TOP250YN

Design Example Report
75 W Single Output, Power-factor Corrected

Title
LED Driver Using TOP250YN
208 VAC – 277 VAC Input
Specification
24 V, 3.1 A Output
Application LED Driver
Author Power Integrations Applications Department
Document
DER-136
Number
Date April 1, 2008
Revision 1.6
Summary and Features

• Single stage PFC based constant voltage, constant current output power
supply
• 208 to 277 VAC input range.
• Average efficiency (over input range) at full load >85%
• Meets ENERGY STAR minimum PF requirement of 0.9 for commercial
environment (0.9 worst case at 277 VAC)
• Meets harmonic content limits as specified in IEC 61000-3-2 for Class C
• Meets EN55015 B conducted EMI limits with >10 dBµV margin
• Fully fault protected
• Auto-restart withstands shorted output indefinitely
• Integrated thermal shutdown protects the entire supply
• Operates with no-load indefinitely
• Full load: 6 rows of 4 diodes part# LW W5SG/GYHY-5K8L-Z
The products and applications illustrated herein (including circuits external to the products and transformer
construction) 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.
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DER-136 75 W Single Output, LED Driver – TOP250YN 1-Apr-2008
Table of Contents
1 Introduction.................................................................................................................4
2 Power Supply Specification ........................................................................................5
3 Schematic...................................................................................................................6
4 PCB Layout ................................................................................................................7
5 Circuit Description ......................................................................................................8
5.1 Input EMI Filtering ...............................................................................................8
5.2 TOPSwitch Primary .............................................................................................8
5.3 Output Rectification .............................................................................................9
5.4 Output Feedback.................................................................................................9
5.4.1 Constant-Voltage Operation.........................................................................9
5.4.2 Constant-Current Operation .......................................................................10
5.5 Soft-Start ...........................................................................................................10
5.6 Post Filter ..........................................................................................................11
6 Bill of Materials .........................................................................................................12
7 Transformer Specification.........................................................................................14
7.1 Electrical Diagram .............................................................................................14
7.2 Electrical Specifications.....................................................................................14
7.3 Materials............................................................................................................14
7.4 Transformer Build Diagram ...............................................................................15
7.5 Transformer Construction..................................................................................16
8 Transformer Spreadsheets .......................................................................................17
9 Specifications For Common Mode Inductor L1.........................................................19
9.1 Electrical Diagram. ............................................................................................19
9.2 Inductance.........................................................................................................19
9.3 Material..............................................................................................................19
9.4 Winding Instructions. .........................................................................................19
10 Performance Data.................................................................................................21
10.1 Efficiency ...........................................................................................................21
10.2 Output Characteristic.........................................................................................22
10.3 Harmonic Content .............................................................................................23
10.4 Harmonic Content in Percentage of Fundamental.............................................23
10.5 Power Factor Vs Line Voltage at Full Load .......................................................24
11 Thermal Performance ...........................................................................................25
12 Waveforms............................................................................................................26
12.1 Drain Voltage and Current, Normal Operation...................................................26
12.2 Output Voltage Start-up Profile..........................................................................27
12.3 Drain Voltage and Current Start-up Profile ........................................................27
12.4 Output Ripple Measurements............................................................................28
12.4.1 Ripple Measurement Technique ................................................................28
12.4.2 Measurement Results ................................................................................29
13 Control Loop Analysis ...........................................................................................30
14 Surge Test ............................................................................................................32
14.1 Surge Test Results with 1.2/50µs Waveform ....................................................32
14.2 Surge Test Results with 0.5µs-100 kHz Ring-Waveform...................................32
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1-Apr-2008 DER-136 75 W Single Output, LED Driver – TOP250YN
15 Conducted EMI .....................................................................................................33

16 Revision History ....................................................................................................34
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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Page 3 of 36 www.powerint.com
1 Introduction
The document presents a power supply design for LED Lighting applications. The design
input voltage range is 208 to 277 VAC. The supply employs a single stage power-factor
corrected circuit to generate a 24 V, 3 A output and meets the Energy Star minimum pf
requirement of 0.9 for commercial applications with a high efficiency of 84%.
This document contains the power supply specification, schematic, bill of materials,
transformer documentation, printed circuit layout, and performance data for this design.
Figure 1 – Populated Circuit Board Photograph.
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2 Power Supply Specification
Description Symbol Min Typ Max Units Comment

Input
Voltage VIN 208 277 VAC 2 Wire – no P.E.
Frequency fLINE 47 50/60 64 Hz
Output
Output Voltage 1 VOUT1 24 28 V
20 MHz Bandwidth
Output Current 1 IOUT1 3.1 A
Total Output Power
Continuous Output Power POUT 75 W
Environmental
Conducted EMI Meets EN55015B
Designed to meet IEC950, UL1950
Safety Class II
1.2/50 µs Surge, IEC 61000-4-5,
Surge 1 kV Series Impedance:
Common Mode: 12 Ω
1.2/50 µs Surge, IEC 61000-4-5,
Surge 0.5 kV Series Impedance:
Differential Mode: 2 Ω
0.5 µs-100KHz Ring-wave IEEE
Ring-wave 2.5 kV C.62.41-1991, Class A,
Differential and Common Mode
o
Ambient Temperature TAMB 0 50 C Free Convection, Sea Level
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3 Schematic
Figure 2 – Schematic.
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4 PCB Layout
Figure 3 – PCB Layout.
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5 Circuit Description
This design uses a discontinuous mode flyback power supply configuration, fed with
minimum capacitance at the input. Using a fixed duty-cycle over an AC line cycle allows
the peak drain current envelope, and therefore the input current, to follow the input AC
voltage waveform to give high power factor and low harmonic content. Although this
simple configuration gives both output regulation and power factor correction in a single
stage converter, it does require higher peak drain currents compared to a standard power
supply with substantiation input capacitance.
Detailed descriptions of each functional block are given below.
5.1 Input EMI Filtering

