Design Example Report

150 W Power Factor Corrected LLC Power

Title
Supply Using HiperPLC (PLC810PG)
140 – 265 VAC Input; 150 W (48 V at 0.05 A –
Specification
3.125 A) Output
Application LED Street Light
Author Applications Engineering Department
Document
DER-212
Number
Date June 1, 2009
Revision 1.1

Summary and Features

• Integrated PFC and LLC controller
• Continuous mode PFC using small low-cost ferrite core and magnet wire
• Frequency and Phase locked PFC and LLC for ripple cancellation in bulk capacitor for
reduced ripple current, reduced bulk capacitor size and reduced EMI filter cost
• Tight LLC duty-cycle matching
• Tight LLC dead-time control
• >95% full load PFC efficiency at 140 VAC using conventional ultrafast rectifier
• >95% full load LLC efficiency
• >92% full load system efficiency

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 [Link]. Power Integrations grants its customers a license under
certain patent rights as set forth at <[Link]

Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

Table of Contents
1 Introduction.................................................................................................................4
2 Power Supply Specification ........................................................................................7
3 Schematic...................................................................................................................8
4 Circuit Description ....................................................................................................10
4.1 Input Filter / Boost Converter / Bias Supply.......................................................10
4.1.1 EMI Filtering ...............................................................................................10
4.1.2 Inrush Limiting............................................................................................10
4.1.3 Main PFC Stage .........................................................................................10
4.1.4 Primary Bias Supply / Start-up ...................................................................11
4.2 Controller / Main LLC Output.............................................................................11
4.2.1 LLC Input Stage .........................................................................................11
4.2.2 LLC Outputs ...............................................................................................11
4.2.3 Controller....................................................................................................11
4.2.4 PFC Control ...............................................................................................12
4.2.5 Bypassing / Ground Isolation .....................................................................12
4.2.6 LLC Control ................................................................................................12
4.3 LLC Secondary Control Circuits ........................................................................12
4.3.1 Voltage Feedback ......................................................................................12
5 PCB Layout ..............................................................................................................13
6 Bill of Materials .........................................................................................................15
7 Magnetics .................................................................................................................19
7.1 Main LLC 48 V Transformer (T1) Specification .................................................19
7.1.1 Electrical Diagram ......................................................................................19
7.1.2 Electrical Specifications..............................................................................19
7.1.3 Materials.....................................................................................................19
7.1.4 Winding Diagram........................................................................................20
7.1.5 Winding Instructions ...................................................................................20
7.2 Transformer Illustrations....................................................................................21
7.3 PFC Choke (L4) Specification ...........................................................................25
7.3.1 Electrical Diagram ......................................................................................25
7.3.2 Electrical Specification ...............................................................................25
7.3.3 Materials.....................................................................................................25
7.3.4 Build Diagram.............................................................................................26
7.3.5 Winding Instructions ...................................................................................26
8 LLC Transformer Design Spreadsheet .....................................................................28
9 Performance Data ....................................................................................................34
9.1 LLC Stage Efficiency .........................................................................................34
9.2 Total Efficiency ..................................................................................................35
9.3 THD and Power Factor......................................................................................36
9.4 Output Regulation .............................................................................................37
10 Waveforms............................................................................................................38
10.1 Input Voltage and Current .................................................................................38
10.2 LLC Primary Voltage and Current .....................................................................38
10.3 PFC Switch Voltage and Current - Normal Operation .......................................39

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

10.4 AC Input Current and PFC Output Voltage During Start-up...............................39

10.5 LLC Start-up ......................................................................................................40
10.6 LLC Output Short Circuit....................................................................................41
10.7 Output Voltage During Start-up .........................................................................42
10.8 Output Ripple Measurements ............................................................................43
10.8.1 Ripple Measurement Technique.................................................................43
10.8.2 Full Load Output Ripple Results .................................................................44
10.8.3 Output Load Step Response ......................................................................45
11 Temperature Profiles.............................................................................................46
11.1 Thermal Results Summary ................................................................................47
11.1.1 Testing Conditions......................................................................................47
11.2 140 VAC, 60 Hz, 150 WOUT................................................................................48
11.3 230 VAC, 60 Hz, 150 WOUT................................................................................49
12 LLC Gain-Phase....................................................................................................50
13 Conducted EMI .....................................................................................................52
14 Line Surge.............................................................................................................53
15 Revision History ....................................................................................................54

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.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

1 Introduction
This engineering report describes a 150 W reference design power supply for 230 VAC
input LED street lights and also serves as a general purpose evaluation board for the
PLC810PG

The design is based on the PLC810PG controller IC which integrates both continuous
current mode (CCM) boost PFC and resonant half-bridge (LLC) control functions together
with high-side and low side drivers for the LLC stage MOSFETs. To allow optimum
design of the LLC transformer (T1) for high efficiency (high k factor – the ratio of parallel
to series inductance) the design operates in burst mode at zero load. The supply is thus
protected against output overvoltage at low/zero load, but it will not deliver a steady
output voltage at zero load. A practical LED street light power supply design that includes
an auxiliary output winding to power the LED driver circuitry may not have this limitation.

DER-212 demonstrates a design using the commonly employed single transformer and
resonant inductor magnetic component (integrated magnetics) for the LLC stage
(common in display applications). However, the PLC810 may as easily be used with
separated transformer and resonating inductor. PI design materials support both
approaches.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Figure 1 – DER-212 Photograph, Top View.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

Figure 2 – DER-212 Photograph, Bottom View.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

2 Power Supply Specification

Description Symbol Min Typ Max Units Comment
Input
Voltage VIN 140 265 VAC 3 Wire input.
Frequency fLINE 47 50/60 64 Hz
Power Factor PF 0.97 Full load, 230 VAC

Main Converter Output

Output Voltage VLG 45.6 48 50.4 V 48 VDC ± 5%
Output Ripple VRIPPLE(LG) 150 mV P-P 20 MHz bandwidth
*
* Supply is protected under
Output Current ILG 0.05 3.13 3.13 A
no-load conditions

Total Output Power

Continuous Output Power POUT 150 W
Efficiency
91 Measured at 140 VAC, Full Load
Total system at Full Load ηMain % Measured at 230 VAC, Full Load
92
Environmental
Conducted EMI Meets CISPR22B / EN55022B
Safety Designed to meet IEC950 / UL1950 Class II
Surge 1.2/50 µs surge, IEC 1000-4-5,
Differential 1 kV Differential Mode: 2 Ω
Common Mode 2 kV Common Mode: 12 Ω
100 kHz Ring Wave 2 kV 500 A short circuit current
o
Ambient Temperature TAMB 0 60 C See thermal section for conditions

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

3 Schematic

Figure 3 – Schematic of PLC810PG LCD Street Light Power Supply Application Circuit, Input Circuit and
PFC Power Stage.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Figure 4 – Schematic of PLC810PG LCD Street Light Power Supply Application Circuit, PFC Circuit
Control Inputs and LLC Stage.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

4 Circuit Description
The main converter uses the PLC810PG in a primary-side-control, PFC + LLC
configuration.

4.1 Input Filter / Boost Converter / Bias Supply

The schematic in Figure 3 shows the input EMI filter, main PFC stage, and primary bias
supply/start-up circuit.

4.1.1 EMI Filtering

Capacitors C1 and C5 are connected directly from Line and Neutral to protective Earth
ground and are used to control common mode noise at frequencies greater than 30 MHz.
Common mode inductors L1 and L2 control EMI at low frequencies and mid-band
(<10 MHz), respectively. Capacitors C2 and C6 control resonant peaks in the mid-band
region.

