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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.
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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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.
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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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
Vin (V) Iin (A) Pin (W) Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)
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
200W PFC + LCC resonant converter reference design for LED lighting
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460VDC, 200Vout
Vin (V) Iin (A) Pin (W) Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)
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
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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230VAC/50Hz, 200Vout Vin,rms (V) Iin,rms (A) Pin (W) P.F. THD Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)
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
277VAC/50Hz, 200Vout Vin,rms (V) Iin,rms (A) Pin (W) P.F. THD Vout (V) Iout (A) Pout (W) Losses (W) Efficiency (%)
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
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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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
200W PFC + LCC resonant converter reference design for LED lighting
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4.3 230VAC/50Hz, Top Side
Designator Part
Designator Value
Sp1 L200 53.4°C
Sp2 T200 57.4°C
Sp3 RT100 71.4°C
200W PFC + LCC resonant converter reference design for LED lighting
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4.4 230VAC/50Hz, Bottom Side
Designator Part
Designator Value
Sp1 Q203 107.4°C
Sp2 D201 77.8°C
200W PFC + LCC resonant converter reference design for LED lighting
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4.5 277VAC/50Hz, Top Side
Designator Part
Designator Value
Sp1 L200 50.5°C
Sp2 T200 61.3°C
Sp3 RT100 61.8°C
200W PFC + LCC resonant converter reference design for LED lighting
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4.6 277VAC/50Hz, Bottom Side
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
200W PFC + LCC resonant converter reference design for LED lighting
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5.2 120VAC/60Hz –200V/1A
200W PFC + LCC resonant converter reference design for LED lighting
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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:
200W PFC + LCC resonant converter reference design for LED lighting
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6.2 Load step from 0.5A to 1A:
200W PFC + LCC resonant converter reference design for LED lighting
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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.
200W PFC + LCC resonant converter reference design for LED lighting
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8 Key Waveforms
8.1 120VAC-60Hz,200V /1A output. C1: switch node waveform at LO, C2: output voltage
200W PFC + LCC resonant converter reference design for LED lighting
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