In addition to the standard filtering (X capacitors C1 and C2 and common-mode inductor
L2), L3 and L4 were added to provide increased differential-mode filtering and surge
immunity. This was required due to the small value of input capacitance (C3) and the
associated increase in switching currents seen by the AC input. Resistors R1 and R2
reduce high-frequency conducted and radiated EMI. Common-mode inductor L1 filters
very high frequency common-mode noise.
Common-mode filtering is provided by L1, L2 and Y-capacitor C9. Together with

transformer E-Shields (that reduce the source of common mode EMI currents), this
allows the design to pass EN55015 B limits with greater than 10 dB of margin.
5.2 TOPSwitch Primary

On application of the AC input, the combination of the in-rush current to charge C1, C2
and C3, together with the parasitic inductance in the AC line, causes a voltage spike that
appears across C3. In a design with a large input capacitance, this voltage rise is
negligible; however, in this case the voltage spike on C3 is sufficiently large to exceed the
BVDSS rating of the MOSFET within TOP250YN (U1). To prevent this, capacitor C4 and
diode D5 limit the maximum voltage across the DC bus while R3 is the bleeder to
discharge capacitor C4 on AC removal.
The discontinuous mode of operation needed for high power factor increases the primary
RMS current for a given output power. Selecting a larger TOPSwitch device (TOP250YN)
than needed for power delivery offsets increases in RMS current (due to DCM operation)
by reducing the RDSON related conduction losses thereby giving higher efficiency and
reduced dissipation.
As the DC input voltage across C3 falls to zero during normal operation, D6 was added in
series with the drain to prevent the DRAIN ringing below SOURCE and reverse biasing
the device. As reverse biasing of the device is not permitted, this diode must be used.
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To provide a high power factor using a single-stage flyback converter, the MOSFET’s
duty cycle must be kept constant over a single AC line cycle (low bandwidth).
In the TOPSwitch-GX the operating duty cycle is a function of the control pin current. This
requires that the current into the C pin be held constant to achieve power factor
correction. The simplest way to achieve this would be to use a very large value for the
CONTROL pin capacitance (C5). However, a large value of C5 causes a large startup
time and a large startup overshoot.
To overcome this difficulty, an emitter follower (Q1) was used as an impedance

transformer with a capacitor C10 in its base. Looking into the emitter of Q1, C10 appears
to be larger (C10 x Q1hfe), and R6 appears to be smaller (R6 / Q1hfe). Capacitor C10,
together with R6, sets the dominant pole of the circuit at approximately 0.02 Hz. Resistor
R7 provides loop compensation, creating a zero at approximately 200 Hz, which gives
additional phase starting at 20 Hz to improve phase margin at gain crossover. Gain
crossover occurred in this design at approximately 35 – 40 Hz. Higher bandwidth is
undesirable as this degrades power factor by increasing the third harmonic content in the
input current waveform. Diode D8 prevents reverse current through Q1 during startup.
Feedback is provided from the secondary via optocoupler U2B, which in turn modulates
the base voltage of Q1 and changes the current into the CONTROL pin.
The primary clamp circuit is formed by D7, R4, R5, C6, and VR1. During normal
operation R5 and C6 set the clamping voltage. Zener VR1 sets a defined upper clamping
voltage and conducts only during startup and load transients. A fast recovery (250 ns)
blocking diode, D7, was used to recover some of the leakage energy, thereby improving
efficiency. Resistor R4 dampens high frequency ringing and improves EMI performance.
5.3 Output Rectification

To reduce power dissipation and increase efficiency, two output diodes were used (D10
and D11). These are connected to separate secondary windings to improve current
sharing between the two diodes. Filtering is provided by C11 and C12. Relatively large
values are necessary to reduce line frequency ripple present in the output due to the low
loop bandwidth required to achieve a high power factor. These values may be reduced
depending on the acceptable current ripple through the LED load.
5.4 Output Feedback

The output feedback is split into two functional blocks: constant-voltage (CV) operation
and constant-current (CC) operation.
5.4.1 Constant-Voltage Operation

Voltage feedback is provided by VR2 and optocoupler U2A. Once the output exceeds
the voltage defined by the forward drop of U2A, VR2 and R16, current flows through the
optocoupler and provides feedback to the primary. As the line and load change, the
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magnitude of current changes to reduce or increase the MOSFET duty cycle which
maintains output regulation. Resistor R16 sets the loop gain in the constant-voltage
region.
The nominal output voltage regulation is set at 28 V, which is above the expected LED
load voltage (when operated at its rated current). Under normal operation, the supply
operates in constant-current mode, and voltage feedback is used only when the output is
unloaded.
5.4.2 Constant-Current Operation

Transistor Q3 and the forward drop of the LED in U2A are used to create a bias voltage
on the base on Q2. The additional drop across R11, R12, and R13 needed to turn on Q2
is equal to the difference between the bias voltage and the VBE of Q2 (~0.5 V). Once Q2
begins to conduct, Q4 also conducts, supplying current through U2A and providing
feedback. Resistor R9 limits the base current from Q4, and R14 sets the gain of the CC
loop. Resistor R10 keeps Q4 off until Q2 is on, while C13 provides loop compensation.
This arrangement gave an average output current in CC operation of 3.1 A.
5.5 Soft-Start
The very low loop bandwidth presents a problem at startup. Once the loop closes and
feedback is provided via U2A, it takes significant time for the loop to respond and
therefore allows significant output overshoot. This is because C10 must charge above
5.8 V before current is supplied into the CONTROL pin of U1.
The standard solution to output overshoot is to provide a soft-finish circuit. Typically this
consists of a capacitor that allows current to flow in the feedback loop before the output
has reached regulation. Here such a passive approach is not practical because of the
capacitor size required.
To overcome this, the circuit formed around transistor Q5 is used to overdrive the
feedback loop during startup. Using an element with gain (Q5) allows enough feedback
current to pre-charge C10 before the output reaches regulation.
A separate auxiliary supply is created by D12 and C15 so that the voltage across C15
rises faster than the main output across C11 and C12. While C16 charges, Q5 is on,
supplying current to charge C10 via the optocoupler, with resistor R21 limiting the
maximum current. Once the voltage across C16 reaches VO-VBE (Q5), Q5 turns off and the
circuit becomes inactive. At power down, C16 is discharged via R18, resetting the circuit
for the next power-up. The time constant of C16 and R18 appears very long; however, in
practice, C10 also takes a significant time to discharge on power down, and even
momentary AC drop outs do not result in any output overshoot.
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5.6 Post Filter

