PowerInt 12W高效高功率因素智能照明电源参考设计DER612详解

PowerInt公司的InnoSwitch-CH系列INN2003K器件是组合了初级,次级和反馈电路的表面安装的离线开关集成电路,包括初级FET,初级边控制器,用于同步整流的次级边控制器,采用创新的FluxLink™技术,从而不需要光耦合器.主要用在智能移动设备的充电器和适配器,LED照明Casambi CBM-001以及高效低压高电流电源.本文介绍了InnoSwitch-CH系列产品亮点和主要特性,框图,以及采用InnoSwitch-CH系列INN2003K的12W高效高功率因素智能照明电源参考设计DER612主要特性和指标,电路图,材料清单和PCB设计图.

The InnoSwitch™ Family of ICs combines primary, secondary and feedback circuits in a single surface-mounted off-line flyback switcher IC. The InnoSwitch IC incorporates the primary FET, the primary-side controller, a secondary-side controller for synchronous rectification and an innovative new FluxLink™ technology that eliminates the need for an optocoupler.

Power Integrations’ FluxLink is a proprietary new communication technology that enables feedback information to be delivered across an isolation barrier without the use of any magnetic materials. FluxLink delivers a very high communication bandwidth which enables a much faster load-transient response. It is also highly reliable and does not suffer from the typical optocoupler degradation mechanisms. It is embedded into the package and by eliminating bulky optocouplers, it saves space and increases power density, which is particularly beneficial for adapters and chargers. Furthermore, this proprietary technology meets all global noise immunity standards. For safety, it complies not only with UL and TUV global isolation standards but also the more stringent CQC 5,000 meter Chinese safety standard.

InnoSwitch provides both accurate constant voltage (CV) and constant current (CC) while maintaining high efficiency across the load range. This is helpful in smart lighting where the CV capability may be used to power controllers and network interface devices, while the CC capability drives the LEDs, Lighting control is achieved by modulating the feedback pin using a PWM signal.
 

图1.InnoSwitch™-CH系列框图

The InnoSwitch™-CH Family of ICs combines primary, secondary  and feedback circuits in a single surface mounted off-line flyback switcher IC. The InnoSwitch-CH IC incorporates the primary FET, the primary side controller and a secondary-side synchronous rectification controller. The new IC also includes an innovative new technology, FluxLink™, which safely bridges the isolation barrier and eliminates the need for an optocoupler.  The incorporation of the secondary side controller enables a shoot-through proof synchronous rectification FET drive while delivering fast transient response, exceeding all world-wide efficiency standards, including the Code of Conduct Version 5 and DoE Version 6 regulations. 

InnoSwitch™-CH系列产品亮点:

Highly Integrated, Compact Footprint
Incorporates flyback controller, 650 V MOSFET, secondary-side sensing and synchronous rectification
Integrated, HIPOT-isolated, feedback link
Exceptional CV/CC accuracy, independent of transformer design or external components
Instantaneous transient response ±5% CV with 0-100-0% load step
EcoSmart™– Energy Efficient
<10 mW No-load @ 230 VAC with optional bias winding
Easily meets all global energy efficiency regulations, including DOE 6/CoC v5
Low heat dissipation
Advanced Protection / Safety Features
Primary sensed output OVP with optional bias winding
Secondary sensed output overshoot clamp
Secondary sensed output OCP to zero output voltage
Hysteretic thermal shutdown
Full Safety and Regulatory Compliance
100% production HIPOT compliance testing at 6 kV DC/1 sec
Reinforced insulation
Isolation voltage = 3,500 VAC UL1577 and TUV (EN60950) safety approved EN61000-4-8 (100 A/m) and EN61000-4-9 (1000 A/m) compliant
Green Package
Halogen free and RoHS compliant
InnoSwitch™-CH系列产品应用:
Chargers and adapters for smart mobile devices
LED lighting
High efficiency, low voltage, high current power supplies
采用InnoSwitch-CH系列INN2003K的12W高效高功率因素隔离反激电源参考设计

DER612主要特性:

• Accurate constant voltage regulation
• Fast transient load response
• High power factor
• Highly energy efficient
• Low standby power
• Low component count
• Integrated protection and reliability features
• Output short-circuit
• Line and output OVP
• Line surge or line overvoltage
• Over temperature shutdown with hysteretic automatic power recovery
• No damage during line brown-out or brown-in conditions
• Meets IEC 2.5 kV ring wave, 2 kV differential surge
• Meets EN55015 conducted EMI

This engineering report describes a constant voltage (CV) output 12 W isolated flyback power supply with a valley-fill passive power factor correction circuit for smart lighting applications. The power supply is designed to provide a 30 V constant voltage output across 0 mA to 400 mA output current load and throughout the input voltage from 90 VAC to 265 VAC.

The power supply IC controller device, InnoSwitch-CH combines primary, secondary and feedback circuits in a single surface-mounted off-line flyback switcher IC. It incorporates the primary FET, the primary side controller and a secondary-side synchronous rectification controller. The device also includes an innovative new technology, FluxLink™, which safely bridges the isolation barrier and eliminates the need for an optocoupler. |

The added valley-fill passive power factor correction circuit is a simple and low cost solution to meet power factor requirements for lighting applications.

DER-612 using InnoSwitch-CH offers a highly efficient constant voltage supply with a fast transient load response. The design achieves high power factor (0.9) at low line. The key design goals were high efficiency, optimized power factor and low components count.

图2.参考设计DER612外形图(顶视图)

图3.参考设计DER612外形图(底视图)
参考设计DER612主要指标:

图4.参考设计DER612电路图
参考设计DER612材料清单:

其它部件:

图5.参考设计DER612变压器电路和结构调图

图6.参考设计DER612 PCB设计图(1)

图7.参考设计DER612 PCB设计图(2)