PFC inductor L4 has a grounded shield band to prevent electrostatic and magnetic noise
coupling to the EMI filter components. Capacitors C3 and C4 provide differential mode
EMI filtering. To meet safety requirements resistors R1, R2 and R3 discharge these
capacitors when AC is removed. The heat sink for PFC switch FET Q2 and PFC output
diode D2 is tied to primary return at the cathode of D3 via capacitor C80 to eliminate the
heat sink as a source of conducted noise into the chassis/protective Earth ground.

4.1.2 Inrush Limiting

Thermistor RT1 provides inrush limiting. It is shorted by relay RL1 during normal
operation, increasing efficiency by approximately 1 - 1.5%.

4.1.3 Main PFC Stage

Components C9, C11, L4, Q2, and D2 form a continuous mode power factor correction
circuit. Components Q1, Q3, R7, R9 and bead 1 buffer the PWM drive signal for Q2 from
the PLC810 controller. Resistor R7 allows the turn-off speed of Q2 to be adjusted to
optimize the losses between D2 and Q2. In this design it was found that efficiency and
EMI were both improved by reducing the value of R7 and adding ferrite beads to the gate
and drain of Q2 (bead 1 and bead 2 respectively). In general, increasing MOSFET turn
on drive current reduces MOSFET switching losses but increases the reverse recovery
current through D2 and associated ringing. An ultra fast diode was selected for D2 as a
lower cost alternative to a silicon carbide or other proprietary diode technology. These
may provide higher efficiency by reducing reverse recovery charge, but significantly
increase solution cost.

A 220 MΩ, 500 V power MOSFET was selected for Q2 to maximize the efficiency of the
PFC stage. A TO-247 package device was selected for better heat transfer.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Capacitor C10 provides local bypassing for the drive circuit. Current sensing for the PFC
stage is provided by R6 and R8. The sense voltage is clamped to two diode drops by D3
and D4, protecting the current sense input of the controller IC during fault conditions.
Diode D1 charges the PFC output capacitor (C9) when AC is first applied. This routes the
inrush current around the PFC inductor L4 preventing it from saturating and causing
stress in Q2 and D2 when the PFC stage begins to operate. Capacitor C11 is used to
shrink the high frequency loop around components Q2, D2 and C9 to reduce EMI. The
incoming AC is rectified by BR1 and filtered by C7. Capacitor C7 was selected as a low-
loss polypropylene type due to its low loss and low impedance characteristics. This
capacitor provides the high instantaneous current through L4 during Q2 on-time.

4.1.4 Primary Bias Supply / Start-up

Components D22, D23, C75, C76, and R109 act as a voltage doubler circuit to rectify
and filter the output of a floating bias winding on PFC choke L4, providing a bias voltage
relatively independent of input voltage.

Components Q24, Q25, Q27, VR9, VR10, VR11, D24, C70, R103, R111, R113, R114,
and R117 constitute the bias regulator and start-up functions. Resistor R113 charges
capacitor C70 through mosfet Q24 to provide start-up bias for controller U1. The Q24
output voltage is clamped by VR10. Transistor Q25 shuts off the start-up circuit when the
primary bias supply reaches regulation. Darlington transistor Q27, R111, and VR9 form a
simple emitter-follower voltage regulator. Transistor Q26 switches on relay RL1 when the
primary bias supply reaches regulation, shorting out thermistor RT1.

4.2 Controller / Main LLC Output

Figure 4 shows the schematic of the main controller circuit and LLC converter stage.

4.2.1 LLC Input Stage

MOSFETs Q10 and Q11 are the switch MOSFETs for the LLC converter. They are driven
directly by the controller IC via resistors R56 and R58. Capacitor C39 is the primary
resonating capacitor, and should be a low-loss type rated for the RMS current at
maximum load. Capacitor C40 is used for local bypassing, and is positioned adjacent to
Q10 and Q11. Resistor R59 provides primary current sensing to the controller for
overpower protection.

4.2.2 LLC Outputs

The secondaries of transformer T1 are rectified and filtered by D9, and C37-38 to provide
the +48 V output.

4.2.3 Controller
Figure 4 also shows the circuitry around the main controller IC U1, which provides control
functions for the input PFC and output LLC stages.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

4.2.4 PFC Control

The PFC boost stage output voltage is fed back to the boost voltage sense pin (FBP of
U13) via resistors R39-41, R43, R46, and R50. Capacitor C25 filters noise. Components
C26, C28 and R48 provide frequency compensation for the PFC. Transistor Q20 turns on
during large signal excursions, bypassing C26. This allows fast slewing of the PFC
control loop in response to a large load step. The PFC current sense signal from resistors
R6 and R8 is filtered by R45 and C73. The PFC drive signal from the GATEP pin is
routed to the main switching FET via R44. This damps any ringing in the PFC drive signal
caused by the trace length from U1 to PFC switch MOSFET Q2.

4.2.5 Bypassing / Ground Isolation

Capacitors C29, C31, and C32 provide supply bypassing for the analog and digital supply
rails for U1. Resistor R55 and ferrite bead L7 provide ground isolation between the PFC
and LLC ground systems. Resistors R37 and R38 isolate the IC analog and digital supply
rails. Ferrite bead L6 provides high frequency isolation between the LLC stage high side
MOSFET drive return and the controller IC.

4.2.6 LLC Control

Feedback from the LLC output sense/feedback circuit is provided by U2, which develops
a feedback voltage across resistor R54. Capacitor C77 filters the feedback signal.
Resistors R49, R51, and R53 set the lower frequency limit for the LLC converter stage.
Capacitor C27 is used to provide output soft start. Resistor R52 sets the LLC upper
frequency limit. Capacitors C30 and C36 are noise filters. The LLC overload sense signal
from resistor R59 is filtered by R47 and C35. Components C23, R42, and D8 provide
bootstrapping for the LLC top side MOSFET drive. Resistors R52 and R53 were selected
to force the LLC converter into burst mode at low/zero output load, protecting the output
from overvoltage. This operation mode was selected (vs. allowing operation at a higher
frequency at no-load) to give adequate dead time and ensure ZVS operation. The
alternative would be to adjust the ratio of parallel and series inductance (k factor)
however this reduces full load efficiency.

4.3 LLC Secondary Control Circuits

Figure 4 shows the secondary control schematic for the LLC stage.

4.3.1 Voltage Feedback

The LLC converter 48 V output is sensed by resistors R67 and R68. Zener diode VR12
drops the 48 V output to protect regulator U3. Components C24, C44, C51, R30, R70,
and R107 provide frequency compensation for the LLC stage.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

5 PCB Layout

Figure 5 – Printed Circuit Layout, Top Side.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

Figure 6 – Printed Circuit Layout, Bottom Side.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