A post filter consisting of L5 and C17 was added to reduce switching frequency ripple on
the output. This also improves noise immunity and improves the reliability of the CC set-
point.
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6 Bill of Materials
Item Qty Part Description Mfg Part Number Mfg
Ref.
1 2 C1 100 nF, 305 VAC, X2 B32922A2104M Epcos
C2
2 1 C3 220 nF, 630 V, Film ECQ-E6224KF Panasonic
3 1 C4 15 µF, 450 V, Electrolytic, (12.5 x 25) EKXG451ELL150MK25S Nippon Chemi-Con
4 1 C5 22 µF, 16 V, Electrolytic, Gen. ECA-1CM220 Panasonic

Purpose, (5 x 11)
5 1 C6 2.2 nF, 1 kV, Disc Ceramic NCD222K1KVY5FF NIC Components Corp
6 1 C7 330 µF, 25 V, Electrolytic, Very Low EKZE250ELL331MJC5S Nippon Chemi-Con

ESR, 53 m, (10 x 12.5)
7 1 C9 2.2 nF, Ceramic, Y1 440LD22-R Vishay
8 1 C10 33 µF, 16 V, Electrolytic, Gen. ECA-1CM330 Panasonic
Purpose, (5 x 11)
9 2 C11 1800 uF, 35 V, Electrolytic, Very Low EKZE350ELL182ML25S Nippon Chemi-Con
C12 ESR, 16 mΩ, (16 x 25)
10 1 C13 10 nF, 50 V, Ceramic, Z5U B37982N5103M000 Epcos
11 1 C14 100 nF, 50 V, Ceramic, Z5U SR205E104MAR AVX Corp
12 2 C15 47 µF, 35 V, Electrolytic, Gen. EKMG350ELL470ME11D Nippon Chemi-Con
C16 Purpose, (5 x 11)
13 1 C17 150 µF, 35 V, Electrolytic, Very Low EKZE350ELL151MHB5D Nippon Chemi-Con
ESR, 72 Ω, (8 x 11.5)
14 4 D1 1000 V, 2 A, Rectifier, DO-15 RL207 Rectron
D2
D3
D4
15 1 D5 1000 V, 1 A, Rectifier, DO-41 1N4007-E3/54 Vishay
16 1 D6 400 V, 9 A, Ultrafast Recovery, 60 ns, BYV29-400 NXP Semiconductors
TO-220AC
17 1 D7 600 V, 3 A, Fast Recovery Diode, FR305-T Diodes Inc.
DO-201AD
18 1 D8 75 V, 300 mA, Fast Switching, DO-35 1N4148 Vishay
19 2 D9 200 V, 1 A, Rectifier, DO-41 1N4003RLG OnSemi
D12
20 2 D10 150 V, 20 A, Schottky, TO-220AB DSSK 20-015A IXYS
D11
21 1 F1 5 A, 250V, Slow, TR5 3721500041 Wickman
22 2 HS1 HEATSINK, Alum, TO-220 2 hole, Custom
HS2 2 mtg pins
23 2 J1 J2 2 Position (1 x 2) header, 0.156 pitch, 26-48-1021 Molex
Vertical
24 1 L1 42 uH, Common Mode Inductor, 4 5943000201 Fair-Rite Toroid
Pins, Toroid
25 1 L2 19 mH, 0.5 A, Common Mode Choke ELF15N005A Panasonic
26 2 L3 L4 330 uH, 0.55 A, 9 x 11.5 mm SBC3-331-551 Tokin
27 1 L5 2.2 uH, 6.0 A RFB0807-2R2L Coilcraft
28 3 Q1 NPN, Small Signal BJT, 40 V, 0.2 A, 2N3904RLRAG On Semiconductor
Q2 TO-92
Q3
29 2 Q4 PNP, Small Signal BJT, 40 V, 0.2 A, 2N3906 Fairchild

Q5 TO-92
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30 2 R1 5.1 kΩ, 5%, 1/4 W, Carbon Film CFR-25JB-5K1 Yageo

R2
31 1 R3 150 kΩ, 5%, 1/2 W, Carbon Film CFR-50JB-150K Yageo
32 1 R4 22 Ω, 5%, 1 W, Metal Oxide RSF100JB-22R Yageo
33 1 R5 100 kΩ, 5%, 2 W, Metal Oxide RSF200JB-100K Yageo
35 1 R7 24 Ω, 5%, 1/8 W, Carbon Film CFR-12JB-24R Yageo
39 1 R11 0.13 Ω, 1%, 3 W ALSR-3F-.13-1% Huntington Electric
40 2 R12 1 Ω, 5%, 1/4 W, Carbon Film CFR-25JB-1R0 Yageo
R13
42 2 R15 1 kΩ, 5%, 1/8 W, Carbon Film CFR-12JB-1K0 Yageo
R22
R20
44 1 R17 1.6 kΩ, 5%, 1/8 W, Carbon Film CFR-12JB-1K6 Yageo
48 1 R23 10.2 kΩ, 1%, 1/4 W, Metal Film MFR-25FBF-10K2 Yageo
49 1 RV1 320 V, 48 J, 10 mm, RADIAL V320LA10 Littlefuse
50 1 T1 Bobbin, EER28, Vertical, 10 pins BEER-28-111-CP TDK
51 1 U1 TOPSwitch-GX, TOP250YN, TO220- TOP250YN Power Integrations
7C
52 1 U2 Opto coupler, 35 V, CTR 80-160%, LTV-817A Liteon
4-DIP
53 1 VR1 200 V, 5 W, 5%, TVS, DO204AC P6KE200ARLG OnSemi
(DO-15)
54 1 VR2 27 V, 5%, 500 mW, DO-35 1N5254B Microsemi
All parts are RoHS compliant.
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7 Transformer Specification
7.1 Electrical Diagram

