RDR-131

RDR-131 POWERINT | Alldatasheet

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5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Title Reference Design Report for 3 W Non- Isolated Constant Current LED Driver Using LNK306DN Specification 85–265 VAC Input, 10 V, 300 mA Output Application LED Lighting / Bulb Retrofit Author Power Integrations Applications Department Document Number RDR-131 Date March 7, 2007 Revision 1.1 Summary and Features

• Extremely small form factor, fits within GU10 lamp base
• Operates over the universal input voltage range (85 – 265 VAC)
• Meets EN55022 B conduc ted EMI requirements
• Drives LEDs in constant current (CC) mode
• Built-in, output overvolt age protection when unloaded
• Allows supply to be tested without the load connected
• Low parts count, low-cost solution: only 25 components
• Non-isolated buck converter configurati on allows use of off-the-shelf inductors (does not require a custom transformer) The products and applications illustrat ed herein (including circuits external to the products and transformer construction) may be covered by one or more U.S. and fo reign patents or potentially by pending U.S. and foreign patent applications assigned to Power In tegrations. A complete list of Power Integrations’ patents may be found at www.powerint.com.

RDR-131 LED Driver – LNK306DN 7-Mar-07 Page 2 of 24 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Table of Contents Important Note: This board has no safety isolat ion. Therefore, all testi ng should be performed using an isolation transformer to provide the AC input to the prototype board.

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1 Introduction

This engineering report describes an LED driv er power supply that uses a member of the LinkSwitch-TN family of devices, the LN K306DN. The circuit regulates its load current to 300 mA while developing about 10 V across three series HB-LEDs. The design provides no safety isolation between the AC input and DC output. Therefore the enclosure must be designed to provide isolation. The report contains the power su pply specification, a circuit diagram, a complete bill of materials, the PI Xls spreadsheet results for the des ign, the printed circuit board layouts, and performance data. Figure 1 – Photographs of (Top and Side views) Populated Circuit Board Assembly.

RDR-131 LED Driver – LNK306DN 7-Mar-07 Page 4 of 24 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 2 – Mechanical Positioning of the Power Supply Assembly Inside the GU10 Bulb Socket Base.

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2 Power Supply Specification

Description Symbol Min Typ Max Units Comment Input Voltage VIN 85 265 VAC 2 Wire – no P.E. Frequency fLINE 47 50/60 64 Hz No-load Input Power (230 VAC) - W Not applicable Output Output Voltage 1 VOUT1 10 V ± 10% at 25 o C Output Current 1 IOUT1 0.3 A Total Output Power Continuous Output Power POUT 3 W Efficiency η 62 % Measured at POUT (3 W), 25 o C Environmental Conducted EMI Meets EN55022B/CISPR22B Safety No input to output isolation Ambient Temperature TAMB 0 40 oC Free convection, sea level

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3 Circuit Diagram

Figure 3a – Circuit Diagram of Filter Board. Figure 3b – Circuit Diagram of Converter Board.

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4 Circuit Description

4.1 Configuration and Assembly Details

The power supply is configured as a non-isolated buck converter. Since it must fit in a GU10 lamp socket base, the supply was split into 2 interconnected boards. A Faraday shield (the third board) was sandwiched bet ween the input rectif ication/EMI filter (bottom) board and the converter (top) board. The shield board is electrically connected to the converter board. This was necessary to meet the conduct ed EMI requirements. The shield consists of a single-sided, cop per-clad PCB that is the same size as the input rectification/EMI filter board.

4.2 AC Input Rectification

A 10 Ω fusible resistor (RF1) will act as a fuse if a catastrophic failure occurs. The input voltage and current are rectifi ed by a bridge rectifier (BR1 ) and smoothed by a pi filter circuit (C1, L1 and C2). The pi filter and RF1 also help attenuate the differential mode conducted EMI that is generated by the switching of the buck converter.