6 Bill of Materials
Item Qty Ref Des Description Mfg Part Number Mfg
1 4 BEAD1 BEAD2 3.5 mm D x 3.25 L mm, 21 Ω at 25 MHz, 1.6mm 2643001501 Fair-Rite
BEAD3 BEAD4 (.063) hole, Ferrite Bead
2 1 BR1 600 V, 8 A, Bridge Rectifier, GBJ Package GBJ806-F Diodes Inc
3 4 C1 C2 C5 C6 330 pF, Ceramic Y1 440LT33-R Vishay
4 2 C3 C4 470 nF, 275 VAC, Film, X2 PX474K31D5 Carli
5 1 C7 470 nF, 630 V, Polypropylene Film ECW-F6474JL Panasonic
6 1 C9 100 µF, 450 V, Electrolytic, Low ESR, (18 x 30) EPAG451ELL101MM35S Nippon Chemi-
Con
7 4 C10 C23 C31 1 µF, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E105K Panasonic
C33
8 1 C11 20 nF, 500 V, Disc Ceramic D203Z59Z5UL63L0R Vishay/BC
9 3 C24 C28 C51 22 nF, 200 V, Ceramic, X7R, 0805 08052C223KAT2A AVX Corp
10 2 C25 C77 10 nF, 200 V, Ceramic, X7R, 0805 08052C103KAT2A AVX Corp
11 2 C26 C29 10 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) EKMG500ELL100ME11D Nippon Chemi-
Con
12 1 C27 2.2 µF, 25 V, Ceramic, X7R, 1206 ECJ-3YB1E225K Panasonic
13 5 C30 C34 C36 2.2 nF, 200 V, Ceramic, X7R, 0805 08052C222KAT2A AVX Corp
C44 C73
14 1 C32 100 nF, 50 V, Ceramic, X7R, 1206 ECJ-3VB1H104K Panasonic
15 1 C35 1 nF, 200 V, Ceramic, X7R, 0805 08052C102KAT2A AVX Corp
16 2 C37 C38 680 µF, 63 V, Electrolytic, Low ESR, 50 mΩ, (16 x EEU-FC1J681 Panasonic
25)

17 1 C39 18 nF, 1600 V, Film 2222 383 50183 Vishay

18 1 C40 100 nF, 630 V, Film ECQ-E6104KF Panasonic
19 1 C68 1 µF, 50 V, Electrolytic, Gen. Purpose, (5 x 11) EKMG500ELL1R0ME11D Nippon Chemi-
Con
20 3 C70 C75 C76 150 uF, 25 V, Electrolytic, Low ESR, 180 mΩ, ELXZ250ELL151MF15D Nippon Chemi-
(6.3 x 15) Con
21 2 C74 C78 1 nF, Ceramic, Y1 440LD10-R Vishay
22 1 C80 3.3 nF, Ceramic, Y1 440LD33-R Vishay
23 1 D1 600 V, 3 A, Recitifier, DO-201AD 1N5406 Vishay
24 1 D2 600 V, 8 A, Ultrafast Recovery, 12 ns, TO-220AC STTH8S06D ST
Semiconductor
25 2 D3 D4 1000 V, 1 A, Rectifier, DO-41 1N4007-E3/54 Vishay
26 1 D8 600 V, 1 A, Ultrafast Recovery, 75 ns, DO-41 UF4005-E3 Vishay

27 1 D9 200 V, 10 A, Dual Ultrafast Recovery, 25 ns, TO- STTH1002CT ST

220AB
28 5 D16 D19 D20 100 V, 0.2 A, Fast Switching, 50 ns, SOD-323 BAV19WS-7-F Diode Inc.
D24 D25
29 2 D22 D23 200 V, 1 A, Ultrafast Recovery, 25 ns, DO-214AC ES1D Vishay

30 1 DER-212 Thermal Conductive insulator, DER-212 Pri Htsnk, Power

PRIMARY 0.5mm Silicone Integrations
INSULATOR
31 1 DER-212 Thermal Conductive insulator, DER-212 Sec Htsnk, Power
SECONDARY 0.5mm Silicone Integrations
INSULATOR
32 1 F1 5 A, 250 V, Slow, TR5 3721500041 Wickman

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

33 1 GREASE1 Thermal Grease, Silicone, 5 oz Tube CT40-5 ITW

Chemtronics
34 1 GND CABLE Cable ASSY, 18 GA GRN/YEL, 6 in, with ring
ASSY, DER- terminal
212
35 1 HS/BRACKET, Heatsink/Mounting Bracket, DER-212
DER-212
36 2 HS3 HS4 HEATSINK, Custom, Al, 1100, 0.090" Thk Power
Integrations
37 1 J3 8 Position (1 x 8) header, 0.156 pitch, Vertical 26-48-1081 Molex
38 1 J4 3 Position (1 x 3) header, 0.156 pitch, Vertical B3P-VH JST
39 1 JP38 Wire Jumper, Non insulated, 22 AWG, 1.4 in 298 Alpha
40 1 JP39 Wire Jumper, Non insulated, 22 AWG, 0.3 in 298 Alpha
41 2 L1 L2 Common Mode Choke Toroidal P/N T22148-902S (Order Fontaine Tech
PI Taiwan) CO. LTD
42 1 L4 CC Mode PFC Choke, PQ32/20
43 2 L6 L7 3.5 mm x 4.45 mm, 68 Ohms at 100 MHz, 22 AWG 2743001112 Fair-Rite
hole, Ferrite Bead

44 4 MAX CLIP1 Hardware, Heatsink MaxClip, TO220/Max247 MAX07G Aavid

MAX CLIP2 11.2lb 0.87 x 12 mm Thermalloy
MAX CLIP3
MAX CLIP4
45 1 MAX CLIP5 Hardware, Heatsink MaxClip, TO218/TO247 16.9lb MAX08G Aavid
0.93 x 18 mm Thermalloy
46 1 NUT1 Nut, Hex, Kep 4-40, S ZN Cr3 plateing RoHS 4CKNTZR Olander
47 6 NUT2 NUT3 Nut, Hex, Kep 6-32, Zinc Plate 6CKNTZR Olander
NUT4 NUT5
NUT6 NUT7
48 1 Q1 NPN, 60 V 1000 MA, SOT-23 FMMT491TA Zetex Inc
49 1 Q2 500 V, 20 A, 220 mOhm, N-Channel, TO-247AC STW20NM50FD ST
50 1 Q3 PNP, 60 V 1000 MA, SOT-23 FMMT591TA Zetex Inc
51 2 Q10 Q11 500 V, 6.8 A, 320 mOhm. N-Channel, TO-247AC IRFIB7N50LPBF IR/Vishay
52 1 Q20 PNP, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3906LT1G On
Semiconductor
53 1 Q24 600 V, 400 mA, 8.5 Ohm, N-Channel, SOT 223 STN1HNK60 ST

54 2 Q25 Q26 NPN, Small Signal BJT, 40 V, 0.2 A, SOT-23 MMBT3904LT1G On

Semiconductor
55 1 Q27 NPN, DARL 80 V 500 MA, SOT-89 BST52TA Zetex Inc
56 3 R1 R2 R3 680 kΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ684V Panasonic
57 2 R6 R8 0.33 Ω, 5%, 2 W, Metal Oxide MO200J0R33B Synton-Tech
corporation
58 1 R7 2.2 Ω, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ2R2V Panasonic
59 2 R9 R103 4.7 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ472V Panasonic
60 1 R30 7.5 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ752V Panasonic
61 2 R37 R38 4.7 Ω, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ4R7V Panasonic
62 2 R39 R40 768 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-768K Yageo
63 3 R41 R43 R46 768 kΩ, 1%, 1/4 W, Metal Film, 1206 ERJ-8ENF7683V Panasonic
64 1 R42 10 Ω, 5%, 1/4 W, Carbon Film CFR-25JB-10R Yageo
65 3 R44 R56 R58 10 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ100V Panasonic
66 1 R45 150 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ151V Panasonic
67 2 R47 R68 1 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ102V Panasonic
68 1 R48 2.2 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ222V Panasonic

