Title Reference Design Report for a 150 W Power Factor Corrected LLC Power Supply Using HiperPFS TM -2 (PFS7326H) and HiperLCSTM (LCS702HG) 90 VAC - 265 VAC Input; Specification 150 W (~43 V at 0 - 3.5 A) Output (Constant Current) Application LED Streetlight Author Applications Engineering Department Document Number RDR-382 Date June 28, 2017 Revision 6.5 Summary and Features Integrated PFC and LLC stages for a very low component count design Continuous mode PFC using low cost ferrite core High frequency (250 kHz) LLC for extremely small transformer size. >95% full load PFC efficiency at 115 VAC >95% full load LLC efficiency System efficiency 91% / 93% at 115 VAC / 230 VAC Start-up circuit eliminates the need for a separate bias supply On-board current regulation and analog dimming 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>. Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Table of Contents 1 2 3 4 Introduction ...................................................................................................... 5 Power Supply Specification ................................................................................. 7 Schematic ......................................................................................................... 8 Circuit Description ............................................................................................ 10 4.1 Input Filter / Boost Converter / Bias Supply ................................................. 10 4.2 EMI Filtering / Inrush Limiting .................................................................... 10 4.3 Main PFC Stage ......................................................................................... 10 4.4 Primary Bias Supply / Start-up .................................................................... 10 4.5 LLC Converter ........................................................................................... 11 4.6 Primary..................................................................................................... 11 4.7 Output Rectification ................................................................................... 13 4.8 Output Current and Voltage Control ............................................................ 13 5 PCB Layout ...................................................................................................... 15 6 Bill of Materials ................................................................................................ 17 7 LED Panel Characterization ............................................................................... 20 7.1 LED Panel Current Sharing ......................................................................... 21 7.2 Constant Voltage Load ............................................................................... 22 8 Magnetics ........................................................................................................ 26 8.1 PFC Choke (L2) Specification ...................................................................... 26 8.1.1 Electrical Diagram ............................................................................... 26 8.1.2 Electrical Specifications ........................................................................ 26 8.1.3 Materials ............................................................................................ 26 8.1.4 Build Diagram ..................................................................................... 27 8.1.5 Winding Instructions ........................................................................... 27 8.1.6 Winding Illustrations ........................................................................... 28 8.2 LLC Transformer (T1) Specification ............................................................. 31 8.2.1 Electrical Diagram ............................................................................... 31 8.2.2 Electrical Specifications ........................................................................ 31 8.2.3 Materials ............................................................................................ 31 8.2.4 Build Diagram ..................................................................................... 32 8.2.5 Winding Instructions ........................................................................... 32 8.2.6 Winding Illustrations ........................................................................... 33 8.3 Output Inductor (L3) Specification .............................................................. 37 8.3.1 Electrical Diagram ............................................................................... 37 8.3.2 Electrical Specifications ........................................................................ 37 8.3.3 Material List ........................................................................................ 37 8.3.4 Construction Details ............................................................................ 37 9 PFC Design Spreadsheet ................................................................................... 38 10 LLC Transformer Design Spreadsheet ............................................................. 42 11 Heat Sinks.................................................................................................... 47 11.1 Primary Heat Sink ...................................................................................... 47 11.1.1 Primary Heat Sink Sheet Metal ............................................................. 47 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 2 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 11.1.2 Primary Heat Sink with Fasteners ......................................................... 48 11.1.3 Primary Heat Sink Assembly ................................................................. 49 11.2 Secondary Heat Sink .................................................................................. 50 11.2.1 Secondary Heat Sink Sheet Metal ......................................................... 50 11.2.2 Secondary Heat Sink with Fasteners ..................................................... 51 11.2.3 Secondary Heat Sink Assembly ............................................................. 52 12 RD-382 Performance Data ............................................................................. 53 12.1 LLC Stage Efficiency ................................................................................... 53 12.2 Total Efficiency .......................................................................................... 54 12.3 Power Factor ............................................................................................. 55 12.4 Harmonic Distribution ................................................................................ 56 12.5 THD, 100% Load ....................................................................................... 56 12.6 Output Current vs. Dimming Input Voltage .................................................. 57 13 Waveforms ................................................................................................... 58 13.1 Input Current, 100% Load.......................................................................... 58 13.2 LLC Primary Voltage and Current ................................................................ 59 13.3 Output Rectifier Peak Reverse Voltage ......................................................... 60 13.4 PFC Inductor + Switch Voltage and Current, 100% Load .............................. 61 13.5 AC Input Current and PFC Output Voltage during Start-up ............................ 62 13.6 LLC Start-up Output Voltage and Transformer Primary Current Using LED Output Load 62 13.7 Output Voltage / Current Start-up Using LED Load ....................................... 63 13.8 LLC Output Short-Circuit............................................................................. 64 13.9 Output Ripple Measurements ...................................................................... 65 13.9.1 Ripple Measurement Technique ............................................................ 65 13.9.2 Ripple Measurements .......................................................................... 66 14 Temperature Profiles ..................................................................................... 67 14.1 90 VAC, 60 Hz, 150 W Output, Room Temperature....................................... 67 14.2 115 VAC, 60 Hz, 150 W Output, Room Temperature ..................................... 70 14.3 230 VAC, 50 Hz, 150 W Output, Room Temperature ..................................... 73 15 Output Gain-Phase ........................................................................................ 76 16 Conducted EMI ............................................................................................. 77 17 Line Surge Testing ........................................................................................ 79 17.1 Line Surge Test Set-up ............................................................................... 79 17.2 Differential Mode Surge, 1.2 / 50 sec......................................................... 80 17.3 Common Mode Surge, 1.2 / 50 sec............................................................ 80 18 Revision History ............................................................................................ 81 Page 3 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Important Notes: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. All testing should be performed using an isolation transformer to provide the AC input to the prototype board. Since there is no separate bias converter in this design, ~280 VDC is present on bulk capacitor C14 immediately after the supply is powered down. For safety, this capacitor must be discharged with an appropriate resistor (10 k / 2 W is adequate), or the supply must be allowed to stand ~10 minutes before handling. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 4 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 1 Introduction This engineering report describes a 43 (nominal) V, 150 W reference design for a power supply for 90-265 VAC LED street lights and other high power lighting applications. The power supply is designed with a constant current output in order to directly drive a 150 W LED panel at 43 V. The design is based on the PFS7326H for the PFC front-end and a LCS702HG for the LLC output stage. Figure 1 - RD-382 Photograph, Top View. Page 5 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Figure 2 - RD-382 Photograph, Bottom View. