200w pfc + lcc resonant converter reference design for led

An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other important disclaimers and information.

TIDT084 - January 2019 1

Copyright © 2019, Texas Instruments Incorporated

Test Report: PMP20946

200W PFC + LCC resonant converter reference design for LED lighting

Description

This reference design uses the UCC28180 CCM PFC controller and the UCC256301 Wide Vin resonant controller as an LCC controller with an integrated driver. It provides up to 200W constant current or constant voltage output from a universal AC input. An external analog dimming voltage signal can be applied to dynamically adjust output current for dimming LED loads.


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2 TIDT084 - January 2019Copyright © 2019, Texas Instruments Incorporated

1 System Specification

1.1 Board Dimension: 9.5” x 2.25” x 2.25”

1.2 Input Characteristics

Minimum Nominal Maximum

108 115~230 305 VAC

50 60 Hz

1.3 Output Characteristics The power supply unit should be able to supply 200W output power continuously.

1.4 Board Photos The photographs below show the top and bottom view of the PMP20946 RevA board, which is built on PMP20947 RevB PCB.

Top Side

Bottom Side


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2 Efficiency, Power Factor, and Harmonics The efficiency curves are shown in the tables and graph below. A 12V fan (NMB Technologies Model # 3610VL-04W-B50-B00) was applied to the board during testing directed toward inductor L200. The following image depicts this setup.


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2.1 Isolated DC-DC stage (LLC-SRC) efficiency – constant output voltage L100 and J200 are opened during the test. DC input is provided at C206 along with 115VAC input for high voltage startup.

60%

65%

70%

75%

80%

85%

90%

95%

0.00 50.00 100.00 150.00 200.00

Effi

cie

ncy

Output Power (W)

LCC Efficiency

400Vin

435Vin

460Vin


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400VDC, 200Vout

Vin (V) Iin (A) Pin (W) Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)

400 0.548 219.20 199.3 1.000 199.30 19.90 90.92

400 0.494 197.60 199.2 0.900 179.28 18.32 90.73

400 0.443 177.20 199.2 0.800 159.36 17.84 89.93

400 0.390 156.00 199.2 0.700 139.44 16.56 89.39

400 0.339 135.60 199.2 0.600 119.52 16.08 88.14

400 0.288 115.20 199.2 0.500 99.60 15.60 86.46

400 0.236 94.40 199.1 0.400 79.64 14.76 84.36

400 0.185 74.00 199.1 0.300 59.73 14.27 80.72

400 0.135 54.00 199.1 0.200 39.82 14.18 73.74

400 0.084 33.60 199.1 0.100 19.91 13.69 59.25

400 0.059 23.60 199.1 0.050 9.96 13.65 42.18

400 0.012 4.80 199.1 0.001 0.20 4.60 4.15

435VDC, 200Vout


435 0.506 220.11 199.4 1.000 199.40 20.71 90.59

435 0.457 198.80 199.2 0.900 179.28 19.52 90.18

435 0.409 177.92 199.1 0.800 159.28 18.64 89.53

435 0.360 156.60 199.1 0.700 139.37 17.23 89.00

435 0.314 136.59 199.1 0.600 119.46 17.13 87.46

435 0.267 116.15 199.1 0.500 99.55 16.60 85.71

435 0.220 95.70 199.1 0.400 79.64 16.06 83.22

435 0.173 75.26 199.0 0.300 59.70 15.56 79.33

435 0.127 55.25 199.1 0.200 39.82 15.43 72.08

435 0.081 35.24 199.0 0.100 19.90 15.34 56.48

435 0.058 25.23 199.1 0.050 9.96 15.28 39.46

435 0.011 4.79 199.1 0.001 0.20 4.59 4.16


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460VDC, 200Vout


460 0.477 219.42 199.2 1.000 199.20 20.22 90.79

460 0.434 199.64 199.2 0.900 179.28 20.36 89.80

460 0.388 178.48 199.2 0.800 159.36 19.12 89.29

460 0.343 157.78 199.2 0.700 139.44 18.34 88.38

460 0.299 137.54 199.2 0.600 119.52 18.02 86.90

460 0.255 117.30 199.1 0.500 99.55 17.75 84.87

460 0.211 97.06 199.1 0.400 79.64 17.42 82.05

460 0.168 77.28 199.1 0.300 59.73 17.55 77.29

460 0.124 57.04 199.1 0.200 39.82 17.22 69.81

460 0.080 36.80 199.1 0.100 19.91 16.89 54.10

460 0.058 26.68 199.1 0.050 9.96 16.73 37.31

460 0.011 5.06 199.1 0.001 0.20 4.86 3.94


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2.2 Isolated DC-DC stage (LLC-SRC) efficiency – constant output current L100 and J200 are opened during the test. DC input is provided at C206 along with 115VAC input for high voltage startup. LED load used (MP22T1-C24-5070-T2-1-00), up to 4 in series.

