(%)
VAC
(VRMS)
Freq
(Hz)
IIN
(mARMS)
PIN
(W) PF %THD
VO
(VDC)
IO
(mADC)
PO
(W)
90 47 75.020 6.728 0.9973 6.6400 15.12 342.80 5.23 77.73
115 60 61.030 6.981 0.9950 8.36 15.17 358.10 5.47 78.30
132 60 53.870 7.054 0.9924 10.09 15.17 361.90 5.52 78.31
180 50 39.540 7.010 0.9853 12.02 15.15 361.10 5.52 78.69
220 50 32.160 6.902 0.9755 12.35 15.13 354.60 5.41 78.33
230 50 31.040 6.934 0.9717 12.21 15.13 356.20 5.43 78.32
265 63 27.800 6.915 0.9384 12.07 15.13 354.80 5.40 78.05
230 50 29.932 6.676 0.9700 12.53 15.08 343.50 5.22 78.21
220 50 30.723 6.577 0.9731 12.59 15.07 339.60 5.16 78.39
180 50 37.740 6.682 0.9839 12.37 15.08 345.10 5.25 78.51
132 60 50.848 6.653 0.9914 10.77 15.08 343.90 5.22 78.40
115 60 58.278 6.665 0.9945 8.7100 15.08 343.80 5.22 78.24
90 47 74.710 6.700 0.9973 6.67 15.06 342.80 5.21 77.73
9.3 Dimmable
Input Input Measurement Load Measurement Efficiency
(%)
VAC
(VRMS)
Freq
(Hz)
IIN
(mARMS)
PIN
(W) PF %THD
VO
(VDC)
IO
(mADC)
PO
(W)
90 47 81.250 7.29 0.9974 6.0100 15.13 349.10 5.33 73.14
115 60 65.400 7.47 0.9941 7.18 15.18 368.00 5.62 75.22
132 60 55.980 7.31 0.9895 9.6 15.16 364.90 5.57 76.16
180 50 41.920 7.35 0.9746 12.23 15.16 371.20 5.67 77.19
220 50 34.910 7.30 0.9507 13.43 15.15 369.20 5.64 77.21
230 50 33.690 7.30 0.9423 13.09 15.14 369.30 5.64 77.21
265 63 30.110 7.09 0.8886 22.46 15.11 359.00 5.45 76.88
230 50 31.986 6.89 0.9370 13.85 15.07 350.00 5.31 77.12
220 50 33.249 6.91 0.9448 13.71 15.07 351.60 5.34 77.25
180 50 39.671 6.94 0.9719 12.7 15.07 352.10 5.35 77.07
132 60 52.683 6.87 0.9877 10.57 15.05 346.60 5.25 76.42
115 60 63.186 7.22 0.9938 7.3500 15.08 358.40 5.44 75.34
90 47 79.780 7.15 0.9974 5.98 15.03 345.50 5.24 73.22
Table 1 – Full Load Characteristic, Verified with 5 White LED Series String.
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9.4 Harmonics
Meets EN61000-3-2 Harmonics contents standards.
Order
Input Current Harmonics (mA)
EN 61000-3-2 Non-Dimmable Dimmable
115 V 230 V 115 V 230 V
1 61.87 32.40 62.19 32.52
3 1.45 1.25 1.92 1.51 P
5 3.72 1.26 3.22 1.57 P
7 0.81 1.61 1.51 1.72 P
9 0.29 1.55 0.84 1.64 P
11 1.69 1.58 1.02 1.63 P
13 0.79 1.61 0.17 1.55 P
15 0.65 1.30 0.69 1.31 P
17 0.90 0.81 1.37 1.05 P
19 1.08 0.69 1.50 0.73 P
21 0.58 0.30 0.81 0.99 P
23 0.81 0.22 1.00 0.53 P
25 0.61 0.13 0.62 0.66 P
27 0.64 0.11 0.34 0.50 P
29 0.67 0.15 0.52 0.45 P
31 0.70 0.14 0.59 0.36 P
33 0.53 0.11 0.57 0.30 P
35 0.43 0.12 0.57 0.39 P
37 0.33 0.12 0.55 0.35 P
39 0.20 0.12 0.43 0.36 P
41 0.06 0.14 0.24 0.28
43 0.13 0.15 0.21 0.24
45 0.20 0.09 0.12 0.27
47 0.15 0.11 0.24 0.18
49 0.10 0.13 0.27 0.15
Table 2 – Harmonics Contents
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0
5
10
15
20
25
30
35
40
45
50
3579111315171921232527293133353739
Harmonic Order
Current (mA)
115 V Limit
115 V Non-Dimmable
115 V Dimmable
230 V Limit
230 V Non-Dimmable
230 V Dimmable
Figure 12 – UUT Harmonic content.
