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8.8W可调光、非隔离、降压式LED驱动器.pdf

8.8W可调光、非隔离、降压式LED驱动器.pdf

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简介:本文档为《8.8W可调光、非隔离、降压式LED驱动器pdf》,可适用于电子通讯领域,主题内容包含PowerIntegrationsHellyerAvenue,SanJose,CAUSATel:Fax:wwwpowerintcomDesignEx符等。

Power Integrations 5245 Hellyer Avenue, San Jose, CA 95138 USA. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Design Example Report Title 8.8 W High Efficiency (>86%) High Power Factor (>0.91) TRIAC Dimmable Non-Isolated Buck LED Driver Using LYTSwitchTM -4 LYT4321E Specification 190 VAC – 265 VAC Input; 57 VTYP, 155 mA Output Application PAR16 LED Driver Author Applications Engineering Department Document Number DER-370 Date December 5, 2013 Revision 1.0 Summary and Features Efficiency >86% at 230 VAC TRIAC dimmable Works with a wide selection of TRIAC dimmers Low-cost, low component count, small PCB Fast start-up time (<300 ms) – no perceptible delay Integrated protection and reliability features Output short-circuit protected with auto-recovery Auto-recovering thermal shutdown with large hysteresis No damage during brown-out conditions PF >0.91 at 230 VAC A-THD <15% at 230 VAC Meets EN55015 conducted EMI PATENT INFORMATION The products and applications illustrated herein (including transformer construction and circuits external to the products) may be covered by one or more U.S. and foreign patents, or potentially by pending U.S. and foreign patent applications assigned to Power Integrations. A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants its customers a license under certain patent rights as set forth at <http://www.powerint.com/ip.htm>. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 2 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Table of Contents 1  Introduction ................................................................................................................. 4  2  Power Supply Specification ........................................................................................ 6  3  Schematic ................................................................................................................... 7  4  Circuit Description ...................................................................................................... 8  4.1  Input EMI Filtering ............................................................................................... 8  4.2  Power Circuit ....................................................................................................... 8  4.3  Bias Supply and Output Feedback ...................................................................... 9  4.4  TRIAC Phase Dimming Control Compatibility ..................................................... 9  5  PCB Layout .............................................................................................................. 11  6  Bill of Materials ......................................................................................................... 13  7  Inductor Specification ............................................................................................... 15  7.1  Electrical Diagram ............................................................................................. 15  7.2  Electrical Specifications ..................................................................................... 15  7.3  Materials ............................................................................................................ 15  7.4  Inductor Build Diagram ...................................................................................... 16  7.5  Inductor Construction ........................................................................................ 16  8  Performance Data .................................................................................................... 17  8.1  Efficiency ........................................................................................................... 17  8.2  Line and Load Regulation .................................................................................. 18  8.3  Power Factor ..................................................................................................... 19  8.4  A-THD ............................................................................................................... 20  8.5  Harmonics ......................................................................................................... 21  8.6  Test Data ........................................................................................................... 22  8.6.1  Test Data, 60 V LED Load ......................................................................... 22  8.6.2  Test Data, 57 V LED Load ......................................................................... 22  8.6.3  Test Data, 54 V LED Load ......................................................................... 22  8.6.4  Test Data, 51 V LED Load ......................................................................... 23  9  Dimming Performance Data ..................................................................................... 24  9.1  Dimming Curve with Leading Edge Type Dimmer ............................................. 24  9.2  Dimmer Compatibility List .................................................................................. 25  10  Thermal Performance ........................................................................................... 27  10.1  Non-Dimming VLED = 60 V LED Load ................................................................ 27  10.2  Dimming VLED = 60 V LED Load ........................................................................ 28  11  Non-Dimming Waveforms ..................................................................................... 29  11.1  Input Voltage and Input Current Waveforms ..................................................... 29  11.2  Output Current and Output Voltage at Normal Operation .................................. 29  11.3  Input Voltage and Output Current Waveform at Start-up ................................... 30  11.4  Drain Voltage and Current at Normal Operation ................................................ 