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

69 1 R49 57.6 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF5762V Panasonic
70 1 R50 22.1 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF2212V Panasonic
71 2 R51 R52 15 kΩ, 1%, 1/16 W, Metal Film, 0603 ERJ-3EKF1502V Panasonic
72 1 R53 8.25 kΩ, 1%, 1/8 W, Metal Film, 0603 ERJ-3EKF8251V Panasonic
73 1 R54 1.8 kΩ, 5%, 1/10 W, Metal Film, 0603 ERJ-3GEYJ182V Panasonic
74 1 R55 1 Ω, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ1R0V Panasonic
75 1 R59 0.22 Ω, 5%, 2 W, Metal Oxide MO200J0R22B Synton-Tech
Corporation
76 1 R66 182 kΩ, 1%, 1/4 W, Metal Film, 1206 ERJ-8ENF1823V Panasonic
77 1 R67 10 kΩ, 1%, 1/8 W, Metal Film, 0805 ERJ-6ENF1002V Panasonic
78 1 R70 470 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ474V Panasonic
79 1 R107 2 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ202V Panasonic
80 1 R109 2.2 Ω, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ2R2V Panasonic
81 1 R111 22 kΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ223V Panasonic
82 2 R112 R117 22 kΩ, 5%, 1/8 W, Metal Film, 0805 ERJ-6GEYJ223V Panasonic
83 1 R113 10 kΩ, 5%, 2 W, Metal Oxide RSF200JB-10K Yageo
84 1 R114 2 MΩ, 5%, 1/4 W, Metal Film, 1206 ERJ-8GEYJ205V Panasonic
85 1 RL1 SPST-NO, 5A 12VDC, PC MNT G6B-1114P-US-DC12 OMRON
86 1 RT1 NTC Thermistor, 5 Ohms, 4.7 A CL150 Thermometrics
87 1 RV1 320 V, 84J, 15.5 mm, RADIAL S14K320 Epcos
88 1 SCREW1 SCREW MACHINE PHIL 4-40X1/2 SS PMSSS 440 0050 PH Building
Fasteners
89 5 SCREW2 SCREW MACHINE PHIL 6-32X1/2 SS PMSSS 632 0050 PH Building
SCREW3 Fasteners
SCREW4
SCREW5
SCREW6
90 1 SCREW7 SCREW MACHINE PHIL 6-32X1/4 SS PMSSS 632 0025 PH Building
Fasteners
91 4 SCREW8 SCREW MACHINE PHIL Flat head, Undercut 6-32 6C25PFUZR Olander
SCREW9 X ¼” Zinc Plated
SCREW10
SCREW11
92 2 STDOFF1 Standoff Hex,6-32, .375L,Alum 2209 Keystone Elect
STDOFF3

93 2 STDOFF2 Standoff Hex, 6-32/snap, .375L,Nylon FTA-A 375 Eagle

STDOFF4 Hardware
94 1 T1 Custom Transformer, LLC, ETD39,Vertical, 14Pins
95 4 TUBE-TO-220 Heatpad, TO-220 Tube 13.5 x 25 mm SPT400-12-11-25 Bergquist
96 1 TUBE-TO-247 Heatpad, TO-247 Tube 13.5 x 25 mm SPT400-12-13.5-25 Bergquist

97 1 U1 Controller, PFC/LLC, 24-pin DIP PLC818PG Power

Integrations
98 1 U2 Opto coupler, 35 V, CTR 80-160%, 4-DIP LTV-817A Liteon
99 1 U3 IC, REG ZENER SHUNT ADJ SOT-23 LM431AIM3/NOPB National
Semiconductor
100 1 VR9 15 V, 5%, 500 mW, DO-213AA (MELF) ZMM5245B-7 Diodes Inc

101 1 VR10 17 V, 5%, 500 mW, DO-213AA (MELF) ZMM5247B-7 Diodes Inc

102 1 VR11 12 V, 5%, 500 mW, DO-213AA (MELF) ZMM5242B-7 Diodes Inc
103 1 VR12 22 V, 5%, 500 mW, DO-35 1N5251B Microsemi

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

104 2 WASHER1 WASHER FLAT #4 SS FWSS 004 Building

WASHER2 Fasteners
105 11 WASHER3 Washer Flat #6, SS FWSS 006 Building
WASHER4 Fasteners
WASHER5
WASHER6
WASHER7
WASHER8
WASHER9
WASHER10
WASHER11
WASHER12
WASHER13

106 1 WASHER14 Bushing Nylon #4 X 0.125 MNI#4-8 Richco Plastic

Co.
107 5 WASHER15 Bushing Nylon #6 X 0.125 MNI#6-8 Richco Plastic
WASHER16 Co.
WASHER17
WASHER18
WASHER19

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

7 Magnetics

7.1 Main LLC 48 V Transformer (T1) Specification

7.1.1 Electrical Diagram

Figure 7 – Transformer Electrical Diagram.

7.1.2 Electrical Specifications

Electrical Strength 60 second, 60 Hz, from pins 1 - 9 to pins 10 - 18 3000 VAC
Pins 7 - 9, all other windings open, measured at
Primary Inductance 820 µH ±10%
100 kHz, 0.4 VRMS
Resonant Frequency Pins 7- 9, all other windings open 700 kHz (Min.)
Pins 7 - 9, with pins 10 - 18 shorted, measured at
Primary Leakage Inductance 100 µH ±10%
100 kHz, 0.4 VRMS

7.1.3 Materials
Item Description
[1] Core: ETD39, Ferroxcube 3F3 material or equivalent, gap for inductance coefficient (AL) of
539 nH/t².
[2] Bobbin: ETD39 vertical, flanged Pinshine P-3907
[3] Tape: Polyester film, 3M 1350F-1 or equivalent, 10.6 mm wide.
[4] Wire: Litz, 75 strands 40WAG, solderable single coated.
[5] Wire: Litz, 175 strands 40WAG, solderable single coated.
[6] Tape: Copper foil 9.0 mm wide.
[7] Tape: Polyester film, 10.0 mm wide.
[8] Copper bus wire #24 AWG.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

7.1.4 Winding Diagram

13
12

9
WD2: 39T – (75/40AWG_Litz wire)

WD1B: 9T - (175/40AWG_Litz wire) 11

WD1A: 9T - (175/40AWG_Litz wire) 10

Figure 8 – LLC Transformer Winding Diagram.

7.1.5 Winding Instructions

For the purpose of these instructions, Bobbin is oriented on winder such that pin side is
General note
on the left side (see illustration). Winding direction as shown is counter-clockwise.
For WD1A and WD1B use two ~60 cm lengths of Litz wire (item [5]). Mark start and
finish of one strand using a tape flag or other means. This strand will be used for WD
1A. Route start and finish leads as shown in illustrations. Start flagged wire strand at pin
WD1A and 1B 10, start unflagged strand at pin 11. Wind 9 simultaneous bifilar turns of Litz wire (item
[5]) from left to right, then from right to left, and continue with tight tension about 4
layers. Finish flagged wire at pin12 and unflagged wire at pin 13. Use 2 layers of tape
(item [3]) for finish wrap.
Starting at pin 7, shield start lead where it enters bobbin with 2cm piece of tape (item
[3]) at side of bobbin, then wind 39 turns of Litz wire (item [4]) on bobbin from left to
WD2
right, then from right to left, and continue with tight tension in 6 layers. Use 2 layers of
tape (item [3]) for finish wrap. Route start and finish leads as shown in illustrations.
Grind core halves for specified primary inductance, insert bobbin, and secure core
halves with one turn of copper tape (item [6]) as shown. Make sure that start and finis of
Assembly copper tape overlap. Solder at overlap, attach wire (item [8]) and connect this wire to pin
2.
Use tape (item [7]) to secure core halves and insulate.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

7.2 Transformer Illustrations

1
For the purpose of these
instructions, bobbin is
oriented on winder such
General note that pin side is on the left
side (see illustration).
Winding direction as shown
is counter-clockwise.
9

For WD1A and WD1B use

two ~60 cm lengths of Litz
wire (item [5]). Mark start
and finish of one strand
using a tape flag or other
means. The marked strand
WD1A and 1B:
will be used for WD 1A.
Route start and finish leads
as shown in illustrations.
Start flagged wire strand at
pin 10, start unflagged
strand at pin 11.