400VDC, 1A (LED load)

Vin (V) Iin (A) Pin (W) Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%) Fsw (kHz) Load

400 0.548 219.20 199.1 0.999 198.90 20.30 90.74 131 199Ω resistive Eload

400 0.504 201.60 183.1 1.000 183.10 18.50 90.82 133 4x LED

400 0.379 151.60 137.4 1.000 137.40 14.20 90.63 136 3x LED

400 0.255 102.00 91.6 0.999 91.51 10.49 89.71 137 2x LED

460VDC, 1A (LED load)

Vin (V) Iin (A) Pin (W) Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%) Fsw (kHz) Load

460 0.476 218.96 199.3 0.994 198.10 20.86 90.48 135 199Ω resistive Eload 460 0.438 201.48 182.5 0.999 182.32 19.16 90.49 136 4x LED 460 0.329 151.34 136.8 0.999 136.66 14.68 90.30 139 3x LED 460 0.225 103.50 91.3 0.999 91.21 12.29 88.12 143 2x LED

112

116

120

124

128

132

136

140

144

87.0%

88.0%

89.0%

90.0%

91.0%

92.0%

93.0%

94.0%

95.0%

90 100 110 120 130 140 150 160 170 180 190 200

Fre

qu

en

cy (

kHz)

Effi

cie

ncy

(%

)

Output Voltage (V)

1A Constant Current Output

400Vin_Eff

460Vin_Eff

400Vin_Fs

460Vin_Fs


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8 TIDT084 - January 2019


2.3 Total efficiency

Total efficiency measurement includes both PFC and isolated DC-DC stages.

120VAC/60Hz, 200Vout Vin,rms (V) Iin,rms (A) Pin (W) P.F. THD Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)

120.5 1.945 233.90 0.997 4.62% 199.2 1.001 199.40 34.50 85.25

120.8 1.747 210.50 0.997 4.34% 199.1 0.900 179.19 31.31 85.13

120.0 1.573 188.21 0.997 4.05% 199.1 0.800 159.28 28.93 84.63

120.4 1.384 166.23 0.997 3.72% 199.1 0.701 139.57 26.66 83.96

120.8 1.197 144.15 0.997 3.42% 199.1 0.600 119.46 24.69 82.87

121.1 1.016 122.68 0.996 3.11% 199.1 0.501 99.75 22.93 81.31

120.1 0.847 101.28 0.995 3.00% 199.0 0.400 79.60 21.68 78.59

120.6 0.668 80.07 0.993 3.16% 199.0 0.300 59.70 20.37 74.56

121.1 0.492 59.04 0.989 3.93% 199.0 0.200 39.80 19.24 67.41

120.1 0.326 38.26 0.977 5.66% 199.0 0.100 19.90 18.36 52.01

120.4 0.240 27.75 0.960 7.14% 199.0 0.050 9.95 17.80 35.86

121.0 0.058 2.77 0.392 96.06% 199.0 0.001 0.20 2.57 7.20

50%

55%

60%

65%

70%

75%

80%

85%

90%

0.00 20.00 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00

Effi

cie

ncy

Output Power (W)

Total Efficiency

120VAC/60Hz

230VAC/50Hz

277VAC/50Hz


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230.1 0.998 226.30 0.985 7.51% 199.2 1.001 199.40 26.90 88.11