WD4 WD6
Shield Shield
WD1
Core Cancellation
8
1 10
WD7
2nd half Primary WD5
Secondary
3
WD2 7
1st half Primary 6
2
4
WD3
Bias
5
Figure 4 – Transformer Electrical Diagram.
7.2 Electrical Specifications

Electrical Strength 60 second, 60 Hz, from Pins 1-5 to Pins 6-10. 3000 VAC
Pins 1-2, all other windings open, measured at
Primary Inductance 171 µH, -0/+10%
100 kHz.
Resonant Frequency Pins 1-2, all other windings open. 1290 kHz (Min.)
Pins 1-2, with Pins 6-7-8-9-10 shorted, measured
Primary Leakage Inductance 3 µH (Max.)
at 100 kHz.
7.3 Materials
Item Description
[1] Core: EER28 PC40 or equivalent gapped for 248 nH/T2
[2] Bobbin: Vertical EER28 10 pins, safety rated
[3] Magnet Wire: 26AWG
[6] Copper foil: 14 mm wide
[7] Triple Insulated Wire: 28AWG
[8] Tape: 14.7 mm
[9] Tape: 16.7mm
[10] Varnish
[11] 2 mm Polyester web tape
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7.4 Transformer Build Diagram

Pins Side
WD7: 1
3 13T x 2 _ #25 AWG
WD6: 1 1T Copper Foil
6
7
8
6T x 4 _ #28 TIW
WD5: 10
1T Copper Foil
WD4: 1 (reversed winding)
4
WD3: 3T x 4 _ #28 AWG
5 (scattered)
3
WD2: 13T x 2 _ #25 AWG
2
WD1: 1 9T x 3 _ #26 AWG
2mm margin tape
Figure 5 – Transformer Build Diagram.
Copper Foil Wrapped in Tape
Starting Lead Finish Side

Connected to Pin 1
Figure 6 – Copper Tape Preparation for Winding 4.
Copper Foil Wrapped in Tape
Starting Side Finish Lead

Connected to Pin 1
Figure 7 – Copper Tape Preparation for Winding 6.
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7.5 Transformer Construction
Place bobbin, item [2], on the winding machine with pins side oriented to the left
Bobbin Preparation hand side. Use 2 mm Polyester web tape [11] on left hand side to meet safety
creepage distances.
Start at pin 1, wind from left to right 9 trifilar turns of item [3] in a uniform, tightly
WD1 Core Cancellation
wound layer. Cut finish lead at the end of the winding.
Tape Use 1 layer of tape, item [8], to hold the winding.
Start at pin 2, wind from left to right 13 bifilar turns of item [4] in a uniform,
WD2 First Half Primary
tightly wound layer. Finish at pin 3.
Start at pin 5, wind 3 quad-filar turns of item [5] from left to right in a single
WD3 Bias
scattered layer. Finish at pin 4.
Prepare copper tape, item [6], as shown in figure 6. Connect starting lead to
WD4 Shield pin 1. Wind 1 turn in reverse winding direction. The finish lead is left
unconnected.
Start at pins 10 and 8, Wind from left to right 6 turns of 4 wires in parallel, item
WD5 Secondary
[7], in a uniform layer. Finish on pins 7 and 6.
Prepare copper tape, item [6], as shown in figure 7. Starting lead is left
WD6 Shield
unconnected. Wind 1 turn and connect finish lead to pin 1.
WD7 Second Half Start at pin 3, wind from left to right 13 bifilar turns of item [4] in a uniform,
Primary tightly wound layer. Finish at pin 1.
Tape Use 3 layers item, [9] as insulation.
Final Assembly Assemble and secure core halves with bobbin. Varnish impregnate item [10].
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8 Transformer Spreadsheets
The standard flyback transformer design approach was modified due to the minimal input
capacitance for high power-factor (PF). A very high capacitance value was entered for
CIN so the design uses the transformer at the peak of the AC line voltage (at low line).
The output power entered was increased from the 75 W specified to 119 W. This was to
compensate for the under-delivery of output power when the AC input voltage waveform
is low.
ACDC_TOPSwitchGX_ INPUT INFO OUTPUT UNIT TOP_GX_FX_043007: TOPSwitch-GX/FX

043007; Rev.2.15; Continuous/Discontinuous Flyback Transformer
Copyright Power Design Spreadsheet
Integrations 2007
ENTER APPLICATION VARIABLES LED DRIVER XFR
VACMIN 208 Volts Minimum AC Input Voltage
VACMAX 277 Volts Maximum AC Input Voltage
fL 50 Hertz AC Mains Frequency
VO 26.00 Volts Output Voltage (main)
PO 119.00 Watts Output Power
n 0.78 Efficiency Estimate
Z 0.50 Loss Allocation Factor
VB 12 Volts Bias Voltage
tC 3.00 mSeconds Bridge Rectifier Conduction Time Estimate
CIN 99999.00 uFarads Input Filter Capacitor
ENTER TOPSWITCH-GX VARIABLES

TOP-GX TOP250 Universal 115 Doubled/230V
Chosen Device TOP250 Power Out 210W 290W
KI 0.70 External Ilimit reduction factor (KI=1.0 for default
ILIMIT, KI <1.0 for lower ILIMIT)
ILIMITMIN 3.969 Amps Use 1% resistor in setting external ILIMIT
ILIMITMAX 4.851 Amps Use 1% resistor in setting external ILIMIT
Frequency (F)=132kHz, F Full (F) frequency option – 132kHz
(H)=66kHz
fS 132000 Hertz TOPSwitch-GX Switching Frequency: Choose
between 132 kHz and 66 kHz
fSmin 124000 Hertz TOPSwitch-GX Minimum Switching Frequency
fSmax 140000 Hertz TOPSwitch-GX Maximum Switching Frequency
VOR 116.00 Volts Reflected Output Voltage
VDS 10.00 Volts TOPSwitch on-state Drain to Source Voltage
VD 0.50 Volts Output Winding Diode Forward Voltage Drop
VDB 0.70 Volts Bias Winding Diode Forward Voltage Drop
KP 1.00 Ripple to Peak Current Ratio (0.4 < KRP < 1.0 : 1.0<
KDP<6.0)
ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES

