Poweint PLC810PG 150W LED街灯照明设计方案

Powerint 公司的PLC810PG 是集成了半桥驱动器的PFC和LLC离线控制器,其中的PFC部分是通用输入连续电流模式(CCM),不需要正弦输入参考,从而降低成本和外接元件.主要应用32-60吋LCD TV电源,150-600W电源和LED街灯照明.本文介绍PLC810PG主要特性, 方框图, 150W LED街灯照明设计DER-212主要特性和指标, PLC810PG LED 街灯照明电源输入电路和PFC功率级, PFC控制输入电路和LLC级以及所用材料清单(BOM).

DER-212:150 W Power Factor Corrected LLC Power Supply Using HiperPLC (PLC810PG)

The PLC810PG is a combined PFC and LLC off-line controller with integrated high voltage half-bridge drivers. Figure 1 shows a simplified schematic of a PLC810PG based power supply where the LLC resonant inductor is integrated into the transformer. The PFC section of the PLC810PG is a universal input continuous current mode (CCM) design that does not require a sinusoidal input reference, thereby reducing system cost and external components.

The DC-DC controller drives an LLC resonant topology. This variable frequency controller provides high efficiency by switching the power MOSFETs at zero voltage, eliminating most switching losses. The LLC controller is built around a current controlled oscillator with a control range selected to support the traditional frequency of operation found in televisions.

To ensure zero voltage switching, the dead time of the LLC switching in the PLC810PG is tightly toleranced and can be adjusted with an external resistor. The highside/lowside duty cycle is also closely matched to provide balanced output currents reducing output diode cost.

A typical PLC810PG LLC design operates at 100 kHz (under nominal conditions). Depending on the LLC circuit design, the switching frequency can vary from half to three times the nominal operating frequency as a result of line and load changes.

The PFC converter is frequency locked to the LLC to minimize noise and electromagnetic interference. Increasing the PFC frequency in synchronization with the LLC at light loads reduces the current at which the PFC boost converter becomes discontinuous improving light load operation and reducing power line harmonics. PFC and LLC primary side fault management is provided.

The phase of the PFC PWM output is dynamically adjusted relative to the LLC phase such that the switching edges do not coincide with noise sensitive events in the PWM and LLC timing circuits. This edge-collision avoidance technology simplifies power supply layout and improves performance. Phase synchronization reduces EMI spectral components and reduces ripple current in the PFC capacitor.

PLC810PG主要特性:

• Highly integrated, eliminates external components

• Frequency and phase synchronized PFC and LLC

• Reduced noise and EMI

• Ripple current reduction in PFC output capacitor

• Edge collision-avoidance simplifies layout

• Comprehensive PFC and LLC fault handling and current limiting

• Proprietary continuous conduction mode PFC for high efficiency with low component cost

• High efficiency Zero Voltage Switching (ZVS) LLC

• Off-time PFC control eliminates AC input sensing components

• Configurable, precise dead time control and frequency limit

• Prevents hard MOSFET switching

• Tight LLC duty cycle symmetry for balanced O/P diode currents

• Lead and halogen free Green package

PLC810PG应用:

• 32”to 60”LCD TV power supplies

• Off-line 150 W to 600 W efficiency-optimized power supplies

• LED street lighting


图1.PLC810PG方框图

150W LED街灯照明设计DER-212 指标:

140–265 VAC Input; 150 W (48 V at 0.05 A –3.125 A) Output

Application LED Street Light

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.

150W LED街灯照明设计方案DER-212主要特点:

• 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

电源指标:


图2.DER-212 顶视图

图3. PLC810PG LED 街灯照明电源输入电路和PFC功率级

图4. PLC810PG LED 街灯照明电源,PFC控制输入电路和LLC级

材料清单(BOM):