30  11.5  Start-up Drain Voltage and Current ................................................................... 32  11.6  Drain Current and Drain Voltage During Output Short Condition ...................... 33  11.7  Output Diode Current and Voltage Waveforms ................................................. 34  11.8  Brown-out .......................................................................................................... 35  12  Dimming Waveforms ............................................................................................. 36  12.1  Input Voltage and Input Current Waveforms ..................................................... 36  05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 3 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 13  Conducted EMI ..................................................................................................... 37  13.1  Test Set-up ........................................................................................................ 37  14  Line Surge Test ..................................................................................................... 39  15  Revision History .................................................................................................... 40  Important Note: Although this board is designed to satisfy safety isolation requirements, the engineering prototype has not been agency approved. Therefore, all testing should be performed using an isolation transformer to provide the AC input to the prototype board. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 4 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 1 Introduction The document describes a non-isolated, high power factor (PF), high efficiency, TRIAC dimmable LED driver designed to drive a nominal LED string voltage of 57 V at 155 mA from an input voltage range of 190 VAC to 265 VAC (50 Hz typical). The topology used is a single-stage non-isolated buck that meets high power factor, constant current output and which provides dimming. This document contains the LED driver specification, schematic, PCB information, bill of materials, transformer documentation and typical performance characteristics. Figure 1 – Populated Circuit Board, Top View. 05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 5 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 2 – Populated Circuit Board, Bottom View. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 6 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 2 Power Supply Specification The table below represents the minimum acceptable performance of the design. Actual performance is listed in the results section. Description Symbol Min Typ Max Units Comment Input Voltage VIN 190 230 265 VAC 2 Wire – no P.E. Frequency fLINE 50/60 Hz Output Output Voltage VOUT 51 57 60 V Output Current IOUT 155 mA VOUT = 54 V, VIN = 230 VAC, 25 C Total Output Power Continuous Output Power POUT 8.8 W Efficiency Full Load 88 89 % Measured at POUT 25 C Environmental Conducted EMI CISPR 15B / EN55015B Safety Non-Isolated Ring Wave (100 kHz) Differential Mode (L1-L2) Common mode (L1/L2-PE) Differential Surge 2.5 500 kV V Power Factor 0.91 Measured at VOUT(TYP), IOUT(TYP) and 230 VAC, 50 Hz Harmonic Currents EN 61000-3-2 Class C Ambient Temperature TAMB C 05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 7 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 3 Schematic Figure 3 – Schematic. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 8 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 4 Circuit Description The LYT4321E (U1) is a highly integrated primary-side controller designed for use in LED applications. It provides high power factor while regulating the output current across a range of input voltage (190 VAC to 265 VAC) in a single conversion stage. All of the control circuitry responsible for these functions plus the high-voltage power MOSFET is incorporated into the IC. 4.1 Input EMI Filtering Fuse FR1 provides protection from component failure and provides extra damping during dimming. MOV RV1 provides a clamp to limit voltage during differential line surge events. Bridge rectifier BR1 rectifies the AC line voltage. EMI filtering is provided by a filter which consists of an inductor (L2) and capacitors C6 and C7. 4.2 Power Circuit The topology chosen in this design is a low-side buck configured to provide high efficiency with small magnetics, low THD, high power factor, and constant current output for the input voltage range of 190 VAC to 265 VAC. Inductor T1 is the main inductor of the buck converter. It consists of two windings - the primary and the bias winding. The primary winding is the main buck inductor. The bias winding is the supply for the IC and helps prevent flicker and shimmer during deep dimming. For TRIAC dimming, a bias supply of at least 25 V supply is required. This requirement ensures adequate voltage to supply the IC at the minimum LED string voltage and with a TRIAC dimmer operates at minimum conduction angle (<30 degrees). Output diode D7 conducts every time U1 turns off, allowing stored energy in T1 to transfer to the load. Diode D5 is necessary to prevent reverse current from flowing back through U1 when the voltage across C7 (rectified input AC) falls below the output voltage. To provide peak line voltage information to U1, the incoming rectified AC peak charges C8 via D3. This is then fed into the VOLTAGE MONITOR (V) pin of U1 as a current via R13 and R14. Resistor R12 is a discharge path for C8 to allow V pin to respond quickly when there is a line sag. The line overvoltage shutdown function, sensed via the V pin, extends the rectified line voltage withstand (during surges and line swells) to the 725 BVDSS rating of the internal power MOSFET. The fast acting line overvoltage detection of LYTSwitch in conjunction with D3 and C8 peak detector capacitor provides a clamp to limit the maximum voltage stress across the power MOSFET of the IC during line surge event. A value of 2.2 F on C8 can withstand 500 V surges, while 4.7 F can withstand 1 kV surge. An additional 270 VAC rated MOV (Metal Oxide Varistor) can be used for >1 kV differential line surge requirement. 