Core Type EER28
Core EER28 P/N: PC40EER28-Z
Bobbin EER28_BO P/N: BEER-28-1112CPH
BBIN
AE 0.821 cm^2 Core Effective Cross Sectional Area
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LE 6.4 cm Core Effective Path Length

AL 2870 nH/T^2 Ungapped Core Effective Inductance
BW 16.7 mm Bobbin Physical Winding Width
M 1.50 mm Safety Margin Width (Half the Primary to Secondary
Creepage Distance)
L 2.00 Number of Primary Layers
NS 6 Number of Secondary Turns
DC INPUT VOLTAGE PARAMETERS

VMIN 294 Volts Minimum DC Input Voltage
VMAX 392 Volts Maximum DC Input Voltage
CURRENT WAVEFORM SHAPE PARAMETERS

DMAX 0.29 Maximum Duty Cycle
IAVG 0.52 Amps Average Primary Current
IP 3.58 Amps Peak Primary Current
IR 3.58 Amps Primary Ripple Current
IRMS 1.11 Amps Primary RMS Current
TRANSFORMER PRIMARY DESIGN PARAMETERS

LP 171 uHenries Primary Inductance
NP 26 Primary Winding Number of Turns
NB 3 Bias Winding Number of Turns
ALG 248 nH/T^2 Gapped Core Effective Inductance
BM 2838 Gauss Maximum Flux Density at PO, VMIN (BM<3000)
BP 3848 Gauss Peak Flux Density (BP<4200)
BAC 1419 Gauss AC Flux Density for Core Loss Curves (0.5 X Peak to
Peak)
ur 1780 Relative Permeability of Ungapped Core
LG 0.38 mm Gap Length (Lg > 0.1 mm)
BWE 27.4 mm Effective Bobbin Width
OD 1.04 mm Maximum Primary Wire Diameter including insulation
INS 0.08 mm Estimated Total Insulation Thickness (= 2 * film
thickness)
DIA 0.96 mm Bare conductor diameter
AWG 19 AWG Primary Wire Gauge (Rounded to next smaller
standard AWG value)
CM 1290 Cmils Bare conductor effective area in circular mils
CMA 1160 Cmils/Amp !!! DECREASE CMA (200 < CMA < 500) Decrease
L(primary layers),increase NS,smaller Core
TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT)

Lumped parameters
ISP 15.66 Amps Peak Secondary Current
ISRMS 7.62 Amps Secondary RMS Current
IO 4.58 Amps Power Supply Output Current
IRIPPLE 6.09 Amps Output Capacitor RMS Ripple Current
CMS 1524 Cmils Secondary Bare Conductor minimum circular mils
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AWGS 18 AWG Secondary Wire Gauge (Rounded up to next larger

standard AWG value)
DIAS 1.03 mm Secondary Minimum Bare Conductor Diameter
ODS 2.28 mm Secondary Maximum Outside Diameter for Triple
Insulated Wire
INSS 0.63 mm Maximum Secondary Insulation Wall Thickness
VOLTAGE STRESS PARAMETERS

VDRAIN 655 Volts Maximum Drain Voltage Estimate (Includes Effect of
Leakage Inductance)
PIVS 115 Volts Output Rectifier Maximum Peak Inverse Voltage
PIVB 55 Volts Bias Rectifier Maximum Peak Inverse Voltage
9 Specifications For Common Mode Inductor L1
9.1 Electrical Diagram

3
4
2
Figure 8 – L1 Electrical Diagram.
9.2 Inductance
Inductance 42 uH
9.3 Material
Item Description
1 Fair-Rite Toroid 5943000201
2 Magnetic wire 26AWG
3 Triple Insulated wire 26AWG
9.4 Winding Instructions

Wind 12 parallel turns using item [2] and item [3]. Wind tightly and uniformly as shown in
figure 9.
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Figure 9 – Picture of L1.
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10 Performance Data
All measurements performed at room temperature, 60 Hz input frequency.
10.1 Efficiency
90
80
Output Efficiency (%)
70
60
50
40
30
20
200 210 220 230 240 250 260 270 280
Line Voltage (AC)
Figure 10 – Efficiency vs Input Voltage. Full Load, Room Temperature, 60 Hz.
INPUT VOLTAGE (AC) OUTPUT EFFICIENCY (%)

208 86.01
215 85.64
230 85.39
240 85.51
265 85.62
277 85.32
Table 1: Measurements of Efficiency vs Line Voltage at Full Load.
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10.2 Output Characteristic
30
25
Output Voltage (DC)
20
15 277 VAC
208 VAC
Lower Current Limit
10 Upper Current Limit
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Output Current (DC)
Figure 11 – Output Characteristic Showing Line and Load Regulation, Room Temperature.
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10.3 Harmonic Content

400
350
300
Input Current (mA)
250
200
150
100
50
0
1 2 3 4 5 6 7 8 9 10
Harmonic
Figure 12 – Input Current Harmonic Content. Full Load, VIN = 230 VAC.
10.4 Harmonic Content in Percentage of Fundamental

Harmonic Iin(mA) At % of Maximum % Allowed By IEC
230VAC Fundamental 61000-3-2. Class C
1 385
2 2.4 0.62 2.0
3 15.6 4.05 29.7
4 2.3 0.60
5 10.5 2.73 10.0
6 1 0.26
7 8.6 2.23 7.0
8 0.5 0.13
9 6.5 1.69 5.0
10 0.4 0.10
Table 2: Harmonic Content in Percentage of Fundamental and IEC 61000-3-2 Limits for C Class
Equipment.
NOTE: Third Harmonic Spec Follows the Formula: 30* PFC. (Power Factor at 230 VAC).
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10.5 Power Factor Vs Line Voltage at Full Load
1.00
0.99
Power Factor
0.98
0.97
0.96
0.95
200 220 240 260 280
Input Voltage (AC)
Figure 13 – Power Factor (PF) vs Input Line Voltage (VAC).
INPUT VOLTAGE (AC) POWER FACTOR