Wind 9 simultaneous bifilar

turns of Litz wire (item [5])
10 from left to right, then from
right to left, and continue
WD1A and 1B:
with tight tension about 4
(Cont’d)
layers. Finish flagged wire
at pin 12 and unflagged
wire at pin 13. Use 2 layers
of tape (item [3]) for finish
18 wrap.

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Use 2 layers of tape (item

[3]) for finish wrap.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Starting at pin 7, shield

start lead where it enters
bobbin with 2cm piece of
tape (item [3]) at side of
bobbin, then wind 39 turns
of Litz wire (item [4]) on
WD2:
bobbin from left to right,
then from right to left, and
continuing for 6 layers.
Finish at Pin 9. Route start
and finish leads as shown
in illustration.

Use 2 layers of tape (item

WD2: [3]) for finish wrap. Route
(Cont’d) start and finish leads as
shown in illustrations.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

Grind core halves for

specified primary
inductance, insert bobbin,
and secure cores with one
turn of copper Tape (item
[6]). Overlap start and
Assembly finish of copper tape.
Solder at overlap, attach
wire (item [8]) and connect
this wire to pin 2.
Use tape (item [7]) to
secure core halves and
insulate.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

7.3 PFC Choke (L4) Specification

7.3.1 Electrical Diagram

Figure 9 – PFC Choke Schematic.

7.3.2 Electrical Specification

Inductance: Pins 1-6, 100 kHz, 0.4 V - 580 µH ± 10%

7.3.3 Materials
Item Description
2
[1] Ferrite core pair, PQ32/20, TDK PC44PQ32/20Z-12 or equivalent, gap for AL of 473 nH/T .
[2] Bobbin, PQ32/20, 12 pin, TDK CPH-E41/12-1S-12PD-Z or equivalent.
[3] Magnet Wire: #20AWG, solderable double coated.
[4] Magnet Wire: #28AWG, solderable double coated.
[5] Tape Polyester Film, 3M 1350F-1 or equivalent, 7.5 mm wide.
[6] Tape Polyester Film, 3M 1350F-1 or equivalent, 10 mm wide.
[7] Tape, Copper Foil, 3M 1125 or equivalent, 6.5 mm wide.
[8] Wire, tinned bus, #24 AWG.
[9] Transformer Varnish, Dolph BC-389 or equivalent (must be baking vs. air-dry varnish).

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

7.3.4 Build Diagram

Core [1]

Solder wire [7] here

Bus Wire [8]

Pin 7
Copper Tape [7]

Overlap and solder ends

Figure 10 – PFC Choke Build Diagram.

7.3.5 Winding Instructions

Bobbin
Pull pins 2, 3, 10, and 11 on bobbin [2].
Preparation
Main
Starting on pin 1, wind 35 turns of wire [3] on bobbin [2]. Finish on pin 6.
Winding
Insulation Use 1 layer of tape [5] for insulation.
Bias
Starting on pin 8, wind 2 turns of wire [4], finishing on pin 7.
Winding
Finish Wrap Use 3 layers of tape [5] for finish wrap.
Core
Assemble bobbin and core halves. Secure core with two wraps of tape (Item 5).
Assembly
Shield Apply 1 turn of copper tape (Item [7]) as shown in Figure 1, centered in bobbin window.
Overlap start and finish ends as shown in Figure 1, and solder to form a shorted turn.
Take 3 cm of hook-up wire [7], solder 1 end of wire to copper foil as shown in Figure 1.
Terminate other end on pin 9 of bobbin.
Shield
Apply 3 turns of tape (item [6]) to insulate copper shield.
Insulation
Varnish Dip varnish finished assembly.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Figure 11 – Finished PFC Choke, Front and Back View.

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

8 LLC Transformer Design Spreadsheet

ACDC_PLC810_031209; ACDC_PLC810_031209_Rev1-[Link]; PLC810
Rev.1.4; Copyright Power Half-Bridge, Continuous mode LLC
Integrations 2008 INPUTS INFO OUTPUTS UNITS Resonant Converter Design Spreadsheet
Enter Input Parameters
Vacmin 140 V Minimum AC input voltage
Vacmax 265 V Maximum AC input voltage
Iacinmax 1.19 A Maximum input AC rms current at Vacmin
Vbulk 385.00 V Nominal PFC output voltage
Vbulkmax 411.95 V Peak PFC OVP voltage (typical is 7% above
Vbulk)
Vbulkmin 300.00 300.00 V Minimum bulk capacitor voltage at the specified
holdup time. Typical value is between 250 - 320
VDC. Max holdup time is at 250 V
fL 50.00 Hz AC Line input frequency
Holdup time 18.00 18.00 ms Bulk capacitor hold up time
CIN_MIN 98.28 uF Minimum value of bulk cap to meet holdup time
requirement; Adjust holdup time and Vbulkmin
to change bulk cap value
bulk ripple 8.16 V Bulk capacitor peak to peak voltage (low freq
ripple)
Vrippeak 389.08 V Bulk cap peak value of ripple voltage
IAC 1.19 A AC input rms current at VACMIN
IAC_PEAK 1.68 A Peak AC input current at full load and VACMIN

Enter LLC (secondary) outputs The spreadsheet assumes AC stacking of the

secondaries
Vo1 48.00 V Main Output Voltage. Spreadsheet assumes
that this is the regulated output
Io1 3.13 A Main output maximum current
Vd1 0.90 0.90 V Forward voltage of diode in main output
Po1 150.24 W Output Power from first LLC output
Vo2 0.00 V Second Output Voltage
Io2 0.00 A Second output current
Vd2 0.00 0.00 V Forward voltage of diode used in second output
Po2 0.00 W Output Power from second LLC output

Enter stand-by (auxiliary) outputs

Vo3 12.00 V Auxiliary Output 1 Voltage
Io3 0.05 A Auxiliary Output 1 maximum current
Vo4 V Auxiliary Output 2 Voltage
Io4 A Auxiliary Output 2 maximum current

Efficiciency and Loss Allocation

P_LLC 150.24 W Specified LLC output power
P_AUX 0.60 W Auxiliary output power
P_PFC 158.95 W PFC output power
P_TOTAL 150.84 W Total output power (Includes Output power from
LLC stage and auxiliary stage)
LLC_n_estimated 0.95 0.95 Efficiency of LLC stage
AUX_n_estimated 0.75 Efficiency of auxiliary output
PFC_n_estimated 0.96 0.96 Minimum efficiency of PFC front end stage
PIN 166.44 W AC input power

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Overall efficiency 0.91 Minimum system efficiency

Ploss_PFC 7.49 W PFC stage power loss
Ploss_LLC 7.91 W LLC stage power loss
Ploss_AUX 0.20 W Auxiliary power loss
Ploss_TOTAL 15.60 W Total power loss

Enter PFC Design Parameters

f_nominal_desired 100.00 kHz Desired full load switching frequency.
Recommended value 66 kHz to 132 kHz
Krp 0.98 0.98 PFC choke ripple current factor. Actual Krp
tends to increase at higher current when using
iron powder/Sendust cores, due to drop in
inductance at higher current
Diode bridge Vf 0.70 V Forward voltage drop of diode bridge
Rdson 0.22 0.22 ohms PFC MOSFET Rdson - use high temp value
from datasheet
Coss 18.18 pF PFC MOSFET high voltage Coss from
datasheet
tON 20.00 ns MOSFET turnon current rise time. Check actual
value
Qrr 26.49 nC Average Qrr of boost diode over AC sinusoid