4.3 LinkSwitch-TN

The PI Xls spreadsheet tool was used to desi gn this converter. When powering the designated LED load, the converter operat es in the continuous conduction mode (CCM). The buck converter stage consists of the integrated MOSFET switch within the LNK306DN (U1), a freewheeling diode (D3) , an output inductor (L2) and an output capacitor (C3). An Ultrafast MURS160T3 was chosen for the freewheeling diode to minimize the amplitude of the MOSFET turn-on spike. The remaining components are involved in sensing the normal-load output current and the no-load output voltage and conveying that information back to the FEEDBACK (FB) pin of the LNK306DN.

4.4 Output Feedback

The LinkSwitch-TN uses On/Off control to regulate the output of the supply. During each enabled switching cycle the drain current ramps to a fixed inte rnal current limit level. When current into the FEEDBACK (F B) pin exceeds 49 µA the next switching is disabled. By adjusting the number of enabled to disabled cycles the amount of energy delivered to the output can be varied to mainta in regulation. The 49 µA threshold is specified at a FB pin voltage of 1.65 V al lowing this pin to be used as a voltage reference. In this design both current and voltage feed back is used. Current feedback limits the LED current during normal operation while vo ltage feedback limits t he output voltage should the LED load be disconnected, for example during production testing. During the off time of U1, the voltage that appears across C2 is equal to the output voltage less a diode drop. In this design two 250 V rated diodes, D1 and D2, were used for space reasons, however a single 600 V diode could be used (in this case the voltage across C2 would be equal to the output voltage).

RDR-131 LED Driver – LNK306DN 7-Mar-07 Page 8 of 24 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com This voltage is divided by R7 and R1 so the voltage at the FB pin is 1.65 V when the output voltage reaches ~12 V. Due to the interaction with th e current sense circuit and the small output capacitor value the actual peak no-load voltage is limited to ~18 V. Current feedback is provided by sensing th e voltage drop across R8 and R10, which is filtered by R4 and C6. On ce the voltage drop exceeds t he VBE of Q1, both Q1 and Q2 turn on, feeding additional current into the FB pin of U1 from C2. By adjusting the ratio of enabled to disabled cycles the average output cu rrent is controlled. As the VBE of Q1 varies with temperature t he circuit exhibits a negativ e output current temperature coefficient. Resistor R11 provides a minimum load to ensure correct operation at zero load. This relatively complicated current sense can be simplified by using the FB pin directly to sense the voltage drop across the sense re sistors. However as the FB pin has a voltage of 1.65 V this resulted in unaccept able dissipation (0.3 A x 1.65 V = 0.5 W) inside the GU10 enclosure. However in le ss thermally challenging designs this approach may be used.

7-Mar-07 RDR-131 LED Driver – LNK306DN Page 9 of 24 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Filter Board Converter Board (Bottom and Top Side) Figure 4 – Printed Circuit Board Layouts.

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5 Bill of Materials

The BOM for each board is presented separately.

5.1 Filter Board Bill of Materials

Item Qty Ref Des Value Description Mfg Part Number Mfg Comment 1 1 BR1 MB6S 600 V, 0.5 A, Bridge Rectifier, SMD, TO-269AA MB6S Vishay 2 2 C1 C2 4.7 µF 4.7 µF, 380 V, Electrolytic, (8 x 11.5) XX380VB4R7M8 X11LL Nippon Chemi-Con 3 3 J1 J2 J3 PCB Terminal

22 AWG

PCB Terminal Hole, 22 AWG N/A N/A 4 0.08 Ft. JP1 Wire Jumper, Non- insulated, 22 AWG, 0.6 in 298 Alpha 5 1 L1 1000 µH 1000 µH, 0.21 A, 5.5 x 10.5 mm SBC1-102-211 Tokin 6 1 RF1 10 Ω 10 Ω, 2.5 W, Fusible/Flame Proof Wire Wound CRF253-4 10R Vitrohm 7 0.17 Ft. W1 Wire Jumper, Non- insulated, 22 AWG 298 Alpha Solder wire in J1 Location (apply teflon tubing (SW1) over wire) 8 0.07 Ft. W2 Wire Jumper, Non- insulated, 22 AWG 298 Alpha Solder wire in J2 location (apply teflon tubing (SW2) over wire) 9 0.03 Ft. W3 Wire Jumper, Non- insulated, 22 AWG 298 Alpha Solder wire in J3 location (teflon tubing not required) 10 0.07 Ft. SJP1 Teflon Tubing for 22 AWG wire TFT-200-22 Alpha Place over JP1 11 0.15 Ft. SW1 Teflon Tubing for 22 AWG wire TFT-200-22 Alpha Place over W1 12 0.06 Ft. SW2 Teflon Tubing for 22 AWG wire TFT-200-22 Alpha Place over W2