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9.5 Power Factor
Line voltage was swept from minimum to maximum and back. The difference seen is due
to the hysteresis between operating states of the internal controller and is deterministic.
0.88
0.90
0.92
0.94
0.96
0.98
1.00
80 100 120 140 160 180 200 220 240 260 280
Input Voltage (VAC)
Power Factor
Non-dimmable
Dimmable
Figure 13 – Power Factor with Respect to AC Input at Full Load.
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9.6 Line Regulation
Line voltage was swept from minimum to maximum and back. The difference seen is due
to the hysteresis between the operating states of the internal controller and is
deterministic.
-7
-5
-3
-1
1
3
5
7
80 100 120 140 160 180 200 220 240 260 280
Line Input Voltage (VAC)
Current Regulation (%)
Dimmable
Non-Dimmable
Figure 14 – Line Regulation, Room Temperature, Full Load.
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9.7 Dimming Performance
9.7.1 Dimming Range
The design was characterized using a programmable AC source to simulate a leading
edge TRIAC dimmer. Data was taken in 1 degree phase angle steps.
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
020406080100120140160180
Dimming Angle (Degrees)
Output Current (A)
Figure 15 – 115 V Phase Angle Dimming Characteristic (Increasing Output Current).
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 20 40 60 80 100 120 140 160 180
Dimming Angle (Degrees)
Output Current (A)
Figure 16 – 115 V Phase Angle Dimming Characteristic (Decreasing Output Current).
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
020406080100120140160180
Dimming Angle (Degrees)
Output Current (A)
Figure 17 – 230 V Phase Angle Dimming Characteristic (Increasing Output Current).
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 20 40 60 80 100 120 140 160 180
Dimming Angle (Degrees)
Output Current (A)
Figure 18 – 230 V Phase Angle Dimming Characteristic (Increasing Output Current).
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9.7.2 Unit to Unit Tracking
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 20 40 60 80 100 120 140 160 180
Dimming Angle (Degrees)
Output Current (A)
Unit 1
Unit 2
Figure 19 – Sample Curve for Unit to Unit Output Current Dimming Performance at 115 V / 60 Hz.
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0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0 20 40 60 80 100 120 140 160 180
Dimming Angle (Degrees)
Output Current (A)
Unit 2
Unit 2
Figure 20 – Sample Curve for Unit to Unit Output Current Dimming Performance at 230 V / 50 Hz.
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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 21 – Thermal Chamber Set-up Showing Box Used to Prevent Airflow Over UUT.
Figure 22 – UUT Within Box.
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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: 5 LED in series (15 V / 350 mA). Ambient of 80°C simulates operation inside
sealed LED replacement enclosure. Supply correctly started up and operated at -30°C
Item Normal Operation (ºC) Output
Shorted
Cold Start-up
(PASS)
90 V
50 Hz
115 V
60 Hz
230 V
50 Hz
265 V
60 Hz
265 V
60 Hz
90 V
50 Hz
265 V
60 Hz
Ambient (ºC) 80 80 80 80 80 -30 -30
Bridge (BR1) 101 112 104 97 92
Fet (damper) (Q2) 99 110 104 100 93
Input Inductor (L2) 96 105 101 99 88
Transformer Core (T1) 101 109 107 106 88
Transformer Winding (T1) 105 114 112 111 87
LNK457 (U1) 113 126 122 120 95
Output Capacitor (C11) 96 103 101 101 81
Output Diode (D5) 110 120 118 118 89
Table 3 – Thermal Data for Dimmable Unit.
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10.4 Thermal Scan
Load: 5 LED in series (15 V / 350 mA)
Figure 23 – LNK457DG Device Temperature at 25ºC Open Air.