208 0.992
215 0.992
230 0.990
240 0.988
265 0.982
277 0.978
Table 3: Power Factor Measurements at Full Load.
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11 Thermal Performance
Two sets of data were taken on the UUT. One set was taken with the unit inside a closed
cardboard box at room temperature. The second set of data was taken with the UUT in a
metal box encapsulated with thermal-conductive Epoxy. Results are shown below.
Temperature (°°C)
Item UUT Open Frame UUT Encapsulated
with thermal epoxy
in a metal case.
208 VAC 277 VAC 208 VAC 277 VAC
Ambient 25 25 25 25
TOPSwitch (U1) 77 78 63 59
Transformer (T1) 77 79 66 63
Output Rectifiers (D10, 70 69 62 57
D11)
Table 4: Temperatures of Critical Components in the Power Supply.
208 VAC, 75 W load, 25 ºC Ambient

Figure 14 – Infrared Thermograph of Open Frame Operation at Room Temperature.
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12 Waveforms
All waveforms are shown with LEDs used as load.
12.1 Drain Voltage and Current, Normal Operation
Figure 15 – 208 VAC, Full Load.

Upper: ID 2.0 A / Div.
Lower: VDRAIN 200 V / Div.
Figure 16 – 277 VAC, Full Load.

Upper: ID 2.0 A / Div.
Lower: VDRAIN 200 V / Div.
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12.2 Output Voltage Start-up Profile
Figure 17 – Start-up Profile, 208 VAC. Figure 18 – Start-up Profile, 277 VAC.
5 V, 50 ms / div. 5 V, 50 ms / div.
12.3 Drain Voltage and Current Start-up Profile
Figure 19 – 208 VAC Input and Maximum Load. Figure 20 – 277 VAC Input and Maximum Load.
Upper: IDRAIN, 2.0 A / div. Upper: IDRAIN, 2.0 A / div.
Lower: VDRAIN, 200 V / div. Lower: VDRAIN, 200 V / div.
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12.4 Output Ripple Measurements
12.4.1 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 the figures below.
Tie two capacitors in parallel across the probe tip of a 4987BA probe adapter. The
capacitors include one (1) 0.1 µF/50 V ceramic type and one (1) 1.0 µF/50 V aluminum
electrolytic. The aluminum-electrolytic capacitor is polarized, so always maintain proper
polarity across DC outputs (see Figure 21 and Figure 22).
Probe Ground
Probe Tip
Figure 21 – Oscilloscope Probe Prepared for Ripple Measurement. (End Cap and Ground Lead
Removed).
Figure 22 – Oscilloscope Probe with Probe Master (www.probemaster.com) 4987A BNC Adapter.
(Modified with wires for ripple measurement, and two parallel decoupling capacitors added).
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12.4.2 Measurement Results
Figure 23 – Output Ripple 208 VAC, Full Load. Figure 24 – Output Ripple 230 VAC, Full Load.
Upper: VOUT, 5 V / div. Upper: VOUT, 5 V / div.
Lower: IOUT, 1 A/ div V, 5 ms / div. Lower: IOUT, 1 A/ div V, 5 ms / div.
Figure 25 – Output Ripple 277 VAC, Full Load.

Upper: VOUT, 5 V / div.
Lower: IOUT, 1 A/ div V, 5 ms / div.
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13 Control Loop Analysis

Following are the loop plots measured at 208 VAC and 277 VAC. Since it is a single
stage PFC power supply, the loop bandwidth is necessarily low and in this case
crossover occurs at approximately 35 – 40 Hz.
Figure 26 – Bode Plot Measured at 208 VAC and Full Load. Crossover Occurs at Approximately 38 Hz
With a Phase Margin of Approximately 50 Degrees.
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Figure 27 – Bode Plot Measured at 277 VAC and Full Load. Crossover Occurs at Approximately 40 Hz
With a Phase Margin of Approximately 45 Degrees.
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14 Surge Test
14.1 Surge Test Results with 1.2/50 µs Waveform
Surge Input Injection Injection Number Of Test Result

Level (V) Voltage Location Phase (°) Surges (Pass/Fail)
(VAC)
+500 230 L to N 90 10 Pass
-500 230 L to N 90 10 Pass
+1000 230 L and N to G 90 10 Pass
-1000 230 L and N to G 90 10 Pass
14.2 Surge Test Results with 0.5 µs-100 kHz Ring-Waveform
Surge Input Injection Injection Number Of Test Result

Level (V) Voltage Location Phase (°) Surges (Pass/Fail)
(VAC)
+2500 230 L to N 90 10 Pass
-2500 230 L to N 90 10 Pass
+2500 230 L and N to G 90 10 Pass
-2500 230 L and N to G 90 10 Pass
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15 Conducted EMI
Figure 28 – Conducted EMI, 230 VAC Full Load, UUT Placed on a Grounded Metal Plate.
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16 Revision History
Date Author Revision Description & changes Reviewed

01-Apr-08 KM 1.6 Added redrawn schematic
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Notes
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For the latest updates, visit our website: www.powerint.com
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 www.powerint.com.
Power Integrations grants its customers a license under certain patent rights as set forth at
http://www.powerint.com/ip.htm.
The PI Logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective
companies. ©Copyright 2008 Power Integrations, Inc.
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DI-136 Design Idea
®
TOPSwitch-GX
75 W Output, High Efficiency, Single Stage Flyback

Power Supply With PFC for LED Ballasts
Application Device Power Output Input Voltage Output Voltage Topology

LED Ballast TOP250YN 75 W 208 – 277 VAC 24 V Flyback
Design Highlights voltage. In a standard flyback converter, this condition is