PFC CHOKE Parameters

Lpfc 583.79 uH PFC choke inductance
ILpk 3.33 A PFC choke peak current at VACMIN
AL 470.00 nH/t^2 nH per turn^2 (from magnetics datasheet). Note
- This value decreases by as much as 15% if a
belly-band is added to reduce EMI
n 35.24 turns PFC choke number of turns
MLT 5.00 cm Mean length per turn
AWG_Choke 20 PFC choke wire gauge
Equivalent Choke Metric Wire 0.80 mm Equivalent diameter of wire in metric units
gauge
Wire length 1.76 m Length of wire used on PFC choke
Strands 3 Number of wires
DCR 21.21 m-ohms DC resistance of wire at 25 C
DCR at 85 C 26.72 m-ohms DC resistance of wire at 85 C
Irms_CHOKE 1.36 A PFC choke rms current
DCR Cu loss 0.05 W PFC choke DC Copper loss for reference at 85
C
ACR_PFC_Choke 53.45 m-ohms Measure or calculate; add 26% to measured
value to get 85 C value
HF Irms 0.58 A RMS current of switching component
HF Cu loss 0.02 W Copper loss due to switching component at 85
C
tot Cu loss 0.07 W Total copper loss at 85 C
LM 10.00 cm Magnetic path length of core used
Hpk 14.74 Oe Peak MMF in Oersteds, calculated at low line
Hpk_SI 1174 A/m Peak MMF in A/m, calculated at low line

PFC FET, Diode and Output Parameters

Isense_R 0.16 ohms Maximum value of PFC current sense resistor
Sense resistor power 0.30 W PFC sense resistor power dissipation at Vacmin
dissipation
Irms_FET 1.11 A PFC MOSFET RMS current measured at
VACMIN
Conduction loss 0.27 W PFC MOSFET conduction loss

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

Trrloss 0.89 W PFC MOSFET loss due to diode Trr

Cossloss 0.15 W MOSFET Coss loss
Crossover loss 0.01 W MOSFET crossover turnon loss
Total PFC loss 1.17 W MOSPFC FET total loss
Diode bridge Ploss 1.51 W Diode bridge estimated loss
PFC Diode RMS current 0.65 A Approximate PFC Diode RMS current at
nominal AC input voltage (VACMIN) (includes
100/120 Hz component)
Bulk capacitor RMS current 0.72 A Approximate Bulk Capacitor RMS current at
nominal AC input voltage (VACMIN) (includes
100/120 Hz component and LLC input current)

LLC TRANSFORMER CALCULATIONS

Po 153.06 W Output from LLC converter including diode loss
Vo 48.90 V Output at transformer windings (includes diode
drop)
Ae 2.10 cm^2 Transformer core cross-sectional area
Lpar 704.00 704.00 uH Parallel inductance. (Lpar = Lopen - Lser for
integrated transformer; Lpar = Lmag for non-
integrated transformer)
Lser 116.00 116.00 uH Leakage inductance of integrated transformer;
Leakage + external inductor for non-integrated
transformer
Lopen 820.00 uH Primary open circuit inductance for integrated
transformer
C 18.00 18.00 nF Series resonant capacitor
fnominal_desired 100.00 kHz Desired full load switching frequency.
Recommended value 66 kHz to 132 kHz

fnominal_actual 87.0 kHz Expected frequency at nominal input voltage

(VBULK) and full load
IRMS_LLC_Primary 0.94 A Primary winding RMS current at full load and
nominal input voltage (VBULK)
IRMS_LLC_Q1 0.67 A RMS current through upper MOSFET in LLC
half bridge
VMIN 295.1 V Minimum Voltage on Bulk Capacitor at minimum
switching frequency
f_AT_VMIN 49.00 kHz Frequency at minimum Bulk capacitor voltage
fpar 45 kHz Parallel resonant frequency (defined by Lpar +
Lser and C)
fser 110 kHz Series resonant frequency (defined by series
inductance Lser and C)
fmin 55 kHz Min frequency, at VBULK _MIN and full load.
Set PLC810 minimum frequency to this value.
Operation below this frequency results in loss of
ZVS
NP_1 39 Primary winding number of turns
NS_1 9.00 9 Secondary winding number of turns
n_RATIO 4.30 4.30 Transformer turns ratio. Adjust this value so that
fnominal_actual is close to fnominal_desired
Bpkfmin 1186 Gauss First Quadrant peak flux excursion at minimum
frequency.
BAC 1487 Gauss AC peak to peak flux density (calculated at
fnominal_actual, VBULK at full load)
LLC sense resistor 0.22 0.22 ohms LLC current sense resistor
Pdiss_LLC_senseR 0.20 W Power dissipation in LLC sense resistor

PRIMARY
Primary gauge 40.00 AWG Individual wire strand gauge used for primary
winding
Equivalent Primary Metric 0.08 mm Equivalent diameter of wire in metric units
Wire gauge

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Primary litz strands 75.00 Number of strands used in Litz wire; for non-litz
non-integrated transformer set to 1
Primary parallel wires 1.00 Number of parallel individual wires to make up
Litz wire
Resistivity_25 C_Primary 49.72 m-ohm/m Resistivity in milli-ohms per meter
Transformer primary MLT 5.00 cm Mean length per turn
Primary turns 38.70 Number of primary turns
Primary DCR 25 C 96.21 m-ohm Estimated resistance at 25 C
Primary DCR 100 C 128.92 m-ohm Estimated resistance at 100 C (approximately
33% higher than at 25 C)
Primary RMS current 1.50 A Measured RMS current through the primary
winding
ACR_Trf_Primary 206.27 m-ohm Measured AC resistance (at 100 kHz, room
temperature), multiply by 1.33 to approximate
100 C winding temperature
Primary copper loss 0.46 W Total primary winding copper loss at 85 C

Separate Series Inductor (For non-integrated transformer only) Ignore this section if using integrated magnetics
Lsep 116.00 uH Desired inductance from separate inductor
Ae_Ind 0.53 cm^2 Inductor core cross-sectional area
Inductor turns 15.00 15 Number of primary turns
BP_fnom 2086 Gauss AC flux for core loss calculations (at fnom and
full load)
BP_fmin 2629 Gauss Peak flux density, calculated at minimum
frequency fmin
Inductor gauge 40.00 AWG Individual wire strand gauge used for primary
winding
Equivalent Inductor Metric 0.08 mm Equivalent diameter of wire in metric units
Wire gauge
Inductor litz strands 125.00 Number of strands used in Litz wire
Inductor parallel wires 1.00 Number of parallel individual wires to make up
Litz wire
Resistivity_25 C_Sep_Ind 29.83 m-ohm/m Resistivity in milli-ohms per meter
Inductor MLT 7.00 cm Mean length per turn
Inductor DCR 25 C 31.32 m-ohm Estimated resistance at 25 C (for reference)
Inductor DCR 100 C 41.97 m-ohm Estimated resistance at 100 C (approximately
33% higher than at 25 C)
ACR_Sep_Inductor 67.16 m-ohm Measured AC resistance (at 100 kHz, room
temperature), multiply by 1.33 to approximate
100 C winding temperature
Inductor copper loss 0.15 W Total primary winding copper loss at 85 C