Figure 24 – Bottom Side of PCB, Trace and Device Temperature.
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11 Waveforms
11.1 Drain Voltage and Current
11.1.1 Normal Steady State Operation
Figure 25 – 90 VAC / 50 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 100 V / div., 2 ms / div.
Lower: IDRAIN, 0.2 A / div.
Figure 26 – 90 VAC / 50 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 100 V / div., 1 s / div.
Lower: IDRAIN, 0.2 A / div.
Figure 27 – 115 VAC / 60 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 100 V / div., 1 ms / div.
Lower: IDRAIN, 0.2 A / div.
Figure 28 – 115 V
A
C / 60 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 100 V / div., 1 s / div.
Lower: IDRAIN, 0.2 A / div.
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Figure 29 – 230 VAC / 50 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 200 V / div., 5 ms / div.
Lower: IDRAIN, 0.2 A / div.
Figure 30 – 230 VAC / 50 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 200 V / div., 5 s / div.
Lower: IDRAIN, 0.2 A / div.
Figure 31 – 265 VAC / 63 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 200 V / div., 1 ms / div.
Lower: IDRAIN, 0.2 A / div.
Figure 32 – 265 VAC / 63 Hz,
6 LED in Series (18.2 V / 350 mA).
Upper: VDRAIN, 200 V / div., 5 s / div.
Lower: IDRAIN, 0.2 A / div.
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11.1.2 AC Start-up
Figure 33 – 265 VAC / 63 Hz,
6 LED in Series (18.2 V / 350 mA).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VO, 5 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 34 – 265 VAC / 63 Hz,
6 LED in Series (18.2 V / 350 mA).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VO, 5 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
11.1.3 115 V TRIAC in Series with AC Input
Figure 35 – 115 VAC / 60 Hz,
45º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 36 – 115 VAC / 60 Hz,
45º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 100 µs / div.
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Figure 37 – 115 VAC / 60 Hz,
90º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 38 – 115 VAC / 60 Hz,
90º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 50 µs / div.
Figure 39 – 115 VAC / 60 Hz,
135º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 40 – 115 VAC / 60 Hz,
135º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 50 V / div.
Ch4(Green): IDS, 200 mA / div., 50 µs / div.
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11.1.4 230 V TRIAC in Series with AC Input
Figure 41 – 230 VAC / 50 Hz,
45º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 42 – 230 VAC / 50 Hz,
45º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 50 µs / div.
Figure 43 – 230 VAC / 50 Hz,
90º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 44 – 230 VAC / 50 Hz,
90º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 100 µs / div.
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Figure 45 – 230 VAC / 50 Hz,
135º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 2 ms / div.
Figure 46 – 230 VAC / 50 Hz,
135º Dimming Phase Angle.
6 LED in Series (18.2 V / 350 mA)
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch4(Green): IDS, 200 mA / div., 20 µs / div.
11.1.5 Fault Conditions (Output Shorted / Open Circuit)
Figure 47 – 265 VAC.
Load Shorted.
Upper: VDRAIN, 200 V / div.
Lower: IDRAIN, 0.2 A / div., 2 ms / div.
Figure 48 – 265 VAC.
Load Shorted.
Upper: VDRAIN, 200 V / div.
Lower: IDRAIN, 0.2 A / div., 1 µs / div.
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Figure 49 – 265 VAC.
Load Shorted.
Upper: VDRAIN, 200 V / div.
Lower: IDRAIN, 0.2 A / div., 50 µs / div.
Figure 50 – 265 VAC.
Load Open.
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VO, 10 V / div.
Ch4(Green): IDS, 200 mA / div., 20 µs / div.
11.2 Output Current Start-up Profile
Figure 51 –90 VAC / 47 Hz.
5 LED in Series (15V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 500 mA / div., 50 ms / div.
Figure 52 –115 VAC / 60 Hz.
5 LED in Series (15V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 500 mA / div., 50 ms / div.
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Figure 53 – 230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 500 mA / div., 50 ms / div.
Figure 54 – 265 VAC / 63 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 500 mA / div., 50 ms / div.