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5.2 Converter Board Bill of Materials

Item Qty Ref Des Value Descripti on Mfg Part Number Mfg Comment 1 3 C1 C2 C6 100 nF 100 nF 25 V, Ceramic, X7R, 0603 ECJ-1VB1E104K Panasonic 2 1 C3 2.2 µF 2.2 uF, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E225K Panasonic 3 2 D1 D2 BAV21WS-7-F 250 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV21WS-7-F Diode Inc. 4 1 D3 MURS160T3

600 V, 1 A, Ultrafast

Recovery, 35 ns, SMB Case MURS160T3G On Semi 5 2 J1 J2 PCB Terminal PCB Terminal Hole, 22 AWG N/A N/A 6 1 L2 1000 µH 1000 µH, 0.3 A L03316-102-RM ICE Components 7 1 Q1 MMST3904 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-323 MMST3904-7-F Diodes Inc 8 1 Q2 MMST3906 PNP, Small Signal BJT, 40 V, 0.2 A, SOT-323 MMST3906-7 Diodes Inc 9 2 R1 R9 4.7 kΩ 4.7 kΩ, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ472V Panasonic 10 3 R3 R4 R6 10 kΩ 10 kΩ, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ103V Panasonic 11 1 R7 30 kΩ 30 kΩ, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ303V Panasonic 12 1 R8 2 Ω 2 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ2R0V Panasonic 13 1 R10 12 Ω 12 Ω, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ120V Panasonic 14 1 R11 1 kΩ 1 kΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ102V Panasonic 15 1 U1 LNK306D LinkSwitch-TN, LNK306D, SO-8 LNK306D Power Integrations 16 0.17 Ft. W2 Wire jumper, non insulated, 22 AWG 298 Alpha Solder wire in J2 Location (teflon tubing is not required) 17 1 J3 CON1 Test Point, RED, Miniature THRU-HOLE MOUNT 5000 Keystone 18 1 J4 CON1 Test Point, BLK, Miniature THRU-HOLE MOUNT 5001 Keystone

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6 PI Xls Design Spreadsheet

ACDC_LinkSwitch- TN_030906; Rev.2.2; Copyright Power Integrations 2006 INPUT INFO OUTPUT UNIT LinkSwitch-TN_Rev_2-2.xls: LinkSwitch-TN Design Spreadsheet INPUT VARIABLES Customer VACMIN 85 Volts Minimum AC Input Voltage VACMAX 265 Volts Maximum AC Input Voltage FL 50 Hertz Line Frequency VO 12.00 Volts Output Voltage IO 0.330 Amps Output Current EFFICIENCY (User Estimate)

0.72 Overall Efficiency Estimate (Adjust to match Calculated,

or enter Measured Efficiency) EFFICIENCY (Calculated Estimate)