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 6 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 2 Power Supply Specification The table below represents the minimum acceptable performance for the design. Actual performance is listed in the results section. Description Input Voltage Frequency Power Factor Symbol Min Typ Max Units Comment VIN fLINE PF 90 47 0.97 265 64 VAC Hz 3 Wire input. 50/60 Full load, 230 VAC Main Converter Output Output Voltage VLG Output Ripple VRIPPLE(LG) Output Current ILG 43 V 300 0.00 3.5 43 VDC (nominal - defined by LED load) mV P-P 20 MHz bandwidth A Constant Current Supply protected for no-load condition Total Output Power Continuous Output Power Peak Output Power Efficiency POUT POUT(PK) Total system at Full Load Main 150 N/A 91 93 W W % Measured at 115 VAC, Full Load Measured at 230 VAC, Full Load Environmental Meets CISPR22B / EN55022B Conducted EMI Safety Surge Differential Common Mode Ambient Temperature Page 7 of 82 Designed to meet IEC950 / UL1950 Class II TAMB 2 4 0 60 kV kV o C 1.2/50 s surge, IEC 1000-4-5, Differential Mode: 2 Common Mode: 12 See thermal section for conditions Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 3 Schematic Figure 3 - Schematic RD-382 Street Light Power Supply Application Circuit - Input Filter, PFC Power Stage, and Bias Supplies. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 8 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Figure 4 - Schematic of RD-382 Street light Power Supply Application Circuit, LLC Stage. Page 9 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 4 Circuit Description 4.1 Input Filter / Boost Converter / Bias Supply The schematic in Figure 3 shows the input EMI filter, PFC stage, and primary bias supply/startup circuit. The power factor corrector utilizes the PFS7326H. The primary and secondary bias supplies are derived from windings on the PFC inductor (L2). 4.2 EMI Filtering / Inrush Limiting Capacitors C1 and C2 are used to control differential mode noise. Resistor R1 is used for damping, improving power factor and reducing EMI. Resistors R2-4 discharge C1 and C2 when AC power is removed. Inductor L1 controls common mode EMI. The heat sink for U1, U3, and BR1 is connected to primary return to eliminate the heat sink as a source of radiated/capacitively coupled noise. Thermistor RT1 provides inrush limiting. Capacitor C33 (Figure 4) filters common mode EMI. Inductor L4 filters differential mode EMI. 4.3 Main PFC Stage Components R17-19 and R23 provide output voltage feedback. Capacitor C15 provides fast dv/dt feedback to the U1 FB pin for rapid undershoot and overshoot response of the PFC circuit. Frequency compensation is provided by C19, C20, and R21, R22, and R24. Resistors R10-12 (filtered by C10) provide input voltage information to U1. Resistor R13 (filtered by C11) programs the U1 for "efficiency" mode. For more information about HiperPFS-2 efficiency mode, please refer to the HiperPFS-2 data sheet. Resistor R14 programs the "power good" threshold for U1. Capacitor C12 provides local bypassing for U1. Diode D2 charges the PFC output capacitor (C14) when AC is first applied, routing the inrush current away from PFC inductor L2 and the internal output diode of U1. Capacitor C13 and R15-16 are used to reduce the length of the high frequency loop around components U1 and C14, reducing EMI. The resistors in series with C13 damp mid-band EMI peaks. The incoming AC is rectified by BR1 and filtered by C9. Capacitor C9 was selected as a low-loss polypropylene type to provide the high instantaneous current through L2 during U1 ontime. Thermistor RT1 limits inrush current at startup. 4.4 Primary Bias Supply / Start-up Components R5-7, R8-R9, Q1, and VR3 provide startup bias for U1. Once U1 starts, components D1, D3, and, C3-5 generate a primary-referred bias supply via a winding on PFC choke L2. This is used to power both the PFC and LLC stages of the power supply. Once the primary bias supply voltage is established, it is used to turn off MOSFET Q1 via diode D6, reducing power consumption. Resistors R8 and R9 protect Q1 from excessive power dissipation if the power supply fails to start. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 10 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Components D7, Q2, C16-17 and VR2 regulate the bias supply voltage for U1 and U3. Components D4 and D5 and C6-8 generate a bias supply for the secondary control circuitry via a triple insulated winding on L2. 4.5 LLC Converter The schematic in Figures 4 depicts a ~43 V, 150 W LLC DC-DC converter with constant current output implemented using the LCS702HG. 4.6 Primary Integrated circuit U3 incorporates the control circuitry, drivers and output MOSFETs necessary for an LLC resonant half-bridge (HB) converter. The HB output of U3 drives output transformer T1 via a blocking/resonating capacitor (C30). This capacitor was rated for the operating ripple current and to withstand the high voltages present during fault conditions. Transformer T1 was designed for a leakage inductance of 49 H. This, along with resonating capacitor C30, sets the primary series resonant frequency at ~259 kHz according to the equation: fR 1 6.28 LL CR Where fR is the series resonant frequency in Hertz, LL is the transformer leakage inductance in Henries, and CR is the value of the resonating capacitor (C30) in Farads. The transformer turns ratio was set by adjusting the primary turns such that the operating frequency at nominal input voltage and full load is close to, but slightly less than, the previously described resonant frequency. An operating frequency of 250 kHz was found to be a good compromise between transformer size, output filter capacitance (enabling ceramic/film capacitors), and efficiency. The number of secondary winding turns was chosen to provide a good compromise between core and copper losses. AWG #44 Litz wire was used for the primary and AWG #42 Litz wire, for the secondary, this combination providing high-efficiency at the operating frequency (~250 kHz). The number of strands within each gauge of Litz wire was chosen in order to achieve a balance between winding fit and copper losses. The core material selected was PW4 (from Itacoil). This material provided good (low loss) performance. Page 11 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Components D9, R35, and C28 comprise the bootstrap circuit to supply the internal highside driver of U3. Components R34 and C25 provide filtering and bypassing of the +12 V input and the VCC supply for U1. Note: VCC voltage of >15 V may damage U3. Voltage divider resistors R26-29 set the high-voltage turn-on, turn-off, and overvoltage thresholds of U3. The voltage divider values are chosen to set the LLC turn-on point at 360 VDC and the turn-off point at 285 VDC, with an input overvoltage turn-off point at 473 VDC. Built-in hysteresis sets the input undervoltage turn-off point at 280 VDC. Capacitor C29 is a high-frequency bypass capacitor for the +380 V input, connected with short traces between the D and S1/S2 pins of U3. Series resistors R41-42 provide EMI damping. Capacitor C31 forms a current divider with C30, and is used to sample a portion of the primary current. Resistor R40 senses this current, and the resulting signal is filtered by R39 and C27. Capacitor C31 should be rated for the peak voltage present during fault conditions, and should use a stable, low-loss dielectric such as metalized film, SL ceramic, or NPO/COG ceramic. The capacitor used in the RD-382 was a ceramic disc with "SL" temperature characteristic, commonly used in the drivers for CCFL tubes. The values chosen set the 1 cycle (fast) current limit at 4.25 A, and the 7-cycle (slow) current limit at 2.35 A, according to the equation: I CL 0 .5 C 31 R 40 C 30 C 31 ICL is the 7-cycle current limit in Amperes, R40 is the current limit resistor in Ohms, and C30 and C31 are the values of the resonating and current sampling capacitors in nanofarads, respectively. For the one-cycle current limit, substitute 0.9 V for 0.5 V in the above equation. Resistor R39 and capacitor C27 filter primary current signal to the IS pin. Resistor R39 is set to 220 the minimum recommended value. The value of C27 is set to 1 nF to avoid nuisance tripping due to noise, but not so high as to substantially affect the current limit set values as calculated above. These components should be placed close to the IS pin for maximum effectiveness. The IS pin can tolerate negative currents, the current sense does not require a complicated rectification scheme. The Thevenin equivalent combination of R33 and R38 sets the dead time at 330 ns and maximum operating frequency for U3 at 847 kHz. The DT/BF input of U3 is filtered by Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 12 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply C23. The combination of R33 and R38 also selects burst mode "1" for U3. This sets the lower and upper burst threshold frequencies at 382 kHz and 437 kHz, respectively. The FEEDBACK pin has an approximate characteristic of 2.6 kHz per A into the FEEDBACK pin. As the current into the FEEDBACK pin increases so does the operating frequency of U3, reducing the output voltage. The series combination of R30 and R31 sets the minimum operating frequency for U3 at ~160 kHz. This value was set to be slightly lower than the frequency required for regulation at full load and minimum bulk capacitor voltage. Resistor R30 is bypassed by C21 to provide output soft start during start-up by initially allowing a higher current to flow into the FEEDBACK pin when the feedback loop is open. This causes the switching frequency to start high and then decrease until the output voltage reaches regulation. Resistor R31 is typically set at the same value as the parallel combination of R33 and R38 so that the initial frequency at soft-start is equal to the maximum switching frequency as set by R33 and R38. If the value of R31 is less than this, it will cause a delay before switching occurs when the input voltage is applied. Optocoupler U4 drives the U3 FEEDBACK pin through R32, which limits the maximum optocoupler current into the FEEDBACK pin. Capacitor C26 filters the FEEDBACK pin. Resistor R36 loads the optocoupler output to force it to run at a relatively high quiescent current, increasing its gain. Resistors R32 and R36 also improve large signal step response and burst mode output ripple. Diode D10 isolates R36 from the FMAX/soft start network. 4.7 Output Rectification The output of transformer T1 is rectified and filtered by D11 and C34-35. These capacitors have a polyester dielectric, chosen for output ripple current rating. Output rectifier D11 is a 150 V Schottky rectifier chosen for high efficiency. Intertwining the transformer secondary halves (see transformer construction details in section 8) reduces leakage inductance between the two secondary halves, reducing the worst-case peak inverse voltage and allowing use of a 150V Schottky diode with consequent higher efficiency. Additional output filtering is provided by L3 and C36. Capacitor C36 also damps the LLC output impedance peak at ~30 kHz caused by the LLC "virtual" output series R-L and output capacitors C34-35. 