• Single stage PFC-based CV/CC power supply prevented by the DC voltage on the input bulk capacitor.
• Meets harmonic content limits as specified in IEC 61000-3-2 for
Class C Equipment (see Figure 2) Resistors R11, R12, R13, Q2, Q3, Q4 and their associated
• Meets minimum PF requirement of 0.9 for industrial environ- circuitry together with the LED in U2, form the low drop CC sense
ments (>0.97 worst case at 277 VAC, see Figure 3) circuit and program the average output current to 3.1 A (±10%).
• High efficiency (>85%) across entire input range Without a load, the output voltage is limited to about 28 V (max)
• Meets EN55015 B conducted EMI limits with >10 dBμV margin by R16 and VR2.
(see Figure 4)
• Auto-restart provides indefinite output short circuit protection The phototransistor (U2B) drives the emitter follower Q1 and the
PFC loop compensation capacitor C10. Capacitor C10 and
Operation resistor R6 set the dominant pole for the PFC at around 0.02 Hz
A flyback converter with no input capacitance operating in while R7 provides loop compensation.
discontinuous conduction mode inherently provides a high power
factor. The schematic shown in Figure 1 takes this approach and Over the period of one line cycle, the current into the control pin of
adds an output current limit to form a high power LED driver. The U1 is constant, giving a constant duty cycle and thereby providing
circuit description below highlights the key circuit differences a PFC input current waveshape.
between this and a standard flyback converter.
The CONTROL pin capacitor C5 sets the startup time with D8,
To prevent large voltage transients due to AC line inductance or isolating U1 from the rest of the feedback components before
surges, a clamp circuit consisting of C4, D5 and R3 limits the DC regulation is reached.
bus voltage to a safe value. Once in steady state, the capacitor is
effectively decoupled from the circuit by D5 so as to not impact An optional soft-start circuit is formed by D12, C15, R18, R19,
Power Factor (PF). Resistor R3 provides a discharge path for C4. R20, C16 and Q5. This charges C10 before the output has
reached regulation and prevents output overshoot.
Diode D6 prevents reverse currents through U1 that would occur
when the AC input voltage is less than the reflected output Diodes D10 and D11 rectify the secondary winding voltage. To
distribute dissipation and improve efficiency, parallel secondary
R1
windings and diodes are used.
5.1 k7
R3 VR1 R5 C11, C12 C13 C17
L4 150 k7 D5 P6KE 100 k7 1800 MF L5 R10 10 nF 150 MF
330 MH 0.5 W 1N4007 200A 2W D10 DSSK20-015A 35 V 2.2 MH 10 k7 50 V 24 V, 3.125 A
1 10 35 V
C6 8
2.2 nF R14 VR2
D1-D4 1 kV D11 DSSK20-015A 470 7 1N5254B
RL207 27V
C2 3 D12
100 nF C3 1N4003 Q4
NC 2N3906
305 VAC 220 nF R4 6,7 R16
630 V 22 7 R9 200 7
1W C15
47 MF 150 7
C4 2 R18
15 MF 35 V R15
R2 D7 100 k7 1 k7
5.1 k7 450 V 1/8 W Q2 1/8 W
L2 FR305 D9 R20
19 mH 1N4003 200 7 2N3904
L3 1/8 W R22
330 MH Q5 1 k7
5 R11 1/8 W
C7 2N3906 0.13 7
C1 330 MF R19 3W
100 nF 25 V 10 7 Q3
305 VAC D6 4 1/8 W 2N3904
BYV29-400 R12
17 R17
T1 C16 1.6 k7
EER28 47 MF
RV1 35 V U2A
320 VAC TOPSwitch-GX R21 R13 RTN
17 LTV817A
Q1 300 7
U1 1/8 W
TOP250YN 2N3904
L1 D L
42 MH D8
CONTROL 1N4148 U2B
C LTV817A
R7
F1 24 7
5A S X F R8
C14 22 7 R6
100 nF 1/8 W 300 k7
208 - 277 50 V 1/8 W C10
VAC R23 33 MF C9
C5
10.2 k7 22 MF 16 V 2.2 nF
1% 16 V 250 VAC
PI-4979-040208
Figure 1. 75 W Single Stage LED Driver Power Supply With PFC, Using a TOP250YN Device.
www.powerint.com April 2008

Key Design Points • Select the TOPSwitch-GX based on acceptable efficiency and
• Use PI Xls spreadsheet to design the transformer. To determine temperature rise using the X pin to program to appropriate
the value of primary inductance, enter a peak power of 106 W, current limit from the design spreadsheet.
which corresponds to an average power of 75 W (106 / √2). • More effective thermal management through the use of
Directly enter into the spreadsheet a minimum DC voltage equal thermally conductive potting compound to spread the heat from
to the peak of the minimum input AC voltage. the transformer, MOSFET and diode to surrounding areas may
• Set the value of KP to 1.0 to ensure critically discontinuous allow a design with reduced size of heat-sink, transformer and
mode at the peak of minimum AC input voltage. Ensure that TOPSwitch-GX.
the converter operates in discontinuous mode (during steady
state operation) at all times to give high power factor. 80
PI-4995-012508
• Discontinuous mode operation increases the primary RMS
70
currents. This impacts the size of both the transformer and the QP
TOPSwitch-GX device. 60
• Select the transformer size based on thermal evaluation. This AV
50
may require selecting a larger core than needed for power
delivery to allow for increased wire size. 40
dBMV
400 30
PI-4993-013008
20
350
10
Input Current (mA)
300
0
250
-10
200
-20
150 0.15 1.0 10.0 100.0
MHz
100 Figure 4. Worst Case Conducted EMI (230 VAC With Output Grounded)
Measured Against EN55015 Limits.
50
0 Transformer Parameters
1 2 3 4 5 6 7 8 9 10
EER28 PC40 / PC44 or equivalent, gapped for
Core Material
Harmonic ALG of 248 nH/t²
Figure 2. Harmonic Content Measured at 208 VAC.
Bobbin EER28, 10 pin, vertical
1.00 Shield: 9T × 3, AWG 26, tape
PI-4994-012508
Primary: 13T × 2, AWG 25, tape

