PowerInt 12W high efficiency and high power factor intelligent lighting power supply reference design DER612 detailed solution

PowerInt's InnoSwitch-CH Series INN2003K devices are surface mount off-line switch ICs that combine primary, secondary and feedback circuits, including primary FETs, primary side controllers, secondary side controllers for synchronous rectification, and innovation FluxLinkTM technology eliminates the need for optocouplers. Mainly used in smart mobile device chargers and adapters, LED lighting Casambi CBM-001 and high efficiency low voltage high current power supply. This article introduces the highlights and main features of the InnoSwitch-CH series. Block diagram, and the 12W high-efficiency high-power factor intelligent lighting power supply reference design using the InnoSwitch-CH series INN2003K DER612 main features and indicators, circuit diagram, bill of materials and PCB design.

The InnoSwitchTM 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 FluxLinkTM 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 It is embedded into the package and by eliminated bulky optocouplers, it saves space and increases power density, which is particularly beneficial for adapters and chargers. further, 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.

Figure 1. InnoSwitchTM-CH Series Block Diagram

The InnoSwitchTM-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, FluxLinkTM, 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.

Highlights of the InnoSwitchTM-CH Series:

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
EcoSmartTM– 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
InnoSwitchTM-CH Series Applications:
Chargers and adapters for smart mobile devices
LED lighting
High efficiency, low voltage, high current power supplies
12W High Efficiency and High Power Factor Isolated Flyback Power Supply Reference Design Using InnoSwitch-CH Series INN2003K

Main features of DER612:

• 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. Device also includes an innovative new technology, FluxLinkTM, 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.

Figure 2. Reference design DER612 outline drawing (top view)

Figure 3. Reference design DER612 outline drawing (bottom view)
Reference design DER612 main indicators:

Figure 4. Reference design DER612 circuit diagram reference design DER612 bill of materials:

Other components:

Figure 5. Reference design DER612 transformer circuit and structure map

Figure 6. Reference design DER612 PCB design (1)

Figure 7. Reference design DER612 PCB design (2)

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