4.8 Output Current and Voltage Control Output current is sensed via resistors R52 and R53. These resistors are clamped by diode D13 to avoid damage to the current control circuitry during an output short circuit. Components R45 and U2 provide a voltage reference for current sense amplifier U5. The reference voltage is divided down by R46-47 and R50, and filtered by C39. Voltage from the current sense resistor is filtered by R51 and C41 and applied to the non-inverting input of U5. Opamp U5 drives optocoupler U4 via D12 and R25. Components R25, R44, R51, C38, and C41 are used for frequency compensation of the current loop. Page 13 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Components VR1 and R43 provide output voltage sensing to protect the power supply in case the output load is removed. These components were selected using a relatively large value for R43 and a relatively low voltage for VR1 to provide a soft voltage limiting characteristic. This helps prevent oscillation at the knee of the V-I curve and improves the startup characteristics of the supply into the specified LED load. Components J3, Q3-4, R48-49, R54-55, R46, and C40 are used to provide a remote dimming capability. A dimming voltage at J3 is converted to a current by R54 and R55 and applied to R46 via current mirror Q3-Q4. This current pulls down on the reference voltage to current sense amplifier U5 and reduces the programmed output current. A dimming voltage of 0-10 VDC provides an output current range of 100% at 0 V to ~20% at 10 VDC input. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 14 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 5 PCB Layout Figure 5 - Printed Circuit Layout, Top Side. Page 15 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Figure 6 - Printed Circuit Layout, Bottom Side. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 16 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 6 Bill of Materials Item Qty Ref Des Description Mfg Part Number Mfg 1 1 BR1 600 V, 8 A, Bridge Rectifier, GBU Case 2 1 C1 470 nF, 275 VAC, Film, X2 PX474K31D5 GBU8J-BP Micro Commercial Carli 3 1 220 nF, 275 VAC, Film, X2 ECQ-U2A224ML Panasonic 4 7 100 nF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB104 Yageo 5 2 C2 C3 C4 C6 C7 C37 C39 C40 C5 C8 1 F, 100 V, Ceramic, X7R, 1206 HMK316B7105KL-T Taiyo Yuden 6 1 C9 470 nF, 450 V, METALPOLYPRO ECW-F2W474JAQ Panasonic 7 1 C10 22 nF, 50 V, Ceramic, X7R, 0805 ECJ-2VB1H223K Panasonic 8 1 C11 1 nF, 200 V, Ceramic, X7R, 0805 08052C102KAT2A AVX 9 1 C12 3.3 F, 25 V, Ceramic, X7R, 0805 C2012X7R1E335K TDK 10 1 C13 22 nF, 630 V, Ceramic, X7R, 1210 GRM32QR72J223KW01L Murata 11 1 C14 120 F, 450 V, Electrolytic, 20 %, (18 x 37mm) 450BXW120MEFC18X35 Rubycon 12 1 C15 47 nF, 200 V, Ceramic, X7R, 1206 13 1 C16 47 F, 50 V, Electrolytic, 20 %, (6.3 x 12.5 mm) 14 2 C17 C19 15 1 C18 16 1 C20 12062C473KAT2A AVX 50YXM47MEFC6.3X11 Rubycon 2.2 F, 25 V, Ceramic, X7R, 0805 C2012X7R1E225M TDK 22 nF 50 V, Ceramic, X7R, 0603 C1608X7R1H223K TDK 47 nF, 50 V, Ceramic, X7R, 0805 GRM21BR71H473KA01L Murata 17 1 C21 330 nF, 50 V, Ceramic, X7R, 0805 GRM219R71H334KA88D Murata 18 1 C22 33 nF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB333 Yageo 19 3 C23 C26 C41 20 2 C24 C25 4.7 nF, 200 V, Ceramic, X7R, 0805 08052C472KAT2A AVX 1 F, 25 V, Ceramic, X7R, 1206 C3216X7R1E105K TDK 21 1 C27 1 nF, 200 V, Ceramic, X7R, 0805 08052C102KAT2A AVX 22 1 C28 330 nF, 50 V, Ceramic, X7R FK24X7R1H334K TDK 23 1 C29 47 nF, 630 V, Film MEXPD24704JJ Duratech 24 1 C30 8.2 nF, 1000V VDC, Film B32671L0822J000 Epcos 25 1 C31 47 pF, 1 kV, Disc Ceramic DEA1X3A470JC1B Murata 08052C223KAT2A AVX 440LD22-R Vishay B32560J475K Epcos EEU-FR1J121LB Panasonic 08052C103KAT2A AVX Kang Yang Hardware Enterprise 26 1 C32 22 nF, 200 V, Ceramic, X7R, 0805 27 1 C33 2.2 nF, Ceramic, Y1 28 2 C34 C35 29 1 C36 30 1 C38 31 2 CLIP_LCS_PFS1 CLIP_LCS_PFS2 32 8 4.7 F, 63 V, Polyester Film 120 F, 63 V, Electrolytic, Gen. Purpose, (8 x 22) 10 nF, 200 V, Ceramic, X7R, 0805 Heat sink Hardware, Clip LCS_II/PFS EM-285V0 33 1 D1 D3 D4 D5 D6 D7 D10 D12 D2 1000 V, 3 A, Recitifier, DO-201AD 1N5408-T Diodes, Inc. 34 1 D8 75 V, 200 mA, Rectifier, SOD323 BAS16HT1G ON Semi 35 1 D9 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 UF4005-E3 Vishay 36 1 D11 DSSK 20-015A IXYS 37 1 D13 DL4002-13-F Diodes, Inc. 38 1 F1 150 V, 20 A, Schottky, TO-220AB 100 V, 1 A, Rectifier, Glass Passivated, DO213AA (MELF) 5 A, 250V, Slow, TR5 37215000411 Wickman 39 1 HS1 HEAT SINK, Custom, Al, 3003, 0.062" Thk 40 1 HS2 HEAT SINK, Custom, Al, 3003, 0.062" Thk 41 1 J1 3 Position (1 x 3) header, 0.156 pitch, Vertical B3P-VH JST 42 1 J2 4 Position (1 x 4) header, 0.156 pitch, Vertical 26-48-1045 Molex 43 1 J3 2 Position (1 x 2) header, 0.1 pitch, Vertical 44 3 JP1 JP2 JP3 Page 17 of 82 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 0 , 5%, 1/4 W, Thick Film, 1206 BAV19WS-7-F Diodes, Inc. Custom Custom 22-23-2021 Molex ERJ-8GEY0R00V Panasonic Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 0 , 5%, 1/8 W, Thick Film, 0805 28-Jun-17 45 2 JP4 JP5 46 1 JP6 Wire Jumper, Insulated, TFE, #18 AWG, 1.4 in ERJ-6GEY0R00V C2052A-12-02 Panasonic Alpha 47 1 JP7 Wire Jumper, Non insulated, #22 AWG, 0.7 in 298 Alpha 48 1 JP8 Wire Jumper, Non insulated, #22 AWG, 0.3 in 49 1 JP9 Wire Jumper, Insulated, #24 AWG, 0.9 in 50 1 JP10 51 1 JP11 52 2 JP12 JP15 Wire Jumper, Non insulated, #22 AWG, 0.5 in 53 1 JP13 Wire Jumper, Insulated, #24 AWG, 0.8 in 54 1 JP14 Wire Jumper, Insulated, #24 AWG, 0.5 in 55 1 L1 56 1 L2 57 1 L3 58 1 59 4 60 1 L4 POST1 POST2 POST3 POST4 Q1 61 3 Q2 Q3 Q4 62 1 R1 63 3 R2 R3 R4 64 3 R5 R6 R7 65 2 R8 R9 66 3 R10 R11 R17 67 1 68 1 69 298 Alpha C2003A-12-02 Gen Cable Wire Jumper, Non insulated, #22 AWG, 0.6 in 298 Alpha Wire Jumper, Non insulated, #22 AWG, 0.8 in 298 Alpha 9 mH, 5 A, Common Mode Choke Custom, RD-382 PFC Choke, 437 uH, PQ32/30, Vertical, 9 pins Output Inductor, Custom, 300 nH, 15%, constructed on Micrometals T30-26 toroidal core 150 H, 3.4 A, Vertical Toroidal Post, Circuit Board, Female, Hex, 6-32, snap, 0.375L, Nylon 400 V, 2 A, 4.4 Ohm, 600 V, N-Channel, DPAK NPN, Small Signal BJT, GP SS, 40 V, 0.6 A, SOT-23 4.7 , 2 W, Flame Proof, Pulse Withstanding, Wire Wound 680 k, 5%, 1/4 W, Thick Film, 1206 298 Alpha C2003A-12-02 Gen Cable C2003A-12-02 Gen Cable T22148-902S P.I. Custom Fontaine Power Integrations Power Integrations 2114-V-RC Bourns 561-0375A Eagle Hardware IRFRC20TRPBF Vishay MMBT4401LT1G Diodes, Inc. WHS2-4R7JA25 IT Elect_Welwyn ERJ-8GEYJ684V Panasonic 1.3 M, 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ135V Panasonic 7.5 k, 5%, 1 W, Metal Oxide RSF100JB-7K5 Yageo 1.50 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1504V Panasonic R12 1 M, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1004V Panasonic R13 49.9 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4992V Panasonic 1 R14 100 k, 1%, 1/4 W, Metal Film MFR-25FBF-100K Yageo 70 3 R15 R16 R34 4.7 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ4R7V Panasonic 71 1 R18 787 k, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF7873V Panasonic 72 1 R19 1.60 M, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF1604V Panasonic 73 1 R20 39 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ393V Panasonic 74 1 R21 6.2 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ622V Panasonic 75 1 R22 487 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF4873V Panasonic 76 1 R23 60.4 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF6042V Panasonic 77 1 R24 3 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ302V Panasonic 78 3 R25 R32 R37 1 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ102V Panasonic 79 3 R26 R27 R28 976 k, 1%, 1/4 W, Thick Film, 1206 ERJ-8ENF9763V Panasonic 80 1 R29 19.6 k, 1%, 1/16 W, Thick Film, 0603 ERJ-3EKF1962V Panasonic 81 1 R30 46.4 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF4642V Panasonic 82 1 R31 5.76 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF5761V Panasonic 83 1 R33 6.81 k, 1%, 1/4 W, Metal Film MFR-25FBF-6K81 Yageo 84 1 R35 2.2 , 5%, 1/4 W, Carbon Film CFR-25JB-2R2 Yageo 85 3 R36 R44 R45 4.7 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ472V Panasonic 86 1 R38 127 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1273V Panasonic 87 1 R39 220 , 5%, 1/10 W, Thick Film, 0603 ERJ-3GEYJ221V Panasonic 88 1 R40 36 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ360V Panasonic 89 2 R41 R42 1 , 5%, 1/4 W, Thick Film, 1206 ERJ-8GEYJ1R0V Panasonic 90 1 R43 CFR-25JB-10K Yageo 91 2 R46 R50 ERJ-6ENF1002V Panasonic 10 k, 5%, 1/4 W, Carbon Film 10 k, 1%, 1/8 W, Thick Film, 0805 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 18 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 92 1 R47 121 k, 1%, 1/8 W, Thick Film, 0805 ERJ-6ENF1213V Panasonic 93 2 R48 R49 100 , 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ101V Panasonic 94 1 R51 20 k, 5%, 1/8 W, Thick Film, 0805 ERJ-6GEYJ203V Panasonic 95 2 R52 R53 0.1 , 5%, 2 W, Thick Oxide MO200J0R1B Synton-Tech 96 2 R54 R55 24.9 k, 1%, 1/8 W, Thick Film, 0805 97 1 98 4 99 1 100 4 101 2 RT1 RTV1 RTV2 RTV3 RTV4 RV1 SCREW1 SCREW2 SCREW3 SCREW4 SPACER_CER1 SPACER_CER2 102 1 103 2 TP1 TP3 104 4 TP2 TP4 TP5 TP6 T1 NTC Thermistor, 2.5 , 5 A Thermally conductive Silicone Grease 320 V, 80 J, 14 mm, RADIAL SCREW MACHINE PHIL 6-32 X 5/16 SS SPACER RND, Steatite C220 Ceramic Integrated Resonant Transformer, Horizontal, 8 pins Test Point, RED, THRU-HOLE MOUNT Test Point, BLK, THRU-HOLE MOUNT 105 1 U1 HiperPFS-2, ESIP16/13 106 1 U2 IC, REG ZENER SHUNT ADJ SOT-23 107 1 U3 HiperLCS, ESIP16/13 ERJ-6ENF2492V Panasonic SL10 2R505 Ametherm 120-SA Wakefield V320LA20AP Littlefuse PMSSS 632 0031 PH Building Fasteners CER-2 Richco TRLEV25043A Itacoil 5010 Keystone 5011 Keystone PFS7326H Power Integrations LM431AIM3/NOPB National Semi LCS702HG Power Integrations 108 1 U4 Optocoupler, 80 V, CTR 80-160%, 4-Mini Flat 109 1 U5 OP AMP SINGLE LOW PWR SOT23-5 110 1 VR1 39 V, 5%, 500 mW, DO-35 111 1 VR2 12 V, 5%, 500 mW, DO-213AA (MELF) 112 1 18 V, 5%, 500 mW, DO-213AA (MELF) ZMM5248B-7 Diodes, Inc. 114 4 VR3 WASHER1 WASHER2 WASHER3 WASHER4 620-6Z Olander Page 19 of 82 Washer Flat #6, SS, Zinc Plate, 0.267 OD x 0.143 ID x 0.032 Thk PC357N1TJ00F Sharp LM321MF National Semi 1N5259B-T Diodes, Inc. ZMM5242B-7 Diodes, Inc. