RDK-382 Power Integrations

Reference Design Report for a 150 W Power Factor Corrected LLC Power Supply Title TM Using HiperPFS -2 (PFS7326H) and TM HiperLCS (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 RDR-382 Number 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 <RDR-382, 150 W Street Light Power Supply 28-Jun-17 Table of Contents 1 Introduction ...................................................................................................... 5 2 Power Supply Specification ................................................................................. 7 3 Schematic ......................................................................................................... 8 4 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. 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