11.3 Input and Output Waveforms
11.3.1 Normal Operation (VIN, IIN, VO and IO)
Figure 55 – 90 VAC / 47 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 50 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 56 – 115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 50 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
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Figure 57 – 230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 58 – 265 VAC / 63 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
11.4 Dimming Operation (VIN, IIN, VO and IO)
Figure 59 – 115 VAC / 60 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 50 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 60 – 230 VAC / 50 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V).
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms/ div.
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Figure 61 – 115 VAC / 60 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V)
Ch1(Yellow): VIN, 50 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 62 – 230 VAC / 50 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V)
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 63 – 115 VAC / 60 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V)
Ch1(Yellow): VIN, 50 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
Figure 64 – 230 VAC / 50 Hz.
45º Dimming Phase Angle.
5 LED in Series (15 V)
Ch1(Yellow): VIN, 100 V / div.
Ch2(Red): VO, 2 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IIN, 50 mA / div., 5 ms / div.
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11.5 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 65 – 115-0-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 2 s / div.
Figure 66 – 115-85-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 2 s / div.
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Figure 67 – 115-85-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 10 ms / div.
Figure 68 – 115-85-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div
Figure 69 – 115-132-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 500 ms / div.
Figure 70 – 115-132-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 10 ms / div.
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Figure 71 – 115-132-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 72 – 115-132-115 VAC / 60 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 100 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 73 – 230-180-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 74 – 230-180-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
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Figure 75 – 230-180-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 76 – 230-265-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50ms / div.
Figure 77 – 230-180-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
Figure 78 – 230-265-230 VAC / 50 Hz.
5 LED in Series (15 V).
Ch1(Yellow): VDS, 200 V / div.
Ch2(Red): VIN, 200 V / div.
Ch3(Blue): IO, 100 mA / div.
Ch4(Green): IDS, 200 mA / div., 50 ms / div.
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12 Line Surge
Differential input line 1.2/50 µs 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 5 LED
in series (14.5 V / 350 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)
+500 230 L1 to L2 90 Line Pass
-500 230 L1 to L2 90 Line Pass
+2500 230 L1 to L2 90 Ring Wave (200 A) Pass
-2500 230 L1 to L2 90 Ring Wave (200 A) Pass
Unit passed all test conditions.
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13 Conducted EMI
13.1 Equipment:
Receiver:
Rohde & Schwarz
ESPI - Test Receiver (9 kHz – 3 GHz)
Model No: ESPI3
LISN:
Rohde & Scharrz
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 79 – Conducted Emissions Measurement Set-up
Showing Conical Ground Plane Inside which UUT was Mounted.
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9 kHz 30 MHz
dBµV
dBµV
6DB
Power Integrations
2 A
V
CLRW
R
SGL
TDF
1 QP
CLRW
R
14.Sep 10 14:50
RBW 9 kHz
MT 500 ms
Att 10 dB AUTO
100 kHz 1 MHz 10 MHz
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
120
LIMIT CHECK PASS
EN55015A
EN55015Q
Figure 80– 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.
Table 4 – Conducted EMI, Maximum Steady State Load, 115 VAC, 60 Hz, and EN55015 Margin.
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6DB
Power Integrations
SGL
TDF
9 kHz 30 MHz
dBµV
dBµV
1 QP
CLRW
R
2 A
V
CLRW
R
RBW 9 kHz
MT 500 ms
Att 10 dB AUTO
14.Sep 10 15:21
100 kHz 1 MHz 10 MHz
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
120
LIMIT CHECK PASS
EN55015A
EN55015Q
Figure 81 – 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.
Table 5 – Conducted EMI, Maximum Steady State Load, 230 VAC, 60 Hz, and EN55015 Margin.
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14 Dimming Compatibility
The operation of a single unit was tested with the dimmers listed in the table below.