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 7 LED Panel Characterization A commercial 150 W LED streetlight was used to test the RD-382 power supply. The LED array consisted of (6) 7 X 4 panels, as 4 wide, 7 deep. For the purposes of testing, the six panels were connected in series-parallel, resulting in an LED array 12 wide, 14 deep (see Figures 8 and 9). The V-I characteristic of the LED panels connected in this manner is shown below in Figure 7. 45 44 Voltage Drop (V) 43 42 41 40 39 38 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 Current (A) Figure 7 - Streetlight LED Array V-I Characteristic. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 20 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 7.1 LED Panel Current Sharing For the purpose of this report, the six LED panels in the street light were partitioned into 3 sections, each section consisting of two LED panels in series. Each panel was internally connected as an array of LEDs 4 wide and 7 deep so that two panels connected in series consisted of an array of LEDS 4 wide by 14 deep. The three sections were connected in parallel, forming a total LED load 12 wide and 14 deep. Using a DC current probe, the current in each 4 wide by 14 deep section was measured to determine the current distribution between sections, with results shown below. 1 2 3 Figure 8 - LED Test Panel Layout. Section # Current (A) Figure 9 - Array of LEDs in Each Test Panel. 1 1.113 A 2 1.159 A 3 1.126 A Maximum difference between sections was <5%. Page 21 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 7.2 Constant Voltage Load Since this power supply has a constant current output tailored for a relatively fixed constant voltage load, the usual constant current electronic load cannot be used for testing. For bench testing at maximum power, a constant resistance load can be used, set such that the supply output is at maximum current and an output voltage of 43-44 V, as indicated by the V-I curve shown in Figure 7. Other testing, including dimming and gain-phase, will require the actual LED load or a constant voltage load that closely mimics its characteristics. The streetlight LED as a load was both large and heavy. In order to facilitate EMI and surge testing, a constant voltage load was constructed to emulate the behavior of the LED array in a much smaller package. The circuit is shown in Figure 8. The load consists of paralleled power Darlington transistors Q1-5, each with an emitter resistor (R1-5) to facilitate current sharing. Base resistors R6-10 help prevent oscillation. A string of thirteen 3 mm blue LEDs (D1-13) are used as a voltage reference to mimic the characteristics of the LED panel. Resistor R11 is adjusted to vary the voltage at which the load turns on to match the characteristics of the LED panel. Resistors R12-14 add extra impedance in series with the load to approximate the characteristics of the LED panel. The completed array with heat sink is shown in Figure 9. A small fan was used to cool the heat sink when the load was operated for extended periods at full power. The V-I characteristics of the CV load are shown superimposed on those of the LED array in Figure 10. An electronic load with appropriate rating and a constant voltage option (with some series resistance) could also be used for testing, but this load has the advantage that no external AC power is needed. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 22 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Figure 10 - Constant Voltage Load Schematic. Page 23 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Figure 11 - Constant Voltage Load with Heat Sink. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 24 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 46 LED Load CV Load Voltage Load (V) 44 42 40 38 36 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 Current (A) Figure 12 - Comparison of Streetlight LED Array V-I Characteristic with CV Load. Page 25 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 4.0 RDR-382, 150 W Street Light Power Supply 28-Jun-17 8 Magnetics 8.1 PFC Choke (L2) Specification 8.1.1 Electrical Diagram Figure 13 - PFC Choke Electrical Diagram. 8.1.2 Electrical Specifications Inductance Resonant Frequency Pins 1-3 measured at 100 kHz, 0.4 VRMS. Pins 1-3. N/A 437 H +5% kHz (Min.) 8.1.3 Materials Item [1] [2] [3] [4] [5] [6] [7] Description Core: TDK Core: PC44PQ32/20Z, gap for ALG of 130 nH/T2. Bobbin: BPQ32/20-112CPFR - TDK. Litz Wire: 30 x #38 AWG Single Coated Solderable, Served. Tape, Polyester Film: 3M 1350-F1 or equivalent, 9.0 mm wide. Magnet Wire, 30 AWG, Solderable Double Coated. Triple Insulated Wire, 30 AWG, Furukawa TEX-E or equivalent. Varnish: Dolph BC-359, or equivalent. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 26 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 8.1.4 Build Diagram Figure 14 - PFC Inductor Build Diagram. 8.1.5 Winding Instructions Winding Preparation Winding #1 Insulation Winding #2 Winding #3 Insulation Final Assembly Page 27 of 82 Place the bobbin on the mandrel with the pin side is on the left side. Winding direction is clockwise direction. Starting at pin 3, wind 58 turns of Litz wire item [3], finish at pin 1. Apply one layer of tape item [4] Starting at pin 11, wind 3 bifilar turns of wire, item [5]. Spread turns evenly across bobbin window. Finish at Pin 12. Starting at pin 8, wind 2 bifilar turns of wire, item [6], directly on top of previous winding. Spread turns evenly across bobbin window. Finish at pin 7. Apply 3 layers of tape item [4]. Grind core to specified inductance. Secure core halves with tape. Remove pins 2, 4, and 9. Dip varnish with item [7]. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 8.1.6 Winding Illustrations Winding Preparation Place the bobbin on the mandrel with the pin side is on the left side. Winding direction is clockwise direction Winding #1 Starting at pin 3, wind 58 turns with 30x #38 served Litz wire, item [3]. Insulation Apply 1 layer of insulating tape, item [4]. Terminate wire at pin 1 Winding #2 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Starting at pin 11, wind 3 bifilar turns with #30 AWG double coated wire, item [5]. Page 28 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Terminate wire at pin 12. Do not apply insulating tape to this winding. Winding #3 Insulation Starting at pin 8, wind 2 bifilar turns with #30 AWG triple insulated wire, item [6]. Apply 3 layers of insulating tape, item [4]. Terminate wire at pin 7 Solder Terminations Page 29 of 82 Solder all wire terminations at pins 1, 3, 7, 8, 11, and 12 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Core Grinding Grind core for specified inductance. Final Assembly Secure core halves with tape. Remove pins 2, 4, and 9. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 30 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 8.2 LLC Transformer (T1) Specification 8.2.1 Electrical Diagram 3 5 WD1: 29T - 125/#44AWG Served Litz 1 WD2A: 6T - 165/#42AWG Unserved Litz 7 6 WD2B: 6T - 165/#42AWG Unserved Litz 8 Figure 15 - LLC Transformer Schematic. 8.2.2 Electrical Specifications Electrical Strength Primary Inductance Resonant Frequency Primary Leakage Inductance 1 second, 60 Hz, from pins 1-3 to pins 5-8. Pins 1-3, all other windings open, measured at 100 kHz, 0.4 VRMS. Pins 2-5, all other windings open. Pins 1-5, with pins 5-8 shorted, measured at 100 kHz, 0.4 VRMS. 3000 VAC 340 H 10% 1800 kHz (Min) 49 H 5% 8.2.3 Materials Item [1] [2] [3] [4] [5] [6] [7] [8] Description Core Pair: Itacoil NFEV25A, PW4 material, gap for ALG of 404 nH/T2. Bobbin: Itacoil RCEV25A. Bobbin Cover, Itacoil GSEV25A. Tape: Polyester Film, 3M 1350F-1 or equivalent, 12 mm wide. Litz wire: 165/#42 Single Coated, Unserved. Litz wire: 125/#44 Single Coated, Served. Copper Tape, 3M-1181; or equivalent, 10 mm wide. Wire, 20 AWG, Black, Stranded, UL 1015 Alpha 3073 BK or equivalent. Page 31 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 8.2.4 Build Diagram 8 7 WD2A: 6T - 165/#42 Unserved Litz ..is twisted and wound in parallel with... 1 WD1: 29T - 125/#44 Served Litz WD2B: 6T - 165/#42 Unserved Litz 6 5 3 Figure 16 - LLC Transformer Build Diagram. 8.2.5 Winding Instructions Secondary Wire Preparation WD1 (Primary) WD2A & WD2B (Secondary) Bobbin Cover Finish Prepare 2 strands of wire item [5] 12" length, tin ends. Label one strand to distinguish from other and designate it as FL1, FL2. Other strand will be designated as FL3 and FL4. Twist these 2 strands together ~20 twists evenly along length leaving 1" free at each end. See pictures below. Place the bobbin item [2] on the mandrel with primary chamber on the left side. Note: primary chamber is wider than secondary chamber. Starting on pin 3, wind 29 turns of served Litz wire item [6] in 5 layers, and finish on Pin 1. Using unserved Litz assembly prepared in step 1, start with FL1 on pins 5 and FL3 on pin 6, tightly wind 6 turns in secondary chamber. Finish with FL2 on pin 6 and FL4 on pin 8. Slide bobbin cover [3] into grooves in bobbin flanges as shown. Make sure cover is securely seated. Remove pins 2, 4 of bobbin. Grind core halves [1] for specified inductance. Assemble and secure core halves using circumferential turn of copper tape [7] as shown, overlap ends, and solder. Solder 3" termination lead of stranded wire item [8] to core band close to pin 4 as shown, secure with two turns of tape item [4]. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 32 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 8.2.6 Winding Illustrations FL1 FL2 FL3 Secondary Wire Preparation FL4 FL1 FL4 Prepare 2 strands of wire item [7] 12" length, tin ends. Label one strand to distinguish from other and designate it as FL1, FL2. Other strand will be designated as FL3 and FL4. Twist these 2 strands together ~20 twists evenly along length leaving 1" free at each end. FL2 FL3 WD1 (Primary) WD1 (Primary) (Cont'd) Page 33 of 82 Place the bobbin item [2] on the mandrel with primary chamber on the left side. Note: primary chamber is wider than secondary chamber. Starting on pin 3, Wind 29 turns of served Litz wire item [6] in 5 layers, and finish on pin 1. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply WD2A & WD2B (Secondary) Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 28-Jun-17 Using unserved Litz assembly prepared in step 1, start with FL1 on pins 5 and FL3 on pin 6, tightly wind 6 turns in secondary chamber. Finish with FL2 on pin 6 and FL4 on pin 8. Page 34 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Bobbin Cover Slide bobbin cover [3] into grooves in bobbin flanges as shown. Make sure cover is securely seated. Finish Remove pins 2, 4 of bobbin. Grind core halves [1] for specified inductance. Assemble and secure core halves using circumferential turn of copper tape [7] as shown, overlap ends, and solder. Solder 3" termination lead of stranded wire item [8] to core band close to pin 4 as shown, secure with two turns of tape item [4]. Page 35 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 28-Jun-17 Page 36 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 8.3 Output Inductor (L3) Specification 8.3.1 Electrical Diagram FL1 3T - 19AWG FL2 Figure 17 - Inductor Electrical Diagram. 