230.0 0.904 204.50 0.985 7.04% 199.1 0.900 179.19 25.31 87.62

230.0 0.810 183.23 0.983 6.12% 199.1 0.800 159.28 23.95 86.93

230.0 0.718 162.11 0.982 6.15% 199.1 0.701 139.57 22.54 86.10

230.0 0.626 140.90 0.979 5.67% 199.1 0.600 119.46 21.44 84.78

230.1 0.536 120.19 0.974 5.15% 199.1 0.500 99.55 20.64 82.83

230.0 0.447 99.31 0.967 4.61% 199.1 0.400 79.64 19.67 80.19

230.0 0.359 78.63 0.954 3.94% 199.0 0.300 59.70 18.93 75.93

230.0 0.272 57.90 0.925 3.42% 199.0 0.201 40.00 17.90 69.08

229.9 0.184 36.54 0.862 12.82% 199.0 0.100 19.90 16.64 54.46

230.0 0.145 26.09 0.784 17.56% 199.0 0.050 9.95 16.14 38.14

230.0 0.066 4.28 0.284 59.05% 199.0 0.001 0.20 4.08 4.65


277.0 0.834 225.20 0.976 8.33% 199.1 1.000 199.10 26.10 88.41

277.0 0.755 203.50 0.974 7.81% 199.1 0.900 179.19 24.31 88.05

277.0 0.678 182.45 0.971 7.29% 199.1 0.800 159.28 23.17 87.30

277.0 0.602 161.26 0.967 6.73% 199.0 0.700 139.30 21.96 86.38

277.0 0.527 140.38 0.962 6.10% 199.0 0.600 119.40 20.98 85.05

277.0 0.453 119.55 0.954 5.34% 199.0 0.500 99.50 20.05 83.23

277.0 0.379 98.79 0.940 4.83% 199.0 0.400 79.60 19.19 80.57

277.0 0.308 78.22 0.918 5.07% 199.0 0.300 59.70 18.52 76.32

277.0 0.237 57.51 0.876 8.67% 199.0 0.200 39.80 17.71 69.21

277.0 0.174 37.23 0.774 16.38% 199.0 0.100 19.90 17.33 53.45

277.0 0.146 26.81 0.665 18.29% 199.0 0.050 9.95 16.86 37.11

277.0 0.075 5.46 0.262 53.85% 199.0 0.001 0.20 5.26 3.64


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2.4 Power Factor and Total Harmonic Distortion

The power factor and total harmonic distortion are shown in the plot below.

0%

5%

10%

15%

20%

25%

30%

0.76

0.78

0.80

0.82

0.84

0.86

0.88

0.90

0.92

0.94

0.96

0.98

1.00

0 20 40 60 80 100 120 140 160 180 200

THD

(%

)

Po

we

r Fa

cto

r

Output Voltage (V)

Power Factor and THD

120VAC_P.F.

230VAC_P.F.

277VAC_P.F.

120VAC_THD

230VAC_THD

277VAC_THD


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3 Dimming Dimming test is performed with J202 pin2 to 3 shorted and 0-10V analog dimming signal externally. LED load used (MP22T1-C24-5070-T2-1-00), 4 in series.

Vdim (V) Vin,rms (V) Iin,rms (A) Pin (W) P.F. THD Vout (V) Iout (A) Pout (W) Eff (%)

10.0 230 0.915 207.20 0.985 7.12% 183 1.000 183.00 88.32

9.0 230 0.821 185.66 0.983 6.50% 181.8 0.900 163.62 88.13

8.0 230 0.732 165.29 0.982 6.21% 180.6 0.800 144.48 87.41

7.0 230 0.645 145.23 0.979 5.72% 179.4 0.700 125.58 86.47

6.0 230 0.559 125.60 0.976 5.27% 178.2 0.600 106.92 85.13

5.0 230 0.478 106.58 0.970 4.78% 176.9 0.500 88.45 82.99

4.0 230 0.399 88.05 0.961 4.22% 175.4 0.400 70.16 79.68

3.0 230 0.321 69.72 0.944 3.67% 173.8 0.300 52.14 74.78

2.0 230 0.242 50.65 0.910 3.52% 171.9 0.200 34.38 67.88

1.0 230 0.164 31.33 0.832 16.79% 169.4 0.100 16.94 54.07

0.5 230 0.132 22.37 0.737 18.56% 167.3 0.050 8.37 37.39

0.1 230 0.088 10.33 0.511 24.63% 163.6 0.010 1.64 15.84


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4 Thermal Images The thermal images below show a top view and bottom view of the board. The board is placed vertically during the test. The ambient temperature was 25ºC with 12V fan applied for airflow. The output was loaded with 200V/1A.

4.1 120VAC/60Hz, Top Side

Designator Part

Designator Value

Sp1 L200 44.8°C

Sp2 T200 56.4°C

Sp3 RT100 103.7°C

Sp4 D104 57.5°C


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4.2 120VAC/60Hz, Bottom Side

Designator Part

Designator Value

Sp1 Q203 98.3°C

Sp2 D201 73.3°C

Sp3 RT100 55.4°C


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Designator Part

Designator Value

Sp1 L200 53.4°C

Sp2 T200 57.4°C

Sp3 RT100 71.4°C


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Designator Part

Designator Value

Sp1 Q203 107.4°C

Sp2 D201 77.8°C


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Designator Part

Designator Value

Sp1 L200 50.5°C

Sp2 T200 61.3°C

Sp3 RT100 61.8°C


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Designator Part

Designator Value

Sp1 Q203 108.5°C

Sp2 D201 75.2°C


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5 Output Ripple Voltages Ripple voltages are shown in the images below, where Channel 1 is the output voltage in AC level and Channel 4 is output current.

5.1 120VAC/60Hz –200V/0A


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5.2 120VAC/60Hz –200V/1A


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6 Load Response Load response is tested at 120VAC/60Hz input, where Channel 1 is the output voltage in AC level, and Channel 4 is output current

6.1 Load step from 0A to 0.5A:


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6.2 Load step from 0.5A to 1A:


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7 Frequency Response Frequency response (voltage loop) of the LLC-SRC stage is tested with 430VDC input at C206 and 200V/1A output. An injection signal is applied to R232.


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8 Key Waveforms

8.1 120VAC-60Hz,200V /1A output. C1: switch node waveform at LO, C2: output voltage


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200w pfc + lcc resonant converter reference design for led

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