05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 9 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Capacitor C10 provides local decoupling for the BYPASS (BP) pin of U1 which is the supply pin for the internal controller. During start-up, C10 is charged to ~6 V from an internal high-voltage current source connected to the DRAIN (D) pin of U1. The use of an external bias supply (via D9 and R19) is recommended to give the lowest device dissipation and provide sufficient supply to U1 during deep dimming condition. Capacitor C10 was chosen to be 4.7 F since LYT4321E has only one power mode. A value of 24.9 k resistor was used for the REFERENCE (R) pin (R17) and 4 M (R13+R14) on the V pin to provide a linear relationship between input voltage and the output current. Output capacitor C12 is the output filter capacitor. Pre-load resistor R24 causes the output to quickly discharge below the LED string voltage when the AC is removed and ensuring that the lamp is extinguished (rather than there being a slight glow for several seconds after AC is removed). 4.3 Bias Supply and Output Feedback A bias winding on T1 is used to provide feedback and supply to the IC. The bias winding voltage is used to sense the output voltage indirectly, eliminating secondary-side feedback components. The voltage on the bias winding is proportional to the output voltage (set by the turn ratio between the bias and primary windings). The flyback voltage on the bias winding is rectified by D8 and filtered by C11 to smooth the voltage and R20 to reduce excess voltage coupled from the leakage inductance energy. The feedback current is then fed to the FEEDBACK (FB) pin thru resistor R25. Diode D9 and R19 link the BP pin to the bias winding. Diode D9 is necessary to isolate the voltage potential of the BP from inhibiting auto-restart function during start-up or in a short-circuit condition. Resistor R19 limits the current supplied to the BP pin from the bias winding. The internal engine within U1 combines the FB pin current, the V pin current, and internal drain current information to provide a constant output current whilst maintaining high input power factor. 4.4 TRIAC Phase Dimming Control Compatibility The requirement to provide output dimming with low cost, TRIAC based, leading edge and trailing edge phase dimmers introduced a number of trade-offs with the design. Due to the much lower power consumed by LED based lighting, the current drawn by the lamp is below the holding current of the TRIAC in many dimmers. This causes undesirable behavior such as limited dim range and/or flickering when the TRIAC fires inconsistently. The relatively large impedance presented to the line by the LED could cause significant ringing to occur due to the inrush current charging the input capacitance when the TRIAC turns on. This effect can cause shimmer as the ringing may cause the TRIAC current to fall to zero and turn off. The damper, bleeder, and linear regulator circuit employed in the design overcome these issues with minimal impact on efficiency of the driver. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 10 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com The PI proprietary active damper consists of main components D1, R6, R7, VR1, R9, Q2, C4, Q1, Q2, R3, R4, R5 and R2. Where Q2 is fully on when there is no TRIAC connected, bypassing R2 which will keep the power dissipation low thereby making the system efficiency high. A TRIAC is detected through C2, R3 and R4 which will momentarily drive Q1 on, keeping C3 grounded and the gate of Q2 low allowing R2 to be in series with the TRIAC to act as damping element (current ringing) every time the TRIAC turns on. The passive bleeder network comprises capacitor C1 and resistor R1. This network damps the input and aso provides the required latching and holding current for the TRIAC dimmer. The linear regulator circuit R22, R23, VR2, Q3, and D10 were added to keep the supply of the IC (BP pin) constant - allowing it to operate normally at very low conduction angle or with very low input voltage and making the IC act as a load (vital for TRIACs with high leakage current). Most high power rated (>600 W) TRIAC dimmers have an LC input filter. If the TRIAC filter capacitance is large enough to provide sufficient energy to charge the input stage of the LED driver, the LED may turn on as the LED load is energized until the input is discharged. The cycle then repeats and causes flickering of the LED load even if the TRIAC is off. The linear regulator is not activated when the bias voltage is higher than VzVR2 +VtQ3 + VfD10. Voltage regulator VR2 is chosen such that the linear regulator will only work during deep dimming when the bias voltage is sufficiently low, this is to minimize Q3 power dissipation. 05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 11 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 5 PCB Layout Figure 4 – Top Side. DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E 05-Dec-13 Page 12 of 41 Power Integrations, Inc. Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com Figure 5 – Bottom Side. 05-Dec-13 DER-370 8.8 W PAR16 HLO Dimmable LED Driver Using LYT4321E Page 13 of 41 Power Integrations Tel: +1 408 414 9200 Fax: +1 408 414 9201 www.powerint.com 6 Bill of Materials Item Qty Ref Des Description Mfg Part Number Mfg 1 1 BR1 1000 V, 0.8 A, Bridge Rectifier, SMD, MBS-1, 4-SOIC B10S-G Comchip Technology 2 1 C1 220 nF, 450 V, Film MEXXF32204JJ Duratech 3 1 C2 100 pF, 1000 V, Ceramic, NPO, 0805 C0805C101MDGACTU Kemet 4 1 C3 33 nF, 50 V, Ceramic, X7R, 0805 CC0805KRX7R9BB333 Yageo 5 1 C4 10 nF 50 V, Ceramic, X7R, 0603 C0603C103K5RACTU Kemet 6 1 C6 22 nF, 400 V, Film ECQ-E4223KF Panasonic 7 1 C7 100 nF, 450 V, Film MEXXD31004JJ1 Duratech 8 1 C8 2.2 F, 400 V, Electrolytic, (6.3 x 11) TAB2GM2R2E110 Ltec 9 1 C10 4.7 F, 10 V, Ceramic, X7R, 0805 C0805C475K8PACTU Kemet 10 1 C11 22 F, 50 V, Electrolytic, (5 x 11) UPW1H220MDD Nichicon 11 1 C12 68 F, 100 V, Electrolytic, (10 x 12.5) UVY2A680MPD Nichicon 12 1 D1 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diodes, Inc. 13 1 D3 600 V, 1 A, Rectifier, Glass Passivated, POWERDI123 DFLR1600-7 Diodes, Inc. 14 1 D5 DIODE ULTRA FAST, SW, 200 V, 1 A, SMA US1D-13-F Diodes, Inc. 15 1 D7 DIODE ULTRA FAST, GPP, 400 V, 1 A SMA US1G-13-F Diodes, Inc. 16 1 D8 250 V, 0.2 A, Fast

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