Winding 1 (Vo1) Note - Power loss calculations are for each

winding half of secondary
Sec 1 Wire gauge 40 AWG Individual wire strand gauge used for secondary
winding
Equivalent secondary 1 Metric 0.08 mm Equivalent diameter of wire in metric units
Wire gauge
Sec 1 litz strands 175 Number of strands used in Litz wire; for non-litz
non-integrated transformer set to 1
Parallel wires sec 1 1 Number of parallel individual wires to make up
Litz wire
Resistivity_25 C_sec1 21.31 m-ohm/m Resistivity in milli-ohms per meter
Transformer Secondary MLT 5.00 cm Mean length per turn
Sec 1 Turns 9.00 Secondary winding turns (each half)
DCR_25C_Sec1 9.59 m-ohm Estimated resistance at 25 C (for reference)
DCR_100C_Sec1 12.85 m-ohm Estimated resistance at 100 C (approximately
33% higher than at 25 C)
Sec 1 RMS current 4.92 A RMS current through Output 1 winding,

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DER-212, 150 W Street Light Power Supply Using PLC810PG 01-Jun-09

assuming half sinusoidal waveshape

DCR_Ploss_Sec1 0.25 W Estimated Power loss due to DC resistance
(both secondary halves)
ACR_Sec1 20.56 m-ohm Measured AC resistance (at 100 kHz, room
temperature), multiply by 1.33 to approximate
100 C winding temperature . Default value of
ACR is twice the DCR value at 100 C
ACR_Ploss_Sec1 1.00 W Estimated AC copper loss (both secondary
halves)
Total secondary winding 1.25 W Total (AC + DC) winding copper loss for both
Copper Losses secondary halves

Winding 2 (Vo2) Note - Power loss calculations are for each

winding half of secondary
Sec 2 Wire gauge 40 AWG Individual wire strand gauge used for secondary
winding
Equivalent secondary 2 Metric 0.08 mm Equivalent diameter of wire in metric units
Wire gauge
Sec 2 litz strands 175 Number of strands used in Litz wire; for non-litz
non-integrated transformer set to 1
Parallel wires sec 2 1 Number of parallel individual wires to make up
Litz wire
Resistivity_25 C_sec2 21.31 m-ohm/m Resistivity in milli-ohms per meter
Transformer Secondary 2 cm Mean length per turn
MLT
Sec 2 Turns 0.00 Secondary winding turns (each half)
DCR_25C_Sec2 0.00 m-ohm Estimated resistance at 25 C (for reference)
DCR_100C_Sec2 0.00 m-ohm Estimated resistance at 100 C for half
secondary (approximately 33% higher than at
25 C)
Sec 2 RMS current 4.92 Arms RMS current through Output 2 winding; Output
1 winding is AC stacked on top of Output 2
winding
DCR_Ploss_Sec1 0.00 W Estimated Power loss due to DC resistance
(both secondary halves)
ACR_Sec2 0.00 m-ohm Actual measured AC resistance (at 100 kHz,
room temperature), multiply by 1.33 to
approximate 100 C winding 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 secondary winding 0.00 W Total (AC + DC) winding copper loss for both
Copper Losses secondary halves

Total Copper loss calculation Does not include fringing flux loss from gap
Primary copper loss (from 0.46 W Total primary winding copper loss at 85 C
Primary section)
Secondary copper Loss 1.25 W Total copper loss in secondary winding
Transformer copper loss 1.71 W Total copper loss in transformer (primary +
secondary)

TURNS CALCULATOR This is to help you choose the secondary turns -

not connected to any other part of spreadsheet
V1 48.00 V Target Output Voltage Vo1
V1d1 0.90 V Diode drop voltage for Vo1
N1 4.00 Total number of turns for Vo1
V2 V Expected outputV
V2d2 V Diode drop voltage for Vo2
N2 2.00 Total number of turns for Vo2

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

Compared to the above spreadsheet, actual operating frequency is considerably higher than the expected
operating frequency of 90 kHz shown. This is due to the effective turns ratio of the transformer, which
results in an operating turns ratio lower than the ratio of primary turns to secondary turns (NP/NS). The
graphs shown below were generated by adjusting the turns ratio in the spreadsheet until the expected
operating frequency shown in the spreadsheet was identical to the actual operating frequency of the unit
under test.

VBULK vs Switching Frequency

500

450

400

350
VBULK (V)

Full load
300
Min load

250

200

150

100
0 100 200 300
Switching Frequency (kHz)
Full Load Primary and MOSFET RMS Currents

3
IRMS (A)

Primary
MOSFET
2

0
30 130 230
Switching Frequency (kHz)

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9 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.

9.1 LLC Stage Efficiency

To make this measurement, the LLC stage was powered separately by connecting an
external 385 VDC supply across bulk capacitor C9, and a 15 V source was applied
between the collector of regulator transistor Q27 and controller ground.

LLC Efficiency vs. Output Power, 385 VDC Input

98.00%

96.00%

94.00%
Efficiency (%)

92.00%

90.00%

88.00%

86.00%

84.00%

82.00%
0 20 40 60 80 100 120 140 160
Output Power (W)

Figure 12 – LLC Stage Efficiency vs. Load, 385 VDC Input.

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01-June-09 DER-212, 150 W Street Light Power Supply Using PLC810PG

9.2 Total Efficiency

Figures below show the total supply efficiency (PFC and LLC stages). AC input was
supplied using a 60 Hz sine wave source.

Total Efficiency vs. Input Voltage

0.94
0.92
0.9
0.88
0.86
Efficiency (%)

100% Load
0.84
50% Load
0.82
20% Load
0.8
10% Load
0.78
0.76
0.74
0.72
0.7
120 140 160 180 200 220 240 260 280
AC Input Voltage

Figure 13 – Total Efficiency vs. Output Power.

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9.3 THD and Power Factor

THD and Power factor measurements were made using a 60 Hz sine wave AC source.

THD vs. Input Voltage

12

10

8
1/2 Load
THD (%)

6 Full Load

0
120 140 160 180 200 220 240 260 280
AC Input Voltage

Figure 14 – Input Current THD vs. Input Voltage, 50% and 100% Load.

Power Factor vs. Input Voltage

0.98

0.96
Power Factor

0.94
Full Load
1/2 Load
0.92

0.9

0.88
120 140 160 180 200 220 240 260 280
AC Input Voltage

Figure 15 – Power Factor vs. Input Voltage, 50% and 100% Load.

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9.4 Output Regulation

The PFC regulates the LLC and standby supply input voltage under normal conditions so
the outputs will not be affected by the AC input voltage. Variations due to temperature
and component tolerances are not represented. The 48 V output varies by less than 1%
over a load range of 2% to 100% load.

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10 Waveforms
All waveforms are measured at room temperature using a 60 Hz sine wave supply unless
otherwise indicated.

10.1 Input Voltage and Current

Figure 16 – 140 VAC, 150 W Load. Figure 17 – 230 VAC, 150 W Load.
Top Trace: Input Current, 1 A / div. Top Trace: Input Current, 1 A / div.
Bottom trace: Input Voltage, 200 V, 5 ms / div. Bottom trace: Input Voltage, 200 V, 5 ms / div.

10.2 LLC Primary Voltage and Current

The LLC stage current was measured by cutting the PC board trace in series with the T1
primary and adding a current sensing loop that measures the LLC transformer (T1)
primary current. The primary voltage waveform was measured at the hot side of ferrite
bead L6.

Figure 18 – LLC Stage Primary Voltage and Current.

Top Trace: Current, 1 A / div.
Bottom Trace: Voltage, 100 V, 2 µs / div.