0.78 Calculated % Efficiency Estimate

CIN 9.40 9.40 uF Input Filter Capacitor Input Stage Resistance 0.00 ohms Input Stage Resistance, Fuse & Filtering Ambient Temperature 50 deg C Operating Ambient Temperature (deg Celsius) Switching Topology Buck Type of Switching topology Input Rectification Type F F Choose H for Half Wave Rectifier and F for Full Wave Rectification DC INPUT VARIABLES VMIN 79.1 Volts Minimum DC Bus Voltage VMAX 374.8 Volts Maximum DC Bus Voltage LinkSwitch-TN LinkSwitch-TN Auto LNK306 Selected LinkSwitch-TN ILIMIT 0.482 Amps Typical Current Limit ILIMIT_MIN 0.450 Amps Minimum Current Limit ILIMIT_MAX 0.515 Amps Maximum Current Limit FSMIN 62000 Hertz Minimum Switching Frequency VDS 6.2 Volts Maximum On-State Drain To Source Voltage drop PLOSS_LNK 0.51 Watts Estimated LinkSwitch-TN losses DIODE VD 0.70 Volts Freewheeling Diode Forward Voltage Drop VRR 600 Volts Recommended PIV rating of Freewheeling Diode IF 1 Amps Recommended Diode Continuous Current Rating TRR 35 ns Recommended Reverse Recovery Time Diode Recommendation BYV26C Suggested Freewheeling Diode OUTPUT INDUCTOR L_TYP 941.6 uH Required value of Inductance to deliver Output Power (Includes device and inductor tolerances) Choose next higher standard available value L 1000 uH Output Inductor, Recommended Standard Value L_R 2.0 Ohm s DC Resistance of Inductor OPERATING MODE CCM Continuous Conduction Mode (at VMIN) KL_TOL 1.15 Inductor tolerance Factor. Accounts for basic (10% - 20%) Manufacturing Tolerances 1.1 < KL_TOL < 1.2 See AN-37 for detailed explanation K_LOSS 0.813 Loss factor. Accounts for "off-state" power loss to be supplied by inductor Calculated efficiency < K_LOSS < 1. See AN-37 for detailed explanation ILRMS 0.33 Amps Estimated RMS inductor current (at VMAX)

7-Mar-07 RDR-131 LED Driver – LNK306DN Page 13 of 24 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com OUTPUT CAPACITOR DELTA_V 0.12 Volts Target Output Voltage Ripple MAX_ESR 467 m- Ohm s Maximum Capacitor ESR (milli-Ohms) I RIPPLE 0.26 Amps Output Capacitor Ripple current FEEDBACK COMPONENTS RBIAS 2.00 k- Ohm s Bias Resistor. Use closest standard 1% value RFB 11.86 k- Ohm s Feedback Resistor. Use closest standard 1% value CFB 10 uF Feedback Capacitor C_SOFT_START 39092 uF If the output Voltage is greater than 12 V, or total output and system capacitance is greater than 100 uF, a soft start capacitor between 1uF and 10 uF is recommended. See AN-37 for details Note: The feedback components in the spreadsheet were not used on the power supply because a higher impedance was required by the CC feedback circuit.

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7 Performance

7.1 Efficiency

Efficiency measured at different line voltages are collected in the table below. Table 1: Efficiency data measured at different AC input line voltages. 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 70 120 170 220 270 VAC Efficienc y Figure 5 – Efficiency vs. Input Voltage, Room Temperature. VAC IN Efficiency 85 0.642 115 0.639 220 0.588 265 0.562

7-Mar-07 RDR-131 LED Driver – LNK306DN Page 15 of 24 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 7.2 Output Current Regul ation Vs. Line Voltage 200 220 240 260 280 300 320 340 360 380 400 50 100 150 200 250 300 Input Voltage (VAC) Output Current (m A Figure 6 – Output Current vs. Input Voltage (stabilized, room temperature operation*).

7.3 Output VI Characteristic

Figure 7 – Output Current vs. Output Voltage. Note: When driving a LED load operation at <6V would not occur, therefore current walkout behavior is acceptable. Output Current (mA) Output Voltage

85 VAC

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8 Waveforms

8.1 Drain Voltage and Current, Normal Operation

Figure 7 – 85 VAC, Full Load. Upper: VDRAIN, 50 V / div. Lower: IDRAIN 0.20 A / div, 5 µs / div. Figure 8 – 265 VAC, Full Load Upper: VDRAIN, 100 V / div. Lower: IDRAIN 0.20 A / div, 5 µs / div.