8.3.2 Electrical Specifications Inductance Pins FL1-FL2, all other windings open, measured at 100 kHz, 0.4 VRMS. 300 nH, 15% 8.3.3 Material List Item [1] [2] Description Powdered Iron Toroidal Core: Micrometals T30-26. Magnet wire: #19 AWG Solderable Double Coated. 8.3.4 Construction Details Figure 16 - Finished Part, Front View. Tin Leads to within ~ 1/8" of Toroid Body. Page 37 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 9 PFC Design Spreadsheet In this design, the spreadsheet generated warnings concerning the high value of KP selected, and for the operating current density of the Litz wire size selected for this design. A high KP value can impact power factor and distortion, so a design generating this warning should be checked for any adverse impact. This design met the requirements for power factor and harmonic distortion, and the high KP value allowed selection of a ferrite core for the PFC inductor, with consequent efficiency improvement. A warning for current density indicates that the design should be checked in its initial stages for excessive temperature rise in the PFC inductor. The guidelines incorporated the spreadsheet are conservative, so that a warning does not necessarily mean that a given design will fail thermally. The measured temperature rise for this design was satisfactory. Hiper_PFSII_Boost_062013; Rev.1.1; Copyright INPUT Power Integrations 2013 Enter Applications Variables Input Voltage Range VACMIN VACMAX VBROWNIN VBROWNOUT VO PO 160.00 fL TA Max INFO OUTPUT Universal 90 265 76.69 68.33 385.00 160.00 50 40 n UNITS V V V V W Hz deg C 0.93 KP 0.750 VO_MIN VO_RIPPLE_MAX tHOLDUP Warning 0.75 365.75 20 18 V V ms VHOLDUP_MIN 310 V I_INRUSH 40 A 18.00 Forced Air Cooling no no PFS Parameters PFS Part Number PFS7326H PFS7326H EFFICIENCY EFFICIENCY MODE R_RPIN 49.9 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com k-ohms Hiper_PFS-II_Boost_062013_Rev11.xls; Continuous Mode Boost Converter Design Spreadsheet Input voltage range Minimum AC input voltage Maximum AC input voltage Expected Minimum Brown-in Voltage Specify brownout voltage. Nominal Output voltage Nominal Output power Line frequency Maximum ambient temperature Enter the efficiency estimate for the boost converter at VACMIN !!!Warning. KP is too high. Reduce KP to below 0.675 for Ferrite cores and to below 0.8 for other core types Minimum Output voltage Maximum Output voltage ripple Holdup time Minimum Voltage Output can drop to during holdup Maximum allowable inrush current Enter "Yes" for Forced air cooling. Otherwise enter "No" Selected PFS device Mode of operation of PFS. For full mode enter "FULL" otherwise enter "EFFICIENCY" to indicate efficiency mode R pin resistor value Page 38 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply C_RPIN IOCP min IOCP typ IOCP max RDSON RV1 RV2 RV3 C_VCC R_VCC C_V C_C Power good Vo lower threshold VPG(L) PGT set resistor 1.00 6.80 7.20 7.50 0.62 1.50 1.50 1.00 3.30 15.00 22.00 22.00 nF A A A ohms Mohms Mohms Mohms uF ohms nF nF 333.00 V 103.79 kohm FS_PK 60.2 kHz FS_AVG 50.2 kHz IP PFS_IRMS PCOND_LOSS_PFS PSW_LOSS_PFS PFS_TOTAL TJ Max 3.97 1.67 1.73 0.78 2.51 100 A A W W W deg C Rth-JS 3.00 degC/W HEATSINK Theta-CA Basic Inductor Calculation 15.30 degC/W LPFC 437 uH LPFC (0 Bias) 437 uH 5 % 1.97 A LP_TOL 5.00 LPFC_RMS Inductor Construction Parameters Core Type Ferrite Ferrite Core Material Auto PC44 Core Geometry Auto PQ PQ32/20 PQ32/20 170 55.5 6530 9.44 5.12 67.1 8.98 58 2.06 1.97 Core AE LE AL VE HT MLT BW NL LG ILRMS Wire type Page 39 of 82 LITZ LITZ mm^2 mm nH/t^2 cm^3 mm cm mm mm A R pin capacitor value Minimum Current limit Typical current limit Maximum current limit Typical RDSon at 100 'C Line sense resistor 1 Line sense resistor 2 Line sense resistor 3 Supply decoupling capacitor VCC resistor V pin decoupling capacitor Feedback C pin decoupling capacitor Power good Vo lower threshold voltage Power good threshold setting resistor Estimated frequency of operation at crest of input voltage (at VACMIN) Estimated average frequency of operation over line cycle (at VACMIN) MOSFET peak current PFS MOSFET RMS current Estimated PFS conduction losses Estimated PFS switching losses Total Estimated PFS losses Maximum steady-state junction temperature Maximum thermal resistance (Junction to heatsink) Maximum thermal resistance of heatsink Value of PFC inductor at peak of VACMIN and Full Load Value of PFC inductor at No load. This is the value measured with LCR meter Tolerance of PFC Inductor Value Inductor RMS current (calculated at VACMIN and Full Load) Enter "Sendust", "Pow Iron" or "Ferrite" Select from 60u, 75u, 90u or 125 u for Sendust cores. Fixed at PC44 or equivalent for Ferrite cores. Fixed at 52 material for Pow Iron cores. Select from Toroid or EE for Sendust cores and from EE, or PQ for Ferrite cores Core part number Core cross sectional area Core mean path length Core AL value Core volume Core height/Height of window Mean length per turn Bobbin width Inductor turns Gap length (Ferrite cores only) Inductor RMS current Select between "Litz" or "Regular" for double coated magnet wire Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply AWG Filar OD 38 30 38 30 0.102 AC Resistance Ratio AWG mm 1.01 Warning J BP_TARGET BM BP LPFC_CORE_LOSS LPFC_COPPER_LOSS LPFC_TOTAL LOSS FIT Layers Critical Parameters IRMS IO_AVG Output Diode (DO) Part Number 28-Jun-17 Auto 8.11 A/mm^ 2 3500 Gauss 1757 3487 0.09 1.80 1.89 79.72% 5.1 Gauss Gauss W W W % 1.91 0.42 A A INTERNAL Type SPECIAL Manufacturer VRRM IF TRR VF PCOND_DIODE PSW_DIODE P_DIODE TJ Max PI 600 3 31 1.47 0.61 0.16 0.77 100 V A ns V W W W deg C Rth-JS 3.85 degC/W HEATSINK Theta-CA Output Capacitor CO 15.30 degC/W 120.00 uF VO_RIPPLE_EXPECTED 11.9 V T_HOLDUP_EXPECTED 19.5 ms ESR_LF ESR_HF IC_RMS_LF IC_RMS_HF 1.38 0.55 0.29 0.85 ohms ohms A A CO_LF_LOSS 0.12 W CO_HF_LOSS 0.39 W Total CO LOSS Input Bridge (BR1) and Fuse (F1) I^2t Rating Fuse Current rating VF IAVG 0.51 W 8.43 3.00 0.90 1.86 A^2s A V A Auto Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Inductor wire gauge Inductor wire number of parallel strands Outer diameter of single strand of wire Ratio of AC resistance to the DC resistance (using Dowell curves) !!! Warning Current density is too high and may cause heating in the inductor wire. Reduce J Target flux density at VACMIN (Ferrite cores only) Maximum operating flux density Peak Flux density (Estimated at VBROWNOUT) Estimated Inductor core Loss Estimated Inductor copper losses Total estimated Inductor Losses Estimated FIT factor for inductor Estimated layers in winding AC input RMS current Output average current PFC Diode Part Number Diode Type - Special - Diodes specially catered for PFC applications, SiC - Silicon Carbide type, UF - Ultrafast recovery type Diode Manufacturer Diode rated reverse voltage Diode rated forward current Diode Reverse recovery time Diode rated forward voltage drop Estimated Diode conduction losses Estimated Diode switching losses Total estimated Diode losses Maximum steady-state operating temperature Maximum thermal resistance (Junction to heatsink) Maximum thermal resistance of heatsink Minimum value of Output capacitance Expected ripple voltage on Output with selected Output capacitor Expected holdup time with selected Output capacitor Low Frequency Capacitor ESR High Frequency Capacitor ESR Low Frequency Capacitor RMS current High Frequency Capacitor RMS current Estimated Low Frequency ESR loss in Output capacitor Estimated High frequency ESR loss in Output capacitor Total estimated losses in Output Capacitor Minimum I^2t rating for fuse Minimum Current rating of fuse Input bridge Diode forward Diode drop Input average current at 70 VAC. Page 40 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply PIV_INPUT BRIDGE PCOND_LOSS_BRIDGE 375 3.10 V W CIN 0.47 uF 9.37 1N5407 ohms R1 1.50 Mohms R3 1.60 Mohms R2 787.00 kohms C1 R4 R6 R7 47.00 60.40 487.00 6.98 nF kohms kohms kohms C2 47.00 nF R5 C3 3.00 2.20 kohms uF D1 BAV116 RT D_Precharge Feedback Components Loss Budget (Estimated at VACMIN) PFS Losses Boost diode Losses Input Bridge losses Inductor losses Output Capacitor Loss Total losses 2.51 0.77 3.10 1.89 0.51 8.78 Efficiency 0.95 Page 41 of 82 W W W W W W Peak inverse voltage of input bridge Estimated Bridge Diode conduction loss Input capacitor. Use metallized polypropylene or film foil type with high ripple current rating Input Thermistor value Recommended precharge Diode Feedback network, first high voltage divider resistor Feedback network, third high voltage divider resistor Feedback network, second high voltage divider resistor Feedback network, loop speedup capacitor Feedback network, lower divider resistor Feedback network - pole setting resistor Feedback network - zero setting resistor Feedback component- noise suppression capacitor Damping resistor in serise with C3 Feedback network - compensation capacitor Feedback network - capacitor failure detection Diode Total estimated losses in PFS Total estimated losses in Output Diode Total estimated losses in input bridge module Total estimated losses in PFC choke Total estimated losses in Output capacitor Overall loss estimate Estimated efficiency at VACMIN. Verify efficiency at other line voltages Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 10 LLC Transformer Design Spreadsheet HiperLCS_040312; Rev.1.3; Copyright Power INPUTS INFO OUTPUTS UNITS Integrations 2012 Enter Input Parameters Vbulk_nom 380 V Vbrownout 287 287 V 362 476 459 V V V 120 uF tHOLDUP Enter LLC (secondary) outputs 23.8 ms VO1 43.00 43.0 V IO1 VD1 PO1 VO2 IO2 VD2 PO2 P_LLC LCS Device Selection Device RDS-ON (MAX) Coss Cpri Pcond_loss Tmax-hs 3.50 0.70 3.5 0.70 151 0.0 0.0 0.70 0.00 151 A V W V A V W W LCS702 LCS702 1.39 250 40 1.5 90 ohms pF pF W deg C Vbrownin VOV_shut VOV_restart CBULK 120.00 HiperLCS_040312_Rev1-3.xls; HiperLCS Half-Bridge, Continuous mode LLC Resonant Converter Design Spreadsheet Nominal LLC input voltage Brownout threshold voltage. HiperLCS will shut down if voltage drops below this value. Allowable value is between 65% and 76% of Vbulk_nom. Set to 65% for max holdup time Startup threshold on bulk capacitor OV protection on bulk voltage Restart voltage after OV protection. Minimum value of bulk cap to meet holdup time requirement; Adjust holdup time