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10.3 PFC Switch Voltage and Current - Normal Operation

Figure 19 – 140 VAC Input, 100% Load. Figure 20 – 230 VAC Input, 100% Load.
Top Trace: Q2 Drain Current, 1 A / div, 5 µs / div Top Trace: Q2 Drain Current, 1 A / div, 5 µs / div
Bottom Trace: Drain Voltage, 100 V, 5 µs/div. Bottom Trace: Drain Voltage, 100 V, 5 µs / div.

10.4 AC Input Current and PFC Output Voltage During Start-up

Figure 21 – Full Load, 140 VAC. Figure 22 – Full Load, 230 VAC.
Top Trace: AC Input Current, 2 A / div. Top Trace: AC Input Current, 2 A / div.
Bottom Trace: PFC Voltage, 100 V, 20 ms / div. Bottom Trace: PFC Voltage, 100 V, 20 ms / div.

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10.5 LLC Start-up

Figure 23 – LLC Start-up. 230 VAC, 100% Load.

Top Trace: LLC Primary Current, 1 A / div.
Bottom Trace: Output Voltage, 20 V, 10 ms / div.

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10.6 LLC Output Short Circuit

The figure below shows the effect of an output short circuit on the LLC primary current. A
mercury displacement relay was used to short the output to get a fast, bounce-free
connection.

Figure 24 – Output Short Circuit Test, 230 VAC.

Top Trace: LLC Primary Current, 2 A / div.
Bottom Trace: 48 V Output, 20 V, 50 µs / div.

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10.7 Output Voltage During Start-up

Figure 25 – 48 V Output at Start-up. Figure 26 – 48 V Output at Start-up.

140 VAC Input, Full Load. 10 V, 20 ms/ div. 230 VAC Input, Full Load. 10 V, 20 ms / div.

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10.8 Output Ripple Measurements

10.8.1 Ripple Measurement Technique

For DC output ripple measurements, use a modified oscilloscope test probe to reduce
spurious signals. Details of the probe modification are provided in figures below.

Tie two capacitors in parallel across the probe tip of the 4987BA probe adapter. Use a
0.1 µF / 50 V ceramic capacitor and 1.0 µF / 100 V aluminum electrolytic capacitor. The
aluminum-electrolytic capacitor is polarized, so always maintain proper polarity across
DC outputs.

Probe Ground

Probe Tip

Figure 27 – Oscilloscope Probe Prepared for Ripple Measurement (End Cap and Ground Lead Removed).

Figure 28 – Oscilloscope Probe with Probe Master 4987BA BNC Adapter (Modified with Wires for Probe
Ground for Ripple measurement and Two Parallel Decoupling Capacitors Added).

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10.8.2 Full Load Output Ripple Results

Figure 29 – 48 V Output Ripple, 200 mV, 2 ms / div. Figure 30 – 48 V Output Ripple, 100 mV, 5 µs / div.

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10.8.3 Output Load Step Response

The figures below show transient response with a 75%-100%-75% load step for the 48 V
output. The oscilloscope was triggered using the rising edge of the load step, and
averaging was used to cancel out ripple components asynchronous to the load step in
order to better ascertain the load step response.

Figure 31 – Output Transient Response 3.13 A – 2.3 A – 3.13 A Load Step.

Top Trace: 48 V Transient Response, 50 mV / div.
Bottom Trace: Output Load Step, 1 A, 500 µs / div.

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11 Temperature Profiles
The board was operated at room temperature in a vertical orientation as shown below.
For each test condition the unit was allowed to thermally stabilize (>1 hr) before
measurements were made. Infrared measurements were correlated to thermocouples
attached using copper tape.

LLC LLC
MOSFETs transformer

LLC
rectifier

PFC
inductor

PFC
boost
diode

Input
bridge
PFC
boost
MOSFET
Figure 32 – Photograph of Board Orientation Used for Thermal Testing.

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11.1 Thermal Results Summary

11.1.1 Testing Conditions

The goal of this design is to maintain the temperature of components below 100 °C at
rated ambient and 100% load (150 W), low line (140 VAC, 60 Hz).

By extrapolating the data below from 21 °C to 60 °C this design meets these

requirements.

Measurement data is presented below. The unit was allowed to thermally stabilize (>1
hours in all cases) before gathering data. Semiconductor plastic and magnetics
temperatures were correlated via thermocouples attached with copper tape.

140 VAC, 60 Hz 230 VAC, 60 Hz

Output Power (W) 150.2 150.2
Input Power (W) 164.5 162.6
Efficiency (%) 91.3 92.37
Output Loading 48 V (A) 3.13 3.13
Temperatures (°C)
Ambient 21 21
LLC rectifier plastic package (D9) 47 48
LLC Upper MOSFET (Q10) plastic package 42 43
LLC Lower MOSFET (Q11 ) plastic package 44 45
PFC diode plastic package (D2) 44 41
PFC MOSFET plastic package (Q2) 42 39
Bridge rectifier plastic package (BR1) 49 43
LLC transformer (T2) surface 47 49
PFC inductor (L4) surface 40 43

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11.2 140 VAC, 60 Hz, 150 WOUT

Figure 33 – Thermal Profile. Room Temperature, 140 VAC, 60 Hz, 150 W Load (1 hr)

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11.3 230 VAC, 60 Hz, 150 WOUT

Figure 34 – Thermal Profile. Room Temperature, 230 VAC, 60 Hz, 150 W Load (1 hr)

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12 LLC Gain-Phase

Figure 35 – LLC Converter Gain-Phase, 100% Load Crossover Frequency – 2 kHz, Phase Margin - 45°.

Figure 36 – LLC Converter Gain-Phase, 50% Load. Crossover Frequency ~1.8 kHz, Phase Margin - ~55°.

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Figure 37 – LLC Converter Gain-Phase, 10% Load. Gain Crossover – 600 Hz, Phase Margin - ~55°.

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13 Conducted EMI
Conducted EMI tests were performed with a 16 Ω resistive load on the 48 V main output.
The unit was placed on a metallic ground plane, which in turn was hard wired to the AC
cord ground. The resistive load was connected to the ground plane with a pair of 2.2 nF
capacitors (one at the positive feed, and one at the return) to simulate the capacitive
coupling of LED modules to a grounded street light casing. The peak shown at `90 MHz
is actually 10 dB lower than shown in the graph, as the EMI receiver changes scale at 80
MHz.

Figure 38 – Conducted EMI, 230 VAC.

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14 Line Surge

Differential input line 1.2/50 µs surge testing was completed on a single test unit to
IEC61000-4-5. Input voltage was set at 230 VAC / 60 Hz. Output was loaded at full load
and operation was verified following each surge event. During testing no output
interruption was seen.

Surge Generator Input Injection

Test Result
Level Impedance Voltage Injection Location Phase
(Pass/Fail)
(kV) (Ω) (VAC) (°)
+1 kV 2 230 L to N 90 Pass
-1 kV 2 230 L to N 270 Pass
+2 kV 12 230 L, N to G 90 Pass
-2 kV 12 230 L, N to G 270 Pass

Notes: 1) A ground plane was placed under the PSU bracket and load resistors (load
resistors are aluminum case units mounted on heat sinks). The resistive load was
bypassed to the ground plane with (2) 2.2 nF capacitors (one at the +48 V input
lead, one at return) to simulate the capacitance of LED arrays to a grounded street
light case, but otherwise feft floating. The input AC safety ground wire was
connected to the ground plane.

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15 Revision History

Date Author Revision Description and changes Reviewed

11-May-09 RH 1.0 Initial Release
01-Jun-09 1.1 Revised PCB Images

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For the latest updates, visit our website: [Link]

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 [Link].
Power Integrations grants its customers a license under certain patent rights as set forth at
[Link]

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PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective
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