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Application Note AN-50 Linkswitch-PL Family

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Application Note AN-50 Linkswitch-PL Family Application Note AN-50 LinkSwitch-PL™ Family Design Guide (Flyback Topology) Introduction The LinkSwitch-PL family of highly integrated monolithic off-line may be used in both the flyback or buck-boost topologies switcher ICs enables implementation of single-stage isolated or however only the flyback is covered in this document. Support, non-isolated, power factor corrected, constant current output with a separate PIXls spreadsheet, for the buck-boost topology is drivers for LED lighting applications. Non-isolated designs are planned and will be covered in a separate application note. compatible with low cost TRIAC based dimmers and provide In addition to this application note, the reader may also find the >300:1 dimming range. The low component count simplifies Reference Design Kits (RDKs) useful. Each contains a fully meeting space constraints of LED retrofit designs (e.g. A19 and functional engineering prototype board, engineering report and candelabra lamp sizes) while the >0.9 PF, low THD and harmonic device samples. Further details on downloading PI Expert, input currents allows a single driver design to be used worldwide. obtaining an RDK, reviewing additional Design Example Reports (DERs) and updates to this document can be found at www. Scope powerint.com. This application note is intended for engineers designing an Basic Circuit Configuration isolated or non-isolated AC to DC power supply driving a A typical application schematic is shown below for a TRIAC constant current LED load. It provides step-by-step guidance on dimmable, non-isolated LED driver. Circuit blocks required for the use of the PIXls design spreadsheet, part of the PI Expert™ interface with TRIAC based phase angle control dimmers are software suite, selection of key components and optimization of labeled Passive, Active Damper, and Bleeder and can be designs especially for TRIAC based dimmers. The LinkSwitch-PL removed for non-dimming applications. C10 R17 1 nF R9 27 Ω 100 V 4.7 kΩ Active Damper Bleeder 15 V, 350 mA 1 7 L2 C7 2.2 mH R12 D5 100 kΩ 1000 pF SS110-TP 630 V C11 2 3 680 μF 25 V R3 R10 750 kΩ 510 Ω R13 4.7 Ω 6 T1 R18 RTN BR1 D2 EE16 MB6S US1J 0.82 Ω 600 V 1% F1 L 3.15 A C4 C5 C6 R15 D4 R4 D6 3.3 kΩ BAV19WS Ω 22 nF 68 nF 68 nF 750 k 630 V 400 V 400 V DL4006 90 - 265 RV1 VAC 275 VAC R2 4.7 kΩ LinkSwitch-PL VR2 U1 MAZS2000ML LNK456DG 20 V D N R20 L1 CONTROL Ω 2.2 mH R21 47 BP 1 kΩ R14 1 kΩ Passive Damper R11 FB 510 Ω S C3 Q3 22 nF C8 C9 50 V μ R16 10 nF 1 F 10 kΩ 50 V 25 V R7 R8 240 Ω 240 Ω PI-6363-020411 Figure 1. Typical TRIAC Dimmable Application Schematic using a LinkSwitch-PL Device. www.powerint.com February 2011 Application Note AN-50 Quick Start Nominal Input VAC VAC Note Voltage (VAC) MIN MAX Readers familiar with power supply design and Power Integrations 100/115 85 132 Japan / USA design software may elect to skip the step-by-step design approach 230/240 195 265 EU / Various described later, and can use the following information to quickly Worldwide design the transformer and select the components necessary for 277 250 308 a first prototype. For this approach, only the information described Single Phase below needs to be entered into the PIXls spreadsheet, other Universal 85 265 USA 3 Phase parameters will be automatically selected based on typical design Table 1. Input Voltage Ranges. requirements. References to spreadsheet cell locations (visible in the PIXls software) are provided in square brackets [cell reference]. 115 VAC input. 50 Hz for single 100 VAC input. Line frequency is not a direct design parameter but is used within the spreadsheet • Enter AC input voltage range VACMIN, VACMAX and minimum line for correct calculation of parameters such as primary RMS current. frequency fL [B3, B4, B5] Nominal Output Voltage, V (V) • Enter nominal output voltage VO [B6] O Enter the nominal output voltage. • Enter nominal output current IO [B9] • Enter efficiency estimate [B10] • Enter loss allocation factor Z [B11] Typical operating voltage range recommended is VO ±25%. For • Select the enclosure type by clicking on cell [B12] and click on comparison the expected LED string voltage variation including the down arrow to select “open frame” or “retrofit lamp” application tolerance and effect of temperature is < ±15%. Wider output • Select dimming or non-dimming design via the drop down menu or voltage variations are possible with considerations for the directly entering Yes or No [B13] practical limitations as described below. • Enter the output diode forward drop [B15]. Use 0.7 V for fast or ultrafast diodes and 0.5 V for Schottky