Test
Voltage
Test
Freq
Power Rating
Manufacturer
Part
Number
Dimmer
Type
Application/
Remarks
Single Unit 2 Units in Parallel
Min Max
Min
(mA)
Max
(mA)
Min
(mA)
Max
(mA)
115 V 60 Hz N.S. 500 W DIING CHUNG WS-5005 TRIAC
Wide angle
operation 0.024 360 0.083 352.2
115 V 60 Hz N.S. 600 W Lutron
TGLV-
600PR TRIAC
Limited angle
operation 7.6 286.9 16.4 296.7
115 V 60 Hz N.S. 600 W
Lutron
(Skylark)
S-600PR-
WH TRIAC
Limited angle
operation 1.5 286 6.89 298
115 V 60 Hz N.S. Smartlabs 2476D Electronic
Electronic
dimmer 2.66 324 0.082 320.6
115 V 60 Hz N.S. 800W
Hsien Long
Co.,Ltd Y-25082A TRIAC
Incandescent
/ Halogen 0.036 357.3 0.014 352
115 V 60 Hz N.S. 300 W Leviton 6615-POW
Electronic
Low
Voltage
Trailing edge
dimmer 91.8 365.8 82.9 354.1
115 V 60 Hz N.S. 600 W Lutron
D-600R-
WH Triac 0.008 282.6 0.008 282.2
100 V 60 Hz 40 W 400 W Panasonic WN575149 TRIAC *** *** 14.16 294.4
100 V 60 Hz 40 W 500 W Panasonic WT57615K TRIAC *** *** 22.54 303.9
100 V 60 Hz 40 W 500 W Toshiba NWD9051 TRIAC *** *** 1.75 331.1
110 V 60 Hz 500 W Songkung *** *** 2.843 346.4
230 V 40 W 500 W Relco
RTM
34LED
DAX S
Two way
switch -
MOS-
FET;
built-in
soft-start
Incandescent
Electronic
transformer
Electro-
mechanical
transformer
25.14 284.9 21.91 281.1
230 V 50 Hz 40 W 160 W Relco RM34DMA TRIAC Incandescent *** *** 87.5* 362 *
230 V 50 Hz 100 W 500 W Relco RT34DMA *** *** 78.1 ** 347**
230 V 50 Hz RH34LED Electronic
Trailing edge
dimmer 8.31 381 2.23 375.9
230 V 50 Hz 40 W 300 W Relco
RTS 34.43
RLI TRIAC Incandescent *** *** 36.29 ** 353.8**
230 V 50 Hz 100 W 500 W Relco RT34DSL
TRIAC
(DIAC in
gate, 2
1.2mH in
series to
TRIAC,
150nF
across
terminals
of
dimmer)
High power
Incandescent *** *** 76.2** 363**
230 V 50 Hz Clipmei 1 347 0.79 359.3
Note:
**** Holding current of dimmer is well above the drawn current of UUT
** 6 units in parallel
* 3 units in parallel
N.S. – Not Specified.
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15 Output Current Production Distribution
Figure 82 shows the production distribution of output current for 267 RD251 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 6.
Measurements were made at room temperature, VO of 16 V and input voltages of 115
VAC and 230 VAC. This distribution includes variations not only from the LinkSwitch-PL
devices but also all the components of the driver.
379.0
376.5
374.0
371.5
369.0
366.5
364.0
361.
5
359.0
356.5
354.
0
351.5
349.0
346.5
50
40
30
20
10
0
230V, 50Hz, 16V Load: Iout
Frequency
Mean 362.0
StDev 5.608
N267
230V, 50Hz, 16V Load: Iout
in mA
372369366363360357354351348345
80
70
60
50
40
30
20
10
0
115V, 60Hz, 16V Load: Iout
Frequency
Mean 356.5
StDev 4.122
N267
115V, 60Hz, 16V Load: Iout
in mA
Figure 82 – Output current distribution plot for RD251
From the data it can be seen that the output current could be centered slightly
(-1.9% at 115 VAC) to achieve the 350 mA nominal output current by adjusting the output
current sense resistor value. Therefore to correctly demonstrate the achievable tolerance
of the design, CP values were calculated versus CPK. CP provides process capability
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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)
IO Tolerance for given CP Value
CP=1.33 CP=1.5 CP=1.67
115 356.5 4.12
4.7% 5.3% 5.9%
230 362.0 5.61
6.4% 7.2% 8%
Table 6 - 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 7 – 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.
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16 Revision History
Date Author Revision Description & changes Reviewed
20-Oct-10 JDC 1.8 Initial Release Apps & Mktg
14-Dec-10 JDC 1.9 BOM Updated Apps & Mktg
03-Feb-11 PV 1.91 Production distribution of
output current added (section
15).
Apps & Mktg
15-Feb-11 PV 1.92 Edited distribution text
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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, 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 2010 Power Integrations, Inc.
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