8.2 Output Current and Voltage

Figure 9 – 85 VAC, Full Load. Upper: VOUT, 5 V / div. Lower: IOUT, 100 mA, 20 µs / div. Figure 10 – 265 VAC, Full Load. Upper: VOUT, 5 V / div. Lower: IOUT, 100 mA, 20 µs / div.

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8.3 Drain Current and Bulk Capacitor Voltage

Figure 11 – 85 VAC, Full Load. Upper: VBULK, 100 V / div. Lower: IDRAIN, 200 mA, 5 ms / div. Figure 12 – 265 VAC, Full Load. Upper: VBULK, 100 V / div. Lower: IDRAIN, 200 mA, 5 ms / div.

8.4 Startup Drain Current a nd Bulk Capacitor Voltage

Figure 13 – 85 VAC, Full Load. Upper: VBULK, 50 V / div. Lower: IDRAIN, 200 mA, 5 ms / div. Figure 14 – 265 VAC, Full Load. Upper: VBULK, 200 V / div. Lower: IDRAIN, 200 mA, 5 ms / div.

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8.5 Startup Output Voltage and Current

Figure 15 – 85 VAC Full Load. Upper: Vout, 5 V / div. Lower: Iout, 200 mA / div, 5 ms / div. Figure 16 – 265 VAC Full Load. Upper: Vout, 5 V / div. Lower: Iout, 200 mA / div, 5 ms / div.

8.6 Fault Conditions

Figure 17 – Drain Current with Output Shorted. 500 mA/div, 2 ms / div. Vin = 265 VAC Note: Peak drain current is 1.95 Amps. Figure 18 – Output Voltage with No Load. 5 V/div, 1 ms / div. Vin = 265 VAC Note: Peak voltage is 18 Volts.

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9 Thermal Measurements

The power supply assembly was install ed into the lamp socket base and the temperature of the LNK306 DN SOURCE pin was measured, while the room ambient temperature was 25 °C. The power supply was driving the three load LEDs (delivering 3 watts). Vin (VAC) Source Pin Temperature (°C) 85 81 115 82 230 97 265 103 These results indicate that additional heat sinking may be required for example by arranging the LED heatsink to contact the top of the SO-8C package of U1.

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10 Conducted EMI

The measurements were taken with the powe r supply driving the 3 LEDs. The worst- case input voltage was at 230 VAC, where t he margin to the test limits was about 7 dBµV. 150 kHz 30 MHz 1 QP CLRWR 2 AV CLRWR SGL TDF dBµV dBµV

1 MHz 10 MHz

-20 -10 LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG EN55022A EN55022Q Figure 19 – Conducted EMI at 230 VAC. Figure 20 – Conducted EMI at 115 VAC. 1 5 0 k H z 30 MHz

1 Q P

2 A V

d B µ V d B µ V 1 MHz 10 MHz - 2 0 - 1 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 1 0 0 LIMIT CHECK MARG LINE EN55022A MARG LINE EN55022Q MARG E N 5 5 0 2 2 A E N 5 5 0 2 2 Q

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10.1 Competitive Product EMI

Figure 21 – Conducted EMI at 115VAC of competitive product. This result was taken to demonstrate the poor EMI performance of similarly rated LED drivers on the market. Power Integrations 1 QP CLRWR 2 AV CLRWR SGL TDF dBµV dBµV RBW 9 kHz MT 100 ms PREAMP OFFAtt 10 dB AUTO 01.Feb 07 08:52 150 kHz 30 MHz -20 -10 100 LIMIT CHECK FAIL LINE EN55022A FAIL LINE EN55022Q FAIL Marker 1 [T1 ] 89.31 dBµV 182.849162999 kHz EN55022A EN55022Q

RDR-131 LED Driver – LNK306DN 7-Mar-07 Page 22 of 24 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Date Author Revision Description & changes Reviewed 02/16/2007 JAJ 1.0 Initial publication 03/7/2007 1.1 Updated pictures

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RDR-131 LED Driver – LNK306DN 7-Mar-07 Page 24 of 24 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 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 Pow er 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 2007 Power Integrations, Inc. Power Integrations Worldwide Sales Support Locations WORLD HEADQUARTERS

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