and Vbrownout to change bulk cap value Bulk capacitor hold up time The spreadsheet assumes AC stacking of the secondaries Main Output Voltage. Spreadsheet assumes that this is the regulated output Main output maximum current Forward voltage of diode in Main output Output Power from first LLC output Second Output Voltage Second output current Forward voltage of diode used in second output Output Power from second LLC output Specified LLC output power LCS Device RDS-ON (max) of selected device Equivalent Coss of selected device Stray Capacitance at transformer primary Conduction loss at nominal line and full load Maximum heatsink temperature Thermal resistance junction to heatsink (with grease and no Theta J-HS 9.1 deg C/W insulator) Expected Junction temperature 103 deg C Expectd Junction temperature Ta max 50 deg C Expected max ambient temperature Theta HS-A 27 deg C/W Required thermal resistance heatsink to ambient LLC Resonant Parameter and Transformer Calculations (generates red curve) Desired Input voltage at which power train operates at Vres_target 380 380 V resonance. If greater than Vbulk_nom, LLC operates below resonance at VBULK. Po 153 W LLC output power including diode loss Main Output voltage (includes diode drop) for calculating Nsec Vo 43.70 V and turns ratio Desired switching frequency at Vbulk_nom. 66 kHz to 300 kHz, f_target 250 kHz recommended 180-250 kHz Parallel inductance. (Lpar = Lopen - Lres for integrated Lpar 291 uH transformer; Lpar = Lmag for non-integrated low-leakage transformer) Primary open circuit inductance for integrated transformer; for low-leakage transformer it is sum of primary inductance and Lpri 341 uH series inductor. If left blank, auto-calculation shows value necessary for slight loss of ZVS at ~80% of Vnom Series inductance or primary leakage inductance of integrated Lres 50.00 50.0 uH transformer; if left blank auto-calculation is for K=4 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 42 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply Kratio Cres 5.8 8.20 8.2 nF Lsec 14.618 uH m 50 % n_eq 4.47 Npri 29.0 29.0 Nsec 6.0 6.0 Ratio of Lpar to Lres. Maintain value of K such that 2.1 < K < 11. Preferred Lres is such that K<7. Series resonant capacitor. Red background cells produce red graph. If Lpar, Lres, Cres, and n_RATIO_red_graph are left blank, they will be auto-calculated Secondary side inductance of one phase of main output; measure and enter value, or adjust value until f_predicted matches what is measured ; Leakage distribution factor (primary to secondary). >50% signifies most of the leakage is in primary side. Gap physically under secondary yields >50%, requiring fewer primary turns. Turns ratio of LLC equivalent circuit ideal transformer Primary number of turns; if input is blank, default value is autocalculation so that f_predicted = f_target and m=50% Secondary number of turns (each phase of Main output). Default value is estimate to maintain BAC<=200 mT, using selected core (below) Expected frequency at nominal input voltage and full load; Heavily influenced by n_eq and primary turns Series resonant frequency (defined by series inductance Lres and C) Expected switching frequency at Vbrownout, full load. Set HiperLCS minimum frequency to this value. Parallel resonant frequency (defined by Lpar + Lres and C) LLC full load gain inversion frequency. Operation below this frequency results in operation in gain inversion region. LLC full load gain inversion point input voltage f_predicted 227 kHz f_res 249 kHz f_brownout 155 kHz f_par 95 kHz f_inversion 135 kHz Vinversion Vres_expected RMS Currents and Voltages 247 390 V V IRMS_LLC_Primary 1.03 A Primary winding RMS current at full load, Vbulk_nom and f_predicted 2.8 A Winding 1 (Lower secondary Voltage) RMS current 1.8 A Lower Secondary Voltage Capacitor RMS current 0.0 A Winding 2 (Higher secondary Voltage) RMS current 0.0 A Higher Secondary Voltage Capacitor RMS current 88 V Resonant capacitor AC RMS Voltage at full load and nominal input voltage Winding 1 (Lower secondary Voltage) RMS current Lower Secondary Voltage Capacitor RMS current Winding 2 (Higher secondary Voltage) RMS current Higher Secondary Voltage Capacitor RMS current Cres_Vrms Virtual Transformer Trial - (generates blue curve) New primary turns 29.0 New secondary turns 6.0 New Lpri 341 uH New Cres 8.2 nF New estimated Lres 50.0 New estimated Lpar 291 New estimated Lsec 14.618 New Kratio 5.8 New equivalent circuit transformer turns ratio 4.47 V powertrain inversion new 247 f_res_trial 249 f_predicted_trial 227 IRMS_LLC_Primary 1.03 Page 43 of 82 uH uH uH V kHz kHz A Trial transformer primary turns; default value is from resonant section Trial transformer secondary turns; default value is from resonant section Trial transformer open circuit inductance; default value is from resonant section Trial value of series capacitor (if left blank calculated value chosen so f_res same as in main resonant section above Trial transformer estimated Lres Estimated value of Lpar for trial transformer Estimated value of secondary leakage inductance Ratio of Lpar to Lres for trial transformer Estimated effective transformer turns ratio Input voltage at LLC full load gain inversion point New Series resonant frequency New nominal operating frequency Primary winding RMS current at full load and nominal input Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply Winding 1 (Lower secondary Voltage) RMS current Lower Secondary Voltage Capacitor RMS current Winding 2 (Higher secondary Voltage) RMS current Higher Secondary Voltage Capacitor RMS current 28-Jun-17 voltage (Vbulk) and f_predicted_trial RMS current through Output 1 winding, assuming half sinusoidal waveshape 2.7 A 1.6 A Lower Secondary Voltage Capacitor RMS current 2.7 A RMS current through Output 2 winding; Output 1 winding is AC stacked on top of Output 2 winding 0.0 A Higher Secondary Voltage Capacitor RMS current Expected value of input voltage at which LLC operates at resonance. Transformer Core Calculations (Calculates From Resonant Parameter Section) Transformer Core Auto EEL25 Transformer Core Ae 0.76 0.76 cm^2 Enter transformer core cross-sectional area Ve 5.35 5.35 cm^3 Enter the volume of core Aw 107.9 mm^2 Area of window Bw 15.50 15.5 mm Total Width of Bobbin Enter the loss per unit volume at the switching frequency and Loss density 200.0 mW/cm^3 BAC (Units same as kW/m^3) MLT 5.20 5.2 cm Mean length per turn Nchambers 2 2 Number of Bobbin chambers Wsep 1.60 1.6 mm Winding separator distance (will result in loss of winding area) Ploss 1.1 W Estimated core loss Bpkfmin 155 mT First Quadrant peak flux density at minimum frequency. AC peak to peak flux density (calculated at f_predicted, Vbulk at BAC 211 mT full load) Primary Winding Npri 29.0 Number of primary turns; determined in LLC resonant section Primary gauge 44 AWG Individual wire strand gauge used for primary winding Equivalent Primary Metric Wire gauge 0.050 mm Equivalent diameter of wire in metric units Number of strands in Litz wire; for non-litz primary winding, set Primary litz strands 125 125 to 1 Primary window allocation factor - percentage of winding space Primary Winding Allocation Factor 50 % allocated to primary AW_P 48 mm^2 Winding window area for primary Fill Factor 25% % % Fill factor for primary winding (typical max fill is 60%) Resistivity_25 C_Primary 75.42 m-ohm/m Resistivity in milli-ohms per meter Primary DCR 25 C 113.73 m-ohm Estimated resistance at 25 C Estimated resistance at 100 C (approximately 33% higher than at Primary DCR 100 C 152.40 m-ohm 25 C) Primary RMS current 1.03 A Measured RMS current through the primary winding Measured AC resistance (at 100 kHz, room temperature), multiply ACR_Trf_Primary 259.81 m-ohm by 1.33 to approximate 100 C winding temperature Primary copper loss 0.27 W Total primary winding copper loss at 85 C Primary Layers 3.02 Number of layers in primary Winding Secondary Winding 1 (Lower secondary voltage OR Single Note - Power loss calculations are for each winding half of output) secondary Output Voltage 43.00 V Output Voltage (assumes AC stacked windings) Sec 1 Turns 6.00 Secondary winding turns (each phase ) RMS current through Output 1 winding, assuming half sinusoidal Sec 1 RMS current (total, AC+DC) 2.8 A waveshape Winding current (DC component) 1.75 A DC component of winding current Winding current (AC RMS component) 2.17 A AC component of winding current Sec 1 Wire gauge 42 AWG Individual wire strand gauge used for secondary winding Equivalent secondary 1 Metric Wire gauge 0.060 mm Equivalent diameter of wire in metric units Number of strands used in Litz wire; for non-litz non-integrated Sec 1 litz strands 165 165 transformer set to 1 Vres_expected_trial 390 V Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 44 of 82 28-Jun-17 Resistivity_25 C_sec1 DCR_25C_Sec1 RDR-382, 150 W Street Light Power Supply m-ohm/m Resistivity in milli-ohms per meter m-ohm Estimated resistance per phase at 25 C (for reference) Estimated resistance per phase at 100 C (approximately 33% DCR_100C_Sec1 15.02 m-ohm higher than at 25 C) Estimated Power loss due to DC resistance (both secondary DCR_Ploss_Sec1 0.37 W phases) Measured AC resistance per phase (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding ACR_Sec1 15.25 m-ohm temperature. Default value of ACR is twice the DCR value at 100 C ACR_Ploss_Sec1 0.14 W Estimated AC copper loss (both secondary phases) Total winding 1 Copper Losses 0.51 W Total (AC + DC) winding copper loss for both secondary phases Capacitor RMS current 1.8 A Output capacitor RMS current Co1 1.8 uF Secondary 1 output capacitor Capacitor ripple voltage 3.0 % Peak to Peak ripple voltage on secondary 1 output capacitor Schottky losses are a stronger function of load DC current. Sync Output rectifier RMS Current 2.8 A Rectifier losses are a function of RMS current Secondary 1 Layers 1.00 Number of layers in secondary 1 Winding Note - Power loss calculations are for each winding half of Secondary Winding 2 (Higher secondary voltage) secondary Output Voltage 0.00 V Output Voltage (assumes AC stacked windings) Secondary winding turns (each phase) AC stacked on top of Sec 2 Turns 0.00 secondary winding 1 RMS current through Output 2 winding; Output 1 winding is AC Sec 2 RMS current (total, AC+DC) 2.8 A stacked on top of Output 2 winding Winding current (DC component) 0.0 A DC component of winding current Winding current (AC RMS component) 0.0 A AC component of winding current Sec 2 Wire gauge 42 AWG Individual wire strand gauge used for secondary winding Equivalent secondary 2 Metric Wire gauge 0.060 mm Equivalent diameter of wire in metric units Number of strands used in Litz wire; for non-litz non-integrated Sec 2 litz strands 