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 .
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
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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
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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.
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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
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RDR-382, 150 W Street Light Power Supply
28-Jun-17
Figure 2 – RD-382 Photograph, Bottom View.
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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
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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.
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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
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RDR-382, 150 W Street Light Power Supply
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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.
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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
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RDR-382, 150 W Street Light Power Supply
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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
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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
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RDR-382, 150 W Street Light Power Supply
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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.
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RDR-382, 150 W Street Light Power Supply
5 PCB Layout
Figure 5 – Printed Circuit Layout, Top Side.
Page 15 of 82
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Figure 6 – Printed Circuit Layout, Bottom Side.
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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
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