Bias: 3T × 4, AWG 28, tape
0.99 Winding Details Shield: 1T Foil 2 mils thick, tape (reverse wound)
24 V: 6T × 4, AWG 28 (TIW), tape
Power Factor
Shield: 1T Foil 2 mils thick, tape

0.98 Primary: 13T × 2, AWG 25, 2 layers tape
Shield (1–NC), Primary (2–3), Bias (5–4),
0.97 Winding Order Shield (1–NC), +12 V (8,9,10–6,7),
Shield (NC–1)
Primary Inductance 180 μH, ±5%
0.96 Primary Resonant 1.2 MHz (minimum)
Frequency
0.95 Leakage
Inductance 3 μH (maximum)
200 220 240 260 280
Table 1. Transformer Parameters.
(AWG = American Wire Gauge, TIW = Triple Insulated Wire,
Input Voltage (AC)
NC = No Connection, )
Figure 3. Power Factor (PF) Plotted Against Input Line Voltage (VAC).
Power Integrations Power Integrations reserves the right to make changes to its products at any time to improve reliability or manufacturability. Power
5245 Hellyer Avenue Integrations does not assume any liability arising from the use of any device or circuit described herein. POWER INTEGRATIONS
San Jose, CA 95138, USA. MAKES NO WARRANTY HEREIN AND SPECIFICALLY DISCLAIMS ALL WARRANTIES INCLUDING, WITHOUT LIMITATION, THE IMPLIED
Main: +1 408-414-9200 WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND NON-INFRINGEMENT OF THIRD PARTY RIGHTS.
Customer Service The products and applications illustrated herein (transformer construction and circuits external to the products) may be covered by
Phone: +1-408-414-9665 one or more U.S. and foreign patents or potentially by pending U.S. and foreign patent applications assigned to Power Integrations.
Fax: +1-408-414-9765 A complete list of Power Integrations' patents may be found at www.powerint.com. Power Integrations grants
Email: usasales@powerint.com its customers a license under certain patent rights as set forth at http://www.powerint.com/ip.htm.
The PI logo, TOPSwitch, TinySwitch, LinkSwitch, DPA-Switch, PeakSwitch, EcoSmart, Clampless, E-Shield, Filterfuse, StackFET,
On the Web PI Expert and PI FACTS are trademarks of Power Integrations, Inc. Other trademarks are property of their respective companies.
www.powerint.com ©2008, Power Integrations, Inc.
D
04/08 DI-136

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Design Example Report

75 W Single Output, Power-factor Corrected

Summary and Features

15 Conducted EMI .....................................................................................................33

Figure 1 – Populated Circuit Board Photograph.

2 Power Supply Specification

Description Symbol Min Typ Max Units Comment

Figure 3 – PCB Layout.

Detailed descriptions of each functional block are given below.

5.1 Input EMI Filtering

Common-mode filtering is provided by L1, L2 and Y-capacitor C9. Together with

5.2 TOPSwitch Primary

To overcome this difficulty, an emitter follower (Q1) was used as an impedance

5.3 Output Rectification

5.4 Output Feedback

5.4.1 Constant-Voltage Operation

5.4.2 Constant-Current Operation

5.6 Post Filter

4 1 C5 22 µF, 16 V, Electrolytic, Gen. ECA-1CM220 Panasonic

6 1 C7 330 µF, 25 V, Electrolytic, Very Low EKZE250ELL331MJC5S Nippon Chemi-Con

29 2 Q4 PNP, Small Signal BJT, 40 V, 0.2 A, 2N3906 Fairchild

30 2 R1 5.1 kΩ, 5%, 1/4 W, Carbon Film CFR-25JB-5K1 Yageo

All parts are RoHS compliant.

7.1 Electrical Diagram

7.2 Electrical Specifications

7.4 Transformer Build Diagram

WD6: 1 1T Copper Foil

WD1: 1 9T x 3 _ #26 AWG

2mm margin tape

Figure 5 – Transformer Build Diagram.

Copper Foil Wrapped in Tape

Starting Lead Finish Side

Figure 6 – Copper Tape Preparation for Winding 4.

Copper Foil Wrapped in Tape

Starting Side Finish Lead

Figure 7 – Copper Tape Preparation for Winding 6.

7.5 Transformer Construction

ACDC_TOPSwitchGX_ INPUT INFO OUTPUT UNIT TOP_GX_FX_043007: TOPSwitch-GX/FX

ENTER TOPSWITCH-GX VARIABLES

ENTER TRANSFORMER CORE/CONSTRUCTION VARIABLES

LE 6.4 cm Core Effective Path Length

DC INPUT VOLTAGE PARAMETERS

CURRENT WAVEFORM SHAPE PARAMETERS

TRANSFORMER PRIMARY DESIGN PARAMETERS

TRANSFORMER SECONDARY DESIGN PARAMETERS (SINGLE OUTPUT EQUIVALENT)

CMS 1524 Cmils Secondary Bare Conductor minimum circular mils

AWGS 18 AWG Secondary Wire Gauge (Rounded up to next larger

VOLTAGE STRESS PARAMETERS

9 Specifications For Common Mode Inductor L1

9.1 Electrical Diagram

Figure 8 – L1 Electrical Diagram.

9.4 Winding Instructions

Figure 9 – Picture of L1.

Figure 10 – Efficiency vs Input Voltage. Full Load, Room Temperature, 60 Hz.

INPUT VOLTAGE (AC) OUTPUT EFFICIENCY (%)

10.2 Output Characteristic

10.3 Harmonic Content

10.4 Harmonic Content in Percentage of Fundamental

10.5 Power Factor Vs Line Voltage at Full Load

Figure 13 – Power Factor (PF) vs Input Line Voltage (VAC).

INPUT VOLTAGE (AC) POWER FACTOR

Table 4: Temperatures of Critical Components in the Power Supply.

208 VAC, 75 W load, 25 ºC Ambient

12.1 Drain Voltage and Current, Normal Operation