0 transformer set to 1 Resistivity_25 C_sec2 59292.53 m-ohm/m Resistivity in milli-ohms per meter Transformer Secondary MLT 5.20 cm Mean length per turn DCR_25C_Sec2 0.00 m-ohm Estimated resistance per phase at 25 C (for reference) Estimated resistance per phase at 100 C (approximately 33% DCR_100C_Sec2 0.00 m-ohm higher than at 25 C) Estimated Power loss due to DC resistance (both secondary DCR_Ploss_Sec1 0.00 W halves) Measured AC resistance per phase (at 100 kHz, room temperature), multiply by 1.33 to approximate 100 C winding ACR_Sec2 0.00 m-ohm temperature. Default value of ACR is twice the DCR value at 100 C ACR_Ploss_Sec2 0.00 W Estimated AC copper loss (both secondary halves) Total winding 2 Copper Losses 0.00 W Total (AC + DC) winding copper loss for both secondary halves Capacitor RMS current 0.0 A Output capacitor RMS current Co2 N/A uF Secondary 2 output capacitor Capacitor ripple voltage N/A % Peak to Peak ripple voltage on secondary 1 output capacitor Schottky losses are a stronger function of load DC current. Sync Output rectifier RMS Current 0.0 A Rectifier losses are a function of RMS current Secondary 2 Layers 1.00 Number of layers in secondary 2 Winding Transformer Loss Calculations Does not include fringing flux loss from gap Primary copper loss (from Primary section) 0.27 W Total primary winding copper loss at 85 C Secondary copper Loss 0.51 W Total copper loss in secondary winding Transformer total copper loss 0.78 W Total copper loss in transformer (primary + secondary) AW_S 48.38 mm^2 Area of window for secondary winding % Fill factor for secondary windings; typical max fill is 60% for Secondary Fill Factor 19% % served and 75% for unserved Litz Page 45 of 82 35.93 11.21 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Signal Pins Resistor Values f_min 155 kHz Dead Time 320 ns Burst Mode 1 1 f_max 847 kHz f_burst_start 382 kHz f_burst_stop 437 kHz DT/BF pin upper divider resistor DT/BF pin lower divider resistor 6.79 129 k-ohms k-ohms Rstart 5.79 k-ohms Start up delay 0.0 ms Rfmin 46.2 k-ohms C_softstart 0.33 uF Minimum frequency when optocoupler is cut-off. Only change this variable based on actual bench measurements Dead time Select Burst Mode: 1, 2, and 3 have hysteresis and have different frequency thresholds Max internal clock frequency, dependent on dead-time setting. Is also start-up frequency Lower threshold frequency of burst mode, provides hysteresis. This is switching frequency at restart after a bursting off-period Upper threshold frequency of burst mode; This is switching frequency at which a bursting off-period stops Resistor from DT/BF pin to VREF pin Resistor from DT/BF pin to G pin Start-up resistor - resistor in series with soft-start capacitor; equivalent resistance from FB to VREF pins at startup. Use default value unless additional start-up delay is desired. Start-up delay; delay before switching begins. Reduce R_START to increase delay Resistor from VREF pin to FB pin, to set min operating frequency; This resistor plus Rstart determine f_MIN. Includes 7% HiperLCS frequency tolerance to ensure f_min is below f_brownout Softstart capacitor. Recommended values are between 0.1 uF and 0.47 uF Resistor in series with opto emitter Lower resistor in OV/UV pin divider Total upper resistance in OV/UV pin divider Ropto 1.2 OV/UV pin lower resistor 19.60 19.6 OV/UV pin upper resistor 2.93 LLC Capacitive Divider Current Sense Circuit k-ohms k-ohm M-ohm Slow current limit 2.35 A Fast current limit 4.24 A LLC sense capacitor 47 pF RLLC sense resistor 37.3 ohms IS pin current limit resistor 220 ohms IS pin noise filter capacitor 1.0 nF IS pin noise filter pole frequency Loss Budget LCS device Conduction loss Output diode Loss Transformer estimated total copper loss Transformer estimated total core loss Total transformer losses Total estimated losses Estimated Efficiency PIN 724 kHz 8-cycle current limit - check positive half-cycles during brownout and startup 1-cycle current limit - check positive half-cycles during startup HV sense capacitor, forms current divider with main resonant capacitor LLC current sense resistor, senses current in sense capacitor Limits current from sense resistor into IS pin when voltage on sense R is < -0.5V IS pin bypass capacitor; forms a pole with IS pin current limit capacitor This pole attenuates IS pin signal 1.5 2.5 0.78 1.1 1.9 5.8 96% 156 W W W W W W % W Conduction loss at nominal line and full load Estimated diode losses Total copper loss in transformer (primary + secondary) Estimated core loss Total transformer losses Total losses in LLC stage Estimated efficiency LLC input power Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 46 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 11 Heat Sinks 11.1 Primary Heat Sink 11.1.1 Primary Heat Sink Sheet Metal Figure 18 - RD-382 Primary Heat Sink Sheet Metal Drawing. Page 47 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 11.1.2 28-Jun-17 Primary Heat Sink with Fasteners Figure 19 - Finished Primary Heat Sink Drawing with Installed Fasteners. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 48 of 82 28-Jun-17 11.1.3 RDR-382, 150 W Street Light Power Supply Primary Heat Sink Assembly Figure 20 - RD-382 Primary Heat Sink Assembly. Page 49 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 11.2 Secondary Heat Sink 11.2.1 Secondary Heat Sink Sheet Metal Figure 21 - Secondary Heat Sink Sheet Metal Drawing. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 50 of 82 28-Jun-17 11.2.2 RDR-382, 150 W Street Light Power Supply Secondary Heat Sink with Fasteners Figure 22 - Finished Secondary Heat Sink with Installed Fasteners. Page 51 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 11.2.3 28-Jun-17 Secondary Heat Sink Assembly Figure 23 - RD-382 Secondary Heat Sink Assembly. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 52 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 12 RD-382 Performance Data All measurements were taken at room temperature and 60 Hz (input frequency) unless otherwise specified. Output voltage measurements were taken at the output connectors. 12.1 LLC Stage Efficiency To make this measurement, the LLC stage was supplied by connecting an external 380 VDC source across bulk capacitor C14, with a 2-channel bench supply to source the primary and secondary bias voltages. The output of the supply was used to power the LED streetlight described in Section 7, and the dimming input of the supply was used to program the current delivered to this load in order to vary the output power. 99 98 Efficiency (%) 97 96 95 94 93 92 91 20 40 60 80 100 120 140 160 Output Power (W) Figure 24 - LLC Stage Efficiency vs. Load, 380 VDC Input. Page 53 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 180 RDR-382, 150 W Street Light Power Supply 28-Jun-17 12.2 Total Efficiency Figures below show the total supply efficiency (PFC and LLC stages). AC input was supplied using a sine wave source. The output was loaded with an electronic load set for constant resistance, with the load adjusted for maximum output current (3.5 A) and 43 V output voltage. 95 94 Efficiency (%) 93 92 91 90 89 88 70 90 110 130 150 170 190 210 230 250 270 290 Input Voltage (VAC) Figure 25 - Total Efficiency vs. Input Voltage, 100% Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 54 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 12.3 Power Factor Power factor measurements were made using a sine wave AC source and a constant resistance electronic load as described in section 12.2. 1.04 1.02 Power Factor 1.00 0.98 0.96 0.94 0.92 0.90 70 90 110 130 150 170 190 210 230 250 270 Input Voltage (VAC) Figure 26 - Power Factor vs. Input Voltage, 100% Load. Page 55 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 290 RDR-382, 150 W Street Light Power Supply 28-Jun-17 12.4 Harmonic Distribution Input current harmonic distribution was measured using a sine wave source and an LED load (Section 7). 1 Harmonic Current (A) Measured Specification Limit 0.1 0.01 0.001 1 2 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 Harmonic Order (n) Figure 27 - Input Current Harmonic Distribution, 230 VAC / 50 Hz Input, 100% Load. 12.5 THD, 100% Load THD was measured using the LED streetlight load described in Section 7 of this report. Input Voltage (VAC) 115 230 Frequency (Hz) 60 50 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com THD (%) 8.30 7.38 Page 56 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 12.6 Output Current vs. Dimming Input Voltage Output dimming characteristics were measured using a sine wave AC source and the streetlight LED array described in Section 7. Dimming voltage was provided using a bench supply. 4.0 3.5 Output Current (A) 3.0 2.5 2.0 1.5 1.0 0.5 0.0 0 2 4 6 8 10 Dimming Input (VDC) Figure 28 - RD-382 Output Current vs. Dimming Voltage. Page 57 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 12 RDR-382, 150 W Street Light Power Supply 28-Jun-17 13 Waveforms 13.1 Input Current, 100% Load Figure 29 - Input Current, 90 VAC, 150 W Load, 2 A, 5 ms / div Figure 31 - Input Current, 230 VAC, 150 W Load, 2 A, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Figure 30 - Input Current, 115 VAC, 150 W Load, 2 A, 5 ms / div. Figure 32 - Input Current, 265 VAC, 150 W Load, 2 A, 5 ms / div. Page 58 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 13.2 LLC Primary Voltage and Current The LLC stage current was measured by inserting a current sensing loop in series with the ground side of resonating capacitor C30 that measures the LLC transformer (T2) primary current. The output was loaded with an electronic load set for constant resistance, with the load adjusted for maximum output current and 43 V output voltage. Figure 33 - LLC Stage Primary Voltage and Current, 100% Load. Upper: Current, 2 A / div. Lower: Voltage, 200 V, 2 s / div. Page 59 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 13.3 Output Rectifier Peak Reverse Voltage Figure 34 - Output Rectifier (D11) Reverse Voltage, 100% Load. Top and Bottom Traces Show Voltages on Each Half of D11, at 50 V, 2 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Figure 35 - Output Rectifier (D11) Reverse Voltage, No-Load. Top and Bottom Traces Show Voltages on Each Half of D11, at 50 V, 2 s / div. Page 60 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 13.4 PFC Inductor + Switch Voltage and Current, 100% Load Since the PFC in this power supply utilizes the internal output diode of the HiperPFS-2, the measured drain current cannot be separated from the PFC inductor current. Figure 36 - PFC Stage Drain Voltage and Current, Full Load, 115 VAC. Upper: Switch + Inductor Current, 2 A / div. Lower: VDRAIN, 200 V, 2 ms / div. Figure 37 - PFC Stage Drain Voltage and Current, Full