diodes. Minimum Output Voltage, VO(MIN) • If any warnings are generated, make changes to the design Enter the minimum LED string voltage. following instruction in the spreadsheet column F • Build transformer following guidance on transformer construc- The minimum output voltage is determined by the output power tion sheet level at which cycle skipping will occur under high-line conditions. • Select key components. See steps 3 and 6 Cycle skipping operation maintains output current regulation but • Build prototype and iterate design as necessary, replacing degrades PF and THD. Cycle skipping occurs when the voltage estimates in the spreadsheets with measured values as across the output current sense resistor (R18 in Figure 1) appropriate (e.g. efficiency). ≥ 520 mV. A warning will be displayed if the entered output • Power Integrations offers transformer prototyping services and voltage will cause this to occur. links to other vendors: for details see www.powerint.com/ Maximum Output Voltage, V componentsuppliers.htm O(MAX) Enter the maximum LED string voltage. Step-by-Step Transformer Design Procedure The practical limitation is determined by the maximum peak drain voltage (effect of reflected output voltage). Step 1. Enter Application Variables VACMIN, VACMAX, fL, VO, VO(MIN), VO(MAX), IO, η, Z, Enclosure, Dimming Application, PO Nominal Output Current, IO (A) and VD Enter the average output current. IO is the desired average output current. The output current from the converter is a DC Determine the input voltage range from Table 1. current with a super imposed line frequency ripple as an AC component. The amplitude of ripple will be determined by the Line Frequency, fL 50 Hz for universal or single 230 VAC input, 60 Hz for single amount of output capacitance and load resistance. ENTER APPLICATION VARIABLES VACMIN 85 85 V Minimum AC input voltage VACMAX 265 265 V Maximum AC input voltage FL 50 Hz Minimum line frequency VO 15.00 15.0 V Nominal Output Voltage VO_MIN 15.0 V Minimum output voltage tolerance VO_MAX 15.0 V Maximum output voltage tolerance IO 0.40 0.400 A Average output current n 0.7 %/100 Total power supply efficiency Z 0.5 Loss allocation factor. Enclosure selections determines thermal conditions and maximum Enclosure Open Frame Open Frame power Dimming applications generally require lower flux density to avoid Dimming Application Yes Yes audible noise problems PO 6.00 W Average output power VD 0.5 V Output diode forward voltage drop Figure 2. Application Variable Section of LinkSwitch-PL Spreadsheet. 2 Rev. A 02/11 www.powerint.com AN-50 Application Note Power Supply Efficiency, η Output Power Table Enter the estimated efficiency of the complete power supply measured at the output terminals under worst case line input 85-265 VAC Product voltage. The worst case will occur at either the lowest or Minimum Output Maximum Output Power Power highest input voltage. Start with a value of 78% until a LNK454D 1.5 W 3 W prototype can be measured. LNK456D 3 W 6 W Power Supply Loss Allocation Factor, Z LNK457D/K/V 4 W 8 W This factor represents the proportion of losses between the LNK458K/V 6 W 11.5 W primary and secondary of the power supply. Z factor is used LNK460K/V 8 W 16 W together with the efficiency number to determine the actual Table 2. Output Power Table. power that must be delivered by the power stage. For example, losses in the input stage (EMI filter, rectification, damper, bleeder, Number of Output Current etc.) are not processed by the power stage (transferred through Serial LEDs 350 mA 500 mA 700 mA 1000 mA the transformer) and therefore, although they reduce efficiency, 1 LNK454 LNK454 LNK454 LNK456 the transformer design is not affected by their effect on efficiency. 2 LNK454 LNK456 LNK456 LNK457 3 LNK456 LNK456 LNK457 LNK458 Z = (secondary side losses)/(total losses) 4 LNK456 LNK457 LNK458 LNK460 5 LNK457 LNK458 LNK460 Examples of primary side losses are losses incurred in the input 6 LNK457 LNK458 LNK460 rectifier and EMI filter, MOSFET conduction losses and primary 7 LNK458 LNK460 side winding losses. Examples of side secondary losses include 8 LNK458 LNK460 the losses in the secondary diode, secondary winding and core 9 LNK458 LNK460 losses, losses associated with the primary clamp circuit and the 10 LNK460 bias winding. 11 LNK460 Starting values: For non-dimming designs 0.5, for dimming 12 LNK460 designs 0.4. Table 3. Device Selection Based on Length of Output LED Series String and Current. A Typical Voltage Drop of 3.5 V per LED is Assumed. Enclosure Select Open Frame or Retrofit Lamp. Open Frame enclosure Step 2. Enter the LinkSwitch-PL Design Variables allows higher output power before a thermal warning is issued by the spreadsheet.
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