Load, 115 VAC. Upper: Switch + Inductor Current, 2 A / div. Lower: VDRAIN, 200 V, 20 s / div. Figure 38 - PFC Stage Drain Voltage and Current, Full Load, 230 VAC. Upper: Switch + Inductor Current, 2 A / div. Lower: VDRAIN, 200 V, 2 ms / div. Figure 39 - PFC Stage Drain Voltage and Current, Full Load, 230 VAC. Upper: Switch + Inductor Current, 2 A / div. Lower: VDRAIN, 200 V, 10 s / div. Page 61 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 13.5 AC Input Current and PFC Output Voltage during Start-up Figure 40 - AC Input Current vs. PFC Output Voltage at Start-up, Full Load, 115 VAC. Upper: AC Input Current, 25 A /div. Lower: PFC Voltage, 100 V, 50 ms / div. Figure 41 - AC Input Current vs. PFC Output Voltage at Start-up, Full Load, 230 VAC. Upper: AC Input Current, 5 A / div. Lower: PFC Voltage, 200 V, 50 ms / div. 13.6 LLC Start-up Output Voltage and Transformer Primary Current Using LED Output Load Figure 42 - LLC Start-up. 115 VAC, 100% Load. Upper: LLC Primary Current, 2 A / div. Lower: LLC VOUT, 20 V, 2 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 62 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 13.7 Output Voltage / Current Start-up Using LED Load Figure 43 - LLC Start-up. 115 VAC, 100% Load, LED Load. Upper: LLC IOUT, 1 A / div. Lower: LLC VOUT, 20 V, 2 ms / div. Page 63 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 13.8 LLC Output Short-Circuit The figure below shows the effect of an output short circuit on the LLC primary current and on the output current. A mercury displacement relay was used to short the output to get a fast, bounce-free connection. Figure 44 - Output Short-Circuit Test. Upper: LLC Primary Current, 2 A / div. Lower: LLC VOUT, 20 V, 10 s / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Figure 45 - Output Short-Circuit Test. Upper: LLC IOUT, 50 A / div. Lower: LLC VOUT, 20 V, 10 s / div. Page 64 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 13.9 Output Ripple Measurements 13.9.1 Ripple Measurement Technique For DC output ripple measurements a modified oscilloscope test probe is used to reduce spurious signals. Details of the probe modification are provided in the figures below. Tie two capacitors in parallel across the probe tip of the 4987BA probe adapter. Use a 0.1 F / 50 V ceramic capacitor and 1.0 F / 100 V aluminum electrolytic capacitor. The aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across DC outputs. Probe Ground Probe Tip Figure 46 - Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed). Figure 47 - Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added). Page 65 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 13.9.2 28-Jun-17 Ripple Measurements Figure 48 - Output Ripple, Full Load, 115 VAC. Upper: IOUT, 1 A / div. Lower: Output Voltage Ripple, 100 mV, 5 ms / div. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 66 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 14 Temperature Profiles The board was operated at room temperature, with output set at maximum using a constant resistance load. For each test condition the unit was allowed to thermally stabilize (~1 hr) before measurements were made. 14.1 90 VAC, 60 Hz, 150 W Output, Room Temperature Figure 49 - Inrush Limiting Thermistor (RT1), 90 VAC Input, 100% Load, Room Temperature. Figure 50 - Common Mode Choke (L1), 90 VAC Input, 100% Load, Room Temperature. Figure 51 - Differential Mode Choke (L4), 90 VAC Input, 100% Load, Room Temperature. Figure 52 - Input Rectifier Bridge (BR1), 90 VAC Input, 100% Load, Room Temperature. Page 67 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply Figure 53 - PFC IC (U1), 90 VAC Input, 100% Load, Room Temperature. Figure 55 - LLC IC (U3), 90 VAC Input, 100% Load, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 28-Jun-17 Figure 54 - PFC Inductor (L2), 90 VAC Input, 100% Load, Room Temperature. Figure 56 - LLC Transformer (T2), 90 VAC Input, 100% Load, Room Temperature. Page 68 of 82 28-Jun-17 Figure 57 - Output Rectifier (D11), 90 VAC Input, 100% Load, Room Temperature. Page 69 of 82 RDR-382, 150 W Street Light Power Supply Figure 58 - Current Sense Resistor (R53), 90 VAC Input, 100% Load, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 14.2 115 VAC, 60 Hz, 150 W Output, Room Temperature Figure 59 - Inrush Limiting Thermistor (RT1), 115 VAC Input, 100% Load, Room Temperature. Figure 60 - Common Mode Choke (L1), 115 VAC Input, 100% Load, Room Temperature. Figure 61 - Differential Mode Choke (L4), 115 VAC Input, 100% Load, Room Temperature. Figure 62 - Input Rectifier Bridge (BR1), 115 VAC Input, 100% Load, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 70 of 82 28-Jun-17 Figure 63 - PFC IC (U1), 115 VAC Input, 100% Load, Room Temperature. Figure 65 - LLC IC (U3), 115 VAC Input, 100% Load, Room Temperature. Page 71 of 82 RDR-382, 150 W Street Light Power Supply Figure 64 - PFC Inductor (L2), 115 VAC Input, 100% Load, Room Temperature Figure 66 - LLC Transformer (T1), 115 VAC Input, 100% Load, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply Figure 67 - Output Rectifier (D11), 115 VAC Input, 100% Load, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 28-Jun-17 Figure 68 - Current Sense Resistor (R53), 115 VAC Input, 100% Load, Room Temperature. Page 72 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 14.3 230 VAC, 50 Hz, 150 W Output, Room Temperature Figure 69 - Inrush Limiting Thermistor (RT1), 230 VAC Input, 100% Load, Room Temperature. Figure 71 - Differential Mode Choke (L4), 230 VAC Input, 100% Load, Room Temperature. Page 73 of 82 Figure 70 - Common Mode Choke (L1), 230 VAC Input, 100% Load, Room Temperature. Figure 72 - Input Rectifier Bridge (BR1), 230 VAC Input, 100% Load, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply Figure 73 - PFC IC (U1), 230 VAC Input, 100% Load, Room Temperature. Figure 75 - LLC IC (U3), 230 VAC Input, 100% Load, Room Temperature. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com 28-Jun-17 Figure 74 - PFC Inductor (L2), 230 VAC Input, 100% Load, Room Temperature Figure 76 - LLC Transformer (T1), 230 VAC Input, 100% Load, Room Temperature. Page 74 of 82 28-Jun-17 Figure 77 - Output Rectifier (D11), 230 VAC Input, 100% Load, Room Temperature. Page 75 of 82 RDR-382, 150 W Street Light Power Supply Figure 78 - Current Sense Resistor (R53), 230 VAC Input, 100% Load, Room Temperature. Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 15 Output Gain-Phase Gain-phase was tested a maximum load using the constant voltage load described in Section 7.1. It is important to use the actual LED load or a load with similar characteristics during gain-phase testing, as a load with different output characteristic will yield inaccurate results. Figure 79 - LLC Converter Gain-Phase, 100% Load Crossover Frequency - 1.5 kHz, Phase Margin - 66. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 76 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 16 Conducted EMI Conducted EMI tests were performed using the constant voltage load described in Section 7.1. The output return was connected to the LISN artificial hand to simulate the capacitance of a typical set of LED panels to chassis ground. The step change in readings at 80 MHz is due to an automatic 10 dB scale change of the EMI receiver rather than an actual peak at 80 MHz. Figure 80 - Conducted EMI, 115 VAC, Full Load. Page 77 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 Figure 81 - Conducted EMI, 230 VAC, Full Load. Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Page 78 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 17 Line Surge Testing 17.1 Line Surge Test Set-up The picture below shows the power supply set-up for surge testing. The supply is placed on a ground plane approximately the size of the power supply. A piece of single-sided copper clad printed circuit material was used in this case, but a piece of aluminum sheet with appropriate insulation would also work. An IEC AC connector was wired to the power supply AC input, with the safety ground connected to the ground plane. The CV output load (described in section 7) was placed on top of the ground plane so that it would capacitively couple to the safety ground. A 48 V fan was located inside the plastic shroud shown in the figure, and used to cool the CV load during testing. An indicator consisting of a GaP yellow-green led in series with a 39 V Zener diode and a 100 ohm resistor was placed across the output of the supply and used as a sensitive output dropout detector during line surge testing. The UUT was tested using a Teseq NSG 3060 surge tester. Results of common mode and differential mode surge testing are shown below. A test failure was defined as a nonrecoverable output interruption requiring supply repair or recycling AC input voltage. Figure 82 - Line Surge Physical Set-up. Page 79 of 82 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 17.2 Differential Mode Surge, 1.2 / 50 sec AC Input Voltage (VAC) 115 115 115 115 115 115 Surge Voltage (kV) +2 -2 +2 -2 +2 -2 AC Input Voltage (VAC) 230 230 230 230 230 230 Surge Voltage (kV) +2 -2 +2 -2 +2 -2 Phase Angle () 90 90 270 270 0 0 Phase Angle () 90 90 270 270 0 0 Generator Impedance () 2 2 2 2 2 2 Generator Impedance () 2 2 2 2 2 2 Number of Strikes Test Result 10 10 10 10 10 10 PASS PASS PASS PASS PASS PASS Number of Strikes Test Result 10 10 10 10 10 10 PASS PASS PASS PASS PASS PASS Number of Strikes Test Result 10 10 10 10 10 10 PASS PASS PASS PASS PASS PASS Number of Strikes Test Result 10 10 10 10 10 10 PASS PASS PASS PASS PASS PASS 17.3 Common Mode Surge, 1.2 / 50 sec AC Input Voltage (VAC) 115 115 115 115 115 115 Surge Voltage (kV) +4 -4 +4 -4 +4 -4 AC Input Voltage (VAC) 230 230 230 230 230 230 Surge Voltage (kV) +4 -4 +4 -4 +4 -4 Phase Angle () 90 90 270 270 0 0 Phase Angle () 90 90 270 270 0 0 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com Generator Impedance () 12 12 12 12 12 12 Generator Impedance () 12 12 12 12 12 12 Page 80 of 82 28-Jun-17 RDR-382, 150 W Street Light Power Supply 18 Revision History Date 04-Mar-14 28-May-14 16-Jul-16 17-Feb-17 28-Jun-17 Page 81 of 82 Author RH RH KM KM RH Revision 6.1 6.2 6.3 6.4 6.5 Description and Changes Initial Release Schematic Updated. Schematic Updated. Brand Style Updated. Updated Heat Sink Drawings Corrected Primary heat sink dwg Reviewed Apps & Mktg Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.power.com RDR-382, 150 W Street Light Power Supply 28-Jun-17 For the latest updates, visit our website: www.power.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.power.com. Power Integrations grants its customers a license under certain patent rights as set forth at http://www.power.com/ip.htm. 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